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BACKGROUND OF THE INVENTION
The invention relates to photographic films which are coated on one face with an antistatic material to reduce the tendency for the accumulation of electrostatic charge. Electrostatic charges are detrimental to such film in the high speed processing thereof because, when discharge of a built-up electrostatic charge occurs, a spark may result which streaks, fogs or spots the photographic emulsion on the opposite face.
The photographically inert, curable topical antistatic agent employed in the instant invention is described generically in U.S. Pat. No. 4,014,854 and is shown coated and cured on various substrates therein. Related compounds are shown in U.S. Pat. No. 4,077,991. Such compounds are crosslinked and cured through hydroxyl groups by aminoplast resins and the like upon various substrates to render them antistatic in U.S. Pat. No. 4,080,161. Various polyglycols or polyglycidol compounds have been shown as topical antistatics or as thermoplastic melt added antistatics in U.S. Pat. Nos. 3,551,152; 3,988,378; 3,879,346; U.K. Pat. No. 1,045,165 (a glycidyl ether); and various other topical antistats are described in American Dyestuff Reporter, Feb. 27, 1967, pages 37-43.
In U.S. Pat. No. 3,442,654, water soluble polyoxyalkylene glycol ethers are employed as anti-fogging agents in photographic film gelatins. U.S. Pat. No. 3,551,152 employs a glycidol adduct of a fatty alcohol initiated polyoxyethylene molecule as an antistat for photographic films. Chem. Abstracts, 74:93456u (1971) also describes polyglycidol compounds as additive in a photographic stabilization bath. Some of these teachings indicate that certain glycols interfere with photographic emulsions.
SUMMARY OF THE INVENTION
In a process for preparing a film bearing a light sensitive emulsion on one face thereof, the opposite face of which is treated with a topical antistatic agent to reduce the tendency of said opposite face to accumulate an electrostatic charge, the improvement of:
(a) applying to said opposite face, in an amount sufficient to reduce its surface resistivity, a photographically inert compound represented by the formula: ##STR1## wherein R is the residue left by removal of m active hydrogen atoms from an initiator compound R(H) m ; m is an integer from 1 to 8; R' is hydrogen or the acyl radical of a carboxylic acid or the carbamoyl radical of a hydrocarbyl isocyanate, said acyl or carbamoyl radical comprising from 1 to about 20 carbon atoms; R 1 each occurrence is independently hydrogen, methyl, ethyl, t-butoxymethyl or--CH 2 OX wherein X is selected from H and the acyl radical of a carboxylic acid or the carbamoyl radical of a hydrocarbyl isocyanate, said acyl or carbamoyl radical comprising 1 to about 20 carbon atoms; v is a positive number such that the product of v and m is a number whereby the resultant molecular weight of said photographically inert compound is about 1,000 to about 6,000; provided that in about 70 to about 95 percent of its occurrences R 1 is hydrogen, in about 5 to about 10 percent of its occurrences R 1 is--CH 2 OX wherein X is H or Y, which Y is the acyl radical of an α,β-unsaturated monocarboxylic acid comprising 3 to 10 carbon atoms; in at least one occurrence X is Y and in no more than two occurrences is the carbamoyl radical of a hydrocarbyl isocyanate or the acyl radical of a carboxylic acid other than Y; and
(b) exposing the photographically inert compound to a free-radical source sufficient to render it durably attached to said opposite face by curing the unsaturated portions thereof
and a film bearing a light sensitive emulsion prepared by this process comprise the instant invention.
The photographically inert compound is prepared as described in U.S. Pat. No. 4,014,854 and is coated on the backside of a film which bears or is to bear a light sensitive emulsion. The compound is then cured by exposure to a suitable free-radical source such as a UV radiation activated initiator, electron beam radiation or other suitable means. The "film" which is so-treated may be made up of or coated with any one of the class of static generating plastics: polycarbonates, polyolefins such as polyethylene and chlorinated polyethylenes, polystyrenes, polyesters, styrene acrylonitriles and cellulose acetates. These materials are normally fabricated in strips commonly thought of as "photographic film" which is normally coated with a negative working light sensitive emulsion for either black and white or color photographic films. These "films" as the term is used herein, also include papers coated with the various plastic materials and a light sensitive emulsion layer which are of the type used for photographic printing from negatives. These also include "instant" developing coated paper films which come directly from a camera bearing a positive working emulsion which is developed in situ.
Due to the tendency of such films to accumulate electrostatic charges which are prone to discharge in processing and handling (and thereby cause spots or shadows on the light sensitive emulsions resulting in photographic reproductions of poor image quality), it is desirable to reduce the tendency of such films to accumulate electrostatic charge. It is, however, necessary that the antistatic agent employed be compatible with the chemicals involved in developing and fixing baths and with the other chemicals employed in the processing of the films and simultaneously avoid fogging or otherwise affecting the unexposed light sensitive emulsion on the film.
It is also desirable that the antistatic agent not be removed by further film processing as in developing and fixing baths. In this fashion, even processed film may maintain its antistatic tendencies and thereby avoid the accumulation of dust which tends to scratch and mar negatives or positive prints upon subsequent handling. It is also detrimental if such an antistatic is leached out by photographic processing baths, thereby affecting the concentrations of such baths or clogging processing equipment.
DETAILED DESCRIPTION OF THE INVENTION
Photographically Inert Compound
In the process and films of the invention, it is preferable to employ as the photographically inert compound represented by Formula (I), a compound wherein R 1 is hydrogen in about 70 to about 80 percent of its occurrences, is methyl or ethyl in about 15 to about 25 percent of its occurrences and is--CH 2 OX in about 5 to about 10 percent of its occurrences, X being H or Y in all occurrences. It is also preferable to employ as the said compound of Formula (I), a compound wherein X is selected from H and the acyl radical of acrylic, methacrylic or cinnamic acid; more preferably from H and the acyl radical of acrylic acid. In another preferred mode, R 1 is H in about 70 to about 95 percent and--CH 2 OX, wherein X is H or the acyl radical of acrylic acid, in about 5 to about 10 percent of its occurrences. Even more preferably, X is H in about 5 percent and the acyl radical of acrylic acid in about 5 percent of its occurrences, m is 1 to 3 and R' is H or the acyl radical of acrylic acid.
Preferably, the molecular weight of the photographically inert compound of Formula (I) is about 2,000 to about 5,000. Also preferably, R is the residue of bisphenol A, glycerol, water or para-phenylphenol.
For its teachings in the preparation of the compounds of Formula (I), U.S. Pat. No. 4,014,854 is hereby incorporated by reference.
While the compound of Formula (I) may itself suitably be rendered crosslinked and cured on the backside of the film by exposure to any suitable free-radical source, when there are less than 2 acrylate moieties per mole it is preferable to add an additional free-radical curable crosslinking agent. Such agents are pentaerythritol tri- or tetra-acrylate, trimethylol propane tri- or di-acrylate, diacetone acrylamide, or similar reactive diluents commonly employed in the UV radiation-curable coating art. Generally, from about 1 to 20 percent by weight of this additive, based upon the compound of Formula (I), will be suitable to give the desired degree of crosslinking for the durability of the antistatic coating desired.
Processing
While the photographically inert compound of Formula (I) may be applied directly to the backside of a film bearing a light sensitive photographic emulsion, better uniformity in wetting and adhesion is obtained by first corona-treating the surface to which the compound of Formula (I) is to be applied. Ordinarily, it will be more convenient to apply the compound of Formula (I) to the backside of the film prior to the application of the light sensitive emulsion to the foreface of the film since one does then not have to worry about the sensitivity of this film to corona treatment, UV radiation, electron beam radiation or heat.
The compound of Formula (I) can be doctored on the backside of the film by any suitable means commonly employed for such application so a uniform coating is attained. A coating weight of about 0.05 to about 0.25 g/ft 2 will normally be a suitable quantity of the compound of Formula (I). The lower molecular weight compounds of Formula (I) are generally viscous liquids which may be applied directly to the backside of the film while the higher molecular weight compounds may suitably be applied from an aqueous or alcohol solution thereof since most are either water soluble or water dispersible. In some instances it may be desirable to add a small amount of a nonionic surfactant to permit their uniform dispersion in an aqueous solution, especially compounds of Formula (I) where in one or two occurrences X is the acyl radical of a carboxylic acid other than Y or is the carbamoyl radical of an isocyanate (e.g., φNHC(O)O--from reaction of φNCO with an OH group).
After the compound of Formula (I) has been applied to the backside of the film, it is dried on the film suitably by evaporating solvent at room temperature or by subjecting it to a flow of forced warm air. It is then cured on the film by subjecting it to a source of free-radical radiation.
Free-Radical Source
Curing of the photographically inert antistatic compound of Formula (I) is achieved by exposure of same to a free-radical source, preferably electron beam radiation or an ultraviolet (UV) radiation activated initiator. If not otherwise detrimental to the film, incorporation of a heat sensitive initiator, such as a peroxide, in compound (I) will render the compound curable by exposure to heat.
Representative free-radical sources include such actinic radiation as carbon arc lamps, mercury lamps of the super high, high, or lower pressure types, xenon lamps, ultraviolet fluorescent lamps, lasers, gamma sources and the like, depending on the type and sensitivity of the free-radical initiator(s) and/or sensitizer(s) employed with the compound of Formula (I). When electron beam radiation is employed, it is itself the free-radical source and no initiator or sensitizer is required.
Exemplary photopolymerization initiators include the benzoins such as benzoin, benzoin methyl ether, α-methyl benzoin, and the like; anthraquinones such as anthraquinone, chloroanthraquinone, t-butyl-anthraquinone; diketones such as benzyl diketone; phenones such as acetophenone, benzophenone; 2-naphthalene sulfonyl chloride; disulfides such as diphenyl disulfide; dyes such as EOSINE G (C.I. 45380); and the like. Diethoxyacetophenone is preferred because it is water soluble. Those skilled in the art are capable of selecting a suitable initiator and/or sensitizer in the appropriate amounts for the type of actinic radiation employed. Suitably, about 0.1 to 5 percent of the initiators are employed based on the weight of the antistatic compound of Formula (I). The time of exposure to the actinic radiation source can likewise be varied by one skilled in the art to attain the degree of cure desired.
SPECIFIC EMBODIMENTS OF THE INVENTION
In the following examples, photographically inert antistatic compounds of Formula (I) are prepared in the manner described in U.S. Pat. No. 4,014,854 and are applied to and cured on various films commonly employed as carriers for light sensitive emulsions.
The polymeric precursors to the compounds of Formula (I) are prepared by contacting water, bisphenol A, p-phenylphenol, glycerine or dodecanol with a mixture of ethylene oxide (EO) and t-butyl glycidyl ether (TBGE) and, in two examples, additionally containing 1,2-propylene oxide (PO), in the presence of a base catalyst, e.g., sodium metal or potassium hydroxide. Sufficient alkylene oxide is employed, on a molar basis, to obtain a polymer of about the molecular weight desired. Molecular weight of the polymeric product is determined from conventional hydroxyl number analysis. The various polymeric precursors to compound (I) are listed as follows in Table I.
TABLE I______________________________________Precursor Compositions Mole Ratios** Approx. +Precursor Initiator* Alkylene Oxides Mol. Weight______________________________________A BPA 90 EO/10 TBGE 5000B PPP 90 EO/10 TBGE 5000C DD 75 EO/25 TBGE 3000D H.sub.2 O 95 EO/5 TBGE 6000E H.sub.2 O 90 EO/10 TBGE 5000F H.sub.2 O 80 EO/20 TBGE 4000G H.sub.2 O 70 EO/30 TBGE 5000H H.sub.2 O 75 EO/25 TBGE 1300I gly 70 EO/20PO/10 TBGE 3000J gly 70 EO/20PO/10 TBGE 5000______________________________________ *BPA = Bisphenol A **EO = Ethylene Oxide PPP = pPhenyl phenol TBGE = tButyl Glycidyl Ether DD = Dodecanol PO = 1,2Propylene Oxide gly = Glycerine + Calculated from hydroxyl number
In a typical esterification reaction, 100 parts (all parts are by weight unless otherwise specified) of Precursor F and 3 parts para-toluenesulfonic acid are heated at about 105° C. for about 1.5 hour to dealkylate the t-butyl groups while a vacuum of about 30 mm Hg is slowly pulled on the reaction mixture to remove the isobutylene generated in the dealkylation. Weight loss indicates that approximately 100 mole percent of the ring-opened TBGE units are dealkylated to form ring-opened glycidol moieties ##STR2## in the backbone of the dealkylated Precursor F. The reaction mixture is then cooled to about 98° C. About 12 parts acrylic acid containing about 0.1 part Cu 2 O inhibitor is added to the reaction mixture. The reaction mixture is then heated at about 100° C. under a vacuum of 150 mm Hg for about 2 hours, then cooled. Titration for unreacted acid in the product indicates that about 39 mole percent of the ring-opened glycidol units are esterified, about 5.1 mole acrylate per mole of the esterified Precursor F. This esterified Precursor F is hereafter referred to as Antistat #1.
In a like manner, the other Precursors are dealkylated and esterified with acrylic acid to various degrees of esterification. In some instances, the Precursor is dealkylated and then reacted with other reactive molecules, e.g., phenyl isocyanate or stearic acid, prior to esterification with acrylic acid. In most instances, the residual p-toluenesulfonic and acrylic acid is permitted to remain in the Antistat product. In a few instances, the residual acids are removed by contacting the Antistat product with a weak base ion exchange resin and in such instances, about 0.01 part phenothiazine is substituted for Cu 2 O as inhibitor. Various Antistats are prepared in the previously described fashion and are described below in Table II.
TABLE II______________________________________Antistat Compositions Residual AcidAntistat Acrylate (meq/g ofNo. Precursor (Mole %)* Antistat)______________________________________ 1 A 24 0.56 2 A 53 0.81 3 A 55 0.86 4 A 56 0.07 5 A 57 0.79 6 A** 47 0.97 7 B 95 -- 8 C+ 47 0.24 9 D 35 0.5910 E 31 0.4711 E 52 0.9612 F 39 0.4513 F 53 1.3614 F 65 1.0515 G 23 1.3116 G 27 1.0917 G 65 1.3418 H 63 1.2119 I 61 0.8320 I 60 0.03______________________________________ *Mole percent of dealkylated ringopened TBGE units esterified with acryli acid. **1 Mole of primary OH per mole Antistat reacted with phenyl isocyanate. +2 Moles of primary OH per mole Antistat reacted with stearic acid.
The Antistats noted above are tested for their antistatic properties by applying to one side of various films which are pretreated with a Lepel corona treatment machine. The Antistats are applied to the corona-treated films as 30 percent or 50 percent (weight) solutions in methanol containing 3 percent (based on Antistat weight) Vicure 10 benzoin butyl ether or in an 80/20 (volume) water/isobutanol solution containing 3 percent (based on Antistat weight) diethoxyacetophenone. These Antistat solutions are drawn onto the corona-treated film surface with a No. 3 Meyer rod and solvent is allowed to evaporate at room temperature. The coated film is then cured by passing it under a 200 watt/in. high pressure mercury vapor lamp (Preferential Surface Care Unit marketed by Linde Div. of Union Carbide Corporation) at a rate of 100 ft/min in air. The number of passes under the mercury vapor lamp required to obtain a tack-free coating is noted. In some examples, added passes under the lamp are employed to examine the effect on permanence and antistatic properties. When applied from the 30 percent solutions, the coating weight of the Antistat is about 0.10 g/ft 2 and from the 50 percent solutions is about 0.15 g/ft 2 .
To test the antistatic properties of a cured Antistat, six equivalent samples of the same Antistat are preconditioned in a constant humidity chamber for about 16 hours. The Surface Electrical Resistivity (SER) is then determined by applying 100 volts across the surface with a Keithley Model 610B Electrometer, a Model 240 Regulated High Voltage Supply and a Model 6105 Resistivity Adapter. Amperage readings on the 6 samples are averaged and SER is calculated from the formula: ##EQU1##
Examples 1-8: On Polyester Film
In the manner described above, Antistats 1, 3, 10-12, 14 16 and 17 are cured on one side of a corona-treated polyester film, both at about 0.10 and 0.15 g/ft 2 . Their SER's are measured and are reported below in Table III. The coated films are conditioned at 17 percent relative humidity. The SER of uncoated blanks is >10 15 ohms.
TABLE III______________________________________SER on Polyester Film Passes Under SER (ohms × 10.sup.-10)Example Antistat Lamp 0.10 g/ft.sup.2 0.15 g/ft.sup.2______________________________________1 1 20 10 32 3 3 8 23 10 3 4 24 11 2 6 35 12 3 9 46 14 3 43 217 16 6 33 188 17 2 190 98______________________________________
Examples 9-11: On Polyethylene Coated Film
In the manner described above, Antistats 2, 13 and 15 are cured on a polyethylene (PE) coated paper of the type used for photographic prints. The coating weight is both about 0.10 and 0.15 g/ft 2 . Their SER's are measured and reported below in Table IV. The coated films are conditioned at 18 percent relative humidity. The SER of uncoated blanks is >10 15 ohms.
TABLE IV______________________________________SER on Polyethylene Coated Film Passes Under SER (ohms × 10.sup.-10)Example Antistat Lamp 0.10 g/ft.sup.2 0.15 g/ft.sup.2______________________________________ 9 2 2 4 210 13 2 20 811 15 2 11 5______________________________________
Examples 12-21: Leaching of Antistats
In the following examples, in the manner previously described, Antistats are cured on corona-treated polyester and PE coated paper films at a coating weight of about 0.10 and 0.15 g/ft 2 . In some instances, Example 17, additional passes under the mercury lamp are employed to test the effect on antistatic properties and leaching. Leaching is evaluated by immersing the cured Antistat-coated films in distilled water at room temperature for 30 minutes, shaking off excess water, allowing to dry at room temperature and conditioning at a given relative humidity (RH), then determining whether a significant rise in SER has occurred. In all cases, the SER rises but not to the level of an uncoated film blank.
The SER's are reported below in Table V.
TABLE V__________________________________________________________________________Leaching of Antistats SER Approximate (ohms × 10.sup.-10) Passes Under Type of Coating Wt. R.H. of Before AfterExampleAntistat Lamp Film* (g/ft.sup.2) Conditioning Bath Bath__________________________________________________________________________12 5 2 M 0.10 19% 8 27013 6 2 " " " 11 4514 9 4 " " " 5 4115 18 2 " " " 45 130016 4 2 PE " 17% 8 1617 4 2 + 8** " " " 11 5318 7 2 " 0.15 20% 2 3119 8 3 " " " 9 36020 19 3 " " " 2 6021 20 ' " " " 21 --__________________________________________________________________________ *PE = Polyethylene coated paper film M = Polyester film **8 Extra passes after tack free | An improved process for preparing a film bearing a light sensitive emulsion, backside coated with a topical antistat, comprising:
(a) applying to the backside a photographically inert compound curable by exposure to a free-radical source which compound is a copolymer comprised of ethylene oxide and glycidyl α,β-unsaturated monocarboxylates and
(b) exposing said compound to a free-radical source sufficient to render it durably attached to the backside by curing the unsaturated portions thereof
and films prepared by said process. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 14/967,026 filed on Dec. 11, 2015 which claims the benefit of Korean Patent Application No. 10-2015-0108716 filed in the Republic of Korea on Jul. 31, 2015, each of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Field of Technology
[0003] The present disclosure relates to an organic light emitting display (OLED) device and more particularly to a foldable OLED device that prevents being damaged by moisture.
[0004] Discussion of the Related Art
[0005] As information technology and mobile communication technology have been developed, a display device capable of displaying a visual image has also been developed. Flat panel display devices, such as a liquid crystal display (LCD) device and an OLED device, are developed and used.
[0006] Among these flat panel display devices, since the OLED device has advantages in response time, contrast ratio, viewing angle, power consumption, and so on, the OLED device is widely developed.
[0007] An emitting diode including an organic emitting layer is susceptible to damage from moisture. To prevent moisture penetration into the emitting diode and protect the emitting diode from external impacts, an encapsulation substrate of glass is attached onto the emitting diode.
[0008] Recently, foldable or bendable display devices (hereinafter “foldable display device”) have been introduced.
[0009] In the foldable OLED device, an encapsulation film including an inorganic layer and an organic layer is used instead of the encapsulation substrate. Namely, by using the encapsulation film for preventing moisture penetration into the emitting diode and to protect the emitting diode, the display device has a foldable property.
[0010] However, when the foldable OLED device is operated under a condition of high temperature and high humidity, the emitting diode is damaged resulting in problems in display quality and a lifetime of the foldable OLED device.
SUMMARY
[0011] Accordingly, the present invention is directed to a foldable OLED device that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0012] An object of the present invention is to provide a foldable OLED device being capable of preventing damage by moisture.
[0013] Another object of the present invention is to provide a foldable OLED device having advantages in production costs.
[0014] Another object of the present invention is to provide a foldable OLED device having a narrow bezel.
[0015] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0016] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, a foldable organic light emitting display (OLED) device comprises a substrate including a display region and a non-display region, the non-display region located at a periphery of the display region; an emitting diode in the display region; and an encapsulation film covering both the emitting diode and an entirety of the display region, and the encapsulation film covering a part of the non-display region without covering at least another part of the non-display region.
[0017] In another aspect, a foldable organic light emitting display (OLED) device comprises a substrate including a folding region along a first direction in which the foldable device is foldable; an emitting diode on substrate; and an encapsulation film including a first inorganic layer covering the emitting diode, an organic layer on the first inorganic layer and a second inorganic layer on the organic layer, wherein in the first direction, the second inorganic layer is wider than the first inorganic layer and covers side surfaces of the first inorganic layer, and in a second direction that is perpendicular to the first direction, a width of the second inorganic layer is substantially the same as a width of the first inorganic layer.
[0018] In another aspect, a foldable organic light emitting display (OLED) device comprises a flexible substrate including a display region and a non-display region located at a periphery of the display region, the flexible substrate folded across a folding region that is along a first direction of the foldable OLED device; an emitting diode in the display region; and an encapsulation film covering both the emitting diode and an entirety of the display region, and the encapsulation film covering a part of the non-display region without covering at least another part of the non-display region.
[0019] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0021] FIG. 1 is a schematic cross-sectional view illustrating a scribing process of a foldable OLED device.
[0022] FIG. 2 is a schematic cross-sectional view illustrating damages in an encapsulation film of a foldable OLED device.
[0023] FIG. 3A is a schematic plane view illustrating a foldable OLED device according to one embodiment of the present disclosure.
[0024] FIG. 3B is a view of the foldable OLED device folded across the folding region according to one embodiment of the present disclosure.
[0025] FIGS. 4A and 4B are schematic cross-sectional views illustrating a foldable OLED device according to a first embodiment of the present disclosure.
[0026] FIG. 5 is a schematic cross-sectional view illustrating a pixel structure of a foldable OLED device of the present disclosure.
[0027] FIGS. 6A and 6B are schematic cross-sectional views illustrating a foldable OLED device according to a second embodiment of the present disclosure.
[0028] FIGS. 7A and 7B are schematic cross-sectional views illustrating a foldable OLED device according to a third embodiment of the present disclosure.
[0029] FIGS. 8A to 8D are schematic views illustrating a foldable OLED device according to a fourth embodiment of the present disclosure.
DETAILED DESCRIPTION
[0030] Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings.
[0031] FIG. 1 is a schematic cross-sectional view illustrating a scribing process of a foldable OLED device, and FIG. 2 is a schematic cross-sectional view illustrating damages in an encapsulation film of a foldable OLED device.
[0032] As shown in FIGS. 1 and 2 , an OLED device 1 includes a flexible substrate 10 , an emitting diode D and an encapsulating film 20 covering the emitting diode D.
[0033] The flexible substrate 10 may include polymer such as polyimide, and the emitting diode D is formed on or over the flexible substrate 10 .
[0034] Although not shown, the emitting diode D includes first and second electrodes facing each other and an organic emitting layer between the first and second electrodes. In addition, on the flexible substrate 10 , a switching thin film transistor (TFT) as a switching element and a driving TFT as a driving element are formed, and the first electrode of the emitting diode D is connected to the driving TFT.
[0035] The encapsulating film 20 covers the emitting diode D to prevent damage to the emitting diode D under conditions of high temperature and high humidity.
[0036] In the encapsulation film 20 , an inorganic layer and an organic layer are alternately stacked. For example, the encapsulation film 20 may have a triple-layered structure including a first inorganic layer 22 on the emitting diode D, an organic layer 24 on the first inorganic layer 22 and a second inorganic layer 26 on the organic layer 24 .
[0037] A plurality of cells are formed on a mother substrate, and each cell is separated by a scribing process to provide the OLED device 1 .
[0038] Namely, a plurality of emitting diodes D are formed in each cell, and the encapsulation film 20 is formed to cover an entire surface of the mother substrate. Then, the scribing process is performed to separate each cell.
[0039] Since the scribing process is performed onto the encapsulation film 20 , the encapsulation film 20 is damaged. Namely, cracks may be generated in the first inorganic layer 22 and the second inorganic layer 26 , and moisture may penetrate into the emitting diode D through the cracks as shown in FIG. 2 . As a result, the emitting diode D may be damaged.
[0040] In the foldable OLED device, stress by folding operation is concentrated into the encapsulation film 20 in a folding region. Accordingly, when damages, such as cracks, are generated in the encapsulation film 20 by the scribing process, the cracks can grow due to the folding operation causing further damage to the emitting diode D.
[0041] FIG. 3A is a schematic plane view illustrating a foldable OLED device according to one embodiment of the present disclosure.
[0042] As shown in FIG. 3 , an OLED device 100 is a foldable OLED device capable of being folded along a folding region FR. For example, the folding region FR is defined along a direction of a minor axis of the foldable OLED device 100 . Alternatively, the folding region FR may be defined along a direction of a major axis of the foldable OLED device 100 .
[0043] When the folding region FR is defined along the direction of the minor axis of the foldable OLED device 100 , a pad region (not shown) is defined in at least one end along the direction of the major axis.
[0044] In the foldable OLED device 100 of the present disclosure, a plurality of pixel regions P are defined on a flexible substrate 110 , and an emitting diode (not shown) is formed in a display region including the plurality of pixel regions P. In addition, an encapsulating film covering the emitting diode is formed.
[0045] In the folding region FR, the encapsulation film has a width smaller than the flexible substrate 110 . Namely, in the direction of the minor axis, both ends of the encapsulation film are positioned inside both ends of the flexible substrate 110 . In addition, the end of the encapsulation film in the folding region and the end of the encapsulation film along a direction, which crosses the folding region, may have a symmetric structure or an asymmetric structure.
[0046] Due to the encapsulation film, damages on the encapsulation film from the scribing process and the folding operation are prevented such that the problem of the display quality and the lifetime in the foldable OLED device 100 is overcome. FIG. 3B is a view of the foldable OLED device 100 folded across the folding region FR shown in FIG. 3A .
[0047] FIGS. 4A and 4B are schematic cross-sectional views illustrating a foldable OLED device according to a first embodiment of the present disclosure, and FIG. 5 is a schematic cross-sectional view illustrating a pixel structure of a foldable OLED device of the present disclosure. FIG. 4B is a cross-sectional view taken along the line A-A′ in FIG. 3 , and FIG. 5 is a cross-sectional view taken along the line B-B′ in FIG. 3 .
[0048] As shown in FIG. 4A , an emitting diode D is formed to correspond to a display region of each cell in a mother substrate (not shown), and an encapsulation film 170 is formed to cover the emitting diode D and correspond to the display region and a part of a non-display region at peripheries of the display region.
[0049] Next, a scribing process is performed to separate each cell such that the flexible OLED device 100 is fabricated.
[0050] Since ends of the encapsulation film 170 are positioned inside scribing lines, the scribing process is not performed to the encapsulation film 170 . Accordingly, the damages, such as cracks, are not generated in the encapsulation film 170 in the scribing process.
[0051] As shown in FIG. 4B , the flexible OLED device 100 fabricated by the above scribing process includes the flexible substrate 110 , where the display region and the non-display region are defined, the emitting diode D corresponding to the display region and disposed on or over the flexible substrate 110 , and the encapsulation film 170 covering the emitting diode D and corresponding to the display region and a part of the non-display region.
[0052] Referring to FIG. 5 , a TFT Tr, the emitting diode D, and the encapsulation film 170 are sequentially stacked on the flexible substrate 110 .
[0053] For example, the flexible substrate 110 may be a polyimide substrate. Since the flexible substrate 110 is inadequate to a process of forming elements, such as the TFT Tr, the process of forming the elements is performed on the flexible substrate 110 attached to a carrier substrate (not shown) such as a glass substrate. After the process of forming the elements, the carrier substrate and the flexible substrate 110 is separated or released.
[0054] The TFT Tr is formed on the flexible substrate 110 . Although not shown, a buffer layer may be formed on the flexible substrate 110 , and the TFT Tr may be formed on the buffer layer.
[0055] A semiconductor layer 122 is formed on the flexible substrate 110 . The semiconductor layer 122 may include an oxide semiconductor material or polycrystalline silicon.
[0056] When the semiconductor layer 122 includes the oxide semiconductor material, a light-shielding pattern (not shown) may be formed under the semiconductor layer 122 . The light to the semiconductor layer 122 is shielded or blocked by the light-shielding pattern such that thermal degradation of the semiconductor layer 122 can be prevented. On the other hand, when the semiconductor layer 122 includes polycrystalline silicon, impurities may be doped into both sides of the semiconductor layer 122 .
[0057] A gate insulating layer 124 is formed on the semiconductor layer 122 . The gate insulating layer 124 may be formed of an inorganic insulating material such as silicon oxide or silicon nitride.
[0058] A gate electrode 130 , which is formed of a conductive material, e.g., metal, is formed on the gate insulating layer 124 . In one embodiment, the gate electrode 130 is formed at a location corresponding to a center of the semiconductor layer 122 .
[0059] In FIG. 5 , the gate insulating layer 124 is formed on the entire surface of the flexible substrate 110 . Alternatively, the gate insulating layer 124 may be patterned to have the same shape as the gate electrode 130 .
[0060] An interlayer insulating layer 132 , which is formed of an insulating material, is formed on an entire surface of the flexible substrate 110 including the gate electrode 130 . The interlayer insulating layer 132 may be formed of an inorganic insulating material, e.g., silicon oxide or silicon nitride, or an organic insulating material, e.g., benzocyclobutene or photo-acryl.
[0061] The interlayer insulating layer 132 includes a first contact hole 134 and a second contact hole 136 exposing both sides of the semiconductor layer 122 . The first contact hole 134 and second contact hole 136 are positioned at both sides of the gate electrode 130 to be spaced apart from the gate electrode 130 .
[0062] In FIG. 5 , the first contact hole 134 and second contact hole 136 extend into the gate insulating layer 124 . Alternatively, when the gate insulating layer 124 is patterned to have the same shape as the gate electrode 130 , there may be no first contact hole 134 and second contact hole 136 in the gate insulating layer 124 .
[0063] A source electrode 140 and a drain electrode 142 , which are formed of a conductive material, e.g., metal, are formed on the interlayer insulating layer 132 . The source electrode 140 and the drain electrode 142 are spaced apart from each other with respect to the gate electrode 130 and respectively contact both sides of the semiconductor layer 122 through the first and second contact holes 134 and 136 .
[0064] The semiconductor layer 122 , the gate electrode 130 , the source electrode 140 and the drain electrode 142 constitute the TFT Tr, and the TFT Tr serves as a driving element.
[0065] In FIG. 5 , the gate electrode 130 , the source electrode 140 and the drain electrode 142 are positioned over the semiconductor layer 122 . Namely, the TFT Tr has a coplanar structure.
[0066] Alternatively, in the TFT Tr, the gate electrode may be positioned under the semiconductor layer, and the source and drain electrodes may be positioned over the semiconductor layer such that the TFT Tr may have an inverted staggered structure. In this instance, the semiconductor layer may include amorphous silicon.
[0067] Although not shown, a gate line and a data line are disposed on or over the flexible substrate 110 and cross each other to define a pixel region. In addition, a switching element, which is electrically connected to the gate line and the data line, may be disposed on the flexible substrate 110 . The switching element is electrically connected to the TFT Tr as the driving element.
[0068] In addition, a power line, which is parallel to and spaced apart from the gate line or the data line, may be formed on or over the flexible substrate 110 . Moreover, a storage capacitor for maintaining a voltage of the gate electrode 130 of the TFT Tr during one frame, may be further formed on the flexible substrate 110 .
[0069] A passivation layer 150 , which includes a drain contact hole 152 exposing the drain electrode 142 of the TFT Tr, is formed to cover the TFT Tr.
[0070] A first electrode 160 , which is connected to the drain electrode 142 of the TFT Tr through the drain contact hole 152 , is separately formed in each pixel region. The first electrode 160 may be an anode and may be formed a conductive material having a relatively high work function. For example, the first electrode 160 may be formed of a transparent conductive material such as indium-tin-oxide (ITO) or indium-zinc-oxide (IZO).
[0071] When the flexible OLED device 100 is operated in a top-emission type, a reflection electrode or a reflection layer may be formed under the first electrode 160 . For example, the reflection electrode or the reflection layer may be formed of aluminum-paladium-copper (APC) alloy.
[0072] A bank layer 166 , which covers edges of the first electrode 160 , is formed on the passivation layer 150 . A center of the first electrode 160 in the pixel region is exposed through an opening of the bank layer 166 .
[0073] An organic emitting layer 162 is formed on the first electrode 160 . The organic emitting layer 162 may have a single-layered structure of an emitting material layer formed of an emitting material. Alternatively, to improve emitting efficiency, the organic emitting layer 162 may have a multi-layered structure including a hole injection layer, a hole transporting layer, the emitting material layer, an electron transporting layer and an electron injection layer sequentially stacked on the first electrode 160 .
[0074] A second electrode 164 is formed over the flexible substrate 110 including the organic emitting layer 162 . The second electrode 164 is positioned at an entire surface of the display area. The second electrode 164 may be a cathode and may be formed of a conductive material having a relatively low work function. For example, the second electrode 164 may be formed of aluminum (Al), magnesium (Mg) or Al—Mg alloy.
[0075] The first electrode 160 , the organic emitting layer 162 and the second electrode 164 constitute the light emitting diode D.
[0076] An encapsulation film 170 is formed on the light emitting diode D to prevent moisture penetration into the light emitting diode D.
[0077] The encapsulation film 170 has a width smaller than the flexible substrate 110 , and the ends of the encapsulation film 170 are positioned on the flexible substrate 110 .
[0078] Namely, as shown in FIG. 4A , since the mother substrate including the encapsulation film 170 , which has a smaller area than the cell, is scribed, the width of the encapsulation film 170 is smaller than that of the flexible substrate 110 such that the ends of the encapsulation film 170 are positioned inside the ends of the flexible substrate 110 . As a result, the damages, such as cracks, in the encapsulation film by the scribing process are prevented.
[0079] In addition, since there is no encapsulation film 170 in the end of the folding region FR, the folding stress generated in the folding operation is not concentrated in the encapsulation film 170 . Accordingly, the damages on the encapsulation film 170 by the folding operation is minimized or prevented.
[0080] In other words, in the ends of the folding region FR, the encapsulation film 170 is removed such that one of the passivation layer 150 (of FIG. 5 ), the interlayer insulating layer 132 (of FIG. 5 ), the gate insulating layer 124 (of FIG. 5 ) and the flexible substrate 110 is exposed and the ends of the encapsulation film 170 are disposed on the one of the passivation layer 150 , the interlayer insulating layer 132 , the gate insulating layer 124 and the flexible substrate 110 .
[0081] On the other hand, to prevent the damages on the passivation layer 150 , the interlayer insulating layer 132 or the gate insulating layer 124 by the scribing process and moisture penetration into the display region, all of the passivation layer 150 , the interlayer insulating layer 132 and the gate insulating layer 124 may be removed in the ends of the folding region FR such that the encapsulation film 170 may contact the flexible substrate 110 in the ends of the folding region FR.
[0082] The encapsulation film 170 includes a first inorganic layer 172 , an organic layer 174 and a second inorganic layer 176 . However, it is not limited thereto.
[0083] For example, the encapsulation film 170 may further include an organic layer on the second inorganic layer 176 to have a quadruple-layered structure or may further include an organic layer and an inorganic layer on the second inorganic layer 176 to have a five-layered structure.
[0084] The first and second inorganic layers 172 and 176 have the same plane area and completely overlap each other. The organic layer 174 is positioned between the first and second inorganic layers 172 and 176 . The organic layer 174 has a plane area smaller than the first and second inorganic layers 172 and 176 and completely overlaps the first and second inorganic layers 172 and 176 . Namely, the organic layer 174 is completely covered and protected by the second inorganic layer 176 such that moisture penetration through the organic layer 174 is prevented.
[0085] For example, when the organic layer 174 has the same plane area as or larger area than the second inorganic layer 176 , a side surface of the organic layer 174 is exposed and moisture penetration may be generated through the side surface of the organic layer 174 . However, in the present disclosure, since the organic layer 174 is completely covered and protected by the second inorganic layer 176 , moisture penetration through the organic layer 174 is prevented.
[0086] Each of the first inorganic layer 172 and second inorganic layer 176 may be formed of silicon oxide or silicon nitride, and the organic layer 174 may be formed of an epoxy compound or an acryl compound.
[0087] Although not shown, a barrier film may be attached to the encapsulation film 170 , and a polarization plate for reducing an ambient light reflection may be attached to the barrier film. For example, the polarization plate may be a circular polarization plate.
[0088] As mentioned above, in the flexible OLED device 100 of the present disclosure, since the encapsulation film 170 is positioned inside the flexible substrate 110 , the damages on the encapsulation film 170 by the scribing process are prevented.
[0089] In addition, since the ends of the encapsulation film 170 in the folding region FR are positioned inside the ends of the flexible substrate 110 , the folding stress is not concentrated in the ends of the encapsulation film 170 .
[0090] Accordingly, the decrease of the display quality and the lifetime in the flexible OLED device 100 generated by the damages on the elements, e.g., the emitting diode D, by the moisture penetration is minimized or prevented.
[0091] FIGS. 6A and 6B are schematic cross-sectional views illustrating a foldable OLED device according to a second embodiment of the present disclosure. FIG. 6A is a cross-sectional view taken along the line A-A′ in FIG. 3 , and FIG. 6B is a cross-sectional view taken along the line C-C′ in FIG. 3 .
[0092] As shown in FIGS. 6A and 6B , a flexible OLED device 200 according to the second embodiment of the present disclosure includes the flexible substrate 210 , where the display region and the non-display region are defined, the emitting diode D corresponding to the display region and disposed on or over the flexible substrate 210 , and the encapsulation film 270 covering the emitting diode D and corresponding to the display region and a part of the non-display region.
[0093] For example, the flexible substrate 210 may be a polyimide substrate. The TFT Tr (of FIG. 5 ), the emitting diode D and the encapsulation film 270 are formed on or over the flexible substrate 210 .
[0094] As illustrated with FIG. 5 , the TFT Tr may include the semiconductor layer 122 , the gate electrode 130 , the source electrode 140 and the drain electrode 142 , and the emitting diode D may include the first electrode 160 , which is connected to the drain electrode 142 , the second electrode 164 , which faces the first electrode 160 , and the organic emitting layer 162 between the first and second electrodes 160 and 164 .
[0095] The encapsulation film 270 covers the emitting diode D and has an area smaller than the flexible substrate 210 . Namely, the ends of the encapsulation film 270 are positioned inside the ends of the flexible substrate 210 .
[0096] In the ends of the folding region FR, the encapsulation film 270 is removed such that one of the passivation layer 150 (of FIG. 5 ), the interlayer insulating layer 132 (of FIG. 5 ), the gate insulating layer 124 (of FIG. 5 ) and the flexible substrate 210 is exposed and the ends of the encapsulation film 270 are disposed on the one of the passivation layer 150 , the interlayer insulating layer 132 , the gate insulating layer 124 and the flexible substrate 210 .
[0097] On the other hand, to prevent the damages on the passivation layer 150 , the interlayer insulating layer 132 , or the gate insulating layer 124 by the scribing process and moisture penetration into the display region, all of the passivation layer 150 , the interlayer insulating layer 132 and the gate insulating layer 124 may be removed in the ends of the folding region FR such that the encapsulation film 270 may contact the flexible substrate 210 in the ends of the folding region FR.
[0098] The encapsulation film 270 includes a first inorganic layer 272 , an organic layer 274 and a second inorganic layer 276 . However, it is not limited thereto.
[0099] For example, the encapsulation film 270 may further include an organic layer and an inorganic layer on the second inorganic layer 276 to have a five-layered structure.
[0100] The first and second inorganic layers 272 and 276 have the same plane area and completely overlap each other. The organic layer 274 is positioned between the first and second inorganic layers 272 and 276 . The organic layer 274 has a plane area smaller than the first inorganic layer 272 and second inorganic layer 276 and completely overlaps the first inorganic layer 272 and second inorganic layer 276 . Namely, the organic layer 274 is completely covered and protected by the second inorganic layer 276 such that moisture penetration through the organic layer 274 is prevented.
[0101] For example, when the organic layer 274 has the same plane area as or larger area than the second inorganic layer 276 , a side surface of the organic layer 274 is exposed and moisture penetration may be generated through the side surface of the organic layer 274 . However, in the present disclosure, since the organic layer 274 is completely covered and protected by the second inorganic layer 276 , moisture penetration through the organic layer 274 is prevented.
[0102] Each of the first inorganic layer 272 and second inorganic layer may be formed of silicon oxide or silicon nitride, and the organic layer 274 may be formed of an epoxy compound or an acryl compound.
[0103] As shown in FIG. 6A , in the folding region FR, the end of the encapsulation film 270 has a first distance D 1 from the flexible substrate 210 .
[0104] On the other hand, as shown in FIG. 6B , in a side along a first direction, which is perpendicular to an extension direction (i.e., a second direction) of the folding region FR, the end of the encapsulation film 270 has a second distance D 2 , which is smaller than the first distance D 1 , from the flexible substrate 210 .
[0105] Namely, the encapsulation film 270 has an asymmetric shape such that a distance between the end of the encapsulation film 270 and the end of the flexible substrate 210 is varied with respect to a direction.
[0106] In other words, in the second direction, where the ends of the folding region FR, in which the folding stress is generated, are disposed, the end of the encapsulation film 270 is positioned to be far away from the end of the flexible substrate 210 , the damage on the encapsulation film 270 by the folding stress is minimized.
[0107] In addition, in the first direction, which may be perpendicular to the extension direction of the folding region FR, since the end of the encapsulation film 270 is disposed to be relatively close to the end of the flexible substrate 210 , efficiency of the mother substrate is increased. Namely, since there is no folding stress in the end of the line C-C′ in FIG. 3 , there is no damage in the encapsulation film 270 even when the end of the encapsulation film 270 has the second distance D 2 , which is a relatively small, from the end of the flexible substrate 210 . In this instance, since the end of the flexible substrate 210 and the end of the encapsulation film 270 is closer, the number of the cells in the direction of the line C-C′ can be increased.
[0108] Moreover, as explained in FIG. 4A , the encapsulation film 270 has a patterned shape, i.e., an island shape, in each cell of the mother substrate, the damage on the encapsulation film 270 by the scribing process is prevented.
[0109] Accordingly, the damage on the emitting diode D by the moisture penetration is prevented, and the production costs of flexible OLED device are reduced.
[0110] FIGS. 7A and 7B are schematic cross-sectional views illustrating a foldable OLED device according to a third embodiment of the present disclosure. FIG. 7A is a cross-sectional view taken along the line A-A′ in FIG. 3 , and FIG. 7B is a cross-sectional view taken along the line C-C′ in FIG. 3 .
[0111] As shown in FIGS. 7A and 7B , a flexible OLED device 300 according to the third embodiment of the present disclosure includes the flexible substrate 310 , where the display region and the non-display region are defined, the emitting diode D corresponding to the display region and disposed on or over the flexible substrate 310 , and the encapsulation film 370 covering the emitting diode D and corresponding to the display region and a part of the non-display region.
[0112] For example, the flexible substrate 310 may be a polyimide substrate. The TFT Tr (of FIG. 5 ), the emitting diode D and the encapsulation film 370 are formed on or over the flexible substrate 310 .
[0113] As illustrated with FIG. 5 , the TFT Tr may include the semiconductor layer 122 , the gate electrode 130 , the source electrode 140 and the drain electrode 142 , and the emitting diode D may include the first electrode 160 , which is connected to the drain electrode 142 , the second electrode 164 , which faces the first electrode 160 , and the organic emitting layer 162 between the first and second electrodes 160 and 164 .
[0114] The encapsulation film 370 covers the emitting diode D and has an area smaller than the flexible substrate 310 . Namely, the ends of the encapsulation film 370 are positioned inside the ends of the flexible substrate 310 .
[0115] In the ends of the folding region FR, the encapsulation film 370 is removed such that one of the passivation layer 150 (of FIG. 5 ), the interlayer insulating layer 132 (of FIG. 5 ), the gate insulating layer 124 (of FIG. 5 ) and the flexible substrate 310 is exposed and the ends of the encapsulation film 370 are disposed on the one of the passivation layer 150 , the interlayer insulating layer 132 , the gate insulating layer 124 and the flexible substrate 310 .
[0116] On the other hand, to prevent the damages on the passivation layer 150 , the interlayer insulating layer 132 or the gate insulating layer 124 by the scribing process and moisture penetration into the display region, all of the passivation layer 150 , the interlayer insulating layer 132 and the gate insulating layer 124 may be removed in the ends of the folding region FR such that the encapsulation film 370 may contact the flexible substrate 310 in the ends of the folding region FR.
[0117] The encapsulation film 370 includes a first inorganic layer 372 , an organic layer 374 and a second inorganic layer 376 . However, it is not limited thereto.
[0118] For example, the encapsulation film 370 may further include an organic layer and an inorganic layer on the second inorganic layer 376 to have a five-layered structure.
[0119] The organic layer 374 is positioned between the first inorganic layer 372 and second inorganic layer 376 . The organic layer 374 has a plane area smaller than the first and second inorganic layers 372 and 376 and completely overlaps the first and second inorganic layers 372 and 376 . Namely, the organic layer 374 is completely covered and protected by the second inorganic layer 376 such that moisture penetration through the organic layer 374 is prevented.
[0120] For example, when the organic layer 374 has the same plane area as or larger area than the second inorganic layer 376 , a side surface of the organic layer 374 is exposed and moisture penetration may be generated through the side surface of the organic layer 374 . However, in the present disclosure, since the organic layer 374 is completely covered and protected by the second inorganic layer 376 , moisture penetration through the organic layer 374 is prevented.
[0121] Each of the first and second inorganic layers 372 and 376 may be formed of silicon oxide or silicon nitride, and the organic layer 374 may be formed of an epoxy compound or an acryl compound.
[0122] As shown in FIG. 7A , in the folding region FR, the end of the encapsulation film 370 has a first distance D 1 from the flexible substrate 310 .
[0123] On the other hand, as shown in FIG. 7B , in a side along a direction, which is perpendicular to an extension direction of the folding region FR, the end of the encapsulation film 370 has a second distance D 2 , which is smaller than the first distance D 1 , from the flexible substrate 310 .
[0124] Namely, the encapsulation film 370 has an asymmetric shape such that a distance between the end of the encapsulation film 370 and the end of the flexible substrate 310 is varied with respect to a direction.
[0125] In other words, in a direction, where the ends of the folding region FR, in which the folding stress is generated, are disposed, the end of the encapsulation film 370 is positioned to be far away from the end of the flexible substrate 310 , the damage on the encapsulation film 370 by the folding stress is minimized.
[0126] In addition, in a direction, which may be perpendicular to the extension direction of the folding region FR, since the end of the encapsulation film 370 is disposed to be relatively close to the end of the flexible substrate 310 , efficiency of the mother substrate is increased. Namely, since there is no folding stress in the end of the line C-C′ in FIG. 3 , there is no damage in the encapsulation film 370 even when the end of the encapsulation film 370 has the second distance D 2 , which is a relatively small, from the end of the flexible substrate 310 . In this instance, since the end of the flexible substrate 310 and the end of the encapsulation film 370 is closer, the number of the cells in the direction of the line C-C′ can be increased.
[0127] Moreover, as shown in FIG. 7A , in a first direction, the second inorganic layer 376 covers a side surface of the first inorganic layer 372 . Namely, in the first direction, the second inorganic layer 376 has a width larger than the first inorganic layer 372 , and an end of the second inorganic layer 376 contacts an upper surface of the flexible substrate 310 . Accordingly, even though the folding stress is concentrated into the encapsulation film 370 , the first inorganic layer 372 , which is a final-protection element for the emitting diode D, is covered with the second inorganic layer 376 such that the damage on the emitting diode D by moisture penetration can be minimized.
[0128] On the other hand, as shown in FIG. 7B , in a second direction, the first and second inorganic layers 272 and 276 have the same width and completely overlap each other. To protect the emitting diode D, the first inorganic layer 372 should have a width being larger than a pre-determined width. In the present invention, since the second inorganic layer 376 in the second direction, where the folding stress is not generated, has the same width as the first inorganic layer 372 , an area increase of the non-display region in the second direction can be prevented.
[0129] Accordingly, the damage on the emitting diode D by the moisture penetration is prevented, the production costs of the flexible OLED device are reduced, and the flexible OLED device having a narrow bezel is provided.
[0130] FIGS. 8A to 8D are schematic views illustrating a foldable OLED device according to a fourth embodiment of the present disclosure. FIG. 8A is a schematic plane view of the foldable OLED device, and FIGS. 8B to 8D are schematic cross-sectional views taken along the lines A-A′, C-C′ and D-D′ in FIG. 8A .
[0131] As shown in FIGS. 8A to 8D , a flexible OLED device 400 according to the fourth embodiment of the present disclosure includes the flexible substrate 410 , where the display region and the non-display region are defined, the emitting diode D corresponding to the display region and disposed on or over the flexible substrate 410 , and the encapsulation film 470 covering the emitting diode D and corresponding to the display region and a part of the non-display region.
[0132] For example, the flexible substrate 410 may be a polyimide substrate. The TFT Tr (of FIG. 5 ), the emitting diode D and the encapsulation film 470 are formed on or over the flexible substrate 410 .
[0133] As illustrated with FIG. 5 , the TFT Tr may include the semiconductor layer 122 , the gate electrode 130 , the source electrode 140 and the drain electrode 142 , and the emitting diode D may include the first electrode 160 , which is connected to the drain electrode 142 , the second electrode 164 , which faces the first electrode 160 , and the organic emitting layer 162 between the first and second electrodes 160 and 164 .
[0134] The encapsulation film 470 covers the emitting diode D and has an area smaller than the flexible substrate 410 . Namely, the ends of the encapsulation film 470 are positioned inside the ends of the flexible substrate 410 .
[0135] In the ends of the folding region FR, the encapsulation film 470 is removed such that one of the passivation layer 150 (of FIG. 5 ), the interlayer insulating layer 132 (of FIG. 5 ), the gate insulating layer 124 (of FIG. 5 ) and the flexible substrate 410 is exposed and the ends of the encapsulation film 470 are disposed on the one of the passivation layer 150 , the interlayer insulating layer 132 , the gate insulating layer 124 and the flexible substrate 410 .
[0136] On the other hand, to prevent damage on the passivation layer 150 , the interlayer insulating layer 132 , or the gate insulating layer 124 by the scribing process and moisture penetration into the display region, all of the passivation layer 150 , the interlayer insulating layer 132 and the gate insulating layer 124 may be removed in the ends of the folding region FR such that the encapsulation film 470 may contact the flexible substrate 410 in the ends of the folding region FR.
[0137] The encapsulation film 470 includes a first inorganic layer 472 , an organic layer 474 and a second inorganic layer 476 . However, it is not limited thereto.
[0138] For example, the encapsulation film 470 may further include an organic layer and an inorganic layer on the second inorganic layer 476 to have a five-layered structure.
[0139] The first and second inorganic layers 472 and 476 have the same plane area and completely overlap each other.
[0140] Alternatively, as shown in FIGS. 8B and 8C , in a first direction, i.e., an extension direction of the folding region FR, the second inorganic layer 476 may cover a side surface of the first inorganic layer 472 ( FIG. 8B ), and in a second direction, which may be perpendicular to the first direction, the second inorganic layer 476 may have the same width as the first inorganic layer 472 to completely overlap each other ( FIG. 8C ). As a result, the damage on the emitting diode D by moisture penetration in the folding region FR and an area increase of the non-display region in the second direction can be prevented.
[0141] The organic layer 474 is positioned between the first inorganic layer 472 and second inorganic layer 476 . The organic layer 474 has a plane area smaller than the first and second inorganic layers 472 and 476 and is completely overlapped by the first and second inorganic layers 472 and 476 . Namely, the organic layer 474 is completely covered and protected by the second inorganic layer 476 such that moisture penetration through the organic layer 474 is prevented.
[0142] For example, when the organic layer 474 has the same plane area as or larger area than the second inorganic layer 476 , a side surface of the organic layer 474 is exposed and moisture penetration may be generated through the side surface of the organic layer 474 . However, in the present disclosure, since the organic layer 474 is completely covered and protected by the second inorganic layer 476 , moisture penetration through the organic layer 474 is prevented.
[0143] Each of the first inorganic layer 472 and second inorganic layer 476 may be formed of silicon oxide or silicon nitride, and the organic layer 474 may be formed of an epoxy compound or an acryl compound.
[0144] As shown in FIG. 8B , in the folding region FR (of FIG. 8A ), the end of the encapsulation film 470 has a first distance D 1 from the flexible substrate 410 .
[0145] On the other hand, as shown in FIG. 8C , in a side along a second direction, which is perpendicular to an extension direction (i.e., a first direction) of the folding region FR, the end of the encapsulation film 470 has a second distance D 2 , which is smaller than the first distance D 1 , from the flexible substrate 410 .
[0146] In addition, as shown in FIG. 8D , in a unfolding region, which is a region in the first direction except the folding region FR (of FIG. 8A ), the end of the encapsulation film 470 has a third distance D 3 , which is smaller than the first distance D 1 , from the end of the flexible substrate 410 . The third distance D 3 may be equal to or different from the second distance D 2 .
[0147] In the ends of the folding region FR, the end of the encapsulation film 470 is positioned to be far away from the end of the flexible substrate 410 such that the damage on the encapsulation film 470 by the folding stress is minimized.
[0148] In addition, in the second direction, which may be perpendicular to the extension direction of the folding region FR, since the end of the encapsulation film 470 is disposed to be relatively close to the end of the flexible substrate 410 , efficiency of the mother substrate is increased.
[0149] Moreover, in the ends of the unfolding region in the first direction, a width of the encapsulation film 470 is increased in comparison to the folding region (FR) such that moisture penetration is minimized.
[0150] Further, as explained in FIG. 4A , the encapsulation film 470 has a patterned shape, i.e., an island shape, in each cell of the mother substrate, the damage on the encapsulation film 470 by the scribing process is prevented.
[0151] Accordingly, the damage on the emitting diode D by the moisture penetration is prevented, and the production costs of flexible OLED device are reduced.
[0152] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A foldable organic light emitting display (OLED) device comprises a substrate including a display region and a non-display region, the non-display region located at a periphery of the display region; an emitting diode in the display region; and an encapsulation film covering both the emitting diode and an entirety of the display region, and the encapsulation film covering and a part of the non-display region without covering at least another part of the non-display region. | 7 |
BACKGROUND
The present invention relates to an armrest and a vehicle seat including the same, and is particularly related to a foldable armrest which is moveable between a raised position and a forward lowered position relative to a seat back and a vehicle seat including the same.
An armrest for a seat of a vehicle, for example an automobile, such as a foldable armrest 110 shown in FIG. 7 , is known. This armrest 110 can be raised at the side of the seat back 120 when unused in order not to inhibit movement of passengers.
To move between the front and rear seating positions in a station wagon, passengers typically walk through an aisle between adjacent seats. However, when the aisle is narrow, the armrests obstruct the aisle and inhibit passengers' smooth walk-through.
In order to overcome this disadvantage, an armrest providing increased effective vehicle interior space by making an armrest storage compartment compact, is proposed (for example, in Japanese Patent Laid-Open No. 2001-314277 (page 7 and 8, FIGS. 2-4) (hereinafter, the '277 Patent)). While the armrest of the '277 Patent comfortably supports a passenger's arm in a used position, the armrest storage compartment becomes compact when the armrest is in an unused position, since the armrest can be folded toward the seat back and stowed upright at the side of the seat back. Therefore, the passengers' walk-through space between adjacent seats can be cleared when this type of armrest is used in a vehicle such as a station wagon.
According to the prior art disclosed in the '277 Patent, the armrest storage compartment becomes compact. However, this armrest requires a two-step operation of lowering the armrest to a horizontal position and rotating it before use. A need therefore exists to overcome this disadvantage.
SUMMARY
It therefore is an object of the present invention to provide an armrest having sufficient area to support arms, supporting arms at a comfortable position, and being stowed compactly to provide a sufficient aisle width for passengers' walk-through, and capable of returning from a stowed position to a used position in a single motion.
It is another object of the present invention to provide a vehicle seat including the above armrest.
To achieve the objects, according to one embodiment of the present invention, an armrest mounted to a side portion of a seat back of a vehicle seat, comprising an armrest main body, and a pivot member supporting the armrest main body at the seat back side of the armrest main body, wherein the armrest main body is pivotally attached to the side portion of the seat back via the pivot member, and wherein the pivot member is skewed toward the vehicle rear at a substantial angle relative to a widthwise horizontal axis of the seat as it extends from a base to a distal end, is provided.
As described above, according to the armrest for various embodiments of the present invention, the armrest main body is fixed to the side portion of the seat back via the pivot member, and the pivot member is skewed toward the vehicle rear at the substantial angle relative to the widthwise horizontal axis of the seat as it extends from the base to the distal end. Thus, when rotated at the seat back side, the armrest main body is at first positioned to extend in an outwardly diverging manner from the seat back as it extends from a base to a distal end in the used position, and the distal end approaches the side portion of the seat back and the armrest is finally stowed upright in the unused position.
Therefore, when unused, the armrest main body is stowed closer to the seat back such that the aisle width between adjacent seats is increased and the passengers' walk-through space is cleared.
In addition, the armrest main body does not approach a seating space too much so as to support a passenger's arm at a comfortable position.
More specifically, the side portion of the seat back preferably has a slant surface tilted inwardly at a substantial angle relative to a horizontal axis in a fore-aft direction of the vehicle as the slant surface extends from a front to a rear, the pivot member is preferably mounted to the slant surface so as to be positioned at a substantial angle relative to the slant surface such that an inner side of the armrest is approximately parallel to the slant surface when the armrest is raised.
Therefore, as when raised, the armrest main body moves toward a back side of the seat back and is positioned upright in close proximity to the slant surface, effective interior space is increased when the armrest main body is stowed.
In addition, by selecting the angle between the pivot member and the slant surface, the amount of travel to the used position of the armrest main body in a lateral direction and the positional relationship between the stowed armrest main body and the seat back can be adjusted.
Furthermore, if an angle between an axis of the pivot member and the slant surface is approximately 90 degrees, the armrest main body and the seat back can be located in close proximity to each other.
To achieve the objects, according to another embodiment of the present invention, an armrest mounted to a side portion of a seat back of a vehicle seat, comprising an armrest main body, and a pivot member supporting the armrest main body at the seat back side of the armrest main body, wherein the armrest main body is pivotally attached to the side portion of the seat back via the pivot member, and wherein the pivot member is skewed vertically upward at a substantial angle relative to a widthwise horizontal axis of the seat as it extends from a base to a distal end, is provided.
As described above, according to the armrest of various embodiments of the present invention, the armrest main body is fixed to the side portion of the seat back via the pivot member, and the pivot member is skewed vertically upward at the substantial angle relative to the widthwise horizontal axis of the seat as it extends from the base to the distal end. Thus, when rotated at the seat back side, the armrest main body is at first positioned to extend in an outwardly diverging manner from the seat back as it extends from a base to a distal end in the used position, and the distal end approaches the side portion of the seat back and the armrest is finally stowed upright in the unused position.
In addition, the armrest preferably comprises a surface approximately perpendicular to a vehicle floor opposite the seat back and a surface inclined toward the seat back when the armrest is raised at the side of the seat back, the surface inclined toward the seat back being on top of the surface approximately perpendicular. Therefore, when stowed at the side of the seat back, the armrest does not intrude into vehicle interior space and sufficient walk-through space is maintained.
Further, the side portion of the seat back is preferably tilted inwardly as it extends from a substantial center to an upper part in front view, wherein an inner side of the armrest is tilted along the side portion of the seat back. Therefore, when stowed upright at the seat back side, the armrest main body is raised to be positioned in close proximity to the slant surface of the seat back and sufficient walk-through space is maintained.
Furthermore, to achieve the objects, according to yet another embodiment of the present invention, a vehicle seat comprising any of the armrests prescribed above and the seat back the armrest mounted thereto, is provided.
According to the armrest and vehicle seat including the same of various embodiments of the present invention, with a simple structure that the pivot member holding the armrest main body at the seat back side is tilted, when stowed upright at the side of the seat back the armrest main body is positioned closer to the seat back. As a result, an aisle width between adjacent seats is increased and sufficient walk-through space is maintained in the vehicle.
Furthermore, since the armrest main body extends in an outwardly diverging manner from the seat in the used position, the armrest main body does not approach a seating space too much so as to have sufficient area to support arms and to be capable to support a passenger's arm at a comfortable position.
In addition, while the armrest according to various embodiments of the present invention has a space-saving design, the armrest is switchable between the stowed position and the used position in a single motion: more specifically, it is switchable to the used position simply by lowering the armrest main body and to the unused position simply by raising it. Therefore such an armrest is easy for passengers to use.
Furthermore, as the armrest comprises few parts so as to be easy to assemble, the number of assembling steps is decreased and manufacturing cost is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated below with reference to various embodiments shown in the drawings and described in more detail below.
FIG. 1 is a pictorial view of an armrest and a seat according to and embodiment of the present invention;
FIG. 2 is a sectional view taken along line A-A of FIG. 1 ;
FIG. 3 is a front view of the armrest in an unused position and the seat;
FIG. 4 is a plan view of the armrest in the unused position and the seat;
FIG. 5 is a pictorial view of the armrests in a used position and in the unused position and the seats;
FIG. 6 is a sectional view of an alternative embodiment taken along line B-B of FIG. 1 ;
FIG. 7 is a pictorial view of a prior art embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to the accompanying drawings. It is to be understood that the present invention is not limited to the specific construction and arrangement of parts described below, and variations may be made without departing from the spirit and scope of the invention.
FIGS. 1 through 5 illustrate an embodiment of the present invention.
FIG. 1 illustrates a seat S having an armrest 10 as viewed from the side. In FIG. 1 the armrest 10 is illustrated in a stowed position. Reference numeral 30 indicates a seat portion of the seat S.
The armrest 10 of this embodiment is mounted to a side portion of a seat back 20 of the seat S of an automobile. The armrest 10 comprises an armrest main body 11 and a pivot shaft 12 corresponding to a pivot member, and the armrest main body 11 is pivotally mounted to the seat back 20 via the pivot shaft 12 .
FIG. 2 is a sectional view taken along line A-A of FIG. 1 illustrating the seat S and the armrest 10 as cut along line A-A and viewed from above. FIG. 2 illustrates the construction of the armrest 10 and its attachment to the seat back 20 .
The armrest main body 11 comprises a frame 13 and a pad 14 integrally disposed to the frame 13 . The outside of the pad 14 is covered with a skin member, not shown in FIG. 2 .
The frame 13 and the pad 14 are formed with a hole 15 . The hole 15 has a diameter sized to engage the pivot shaft 12 . The armrest main body 11 is mounted to the seat back 20 via the pivot shaft 12 .
The seat back 20 comprises a back frame 21 , a pad 22 and a bracket 23 to which the armrest is mounted. The outside of the pad 22 is covered with a skin member, not shown in FIG. 2 .
The pivot shaft 12 is secured to the bracket 23 and projects therefrom. The pivot shaft 12 is provided with a pivot part 12 a engaged with the hole 15 of the armrest main body 11 at the distal end. The pivot part 12 a is made of resin and structured such that the armrest main body 11 can smoothly slide and rotate around the pivot shaft 12 . A nut 12 b is screwed to a distal end of the pivot part 12 a and secures the armrest main body 11 to the pivot shaft 12 so as to prevent the armrest main body 11 from falling out of the pivot shaft 12 .
The lower side of FIG. 2 corresponds to the front side of the vehicle. As illustrated in the figure, the side portion of the seat back 20 has a slant surface 24 tilted at a substantial angle relative to a horizontal axis y in a fore-aft direction of the vehicle as the slant surface 24 extends from a front to a rear.
The pivot shaft 12 is mounted to the slant surface 24 so as to be positioned at a substantial angle relative to the slant surface 24 such that an inner side of the armrest 10 is approximately parallel to the slant surface 24 when the armrest 10 is raised. The pivot shaft 12 of this embodiment is positioned at an angle of approximately 90 degrees relative to the slant surface 24 .
Regarding a positional relationship between the seat S and the pivot shaft 12 , the pivot shaft 12 is skewed toward the vehicle rear at a substantial angle relative to a widthwise horizontal axis x of the seat S as it extends from a base to a distal end. The pivot shaft 12 of this embodiment is skewed horizontally at an angle 1 relative to the horizontal axis x.
The armrest main body 11 of this embodiment is mounted to the side portion of the seat back 20 , and the pivot shaft 12 is tilted corresponding to the slant surface 24 of the side portion of the seat back 20 . Thus when the armrest main body 11 is raised at the side of the seat back 20 , the armrest main body 11 moves toward a back side of the seat back 20 and is positioned upright in close proximity to the slant surface 24 .
The angle of the pivot shaft 12 relative to the slant surface 24 is not limited to 90 degrees; it may be another angle. By selecting the angle of the pivot shaft 12 , the amount of travel to the used position of the armrest main body 11 in a lateral direction and the positional relationship between the stowed armrest main body 11 and the seat back 20 can be adjusted.
As the angle between the pivot shaft 12 and the slant surface 24 becomes more acute, that is, the angle 1 becomes greater, the armrest main body 11 extends in a more outwardly diverging manner from the seat S and a spacing between the armrest main body 11 and the seat S in the used position increases. At the same time the armrest main body 11 is positioned closer to the seat back 20 in the stowed position.
As the angle between the pivot shaft 12 and the slant surface 24 becomes more obtuse, that is, the angle 1 becomes smaller, the armrest main body 11 becomes closer to the seat S in the used position, and is raised further away from the seat back 20 in the stowed position.
FIGS. 3 through 5 illustrate the armrests 10 in the used position and in the unused position.
FIG. 3 illustrates the armrest 10 in the unused position; more specifically, it illustrates the armrest main body 11 being stowed upright at the side of the seat back 20 . FIG. 3 illustrates the armrest 10 and the seat S viewed from the front of the vehicle.
As illustrated in the figure, the side portion of the seat back 20 is tilted inwardly as it extends from a substantial center to an upper part in front view, and an inner side of the armrest main body 11 is tilted along the side portion of the seat back 20 . Thus, when stowed, the armrest main body 11 is positioned upright in close proximity to the side portion of the seat back 20 .
The armrest main body 11 is formed such that a surface 16 thereof opposite the seat back 20 is approximately perpendicular to a vehicle floor when mounted to the side portion of the seat back 20 . Therefore, when stowed at the side of the seat back 20 , the armrest main body 11 does not intrude into vehicle interior space and sufficient walk-through space is maintained. The armrest main body 11 of this embodiment is formed such that a top of the surface 16 approximately perpendicular is inclined toward the seat back 20 to correspond with an exterior shape of the seat back 20 when mounted to the side portion of the seat back 20 .
FIG. 4 illustrates the armrest main body 11 stowed at the side of the seat back 20 , as viewed from above the seat S. A width w of the armrest main body 11 defines a width of a support surface for supporting a passenger's arm when the armrest 10 is in use. As the slant surface 24 of the seat back 20 becomes steeper, that is, the angle 2 becomes greater, the width w of the support surface of the armrest 10 becomes greater.
FIG. 5 is a pictorial view of the armrests 10 in the used position and in the unused position in the vehicle. In FIG. 5 , the armrests 10 of rear seats are in the used position and the armrests 10 of front seats are in the unused position. The seat back 20 of the seat S of this embodiment comprises the slant surface 24 , to which the pivot shaft 12 is mounted so as to be skewed toward the vehicle rear at the substantial angle relative to the widthwise horizontal axis of the seat S as the pivot shaft 12 extends from the base to the distal end, and via this pivot shaft 12 the armrest main body 11 is pivotally attached to the side portion of the seat back 20 . Therefore, since the armrest main body 11 extends in an outwardly diverging manner from the seat S in the used position, the armrest main body 11 does not approach a seating space too much so as to support a passenger's arm at a comfortable position.
Reference numeral 17 in FIG. 5 indicates a support surface 17 on which a passenger puts his or her arm when the armrest 10 is used. The armrest main body 11 is formed such that the support surface 17 is positioned horizontally in the used position.
The armrest main body 11 is raised at the side of the seat back 20 when the armrest 10 is not used. In this case, since the armrest main body 11 is pivotally attached to the pivot shaft 12 being skewed toward the vehicle rear at a substantial angle relative to the widthwise horizontal axis of the seat S as the pivot shaft 12 extends from the base to the distal end, the armrest main body 11 moves toward the back side of the seat back 20 and is positioned in close proximity to the side portion of the seat back 20 and stowed.
Furthermore, since the armrest main body 11 is formed such that the surface 16 thereof opposite the seat back 20 is approximately perpendicular to the vehicle floor when mounted to the side portion of the seat back 20 , the armrest main body 11 does not intrude into vehicle interior space. Therefore, the overall width of the seat back 20 is reduced and sufficient walk-through space 40 is maintained.
In this embodiment, as illustrated in FIG. 5 , the distance between a center of the seat portion 30 and a lateral side of the armrest main body 11 is 331 mm (arrow a) in the used position of the armrest 10 , and is 277 mm (arrow b) when the armrest 10 is stowed at the side of the seat back 20 . Thus, the armrest 10 of this embodiment is stowed 54 mm more compactly in width in the stowed position than in the used position, and the width of the walk-through space 40 is 108 mm greater when both armrests 10 of adjacent seats are used than when they are stowed.
FIG. 6 illustrates another embodiment. In this embodiment, the same or similar reference numerals are applied to the same or similar members and arrangements as or to the previous embodiment, and their description will be omitted or simplified.
FIG. 6 is a sectional view taken along line B-B of FIG. 1 as the seat S and the armrest 10 are cut along line B-B and viewed from the front. While the pivot shaft 12 of the previous embodiment is skewed horizontally at the angle 1 relative to the widthwise horizontal axis x of the seat as it extends from the base to the distal end, a pivot shaft 12 of this embodiment is skewed vertically upward at a substantial angle relative to the widthwise horizontal axis x of the seat as it extends from the base to the distal end.
More specifically, the pivot shaft 12 of this embodiment is mounted so as to be skewed at an angle 3 relative to the horizontal axis x, and the armrest main body 11 extends in an outwardly diverging manner from the seat S when in use. When the armrest main body 11 is being stowed, the armrest main body 11 moves toward the seat back 20 and is raised upright to be stowed in close proximity to the side portion of the seat back 20 .
In this embodiment, the side portion of the seat back 20 is tilted inwardly as it extends from a substantial center to an upper part in front view such that the armrest main body 11 does not interfere with the side portion of the seat back 20 when raised.
Though the side portion of the seat back 20 has the slant surface 24 or is tilted inwardly from the substantial center to the upper part in front view in the embodiments described above, the seat back 20 may be configured to have no such slant surfaces. In this case, the armrest main body 11 is configured to have a shape that does not interfere with the side portion of the seat back 20 when raised.
The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. The word mechanism is intended to be used generally and is not limited solely to mechanical embodiments. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the present invention.
TABLE OF REFERENCE CHARACTERS
10
armrest
11
armrest main body
12
pivot shaft (pivot member)
12a
pivot part
12b
nut
13
frame
14
pad
15
hole
16
surface
17
support surface
20
seat back
21
back frame
22
pad
23
bracket
24
slant surface
30
seat portion
40
walk-through space
S
seat
x
widthwise horizontal axis of the seat
y
horizontal axis in the fore-aft direction of the vehicle
1,
angle between the widthwise horizontal axis of the seat
and the pivot shaft
2
angle between the horizontal axis in the fore-aft
direction of the vehicle and the slant surface of the seat back | An armrest is provided having sufficient area to support arms at a comfortable position. The armrest is capable of being stowed compactly to provide aisle width sufficient for passengers' walk-through, and also is capable of moved from its stowed position to its used position in a single motion. The armrest is mounted to a side portion of a seat back of a vehicle seat. The armrest includes an armrest main body and a pivot member supporting the armrest main body at the seat back side of the armrest main body. The armrest main body is pivotally attached to the side portion of the seat back via the pivot member, and the pivot member is skewed toward the vehicle rear at a substantial angle relative to a widthwise horizontal axis of the seat as it extends from a base to a distal end. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of the Provisional Allocation filed on or about Oct. 5, 2009 with the title, APPARATUS AND METHOD FOR PRESERVING FOOD.
BACKGROUND OF THE INVENTION
[0002] The problem of preserving food and other products such as flowers and the like is an issue confronting commercial companies and consumers everyday. It is common to store foods in refrigerators and freezers to extend the useful life of food; however, the food deteriorates and spoils despite these measures. It is common to add chemicals as additional preservatives to foods, but this adds costs and many people have an aversion to added chemicals.
[0003] One of the sources responsible for spoiling food is the presence of oxygen. Both commercial companies and consumers approach the reduction of oxygen in contact with packaged food by reducing, or effectively removing most of the air in the package. This can be a problem because some foods in a low pressure environment can lose components such as low density oils, thereby changing the taste of the food being preserved. In addition, processes that aim to remove air physically from packages can be expensive and/or inconvenient to implement. Often products being stored can be crushed by such processes, or sharp edges of products can puncture through package wrappings.
[0004] Innovative processes for preserving foods such as meats in commercial processing include injecting gases such as nitrogen and carbon dioxide to lower the oxygen level within a package by displacing air, thereby effectively reducing the oxygen content. This approach avoids a reduced pressure which might harm the taste of the food. Additionally, the gasses used to displace air inside these packages can have bacteria-reducing properties which further help to preserve foods. A similar approach for displacing air is taken for other products such as flowers.
[0005] There is a need for an apparatus and method, suitable for both commercial and consumer use, which preserve food easily by replacing much of the oxygen in a package of food or other products with a gas such as carbon dioxide which will not harm the taste or quality of the food or product.
SUMMARY OF THE INVENTION
[0006] In one embodiment, the invention relates to an apparatus comprising enclosure means operable to enclose air and a substance such as a food to be preserved, electrical terminal means operable for being connected to a voltage source and having a first portion extending into the enclosure means and having a second portion extending outside the enclosure, and holding means electrically connected to the electrical terminal means and operable for holding a material capable of oxidizing to create carbon dioxide, whereby the enclosure means can be relatively sealed against gases and the material can be oxidized by applying sufficient heat through electrical power to the electrical terminal means to the material, thereby reacting the oxygen within the enclosure means with the material and creating carbon dioxide. The enclosure means need not have a complete seal against gases for all applications of the invention; however, it is preferable to have a relatively air tight seal for many applications of the invention. The extent of the sealing needed for a particular application of the invention can be determined experimentally.
[0007] In another embodiment, the invention relates to a method of enclosing a substance to be preserved in an enclosure relatively sealed against gases, and enabling a carbon substance within the enclosure to burn so that the oxygen in the enclosure is reacted to produce carbon dioxide.
[0008] It is convenient to use commercially available carbon fiber, or relatively thin carbon rods, or the like to be burned within the enclosure. The goal is to burn the carbon fiber or carbon rod so the amount of electrical current needed to initiate the oxidation of the carbon depends on the electrical resistance; hence, the diameter of the carbon is an important factor and a preferable effective diameter of the carbon can be determined experimentally.
[0009] The commercially available carbon fibers are similar in appearance to a bundle of thread and are electrically conductive. Passing electrical current through the carbon fibers can cause the carbon fibers to heat due to electrical resistance and sufficient heat results in the carbon to burn, create carbon dioxide. The electrical current needed to initiate the burning is relatively high, but it is for a very short time. The onset of burning is easily observable, and it can be determined experimentally.
[0010] The minimum amount of carbon needed to be burned to consume the oxygen within the enclosure can be calculated using well known chemistry principles. It is not necessary to use the minimum. It is, however, wasteful to exceed the minimum greatly due to the extra carbon and the required electrical power needed. Simple experimentation can be carried out to determine a suitable combination of carbon and electrical power to achieve the goal of chemically binding most of the oxygen with the carbon to form carbon dioxide and achieve a suitable reduction of local oxygen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a perspective view of first embodiment of the invention connected to an electrical power source.
[0012] FIG. 2 shows a perspective view of the embodiment shown in FIG. 1 with the cover open.
[0013] FIG. 3 shows a perspective view of a second embodiment of the invention.
[0014] FIG. 4 shows a perspective view of an embodiment of a portion of the invention.
[0015] FIG. 5 shows a plan view of another embodiment of a portion of the invention.
[0016] FIG. 6 shows a perspective view of a yet another embodiment of a portion of the invention.
[0017] FIG. 7 shows a perspective view of a third embodiment of the invention.
[0018] FIG. 8 shows a perspective view of a fourth embodiment of the invention.
[0019] FIG. 9 shows the electrical circuit used in the embodiment of FIG. 8 .
[0020] FIG. 10 shows a perspective of another portion of the invention.
[0021] FIG. 11 shows the embodiment shown in FIG. 8 used with the embodiment shown in FIG. 1
[0022] FIG. 12 shows an exploded sectional view of a fifth embodiment of the invention.
[0023] FIGS. 13 , 14 , and 15 show plan views of three components used together to carry out the invention in a fifth embodiment.
[0024] FIG. 16 shows a side elevational view of a sixth embodiment of the invention.
[0025] FIG. 17 is a perspective view of the invention showing some details in the construction.
[0026] FIG. 18 is a block diagram of yet another embodiment of the invention.
[0027] FIG. 19 is a representative view with a portion removed to show the interior of a simple portable embodiment of the invention for convenient use in containers without any special arrangement.
DESCRIPTION OF THE INVENTION
[0028] In FIG. 1 , a container 1 is used. It is convenient to use a container 1 made from non-electrically conducting material such as plastic, but a metal container 1 could be used. Container 1 should be able to close tightly and be relatively resistive to gases moving in or out; however, it may not be necessary to have a tightly closed container 1 for all applications of the invention. The degree of the enclosure to resist movement of gases in, or out depends on the intended application of the invention and can be determined experimentally. Typically, a container 1 with a good air seal such as used conventionally for food is suitable, although a strong seal against air entering the closed container 1 is preferable.
[0029] The container 1 is shown as being cylindrical, but other shapes may be used. It is not believed that a cylindrical shape has significant advantages over containers with different shapes such as a shape like a box although the interior air might move better towards a burning carbon in a cylindrical or spherical shaped container 1 .
[0030] Container 1 has a hinge 2 and FIG. 2 shows the container 1 in its open position. Electrodes 3 and 4 pass though cover 5 with a preferably air tight seal and have outer ends 7 and 8 suitable to be connected to an electrical power source 9 . The degree of the seal for the electrodes 3 and 4 can be determined experimentally. If the container 1 were made from an electrically conducting material such as metal, then insulation around the electrodes 3 and 4 would be needed to prevent the electrical path between the electrodes 3 and 4 being through the metal container 1 . Alternatively, the electrodes 7 and 8 can communicate electrical power from outside the container 1 to its interior without passing through the container 1 using microwaves, or capacitance, or other known ways for transferring electrical power from outside to inside the container 1 . Locking mechanism 10 is used to hold the cover 5 in a closed position. The electrodes 3 and 4 have ends 11 and 12 which have mechanisms to hold a carbon fiber 13 . For testing the invention, it was convenient to mount the electrodes 3 and 4 so that the fiber 13 was relatively horizontal, but the orientation of the fiber 13 is not apparently important so other orientations may be used for the convenience of the application of the invention.
[0031] Closure of switch 14 causes an electrical voltage to go from electrical power source 9 though wires 16 and 17 to electrodes 3 and 4 through carbon fiber or carbon fibers 13 . Sufficient electrical power causes the carbon fiber 13 to ignite and burn to consume oxygen and produce carbon dioxide. A device 18 can be used to allow air in the container 1 to move freely to the carbon fiber 13 , and prevent pieces of the burnt carbon fiber 13 from falling onto food that might be placed at the bottom of the container 1 .
[0032] FIG. 3 shows a container 20 which is an embodiment essentially the same as container 1 with the difference being that electrodes 21 and 22 are at the side of the container 20 and a carbon fiber 23 extends across between electrodes 21 an 22 .
[0033] FIG. 4 shows an embodiment for using a carbon fiber 25 in a holder 26 . The holder 26 is a non-conductive material which preferably does not burn when the carbon fiber 26 burns.
[0034] FIG. 5 . shows a plan view of a holder 27 for a set of carbon fibers 28 - 32 . Instead of using separate pieces of carbon fiber or fibers 13 such as shown in FIGS. 1 and 3 , a holder 27 can be used and the operator of the might decide to use the unused carbon fiber or fibers from a previous employment of the invention.
[0035] FIG. 6 shows a sectional view of a cartridge 34 for carbon fiber or fibers 36 . A portion of a roll 37 of the carbon fibers 36 extends across part of the cartridge 34 . Connections are made to two portions of the carbon fiber 36 when it is used in the invention. A portion of the carbon fiber 36 consumed by the operation of the invention. Additional carbon fiber 36 is unrolled from the roll 37 for the next use.
[0036] FIG. 7 is an embodiment similar to the container 1 shown in FIG. 1 , but the electrical source is a battery 39 controlled by a switch 40 .
[0037] FIG. 8 is another embodiment of the invention in the form of a tubular case 41 containing a carbon fiber holder, a carbon fiber 43 , a switch 42 , and a battery 45 . The electrical circuit for the case 41 is shown in FIG. 9 . Case 41 has openings 46 so that the inner chamber holding the carbon fiber 43 can communicate with external air. When the carbon fiber 43 is burned, the carbon fiber 43 uses oxygen inside the case 41 and air from outside the case 41 is available for being consumed.
[0038] The case 41 can be used with a container 47 shown in FIG. 10 having an opening 48 which has a tube 49 such as a plastic tube 49 having an end portion 50 usually closed. When the case 41 is inserted into the tube 49 , it is pushed down so that the portion with the holes 46 can communicate with the interior of the container 47 as shown in FIG. 11 . Closing the circuit with switch 42 causes the carbon fiber 43 to reach a temperature to burn and react with oxygen both within and outside the case 41 . That is, the oxygen in the container 47 is part of the burning and is replaced by carbon dioxide. Withdrawal of the case 41 is done and the end 50 automatically seals the container 47 .
[0039] FIG. 12 shows a sectional view of an exploded portion of another embodiment, and reference should be had to FIGS. 13 , 14 , and 15 . The top portion 52 of a container has threads suitable to receive a special cover 53 . The special cover 53 has outside threads suitable to receive special cover 54 . Special cover 54 contains a carbon fiber 56 being held in a holder 57 having external terminals 58 and 59 . The cover 53 fits on the top portion 52 . The top portion 52 has an opening 60 . The cover 53 can be tightened so that the central portion 61 covers and presses against the opening 60 to form a seal. In operation of the invention, the special cover 54 is used to replace the oxygen with carbon dioxide and then special cover 53 is used to seal the container so that special cover 54 can be removed for use on a different container.
[0040] FIG. 16 shows an embodiment in which the box 62 is the system for holding and burning a carbon fiber to replace oxygen with carbon dioxide. Box 63 is a container which is connected by tube 64 for gas communication to box 62 so that when box 62 is operated according to the invention to create carbon dioxide, the oxygen in box 63 is replaced by carbon dioxide. After completing the process of reducing the oxygen in box 63 , the tube 64 can be closed with a clamp not shown and cut off above the clamp so that box 62 can be used again for a different box 63 not shown.
[0041] FIG. 18 shows an embodiment of the invention having use for changing an atmosphere such as in a laboratory requiring an atmosphere relatively low in oxygen and relatively high in carbon dioxide. Container 120 could contain a petri dish or some other item. Device 121 pumps air from container 120 through tube 122 , and retains the air separate from container 120 while device 121 is activated using the invention to burn carbon (not shown) to transform the oxygen in the device 121 into mostly carbon dioxide. Thereafter, the mixture of air and carbon dioxide in the container 121 is moved through tube 123 into container 120 . The lower pressure in the container 120 due to the air being exhausted into the device 121 will move the gases in the device 121 into the container 120 . The tubes 122 and 123 need not be separate tubes.
[0042] FIG. 19 is an embodiment for a simple device 125 according to the invention suitable for use in containers which have not been adapted for the invention. A portion of the device 125 has been removed to show the interior. The device 125 includes a battery 126 , circuitry 127 , and a portion 128 having carbon fibers 129 . Pressing switch 130 connects the battery 126 to the circuitry 127 after a predetermined time, the battery 126 is connected to the carbon fibers 129 and air entering the openings 131 react with the carbon fibers 129 . The device 125 can be used by pressing the switch 130 and placing the device 125 into a container (not shown) and closing the container. The device 125 will thereafter transform most of the oxygen in the container into carbon dioxide.
[0043] The device 125 can be made to be reused. If necessary, the battery can be replaced, or recharged, and new carbon fibers 129 can be used.
Experimental Phase
[0044] An 89 mL hermetically sealed container (The Container Store Incorporated, Coppell, Tex.) was adapted for experimentation, so that it utilized the invention. A container of this size was chosen so that it could be easily stored and produced in large quantities; however, the device could have been easily scaled larger. The following aspects of the container were optimized: Varying lengths and numbers of carbon fibers were tested to determine an optimal mass and length for transforming the 89 mL atmosphere within the container, without creating excessive heat. Calculations were performed, which confirmed that the 0.09 g of carbon fibers used in each container was sufficient for transforming the atmosphere.
[0045] Different approaches to securing carbon fibers in place were tried to determine a simple yet effective method of keeping the fibers in their correct position within the containers. Carbon fibers were securely held in place between a nut and bolt head screwed tightly into one another other. The other end of the respective bolts extended outside the container to receive electrical current, thereby forming outside terminals.
[0046] The duration of the electrical current that was applied to the outside terminals was optimized through trial and error, to ensure a complete transformation of the atmosphere with a minimal amount of generated heat. Electrical current at about 12 volts from an automobile charger was applied to the carbon fibers for about 9 seconds. Carbon fibers were considered completely burned when there was a drop in electrical current (which was read from a meter on the car charger).
[0047] The carbon fibers were positioned in different orientations within the containers, in order to optimize the placement within the container, so that the entire container's atmosphere would be transformed. In the orientation ultimately used, carbon fibers were placed horizontally inside the container at about half height of the container.
[0048] Silicone rubber sealant was used to improve the gas seals around the bolts penetrating into the containers.
Construction of the Experimental Device
[0049] As shown in FIG. 17 , two parallel holes 100 were drilled about halfway between the top and bottom of the container 101 . A bolt 102 was fitted through each hole 100 , with its head 103 inside the container, facing outward. The bolts 102 were secured, using a washer 104 and a nut 105 on either side of the container wall. Between the two bolts 102 , fixed opposite one another, was 6 cm carbon fiber 107 (24000 tow). The carbon fibers 107 were covered on each end by 1 cm of aluminum foil 108 . It was held securely in position by the nut 105 and head 103 of each bolt, which were tightly pressed against one another. Silicone rubber sealant was used to seal the container around the holes 100 , which were drilled to accommodate the bolts. The container, as purchased, included a rubber ring to form a seal when the container 101 is close. An additional rubber ring was added around each container cover, to improve the hermetic seal.
[0050] To activate the carbon fibers 107 , the red clip (not shown) from a battery charger (not shown) was attached to one of the protruding bolts, and the black clip (not shown) to the other. With the connections in place, the charger was turned on, and electrical current was delivered to the carbon fibers 107 .
[0051] In order to test for air leaks in the container 101 , each container 101 was closed and submerged in a pot of near-boiling water for 35 seconds. The heat from the water surrounding the container 101 caused the air from within the container 101 to expand. If there were any leaks in a given container 101 , bubbles formed around the leaking area(s) of the container 101 . Any area(s) found to leak were filled with additional silicone rubber sealant. Once each container 101 was resealed, the seal test was repeated to verify that it was leak proof. All containers 101 were required to pass this seal test before use in the experiment. This was, of course, an indirect test and it presumes that if air cannot leak out, then hopefully, air cannot leak into the container 101 .
[0052] Three types of containers 101 were used to determine whether the atmosphere within the container 101 prevents growth of spoilage bacteria: hermetically sealed containers activated with the process according to the invention, identical containers not activated with the inventive process, and commercially available reclosable plastic sandwich bags (Presto Products Company, Appleton, Wis.).
[0053] 0.5 g samples of ground beef (Safeweay, 80% lean) were stored in each of the aforementioned containers for the following lengths of time: no incubation (T 0 ), 1 day (T 1 ), 2 day (T 2 ), 3 days (T 3 ), 6 days (T 4 ), 8 days (T 5 ), 14 days (T 6 ), 18 days (T 7 ), and 32 days (T 8 ). All samples were stored at 4° C. during incubation. Two replicates per time point were processed to increase accuracy and reduce experimental error.
[0054] The activated containers 101 were used to verify whether the transformed atmosphere inhibits the growth of spoilage bacteria. The non-activated containers 101 were used as a yardstick for ascertaining how well the transformed atmosphere in the activated containers is preserved over time, and how long the effects of transformed atmosphere last. The plastic bags were use to compare the efficacy of invention to a conventional method of preserving meat.
[0055] After each time point, meat samples were removed from their respective containers and photographed. Each sample was subsequently placed in 2 ml of 0.1% bactopeptone water and homogenized using a Tissue Tearor™ homogenizer (Biospec Products Incorporated, Bartlesville, Okla.) for 10 seconds. Homogenates were then vortexed using a Fisher Vortex Genie 2™ (Fisher Scientific, Waltham, Mass. for 45 seconds and centrifuged for 30 seconds in a microfuge (Fisher Scientific, Waltham, Mass.).
[0056] Supernatant fluid was used to make decimal dilutions. 0.1 mL from each dilution was then plated on Lysogeny Broth (LB) agar and on Eosine Methylene Blue (EMB) agar. The first medium supports the growth of a large variety of bacteria, while EMB supports the growth of coliforms, which comprise the notorious meat spoilage bacteria. LB agar was used in place of tryptic soy agar, which was not available at the time of experimentation. Media was incubated at 37 C for 18-24 hours. Plaque forming units were counted and expressed as log colony forming units per gram of meat.
[0057] Due to observations made on day 6, the procedures were modified from T 5 onwards. Samples thereafter were no longer homogenized, and vortex was undertaken for 2 minutes instead of the prior 45 seconds.
Results
[0000]
Cost Analysis for device activation
Electricity used in activation=0.00015¢
The applied current had an upper limit of 2 amps. There was an electrical resistance of approximately 1 ohm for the length of 24000 tow carbon fiber used in each device.
An electrical charge was applied for nine seconds to burn the carbon fiber tow. The oxygen was consumed in even fewer seconds, as indicated by a drop in electrical current (which was read from a meter situated on the car charger).
[0062] The electrical charge can be estimated by multiplying estimated resistance times estimated electrical current (4 watts). The typical cost for electricity is about 15¢ per kilowatt-hour. The cost of the charge used is 4 watts×1/1000=0.004 kilowatts; 0.004 kilowatts×9/3600=0.00001 kilowatt hour; 0.00001 kilowatt hour×150 per kilowatt hour=0.00015¢.
b.) Carbon Fiber Usage per Device=0.01311¢
[0063] A 250 yard roll of carbon fiber (24000 tow) sells for $49.95 from Fibre Glaste Developments Corporation (Brookeville, Ohio). If one centimeter at this price costs 0.002185¢, then the 6 centimeters used in each container costs 0.01311¢.
Device Testing
[0064] Three types of containers 101 were used to assess the efficacy of meat preservation using the invention: an activated container 101 according to the invention, an identical container 101 where the atmosphere was left unchanged (non-activated container), and a reclosable sandwich sized plastic bag, similar to what may be used in a home setting. Samples of commercially available ground beef (0.5 g) were stored in the aforementioned containers at 4 C for 32 days and microbial analysis was carried out on samples at 9 separate time points, including the initial analysis on day 0. The experiment was conducted in duplicate, so two samples of meat from each type of container were tested at each time point. Average bacterial counts were represented as log (base 10) colony forming units per gram (log CFU/g). Bacterial counts were taken from both LB agar plates, which support a broad range of microflora, and EMB agar plates, which selectively support food spoilage bacteria.
[0065] The total bacterial counts in the activated containers dropped by 48% after the first day, from 2.70 log CFU/g to 1.30 log CFU/g, and only reached the 2.70 log CFU/g level again on day 14. Total bacterial counts were lowest at all time points, except on day 32, in meat samples stored in the activated containers. Total counts taken from the non-activated containers and bags between days 0 and 14, rose steadily and at a similar rate. However, counts on day 18 taken from the bags were significantly lower than in the former. By day 32, total bacterial counts taken from all containers were similar.
[0066] Food spoilage bacteria counts in the activated containers declined from day 0 to 8, when they reached zero. Counts then remained at zero until day 18, after which they began to rise. Counts taken from the non-activated containers and bags between days 0 and 14, rose steadily and at a similar rate. However, counts on day 18 taken from the bags were significantly lower than in the former. By day 32, food spoilage bacteria counts taken from the activated and non-activated containers were similar, but counts taken from the bags were at zero. Little change in meat texture was observed between day 0 and day 1. By day 6, meat texture in all samples began to change. By day 18, samples stored in bags became extremely pasty. Samples stored in non-activated containers at this time point appeared extremely dry, and samples stored in activated containers appeared dry, but to a lesser extent.
[0067] The lyzate prepared from ground beef stored in the bag, on day 8, appeared extremely viscous. The lyzate prepared from ground beef taken from the non-activated container, on the same day, appeared less viscous; while the lyzate prepared with meat taken from the activated containers, on the same day, seemed the least viscous. On day 32, the lyzates all looked comparable, and extremely viscous.
Discussion and Conclusions
Analysis of Results
[0068] The objective was to isolate the effect, if any, of the inventive process on bacterial growth on ground beef. Ground beef was used in testing, but it is surmised that comparable results would be obtained using other meats or foods because of the way the invention preserves food. The inventive process changes the atmosphere around a food like the industry used modified atmosphere packaging process (MAP), so applications of the invention are expected to be similar to those exhibited by MAP. The invention is expected to inhibit aerobic bacteria, by creating microaerophilic conditions inside a container, and Gram-positive bacteria, by elevating carbon dioxide content to over 10 percent. The majority of significant meat spoilage bacteria are aerobic and/or Gram-positive, so the inventive process was hypothesized to extend shelf life by inhibiting bacterial growth during the 32 days of testing. Based upon the data analyzed in this study, the invention was found to extend shelf life during the first 18 days, but not until 32 days. This indicated that the invention slowed deterioration and spoilage for a substantial, but not an unlimited, length of time.
[0069] Samples stored using the invention had the lowest bacterial counts through day 18 on both the LB agar plates, which support a broad range of microflora, and the EMB agar plates, which are selective towards food spoilage bacteria. By day 14, counts of bacteria on samples stored using the invention were at 2.70 log while counts from samples stored in non-activated containers and bags were at 6.37 log and 6.38 log, respectively. This indicates a difference of approximately 3.675 log on day 14, or a 4760 fold reduction in bacteria using the invention.
[0070] Bacterial growth on samples stored both in bags and non-activated containers was similar between days 0 and 14; however, growth on the latter appeared more logarithmic. This can be explained by a more consistent packaging of samples stored in the non-activated containers. The samples stored in plastic bags were not always placed at the same spot within the bags, and it is surmised that the plastic bags were not produced with the same degree of quality control as the non-activated containers.
[0071] LB bacterial counts in non-activated containers and bags between days 14 and 32 dropped 3.17 log and 3.44 log, respectively. This suggests that, between days 14 and 32, nutrients from meat stored in these containers were depleted, and as a result bacteria on these samples died off. Between days 14 and 18, bacterial growth in the non-activated containers started to level off, only increasing by 0.08 log. However, bacterial growth during the same period of time in the plastic bags plummeted by 3.3 log. It is believed that this difference arose because nutrients in samples stored in the plastic bags were depleted a couple of days before nutrients in samples stored in non-activated containers. This could indicate that bacteria grew faster on meat stored in the plastic bags than in non-activated containers.
[0072] Bacterial counts in all three containers were similar on day 32. This indicates that benefits of the invention did not last until day 32. The invention likely delays or slows bacterial growth; however, results indicate that invention does not completely eliminate it. The activated containers actually had the highest bacterial counts at this time point. This might have been because bacterial growth in the plastic bag and non-activated containers had already been depleted of nutrients by this time. However, growth on samples stored in the activated containers was still on the rise.
[0073] LB bacterial counts on ground beef stored using invention rose consistently throughout the experiment but decreased between days 0 and 1, and between days 3 and 8. The first decrease of 1.4 log was likely caused by the microaerophilic atmosphere and the elevated concentration of carbon dioxide introduced by the inventive process. The second decrease of 0.76 log could have been caused by a dominance of Lactobacillus bacteria by day 8 on samples stored using the invention, because Lactobacilli produce an antimicrobial agent to inhibit competing microorganisms. A dominance of Lactobacillus bacteria by day 8 seems consistent with the results.
[0074] No bacteria were detected on the EMB plates for the samples stored with invention on day 8, and Lactobacilli do not grow on EMB because they are Gram-positive. Changes in meat texture and tenderness were observed in samples by day 6 . These changes, which ere likely a result of enzymatic degradation, were most prevalent in samples stored in the plastic bags, and least prevalent in samples stored in activated containers. After processing samples with a tissue homogenizer, lyzates prepared from samples at this time point appeared turbid and extremely viscous. Microbial analysis carried out at this time point indicated that bacterial counts taken from these lyzates were at or near zero. It was speculated that the high viscosity of the lyzates prevented bacterial growth on the surface of the plates, resulting in low bacterial counts. Since high viscosity might have limited bacterial growth on the surface of agar plates, the researcher decided to vortex subsequent meat samples in 0.1% Bactopeptone, rather than homogenize them.
[0075] Meat samples kept in plastic bags at day 8, after vortexing, were extremely viscous. This suggests that the samples had undergone significant amounts of enzymatic degradation by this time point. Meat samples kept in non-activated containers still retained some tissue integrity, suggesting that the amount of degradation in these samples was lower than in samples stored in plastic bags. Meat samples stored in activated containers at this time point retained the most tissue integrity, which suggests that enzymatic degradation was lowest in these samples. It can be surmised that the transformed atmospheres slowed the enzymatic degradation in samples stored in activated containers, because certain modified atmospheres have been shown to slow such degradation (Lambert, Smith, & Dodds, 1991). Lyzates prepared from meat samples stored in all three containers were indistinguishable on day 32. This indicates that the inventive process slows enzymatic degradation for a substantial, but not unlimited, length of time. | The invention is a process and apparatus for eliminating most of the oxygen in a closed container by reacting the oxygen with carbon, such as carbon fibers, by electrically heating the carbon fibers until the carbon binds the oxygen into carbon dioxide, thereby removing the oxygen, and replacing the oxygen with carbon dioxide. This is important for preserving foods, certain plants, and other products which deteriorate in the presence of oxygen.
The apparatus and process of the invention have significant economic value over the prior art. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to spring powered door closers, such as disclosed in U.S. Pat. Nos. 3,246,362, 4,064,589, and 5,666,692, which disclosures are incorporated herein by reference. In such closers it is known that the closing power or force required to open the door against the spring force of the closer can be adjusted by providing greater or lesser compression of the springs in the closer. This can be accomplished by rotating a screw that moves a plate internally of the closer body that further compresses the spring, or allows the spring to expand, depending upon the direction of rotation of the screw. Such an arrangement is disclosed in the '692 patent.
SUMMARY OF THE INVENTION
The present invention allows the power of the closer to be adjusted by a user through the use of a powered arrangement, rather than through a manual operation by the user. Such a device is particularly useful to allow for greater accessibility to spaces closed by heavy doors, or doors with high powered door closers. In some situations, it is necessary to have a door closer high powered, such as to assure that the door remains in a closed position when the door is subject to high wind forces, or where the ambient pressure in the building or closed space is significantly different from the ambient pressure outside of the building or closed space.
A drawback of a high powered door closer is that it may be difficult for all persons to open the door against the normal high power of the closer. For this reason, a device according to the present invention is provided to adjust the power of the door closer to a much lower power, upon receipt of a signal from such a user, so that the door can be opened more easily. After a set time, the power of the door closer will be returned to the higher power level to provide the security to the building or space normally provided by the closed door.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a plan view of the interior of a door closer power adjusting device embodying the principles of the present invention.
FIG. 2 illustrates a plan view of the interior of an alternative embodiment of a door closer power adjusting device embodying the principles of the present invention.
FIG. 3 illustrates a side view of the interior of the device of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In an embodiment of the invention, as illustrated in FIG. 1 , door closer power adjusting device 10 includes a housing 12 for accommodating a number of internal components. One of the components, a powered unit in the form of a high torque motor 20 , such as a 12 volt portable drill motor, can be used to rotate a shaft 22 connected, via an appropriate interface, to a power adjustment screw 24 of a door closer 26 . The motor 20 and shaft 22 can be located in a door transom 28 so that they are not visible to the user during normal usage. Other types of powered units may be utilized to move a plate 27 in the door closer 26 against which one or more springs 29 in the door closer are compressed, including other types of motors, gear arrangements, and hydraulic or pneumatic movable pistons which may move the plate directly without use of a rotatable adjustment screw.
A switch 30 may be provided to allow the user to activate the motor 20 to rotate the power adjustment screw 24 to lower the power required to open the door. The switch may be in the form of a touch pad, push button, toggle switch, motion detector, infra red proximity switch or other known arrangements, including a remotely operated switch using a wired or wireless connection.
The shaft 22 of the motor 20 can carry an external thread 32 , on which is carried a traveling nut 34 , which moves into engagement with a limit switch 36 to deactivate the motor once the power adjustment screw 24 has rotated sufficiently to lower the power of the door closer 26 to an appropriate level. The limit switch 36 may also be carried on the nut 34 and moved into engagement with a fixed stop member to operate the switch once the shaft has rotated sufficiently. A similar arrangement could be used if a movable piston were used.
A signal device 38 , such as a green light, for example a green LED, can be illuminated to signal to the user that the door closer 26 has reached the low power state. Other types of visible or audible signaling devices could also be used.
After the passage of a predetermined time period, as determined by an electronic timing circuit 40 , sending a signal through a control unit 41 that all of the electrical devices are connected to, the motor 20 is reversed and the shaft 22 is rotated in the opposite direction to return the closer 26 to the higher power setting. Again, the nut 34 carried on the shaft 22 can be used to engage the limit switch 36 to terminate operation of the motor 20 when the shaft 22 has rotated a sufficient amount to return the closer 26 to the high power setting. Thus, the two switching functions associated with the movement of the nut 34 on the shaft 22 can be accomplished by a single switch having two engagement positions.
A further signal device 42 , such as a red light, for example, a red LED, can be illuminated to signal to the user that the door closer 26 is no longer in the low power state and/or is in the high power state. This signal device 42 may be activated as soon as the motor 20 is activated to return the closer 26 to the high power setting, and may remain activated until such time as the closer is fully returned to the low power setting. Again, other types of signaling devices as described above could be used.
The motor 20 may be powered through a normal 110 volt ac power line 44 , which electrical power is converted to 12 volt dc power at a voltage converter unit 46 .
An override switch 48 may be provided to return the power setting for the door closer 26 to the high power, in advance of the normal time delay, if desired. This switch 48 may be constructed identically to or differently from the switch 30 .
Also, a complete override switch 50 may be provided to disconnect the switches 30 , 48 for changing the power setting for the door closer 26 if that is desired as well. This complete override switch may be located remotely from the door.
In another embodiment of the invention, as illustrated in FIGS. 2 and 3 , door closer power adjusting device 110 includes a housing 112 for accommodating a number of internal components. One of the components, a powered unit in the form of a high torque motor 120 , such as a 12 volt portable drill motor, can be used to rotate a shaft 122 connected, via an appropriate interface, to a power adjustment screw 124 of a door closer 126 of the type described above. The motor 120 and shaft 122 can be located in a door transom 128 so that they are not visible to the user during normal usage. Other types of powered units may be utilized to move a plate in the door closer 126 against which one or more springs in the door closer are compressed, including other types of motors, gear arrangements, and hydraulic or pneumatic movable pistons which may move the plate directly without use of a rotatable adjustment screw.
A switch as described above with regard to switch 30 , may be provided to allow the user to activate the motor 120 to rotate the power adjustment screw 124 to lower the power required to open the door. The switch may be in the form of a touch pad, push button, toggle switch, motion detector, infra red proximity switch or other known arrangements, including a remotely operated switch using a wired or wireless connection.
The shaft 122 of the motor 120 can carry an external thread 132 , on which is carried a traveling nut 134 , which moves into engagement with a limit switch 135 , 136 at each end of its travel to deactivate the motor once the power adjustment screw 124 has rotated sufficiently to lower the power of the door closer 126 to an appropriate level, or has returned to its initial, full power position. The two positions of the nut 134 can thus be detected by two separate switches. A similar arrangement could be used if a movable piston were used.
As in the embodiment described above with respect to FIG. 1 , a signal device (not separately shown here), such as a green light, for example a green LED, can be illuminated to signal to the user that the door closer 126 has reached the low power state. Other types of visible or audible signaling devices could also be used.
After the passage of a predetermined time period, as determined by an electronic timing circuit as described previously, sending a signal through a control unit that all of the electrical devices are connected to, the motor 120 is reversed and the shaft 122 is rotated in the opposite direction to return the closer 126 to the higher power setting. Again, the nut 134 carried on the shaft 122 can be used to engage the first limit switch 135 to terminate operation of the motor 120 when the shaft 122 has rotated a sufficient amount to return the closer 126 to the high power setting. The two switches 135 , 136 could be incorporated into a single switch if desired.
A further signal device as described with respect to FIG. 1 , such as a red light, for example, a red LED, can be illuminated to signal to the user that the door closer 126 is no longer in the low power state and/or is in the high power state. This signal device may be activated as soon as the motor 120 is activated to return the closer 126 to the high power setting, and may remain activated until such time as the closer is fully returned to the low power setting. Again, other types of signaling devices as described above could be used.
The motor 120 may be powered through a normal 110 volt ac as described above, which electrical power is converted to 12 volt dc power at a voltage converter unit.
An override switch as described above may be provided to return the power setting for the door closer 126 to the high power, in advance of the normal time delay, if desired. This switch may be constructed identically to or differently from the other user operable switches.
Also, as described above, a complete override switch may be provided to disconnect the user operated switches for changing the power setting for the door closer 126 if that is desired as well. This complete override switch may be located remotely from the door.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | A door closer power adjusting device for a door closer having a spindle driven by a compressed spring with a movable plate for adjusting spring compression, or with a screw for adjusting spring compression, between a high and low level of compression. A powered unit moves the plate in a first direction to achieve the low level of compression and in a second direction to achieve the high level of compression. A switch activates the powered unit in the first direction and a first switch is engaged when the spring is compressed to the low level of compression to deactivate the powered unit. A timing circuit activates the powered unit in a second direction after passage of a predetermined time. A second switch is engaged when the spring is compressed to the high level of compression to deactivate the powered unit. | 4 |
FIELD OF THE INVENTION
The invention relates to a bipolar endoscopic instrument having a tubular stem with two arms mutually pivotably supported on a shaft mounted at the distal end of said stem, the pivoting motion of the aims being caused by a push/pull element mounted in axially displaceable manner in the stem, the arms being connected by mutually insulated electric power leads to the terminals of a high-frequency voltage source.
BACKGROUND OF THE INVENTION
An example of an instruments of this type includes bipolar gripping forceps to grip and coagulate tissue. However, such instruments also may be other devices having different functions such as scissors.
In general, bipolar instruments comprise two arms pivotable about a support shaft and each is electrically conductively connected to a different terminal of a high frequency (hf) generator. The arms are made to pivot by a push/pull element displaceably mounted in the stem. The distal end of the push/pull element is connected to the arms by a suitable mechanism which converts axial displacement of the element into a pivoting motion of the arms. Said mechanism illustratively may be a knuckle joint or the like.
An instrument of this general type has been disclosed in German Gebrauchsmuster 296 04 191 which describes a coagulating gripping forceps wherein power is applied to one arm through the shank and to the other arm through the electrically conducting push/pull element. This known design is comparatively elaborate and requires careful insulation, especially in the area of the coupling between the arms and the distal end of the push/pull element also acts as an electric conductor.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a bipolar endoscopic instrument wherein the power feed to the arms is significantly simplified as compared with the prior art.
This object is achieved by an instrument wherein the shaft pivotably supports the arms and at the same time also assumes an electrical conducting function for both power leads. For that purpose, the shaft comprises two mutually insulated, electrically conductive zones, each one electrically connected to one of the two arms, and each one in contact with one of the two leads leading to the hf generator, the contact in the case of rotating zones being for instance a sliding contact.
Advantageously, the shaft comprises a cylindrical insulating element made of a non-conductive material insulating from each other two electrically conductive zones formed by two conductive sleeves. Illustratively, the cylindrical insulating element may extend the full length of the shaft with the conductive sleeves slipped over its ends. It will be appreciated that the sleeves are held so as to stay out of contact with one another. For that purpose, the insulating element may be fitted for instance with a centrally peripheral projection spacing the sleeves from each other. To achieve problem-free mounting of the shaft, the projection approximately corresponds to the sleeve wall thickness so that the shaft diameter can be uniform over its full length. A metal (steel) or ceramic core may be inserted into the insulating element to impart higher mechanical strength to it.
Moreover, to increase the bending strength, one of the two electrically conductive sleeves may be fitted with a larger wall thickness. Taking into account the small shaft cross-section available, the insulating element, which in any event is made of an elastic plastic, extends over only part of the length of the shaft. Therefore, an electrically conductive sleeve having substantially a larger wall thickness can be provided in the remaining, free portion of the shaft than is possible in the next discussed design. As a result the shaft's bending strength is substantially increased over its full length.
The insulating element furthermore might be configured in such a way that one of its ends may receive one of the sleeves in a centered manner whereas a slip-on zone is formed at the opposite end of the insulating element. In such a configuration, the insulating element would align all essential shaft components with each other. As a rule, however, even this embodiment comprises a central and illustratively metallic core simultaneously enhancing strength and, regardless of insulating-body design, mutually aligning, i.e. centering the individual shaft components.
As is known to the expert, little space is available in the distal region of the instruments of this type. Consequently, the spacings between electrically conductive zones which must be insulated from each other are minute. Therefore, the insulating materials employed must be selected to offer adequate dielectric (breakdown) strength, and this selection is readily performed by the expert regarding the known spacings and operational voltages. Plastics having high bending strengths, temperature resistance and breakdown strength are preferred insulators. However, ceramics also may be used as insulators. Ceramics offer the advantage over plastic that, in the presence of saline water, the almost inevitable weak currents cannot cause carbonization at the insulation surface. On the other hand, ceramics are more susceptible to breaking.
Regardless of the insulating material used, dielectric breakdowns may arise wherever an electrical connection caused by conducting air is possible between two mutually insulated, electrically conductive zones. Especially critical in this respect are the contact areas of mutually adjoining parts in which gaps may be created following improper assembly, for instance connecting a metallic core zone with an electrically conductive sleeve. Such gaps are critical because the minute spacings between the conductive zones are inadequate to reliably preclude dielectric breakdown through conductive air. Therefore it is necessary to, for example, bond the mutually adjoining shaft components, a cement of high breakdown strength being required. Bonding during assembly is an elaborate procedure. If the assembly is to be substantially cement-free, then, according to another embodiment of the invention, further insulating components are optionally provided to lengthen the path of a current between the electrically conductive zones. Such components in turn may be again in the form of sleeves (FIG. 5).
Another way to avert any undesired currents is to coat metallic areas not used in electrical conduction with an insulating material. This is especially significant at the alms if only their parts used in actual coagulation were conductive. Thin coatings entailing no significant diameter enlargement may be used to insulate the arms and individual shaft components such as the metal core.
Using the shaft of the invention, the power can be fed in exceedingly simple ways to the arms. The power leads from the hf generator may be shifted to mutually opposite sides into the stem and may terminate with their ends in boreholes in this stem, the shaft by its ends being received in those boreholes. The ends of the power leads illustratively may be sliding contacts resting against the shaft.
This design provides in an especially simple manner two power feeds which are mutually insulated over the full length of the instrument, for the arms.
In this design, only insulation in the mechanism converting the push/pull motion into a pivoting motion need be provided. Conventional arms are fitted with levers extending from the shaft in the proximal direction into the stem where they act on a suitable mechanism. Typically, the mechanism is a knuckle joint comprising comparatively many mutually moving pairs that may easily drop off and jeopardize the patient; insulation in this design is laborious. Therefore, a further embodiment of the invention provides that a cam mechanism be used to pivot the arms. Illustratively, such a cam mechanism comprises a coupling element at the distal end of the push/pull element containing two slots (or cams) running obliquely to the stem axis. The levers of each arm have a laterally projecting stub slidingly received in one of the two slots. When the coupling element is displaced due to the actuation of the push/pull element, the stub guided in the elongated slot is deflected and pivots the arm associated to it. The cam mechanism may be varied to comprise a coupling element with laterally projecting stubs which in turn are slidingly guided in slots or elongated apertures in the arms.
When using a cam mechanism, the insulation of the metallic levers or of the arms possibly connected to them in conductive manner only requires that the coupling element have correspondingly insulated properties. In the simplest case the element as whole is of insulating material. However, the slots may be made as separate parts from other materials such as metals and be inserted into the element otherwise made of an insulator. Strength is increased in this manner.
In another advantageous embodiment of the invention, a slider running in the distal direction is fitted on the coupling element. The slider comprises an elongated slot enclosing the shaft. Upon actuation of the push/pull element, the slider reciprocates axially and thereby expels any liquid between the portions of the arms near the shaft. As a result a sharp reduction in the otherwise frequent leakage currents can be achieved.
Another embodiment concerns the aims. An especially simple design consists in making the arms and the levers being made of a metallic material, that is being electrically conductive. A safety circuit inserted into the hf generator typically used in such applications prevents current interruption and shorts in case the arms should touch each other.
As already mentioned above, preferably the arms are made conductive only in zones in mutually opposite segments. Those segments which, for instance, when closing the arms will move toward each other are opposite. Gripping forceps comprising such arms allow extremely precise coagulation or other electro-surgical work. The forceps illustratively may be manufactured by applying an insulating coating to the arms made of conductive material and then removing this coating in the areas of desired conductivity.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below with reference to several Figures showing different illustrative embodiments.
FIG. 1 is a section of the distal end of the stem in a first embodiment of the invention,
FIG. 2 is a section along line II--II of FIG. 1,
FIG. 3 is an end elevation in section in the direction of line III--III of FIG. 1, the insulating element being sealed at one of its ends contrary to the embodiment of FIG. 1,
FIG. 4 is an end elevation, in section, of a second illustrative embodiment,
FIG. 5 is an end elevation, in section, of a third illustrative embodiment, and
FIG. 6 is an end elevation, in section, similar to the embodiment of FIG. 5 in a slightly modified form.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 show the distal region of a bipolar endoscopic instrument 10 which in this case is a gripping forceps. Instrument 10 comprises a stem 11 made of an insulating material such as liquid crystal polymer (LCP), polyaiyletherketone (PEEK) or polyphenylen sulfone (PPSU) and which at its distal end terminates in two mutually opposite lateral forks (FIGS. 3-6).
Two mutually pivotable forceps arms 12 and 13 are mounted on instrument 10 and are held on a shaft 14. Shaft 14 has a cylindrical insulating element 15 of electrically non-conductive material into which is inserted a cylindrical core 16 of a metallic material such as steel to reinforce the insulating element. Electrically conductive sleeves 17 and 18 are mounted on insulating element 15 to ensure on one hand conductive contact with arms 12 and 13 and on the other hand contact with leads 19 and 20 ensuring connection to the terminals of an hf generator schematically shown at 34. Sleeves 17 and 18 are spaced apart from each other by a central enlargement 15' of the periphery of insulating element 15. One end of the insulating element may be sealed by a transverse wall 15" (FIG. 3) in which event central core 16 is sheathed entirely in insulation in this region. As shown, the thickness of enlargement 15' corresponds to the wall thickness of sleeves 17 and 18 and, as a result, the outer diameter of shaft 14 is essentially uniform over its full length. In this manner, shaft 14 can be inserted during assembly into stem 11 and through the boreholes of arms 12 and 13 without difficulty.
A push/pull element 21 extends inside stem 11 and is affixed at its end to a coupling element 22. Diagonal slots 23 and 24, shown in FIG. 2, are in opposite sides of coupling element 22. Stubs 27 and 28 laterally projecting from levers 25 and 26 are received in sliding relationship in slots 23 and 24. Levers 25 and 26 extend proximally from alms 12 and 13, respectively. When coupling element 22 is axially displaced by the push/pull element inside the stem 11, the stubs 27 and 28 are driven in the slots of coupling element 22 and pivot levers 25 and 26 and hence the arms 12 and 13 are made to pivot in opposite directions.
As mentioned above, the special design of the shaft allows feeding power to both arms 12 and 13 in an especially simple and mutually insulated manner. The current leads 19 and 20 can be installed in simple manner in stem 11 which, as already mentioned, comprises an electrical insulating material. It is enough to mount, for instance, sliding contacts 29 and 30 at the distal ends of power leads 19 and 20, the contacts making electrical contact with sleeves 17 and 18. Such illustrative sliding contacts are of simple design and relatively malfunction-proof. Further insulation is required merely to electrically separate the arms, i.e., their levers from each other in the region of the coupling element 22. Advantageously, the coupling element 22 need not be made of an electrically conductive material. PEEK, PPSU or again LCP may be used. Also and illustratively, stubs 27 and 28 or levers 25 and 26 need not be electrically conductive everywhere. In each case when using the shown cam drive, insulation possible with economy of parts. FIG. 1 also indicates that a slider 31 is present at the coupling element 22 and extends in the proximal direction. This slider 31 is elucidated in relation to FIG. 2.
FIG. 2 again shows push/pull element 21 allowing axial displacement of coupling element 22 inside stem 1. As mentioned above, slots 23 and 24 in coupling element 22 which slidingly receive stubs 27 and 28 of levers 25 and 26. When the coupling element is displaced, these stubs are deflected and in the process pivot arms 12 and 13 (only arm 13 being shown in FIG. 2) about shaft 14. FIG. 2 further shows that the slider 31 extends as far as a region which is proximal to the shaft 14 to make possible problem-free axial adjustment, and that it comprises an elongated slot 32 in the vicinity of, and enclosing, shaft 14. When during instrument use the slider is advanced by means of coupling element 22, it will expel any liquid accumulated between the zones of the arms close to the shaft and thereby prevents possible shorting in this zone. The slider always is made of the same electrically non-conductive material as the coupling element.
FIGS. 3-6 are sectional views from which the arms and associated parts were omitted for the sake of clarity.
FIG. 3, which shows the embodiment of FIG. 1 in slightly modified form, will be discussed only briefly. In this cross-section, the distal part of stem 11 forms two laterally spaced, fork-shaped zones, shaft 14 being mounted between said zones. Insulating element 15 is sealed at its end by a transverse wall 15". The entire inner surface of insulating element 15 therefore encloses in this region the mostly metallic core 16 and thereby prevents for instance dielectric breakdown between lead 19 and the metal core.
FIG. 4 shows a shaft 140 of a further embodiment. Shaft 140 of FIG. 4 is mounted in a stern 110 and comprises a central core 160 in the manner of the first embodiment and having a head 160'. Beginning with the head 160'the following components are slipped onto the core 160: an insulating ring 200, an insulating element 150 extending over a portion of the shaft, an electrically conductive sleeve 170 slipped on the insulating element and a further electrically conductive sleeve 180 kept from the sleeve 170 insulating element 15. The components are kept in place at one end of the core 160 by head 160'and a rotaining ring 190. The other end of the shaft is held in place by a cap 210 welded on it. The essential difference from the embodiment of FIG. 3 is that, in the embodiment of FIG. 4, insulating element 150 only extends over part of the shaft's length. Electrically conductive sleeve 180 is slipped on the core 160 at its free zone and its wall thickness is substantially larger than that of the sleeve 180 in FIG. 3. Because such electrically conductive sleeves always will be metallic or the like, shaft 140 of the embodiment of FIG. 4 has clearly increased bending strength. Otherwise the principle of the shaft design is the same as that of FIG. 3.
A problem however arises as already mentioned above, for instance, due to the boundary zone between the insulating ring 200 and the insulating element 150. Unless there be adequate bonding, a gap may from which is filled with air as the conductive medium. As regards conventional shaft dimensions, the spacings between electrically conductive sleeve 170 and metal core 160 are insufficient to preclude dielectric breakdown at all possible operational voltages. Therefore, assembly requires that the boundary surfaces be carefully cemented. Alternatively, as shown in FIG. 5, a special insulating ring 200' may be provided to extend the path which must be followed by current to arc between the sleeve 170 and the core 160. In the latter embodiment, cementing no longer is mandatory and assembly is made easier.
Lastly, FIG. 6 shows another embodiment of a shaft 240 of the invention. Basically the shaft 240 may be designed as that shown in FIG. 4. Again a core 260 with head 260' is provided. However, contrary to the design of FIG. 4, the separate insulating ring and insulating element are absent. Instead, both components are consolidated into one insulating element 250 whereby any gap between the sleeve 270 and the core becomes so long (as in the embodiment of FIG. 5) that dielectric breakdown no longer need be expected. In this design however assembly requires an additional insulating ring 300 in the center zone to prevent dielectric breakdown between electrically conductive sleeves 270 and 280. Otherwise the embodiment of FIG. 6 is the same configuration as in FIG. 5. | A bipolar endoscopic instrument has a tubular stem fitted at its distal end with two arms pivotally supported on a shaft. The arms are pivoted by actuating an axially displaceable push/pull element mounted in the stem. The arms are connected through mutually electrically insulated leads to the terminals of a high-frequency power source, the shaft having two mutually insulated, electrically conductive segments each electrically connected to one of the electrical leads and the arm associated with this lead. | 0 |
This is a division of application Ser. No. 829,887, filed Sept. 1, 1977, now U.S. Pat. No. 4,106,531.
The invention relates to an apparatus for forming the selvage on a knit-weaving loom comprising a knitting mechanism for building a warp-knit structure from loops of weft thread unwound from a stationary supply, means for beating up the stitch connecting loops into the fabric fell, said knitting mechanism comprising, on the one hand, a system of lapping guides the lapping arms of which are reciprocatorily swingable in open shed position from an intermediate start position to one of extreme lapping positions and back again, the lapping guides permanently protruding between warp threads of at least one of the two shed planes and, on the other hand, a system of knitting needles with closable hooks, the number of which corresponds to that of the lapping guides, the knitting needle system being arranged across the fabric and mounted for reciprocation from a foremost, starting position in front of the beat-up plane of the fabric to an operating position in open shed position and back again, in order to engage the weft threads being laid.
The characteristic feature of the knit-woven fabric, which can be manufactured on the knit-weaving machine disclosed in the Czechoslovak Inventor's Certificate No. 153,246, consists of a warp-knit structure built from weft thread loops and comprising stitch wales disposed between groups of warp threads binding with stitch connecting loops in a weave. It has been proved that, from the viewpoint of utility parameters, the knit-woven fabrics according to Czechoslovak Inventor's Certificates Nos. 162,119 and 162,120 are particularly advantageous.
Thus, for instance, the knit-woven fabrics disclosed in the Czechoslovak Inventor's Certificate No. 162,120 are manufactured in an open two-coarse atlas structure of which closed reverse stitches are built by end bights of hairpin-shaped weft loops. Pairs of the connecting loops of reverse stitches which are substantially parallel with one another bind, in a longitudinal strip between the wales of reverse stitches, with warp threads in a weave. Between the reverse stitches of the wale there are located tuck loops which actually represent a connecting bight or bridge between successive weft loops built from one and the same weft threads.
A disadvantage of the afore-mentioned fabrics consists in selvages built of weft thread loops alternating with marginal loops of marginal weft thread, the former overlapping the latter.
The weft thread loops are not interlaced to a wale but lie loose on the marginal loops. Such selvages are not firm, are not aesthetic, and do not meet the claims laid upon the fabric selvage with regard to further fabric processing in finishing plants. The warp threads of such fabrics, if subjected to stress in a transverse direction, become loose whereby the appearance of the final product deteriorates.
Another drawback thereof is that it is necessary to use, at least for the marginal warp thread, a plain weave in order that said warp thread may pass over the weft thread loop at the one side, and over the marginal weft loop at the other side.
For carrying out the method of producing knit-woven fabrics in accordance with the inventions an apparatus is provided on a knit-weaving machine for manufacturing knit-woven fabrics, said machine comprising a knitting mechanism for building a warp-knit structure from loops of weft thread unwound from a stationary supply, means for beating up stitch connecting loops into the fabric fell, said knitting mechanism comprising, on the one hand, a system of lapping guides the lapping arms of which are reciprocatorily swingable in an open shed position from an intermediate start position to one of extreme lapping positions and back again, the lapping guides protruding permanently between warp threads of at least one of the two shed planes, and, on the other hand, a system of knitting needles with closable hooks, the number of which corresponds to that of the lapping guides, the knitting needle system being arranged across the fabric and mounted for reciprocation from a foremost start position in front of the beat-up plane of the fabric to an operating position in open shed and back again, in order to engage the weft threads being laid.
In accordance with the invention, on each side of the system of lapping guides there is disposed an auxiliary lapping guide for laying the lock thread which is unwound from a supply package into the marginal knitting needle, the operation of said auxiliary lapping guide being the same as that of the lapping guides.
According to a second embodiment of the apparatus, with each of the auxiliary lapping guides there is associated a hook disposed at either side of the system of knitting needles and movable in synchronism with knitting needles for temporarily engaging the lock thread laid by the auxiliary lapping guide, and the marginal weft thread laid by the marginal lapping guide.
According to a third embodiment of the apparatus, the intermediate starting position of the marginal lapping guide is oriented relative to the intermediate starting position of the auxiliary lapping guide, in such a manner that the geometrical projections of the two guides onto a horizontal plane are concurrent.
The apparatus according to the invention is simple, reliable in operation and usable in existing knit-weaving machines without the necessity of substantial constructional adaptations of the knitting mechanism thereof.
The selvage structure of knit-woven fabric and the method for producing the same can be applied also to the knit-woven fabrics disclosed in German Publication (DT OS) No. 2,034,120. However, the machine for manufacturing the aforementioned fabrics requires a suitable adaptation for this purpose.
Some preferred embodiments of knit-woven fabric selvage structures and of apparatus for manufacturing the same will be hereinafter described with reference to the accompanying drawings in which
FIG. 1a is a side view of the operating mechanism of a schematically shown knit-weaving machine;
FIG. 1b is a top view of the mechanism shown in FIG. 1a;
FIG. 2 is a fragmentary view of a knit-woven fabric with an unfirm selvage, forming the subject matter of the Czechoslovak Inventor's Certificate No. 162,120;
FIGS. 3-8, inclusive, are views showing six various different embodiments of selvage structures according to the invention;
FIGS. 9-11, inclusive, are schematic views of three different exemplary embodiments of apparatus for knit-woven fabric selvage structure; and
FIGS. 12-32, inclusive, illustrate different processes of producing various knit-woven fabric selvage structures.
DESCRIPTION OF PREFERRED EMBODIMENTS
As hereinbefore set forth, FIGS. 1a and 1b schematically illustrate the known operating mechanism of a knit-weaving loom. A cross bed 1 disposed between side frames (not shown) of the loom under warp threads 2 and in front of heald frames 3a, 3b supports an array of lapping guides 4 arranged side-by-side thereon and mounted for swinging. Each lapping guide 4 has a stem 5 extending to its intermediate part into a tonque-shaped arm 6 terminating in a thread guiding eyelet 7 to be threaded-in with warp thread 2. Warp threads 2 as well as weft threads 8 are unwound from warp beams (not shown), or any other supply package disposed on a creel provided on the loom. The swinging movement of the lapping guides 4 is derived from a bar 9 supported in the bed 1 to reciprocate therein by means of a motion mechanism (not shown) of the knit-weaving loom.
Further the knit-weaving loom comprises a sley 10 provided with a reed 11, the swinging movement of the former being derived from a not shown mechanism. The dent spacings of the reed 11 are threaded-in with warp threads 2. Those spacings between the dents of the reed 11 designed as passages for the lapping guides 4 are wider than those designed for warp threads 2. In the shed exchange phase in which the sley 10 is in its rear or delay position, the lapping guides 4 simultaneously swing from their intermediate start position to one of two extreme positions and back again, while during the next shed exchange phase they swing again from said intermediate start position to the opposite extreme or thread-laying position and back again.
Opposite each lapping guide 4 there is situated a knitting needle 12 having a hook 13 to be closed, for example, by a latch 14, the longitudinal axis of the needle 12 being concurrent relative to the axis 4a of the swinging movement of the lapping guide 4.
The inoperative stem extremities of the knitting needles 12 are fixed in a bed 15 provided with a collar 16 encircling an eccentric cam 17 which is secured on a shift 18 driven in a one-to-one gear ratio from the main shaft of the loom. The cam 17 is rotatable in the direction of the arrow 19.
The knitting needles 12 are mounted for reciprocation from their foremost start position to their operating position in open shed and back again. During this movement, the needle hooks 13 describe -- in the direction of arrow 20 -- an endless drop-shaped path 21 arising from the fact that the needle stems bear upon an operating edge 22 of a support bar 23 designed for guiding a fabric 24 being produced. The fabric 24 is withdrawn over a breast beam (not shown) to a not shown take-up means. The knitting needles 12 are displaced from their foremost start position situated in front of the beat-up plane of the fabric 24, to their rear operating position while the lapping guides 4 are being simultaneously swung to one of their extreme positions. During the upward movement of the needle hooks 13, the lapping guides 4 lay weft threads 8 into the hooks 13. During the subsequent backward movement of knitting needles 12 to their start position there are built new stitches in the hooks 13 of the knitting needles 12 from laid-on loops of weft threads 8 by drawing said loops through the old stitches entrapped on the knitting needle stems in the previous work cycle.
The lapping guides 4 simultaneously return to their intermediate start positions whereupon the beat-up of the thus built pair of stitch connecting loops into the fabric fell follows. In the next work cycle, the knitting needles 12 and the lapping guides 4 operate again, except that the latter swing from said intermediate start position to the opposite extreme one and back again.
FIG. 2, labelled "Prior Art;" shows a selvage portion of a knit-woven fabric produced in accordance with the Czechoslovak Inventor's Certificate No. 162,120. The fabric comprises a longitudinal marginal strip 25 produced from weft loops 26 of weft thread 8' and from marginal loops 27 of the marginal weft thread 8". End bights 28 of the weft loops 26 are not interlaced to wale but lie loose on the marginal loops 27 of the marginal weft thread 8". The wale of stitches 29 situated always between adjacent longitudinal strips 25 is produced in this case alternately from closed reverse stitches 30a, 30b of the weft loops.
FIGS. 9 to 11 inclusive show three preferred embodiments of the mechanisms for producing respective knit-woven fabric selvage structure according to the invention.
In accordance with a first one of these embodiments (FIG. 9) an auxiliary lapping guide 45 is provided at either side of the lapping guide array, said lapping guide 45 serving for laying the lock thread 35, unwound from a not shown supply package, into the respective marginal knitting needle 12'.
The shape and operation of said auxiliary lapping guide 45 correspond to those of the lapping guides 4. Practically, the number of lapping guides 4 is thus increased by two additional ones only.
According to a second of preferred embodiments (FIG. 10), a hook 47 situated at either side of the knitting needle system, is associated to each of the auxiliary lapping guides 45. Such hook 47 is operable simultaneously with the knitting needles 12 and may be embodied, for example, as a latchless knitting needle.
In accordance with a third preferred embodiment of the apparatus for producing selvage structures (FIG. 11), there are provided auxiliary lapping guides 45 substantially as shown in FIG. 8. However, the intermediate start position of the marginal lapping guide 4' is oriented relative to the intermediate start position of the auxiliary lapping guide 45 in such a manner that their geometrical projections onto a not shown horizontal plane are concurrent. Such an operating position of the marginal lapping guide 4' is provided for, e.g., by laterally bending the arm 6 of the lapping guide 4.
By means of the embodiment of the apparatus shown in FIG. 9 it is possible to produce the marginal structure shown in FIGS. 3 and 8, respectively.
FIGS. 12 to 19 inclusive show the process of producing the marginal structure as shown in FIGS. 3 and 8. For the sake of clarity, the knitting needles 12 are tilted down through a right angle into the horizontal plane. The warp threads 2 in the upper shed plane are indicated by short heavy lines 46.
The individual positions of the lapping guides and the corresponding positions of the knitting needles are designated as follows:
A -- lapping guides in the intermediate start position;
B -- lapping guides in an extreme lapping position (moved outwards);
C -- lapping guides in the opposite lapping position (moved inwards);
Ab -- lapping guides between the positions A and B (moving from A to B);
Ba -- lapping guides between the positions A and B (moving from B to A);
Ac -- lapping guides between the positions A and C (moving from A to C);
Ca -- lapping guides between the positions A and C (moving from C to A);
FIG. 12: The lapping guides 4, 45 are in the position A. The knitting needles 12 are in their first positions with old stitches in the closed hooks 13, the not shown reed in the beat-up position, warp threads 2 in the shed exchange phase.
FIG. 13: The lapping guides 4, 45 are in the position AB. In the opening shed position of the warp threads 2, the lapping guides 4, 45 move to the extreme lapping position B while the knitting needles 12 enter the shed under the weft threads 8. The last but one needle 12 enters the shed under the weft thread 8' and the marginal knitting needle 12' under the marginal weft thread 8".
FIG. 14: The lapping guides 4, 45 are in the position B. The hooks 13 of the knitting needles 12 rise and take up the weft threads 8' while the knitting needle 12' takes up the marginal weft thread 8". The weft thread 8' is laid into the hook 13 of the marginal knitting machine 12' and the marginal weft thread 8" is laid onto the latch 14 of said needle 12'. The lock thread 35 is in inoperative or not knitting position.
FIG. 15: The lapping guides 4, 45 are in the position BA. The shed is in the closing phase, lapping guides 4, 45 return to their intermediate start positions and the knitting needles 12 to their foremost positions while their hooks 13 with wefts in are being closed by weft threads laid onto the stems of the knitting needles 12, the latch 14 of the marginal knitting needle 12' only being closed by the old stitch.
FIG. 16: The lapping guides 4, 45 are in the position A and the knitting needles 12 are in their front position. In the closed hook 13 of the marginal knitting needle 12' there is laid the double stitch 36 produced by the stitch 32a from the weft thread 8' and by the stitch 33a from the marginal weft thread 8" which double stitch 36 was drawn through old stitch 34a from the lock thread 35. Simultaneously a shed exchange occurs and the reed 11 is in the beat-up position. Thus the first work cycle is over.
FIG. 17: The lapping guides 4, 45 are in the position AC. As the shed opens, the lapping guides 4, 45 move into their extreme lapping position while the knitting needles 12, 12' enter the shed under the weft threads 8', under the marginal weft thread 8" and under the lock thread 35.
FIG. 18: The lapping guides 4, 45 are in the position C. The shed is in fully open phase. The marginal weft thread 8" is laid into the hook 13 of the knitting needle 12 and onto its stem there is laid the weft thread 8' which is laid into the hook of a not shown knitting needle adjacent the knitting needle 12 shown in FIG. 18. The lock thread 35 is laid into the hook 13, or onto the latch 14 of the marginal knitting needle 12'.
FIG. 19: The lapping guides 4, 45 are in the position CA. During the movement of the knitting needles 12 to the foremost position, a new stitch is being built on the marginal knitting needle 12' from the lock thread 35 by drawing it through a double stitch while on the needle 12 there is formed also a new stitch from the marginal weft thread 8" by drawing it through the old stitch. In this way the second work cycle is ended in the position of the knitting mechanism members as shown in FIG. 12.
FIGS. 20-27 show schematically the process of producing the selvage structure according to FIG. 4 by means of the apparatus illustrated in FIG. 10, which apparatus is characterized in that to each of the auxiliary lapping guide 45 there is associated the hook 47 arranged in either side of the knitting needle system.
FIG. 20: The lapping guides 4, 45 are in the position A, the knitting needles 12 in the foremost position and the weft threads are beaten into the fell of the fabric 24.
FIG. 21: The lapping guides 4, 45 are in the position AB, the knitting needle 12 enters the shed under the weft thread 8', the marginal knitting needle 12' under the marginal thread 8" and the hook 47 under the lock thread 35.
FIG. 22: The lapping guides 4, 45 are in the position C. The hooks 13 of the knitting needles 12 and the hook 47 rise and take up the weft threads 8. The weft thread 8' is laid into the hook 13 of the marginal knitting needle 12', and on its stem there is laid the marginal weft thread 8" and the lock thread 35.
FIG. 23: The lapping guides 4, 45 are in the position CA. The marginal knitting needle 12' pulls the weft thread 8', the latch 14 of the marginal knitting needle 12' closes the hook 13 by the marginal weft thread 8", and the hook 47 tensions the marginal weft thread 8" and the lock thread 35.
FIG. 24: The lapping guides 4, 45 are in the position A. The marginal knitting needle 12' has drawn a loop of the weft thread 8' through the old stitch whereby a new stitch is built while the marginal weft thread 8" and the lock thread 35 are held in the hook 47; the not shown reed beats up the weft threads into the fabric and a shed exchange occurs whereby the first work cycle is over.
FIG. 25: The lapping guides 4, 45 are in the position AC.
FIG. 26: The lapping guides 4, 45 are in the position C. About at a half of the path of knitting needles 12 and the hook 47, i.e., between the foremost and the rear positions thereof, the lock thread 35 and the marginal weft thread 8" slip out of the hook 47 and are engaged by the marginal knitting needle 12'. In such situation depicted in FIG. 26, the marginal weft thread 8" encircling the stem of the marginal knitting needle 12' is laid into the lock 13 of the last but one knitting needle 12 while the lock thread 35 is laid over the latch 14 into the hook 13 of the marginal knitting needle 12'.
FIG. 27: The lapping guides 4, 45 are in the position CA. In the next phase of movement of lapping guides 4, 45 to the position A, the marginal knitting needle 12' draws a loop of lock thread 35 through the old stitch, and the last but one knitting needle 12 draws a loop of the marginal weft thread 8" through the old stitch. Thereafter the knitting mechanism will assume the position according to FIG. 20.
A condition of producing the marginal wale 31 shown in FIG. 4 resides in that during the inward laying, the marginal weft thread 8" must be reliably laid onto the stem of the marginal knitting needle 12', and the lock thread 35 into its hook 13, or onto its latch 14 (FIG. 26); this can be achieved, for example, by a suitable selection of length of the latch 14.
FIGS. 20-25 and 28-29 show schematicaly the process of producing the selvage structure according to FIG. 5 by means of the apparatus arrangement illustrated in FIG. 10, by using a latch 14' as long as possible in view of the correct function of knitting needle. The process of producing the selvage structure in accordance with FIG. 5 is the same as that for producing the structure shown in FIG. 4, up to the position AC shown in FIG. 25. The next steps for the position C are shown in FIG. 28.
FIG. 28: The lapping guides 4, 45 are in the position C. The marginal weft thread 8" and the lock thread 35, after having slipped out of the hook 47, encircle the marginal knitting needle 12', in such a manner that the lock thread 35 is laid into the hook of the marginal knitting needle 12', the marginal weft thread 8" onto the latch 14' of the marginal knitting needle 12' and into the hook 13 of the adjacent knitting needle 12.
FIG. 29: The lapping guides 4, 45 are in the position CA. The knitting needles 12 pull the laid threads. In the hook 13 of the marginal knitting needle 12' there is received the lock thread 35 and the marginal weft thread 8" which latter, however, is simultaneously in the hook 13 of the last but one knitting needle 12. In this way there are built on the marginal knitting needle 12' double stitches 40 in the marginal wale 31 (FIG. 5) which double stitches bind with stitches 32c from the weft threads 8'.
A condition of producing the marginal wale 31 shown in FIG. 5 consists in that during the inward laying, the marginal weft thread 8" must be reliably laid onto the latch 14' of the marginal knitting needle 12' (FIG. 28). This can be achieved, for example, by a suitable selection on length of the latch 14' of said needle.
FIGS. 20, 21, 30-32 and 25-27 show schematically the process of producing the selvage structure according to FIG. 6 by means of the apparatus arrangement illustrated in FIG. 10, by using suitably long latch 14' of the marginal knitting needle 12'. Another condition is to apply such a tension of the marginal weft thread 8" that a length of said thread between the stitch on the last but one knitting needle 12 and the marginal lapping guide 4 will be as straight as possible so that said length will pass over the latch 14' of the marginal knitting needle 12'. The foregoing is apparent from FIG. 30, which shows the lapping guides 4, 45 in the position B.
When comparing FIG. 30 with FIG. 22, a difference can be found in that in FIG. 30 the marginal weft thread 8" passes over the prolonged latch 14' of the marginal knitting needle 12'.
FIG. 31: The lapping guides 4, 45 are in the position BA. The knitting needles 12 and the hook 47 pull the threads laid in. In the hook 47 there are entrapped the lock thread 35 and the marginal weft thread 8" which latter simultaneously lies in the hook 13 of the marginal knitting needle 12' together with the weft thread 8'.
FIG. 32: The lapping guides 4, 45 are in the position A. The marginal knitting needle 12' has drawn, through the old stitch 34d from the lock thread 35, the stitch 32 from the weft thread 8' and the stitch 33 from the marginal weft thread 8" which stitches, in the next work cycle, become double stitch 41 (FIG. 6). The individual phases of said next cycle are shown in FIGS. 25-27, except that the double stitch 41 (not there shown) is drawn over the stem of the marginal knitting needle 12'.
The stitches 34d built from the lock thread 35 simultaneously form the tuck 42 of the connecting loops 38 of the stitches 33d from the marginal weft thread 8" (FIG. 6).
The tuck 42 will arise because the marginal weft thread 8" is laid onto the stem of the marginal knitting needle 12', as results from FIG. 26, and that in the following motion phases, said thread 8" is underlapped by a loop of the lock thread 35.
FIGS. 20, 21, 30-32, 25, 28 and 29 schematically show the process of producing the selvage structure according to FIG. 7 by means of the apparatus arrangement illustrated in FIG. 10.
It is a condition of producing the afore-described selvage structure that during the movement of the lapping guides 4, 45 from the position A to the position B, both the weft thread 8' and the marginal weft thread 8" (FIGS. 30, 31) must be laid into the hook 13 or onto the latch 14' of the marginal knitting needle 12', and that during the laying motion from the position A to the position C both the marginal weft thread 8" and the lock thread 35 (FIGS. 28, 29) must be laid into the same hook 13. In this way there arise double stitches 43 produced by stitches 32e from the weft thread 8' and by stitches 33e from the marginal weft thread 8", which double stitches 43 bind with double stitches 44 built by stitches 33e from the marginal weft thread 8" and by stitches 34e from the lock thread 35.
The afore-mentioned conditions can be achieved by using a marginal knitting needle 12' having a latch 14' as long as possible.
By means of the arrangement shown in FIG. 11, which uses the bent marginal lapping guide 4', it is possible to build-in a manner similar to the apparatus arrangement according to FIG. 10 -- the selvage structures illustrated in FIGS. 4, 5, 6 and 7. The encircling of the marginal knitting needle 12' (FIG. 11), as the lapping guides 4, 45 move from the position A to the position C, is ensured since the marginal knitting needle 12', during its movement into the shed, passes the marginal weft thread 8" at the left side thereof, that is, at the right-hand fabric selvage.
FIGS. 3 to 8 show selvage structures at the right-hand side of the fabric. The left-hand selvage structures (not shown) are mirror images of the right-hand ones. The process of building the left-hand selvage structures corresponds to that of building the right-hand ones. Also FIGS. 9-11 show a knitting mechanism for building right-hand selvage structures. The function of the knitting mechanism for building left-hand selvage structures is the same as that of the knitting mechanism for building the right-hand selvage structures.
The selvage structures as illustrated in FIGS. 3 to 7 are feasible in manufacturing knit-woven fabrics disclosed in the Czechoslovak Inventor's Certificates Nos. 162,119 and 162,120 under the conditions set forth with each particular selvage structure.
In the event the constant lapping conditions, especially as regards the marginal weft thread 8", are not kept -- which is possible if using weaves other than a plain weave -- a wale may arise which is built by parts of or individual stitches which are typical for the particular kinds of weave. This, however, is not a drawback since in every case a firm run-proof selvage of knit-woven fabric is obtained.
Although the invention is illustrated and described with reference to a plurality of preferred embodiments thereof, it is to be expressly understood that it is in no way limited to the disclosure of such a plurality of preferred embodiments, but is capable of numerous modifications within the scope of the appended claims. | There is disclosed an apparatus for producing a selvage structure of a knit-woven fabric. The knit-woven fabric is produced in a warp-knit structure from weft thread loops and comprises spaced apart stitch wales with warp thread groups disposed therebetween, the warp threads being interlaced with stitch connecting loops to form a weave. The selvage of such fabric consists of a weft thread and a marginal weft thread, and comprises a marginal wale built by mutually binding stitches from a weft thread, stitches from a marginal weft thread, and stitches from a lock thread.
The apparatus for producing the aforedescribed selvage structure comprises a knitting mechanism for building a warp-knit structure from loops of weft thread, unwound from a stationary supply, said knitting mechanism comprising, on the one hand, a system of lapping guides the lapping arms of which are reciprocatorily swingable in open shed from an intermediate start position to one of extreme lapping positions and back again, the lapping guides protruding permanently between warp threads of at least one of the two shed planes, and, on the other hand, a system of knitting needles with closable hooks, of which number corresponds to that of lapping guides, the knitting needle system being arranged across the fabric and mounted for reciprocation from a foremost start position in front of the beat-up plane of the fabric to an operating position in open shed and back again, in order to engage the weft threads being laid, at either side of the system of lapping guides an auxiliary lapping guide is arranged for laying the lock thread, into the marginal knitting needle, the operation of said auxiliary lapping guide being the same as that of the lapping guides. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/020,983, filed Jan. 28, 2008; which is a continuation of U.S. patent application Ser. No. 11/286,268, filed Nov. 22, 2005, now U.S. Pat. No. 7,370,381; which claims priority to U.S. Provisional Application Ser. No. 60/630,552 filed on Nov. 22, 2004, each of these applications are fully incorporated herein by reference for all purposes.
BACKGROUND
[0002] 1. Technical Field
[0003] The technical field relates to a scheme for ranking results, and more specifically, to a rating scheme to rank video search results by a number of factors.
[0004] 2. Background Art
[0005] Standard web crawlers were originally designed for web pages where the bulk of useful information about the page was contained in an HTML text file. In web pages today, it is increasingly common for the useful information about the page to be contained in a variety of different files, which are all assembled in the browser to create the complete application. Because of this, standard web crawlers are unable to find much of the multimedia and video content available on modern web pages.
[0006] Even for the video content that is found by standard web crawlers, the result of the search often provides video content that may be out-of-date, poor quality, or not relevant to a search query from a user. Traditional search engines lack the ability to efficiently and more accurately organize these search results. There is a need for improved techniques for organizing the results from such searches to provide higher accuracy and greater ease of use for the user.
SUMMARY
[0007] The present invention provides solutions for at least some of the drawbacks discussed above. Specifically, some embodiments of the present invention provide a Ranking Engine that is a rating scheme used in the Truveo Search Engine to rank video search results by factors such as, but not limited to, popularity, timeliness and/or user preferences. It enables the Truveo Search Engine to provide highly targeted search results to users. It is designed to operate effectively in the absence of any user input, however, it uses any provided user input to improve the accuracy of the search results. In one aspect, the present invention provides memory-based reasoning algorithms to ensure highly accurate search results with minimal user input. Extensive metadata enables advanced parametric search when desired. At least some of these and other objectives described herein will be met by embodiments of the present invention.
[0008] In one embodiment of the present invention, a computer-implemented method is provided for a ranking engine. The method comprises assigning a score to each file or record based on at least the following factors: recency, editorial popularity, and clickthru popularity. The files are organized based on the assigned scores.
[0009] In another embodiment of the present invention, a computer-implemented method is provided for a ranking engine. The method comprises assigning a score to each file or record based on at least the following factors: recency, editorial popularity, clickthru popularity, favorites metadata, and favorites collaborative filtering. The files are organized based on the assigned scores.
[0010] In yet another embodiment of the present invention, a computer system is provided that comprises of a ranking engine having programming code for displaying results of a search query based on scores, wherein the scores for files found in the search are based on at least the following factors: recency, editorial popularity, and clickthru popularity.
[0011] In a still further embodiment of the present invention, a computer system is provided that comprises of a ranking engine having programming code for displaying results of a search query based on scores, wherein the scores for files found in the search are based on at least the following factors: recency, editorial popularity, popularity, favorites metadata, and favorites collaborative filtering.
[0012] The files may be media files, video files, video streams, or the like. The editorial popularity may be weighted between 1 and 0 and is based on at least one of the following: Neilsen ratings, known brand names, website popularity (e.g. Alexa ranking), or the judgment of a professional or corporation with expertise in online media. In one embodiment, the weighting of favorites metadata is R md =0 if no matches are found or 1 if a keyword field in the metadata of the file matches any favorite titles in a user's favorite titles file, any favorite people in a user's favorite people file, or any keyword in a user's favorite keywords file.
[0013] In yet another embodiment of the present invention, a computer-implemented method is provided for organizing a collection of files from an Internet search. The method comprises assigning a score to each file based on favorites collaborative filtering W cf R cf and at least one of the following factors: recency W r R r , editorial popularity W e R e , clickthru popularity W c R c , and favorites metadata W md R md . The files are organized based on the assigned scores.
[0014] In yet another embodiment of the present invention, a computer system is provided that comprises of a ranking engine having programming code for displaying results of a search query based on scores, wherein the scores for files found in the search are based on favorites collaborative filtering W cf R cf and at least one of the following factors: recency W f R f , editorial popularity W e R e , clickthru popularity W c R c , and favorites metadata W md R md .
[0015] For any of the embodiments herein, the files may be media files, video files, video streams, or the like. Optionally, the editorial popularity may be weighted between 1 and 0 and is based on at least one of the following: Neilsen ratings, known brand names, website popularity (e.g. Alexa ranking), or the judgment of a professional or corporation with expertise in online media. In one embodiment, the weighting of favorites metadata is R md =0 if no matches are found or 1 if a keyword field in the metadata of the file matches any favorite titles in a user's favorite titles file, any favorite people in a user's favorite people file, or any keyword in a user's favorite keywords file.
[0016] A further understanding of the nature and advantages of the invention will become apparent by reference to the remaining portions of the specification and-drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a schematic of one embodiment of the present invention.
[0018] FIG. 2 is a graph showing variables plotted for recency ranking according to the present invention.
[0019] FIG. 3 is a graph showing the relationship of similarity and popularity weighting according to the present invention.
[0020] FIG. 4 shows one embodiment of a display showing results from a search query.
[0021] FIG. 5 shows one embodiment of a user interface according to the present invention.
DETAILED DESCRIPTION
[0022] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. It may be noted that, as used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a crawler” may include multiple crawlers, and the like. References cited herein are hereby incorporated by reference in their entirety, except to the extent that they conflict with teachings explicitly set forth in this specification.
[0023] Referring now to FIG. 1 , a schematic is shown of the Truveo Search Engine which is configured for use with the present ranking scheme. As seen in FIG. 1 , the search engine may include a recommendation engine 10 . The engine 10 may use reasoning algorithms to provide highly accurate search results with minimal user input. In one embodiment, the recommendation engine may use a ranking scheme as set forth below.
[0024] Truveo Ranking Scheme:
[0000]
[0000] where: 0<R i <1
and: 1=W r +W e +W c +W md +W cf
0<R T <1
Term 1: Recency Ranking:
[0025]
R
r
{
1
-
1
t
e
(
d
c
-
d
F
)
,
For
(
d
c
-
d
F
)
<
t
e
0
,
For
(
d
c
-
d
F
)
>
t
e
[0000] where:
t e =expiration time (perhaps ˜30 days)
d c =current date
d F =date found
This yields the relationship as shown in FIG. 2 .
Term 2: Editorial Popularity Ranking:
[0026] Each database entry (e.g., item) is assigned a value for ‘EDITORIAL_RANK’, based on how popular the content is expected to be. This could be based on expected viewership for known brand names, previous Neilsen ratings, etc. The most popular content should approach R e =1. Unknown or unpopular content should approach R e =0. Optionally, the editorial popularity rank may also have a time decay component to give weight or more weight to more recent popularity information.
Term 3: Clickthru Popularity Ranking:
[0027]
R
c
=
W
cpm
R
cpm
+
W
cph
R
cph
+
W
cpd
R
cpd
where
:
R
cpm
=
clicks
per
minutes
ranking
=
C
P
M
Max
(
cpm
)
,
(
0
<
R
cpm
<
1
)
over
all
items
R
cph
=
clicks
per
hour
ranking
=
C
P
H
Max
(
cph
)
over
all
items
,
(
0
<
R
cph
<
1
)
R
cpd
=
clicks
per
day
ranking
=
C
P
D
Max
(
cpd
)
,
(
0
<
R
cpd
<
1
)
over
all
items
and
1
=
W
cpm
+
W
cph
+
W
cpd
.
[0028] To implement the clickthru popularity rating, the following fields need to be added to the video data table:
[0000]
TOTAL_CLICKS =
the running tally of clicks that this
item has seen since DATE_FOUND
CPM =
clicks per minute
CPM_COUNTER_BUFFER =
running tally of clicks on this item since
CPM_LAST_CALC
CPM_LAST_CALC =
the time when CPM was last calculated
and CPM_COUNT_BUFFER was
flushed
[0029] Similarly: CPH, CPH_COUNT_BUFFER, CPH_LAST_CALL for clicks-per-hour, and CPD, CPD_COUNT_BUFFER, CPD_LAST_CALC for clicks-per-day.
[0030] These fields can be calculated and update as follows:
[0031] For every user with cookies enabled, each clicked item is stored anonymously in a cookie. Upon a subsequent request to the Truveo search engine (during that same session), the clickthru data in the cookie is processed as follows:
[0000] For every item clicked, increment TOTAL_CLICKS, CPM_COUNT_BUFFER, CPH_COUNT_BUFFER, and CPD_COUNT_BUFFER by 1.
For CPM, if CURRENT_TIME−CPM_LAST_CALL>1 minute,
CPM=CPM_COUNT_BUFFER/(CURRENT_TIME−CPM_LAST_CALC)
[0032] reset CPM_COUNT_BUFFER to 0
set CPM_LAST_CALC to CURRENT_TIME
Similarly for CPD and CPH
[0033] Once this is complete, the user's browser cookie may be flushed to eliminate all cached clickthrus.
Term 4: Favorites Metadata Ranking:
[0034] Note that if the user has not registered for an account, this Ranking, R md , is zero.
[0035] If the user does have a valid account, R md will be determined as follows: User FAVORITES METADATA is stored in 3 database tables: FAVORITE_TITLES, FAVORITE_PEOPLE, FAVORITE_KEYWORDS.
[0036] For a Given Video Data Item:
[0000] If any entry in FAVORITE_TITLES matches any part of the TITLE field or the KEYWORDS Field, R md =1.
[0037] —OR—
[0038] If any entry in the FAVORITE_PEOPLE table matches any part of any of the fields: ACTOR, DIRECTOR, KEYWORDS, PRODUCER, WRITER, LONG_DESCRIPTION, SHORT_DESCRIPTION, R md =1
[0039] —OR—
[0040] If any entry in the FAVORITE_KEYWORDS table matches any part of any of the fields: ACTOR, CATEGORY, DIRECTOR, GENRE, HOST_SITE_NAME, HOST_SITE_URL, KEYWORDS, LONG_DESCRIPTION, SHORT_DESCRIPTION, PRODUCER, TITLE, WRITER, R md =1.
[0000]
Otherwise
,
R
md
=
0
Therefore
:
R
md
=
{
0
,
if
no
metadata
match
1
,
if
metadata
match
[0041] Note: Be sure to Filter matches on trivial metadata entries like single characters, articles or whitespace characters.
[0042] A user's favorites may be determined by, but not limited to, providing a mechanism for the user to indicate their favorite videos, recording the video items they select to view (e.g. through the use of cookies), or by recording the video items they choose to forward via e-mail to other people. The FAVORITE_TITLE, FAVORITE_PEOPLE, and FAVORITE_KEYWORDS tables are populated for the user by extracting the appropriate meta data from the video record of the indicated favorite video.
[0043] Optionally, embodiments of the present application may also include the use of a unique cookie to identify an anonymous user as a substitute for a user account.
Term 5: Favorites Collaborative Filtering Ranking:
[0044] A listing of the Favorite Items (video data records) for each user is stored in the database table FAVORITE_ITEMS.
[0045] Note that, if the user has not registered for an account, this ranking, R cf , is zero.
[0046] If the user does have a valid account, R cf is determined as follows:
[0047] First, calculate the distance between user i and all other users, j:
[0000]
D
i
,
j
=
distance
between
user
i
+
j
=
n
i
-
n
i
,
j
n
i
=
1
-
n
i
,
j
n
i
[0000] where n i is the number of Favorite items user i has stored, and n i,j is the number of user i's Favorites that match Favorites of user j.
[0048] Note that if all of user i's Favorites match a Favorite of user j, then D i,j =0. If none match, D i,j =1.
[0049] Similarly, a measure of the similarity between user i and j can be calculated as follows:
[0000] S i,j =similarity between users i and j =(1 −D i,j =
[0050] Note: S i,j =1 when the users are completely similar, and 0 when there are no similar Favorites between users.
[0051] We can now select the K-Nearest Neighbors to user i based on the similarity ranking. For example, assuming user i has three Favorite items:
[0052] For: User i
[0053] Favorites: ITEMID=103 ITEMID=107 ITEMID=112 n i =3
[0054] K-Nearest Neighbors can be selected as follows:
[0000]
User ID
(j)
n i,j
D i,j
S i,j
Favorite Items ID
1
1
0.66
0.33
101, 102, 103, 110
2
2
0.33
0.66
103, 104, 105, 106, 107
3
0
1
0
101
4
3
0
1
103, 104, 107, 112
5
2
0.33
0.66
106, 107, 109, 110, 111,
112
6
1
0.66
0.33
103, 104
Reranking the Users by Decreasing Similarity:
[0055]
[0000]
Favorite Items Not Already
User ID
S i,j
Stored by User i
4
1
104
K-Nearest Neighbors,
2
0.66
104, 105, 106
where K = 4
{open oversize brace}
5
0.66
106, 109, 110, 111
1
0.33
101, 102, 110
6
0.33
104
3
0
101
[0056] From this ordered list, the K-Nearest Neighbors are the first K items.
[0057] From the K-Nearest Neighbors, we can also determine a popularity rating for each new Favorite item. This can be calculated from the fraction of the K neighbors that have item l in their Favorites list.
[0058] Specifically:
[0000]
[0059] Therefore,
[0000]
Users with
Item ID
This Item
P 1
S max, l
104
4, 2, 1
0.75
1
106
2, 5
0.5
0.66
110
5, 1
0.5
0.66
105
2
0.25
0.66
109
5
0.25
0.66
111
5
0.25
0.66
101
1
0.25
0.33
102
1
0.25
0.33
[0060] Where: S max,l =Maximum similarity across all users with item l in their Favorites list
[0061] Note: Popularity=1 when all KNN contain item l, and P 1 =0 when no KNN contain item l.
[0062] Now, we can determine a ranking for every new item in the K-Nearest Neighbors list:
[0063] For a Given Item l:
[0000] R cf,l =W sim ( S max,l )+(1 −W sim ) P l ,
[0000] where:
W sim =similarity weighting factor
[0000]
=
C
max
sim
(
1
-
1
1
+
n
i
)
,
[0000] where:
0≦C max sim ≦1
[0064] In other words, R cf is a weighted sum of the maximum user similarity for item l and the popularity of item l among KNN such that 0≦R cf ≦1.
[0065] The weighting factor is calculated as a function of n, since the relative importance of user similarity, as compared to popularity, increases with the number of specified Favorite items. In other words, if a user has only specified one Favorite item, n i =1, then the similarity will be either 0 or 1, and therefore it does not have much meaning. Therefore, when n i is small, similarity should be weighed less than popularity.
[0066] C max sim should be set to the value that the similarity weighting factor should approach as n i becomes large. A good range is probably 0.3≦C max sim ≦0.8.
[0067] More specifically, the relationship of the similarity and popularity weighting coefficients can be plotted as shown in FIG. 3 .
[0068] Now, for each new item in KNN, we can calculate the Rank R cf :
[0000]
Item ID
P 1
S max, l
R cf, 1
104
0.75
1
0.86
Assume C max sim = 0.6.
106
0.5
0.66
0.57
For n i = 3:
110
0.5
0.66
0.57
W sim = 0.45
105
0.25
0.66
0.43
109
0.25
0.66
0.43
111
0.25
0.66
0.43
101
0.25
0.33
0.29
102
0.25
0.33
0.29
Note:
R cf is always between 0 and 1
If the maximum similarity to user i for item l is 1, and item l is a Favorite of all
KNN users, R cf = 1
[0069] The popularity will never be below 1/KNN, but the similarity can be zero. As a result, R cf will never be 0 unless C max sim =1 and n i ∞.
[0070] Optionally, embodiments of the present invention may also include a factor for crawl quality in the ranking of search results. By way of non limiting example, Application Crawler results are ranked higher than RSS feed results and RSS feed results higher than results from a generic web crawler.
[0071] Referring now to FIG. 4 , one embodiment of a user interface for presenting the search results is shown. As seen in FIG. 4 , the results may display description of the video content, length of video, time the video was posted, title, website origin, video type, and/or video quality.
[0072] Referring now to FIG. 5 , another embodiment of a user interface is shown. This intuitive Media Center user interface may be used to bring web video to a television and other non-PC video devices. In one embodiment, the present invention provides TiVo style recommendations as well as keyword queries. As seen in FIG. 1 , the television interface (or Media Center interface) shown in FIG. 5 may access the results from the ranking engine and application crawler. Again, video quality, bit rate, description, and other information may be displayed. Videos may also be categorized based on categories such as, but not limited to, news, sports, movies, and other subjects.
[0073] While the invention has been described and illustrated with reference to certain particular embodiments thereof, those skilled in the art will appreciate that various adaptations, changes, modifications, substitutions, deletions, or additions of procedures and protocols may be made without departing from the spirit and scope of the invention. For example, with any of the above embodiments, the recommendation may use a ranking scheme having only a subset of the ranking terms set forth in the formula. By way of example and not limitation, some embodiments may not include Term 5, the Favorites Collaborative Filtering Ranking. In other embodiments, variations may be made to the present embodiment such as but not limited to computing the ranking terms in a different order or the like. It should be understood that the present ranking scheme is not limited to video files and may be used to rank or organize other types of files. It should be understood that the term “files” as in “video files” may include the delivery of the content of the file in the form of a stream from a server (i.e. a media server).
[0074] The publications discussed or cited herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed. U.S. Provisional Application Ser. No. 60/630,552 filed Nov. 22, 2004 and U.S. Provisional Application Ser. No. 60/630,423 filed Nov. 22, 2004, are fully incorporated herein by reference for all purposes. All publications mentioned herein are incorporated herein by reference to disclose and describe the structures and/or methods in connection with which the publications are cited.
[0075] Expected variations or differences in the results are contemplated in accordance with the objects and practices of the present invention. It is intended, therefore, that the invention be defined by the scope of the claims which follow and that such claims be interpreted as broadly as is reasonable. | A computer-implemented method is provided for ranking files from an Internet search. In one embodiment, the method comprises assigning a score to each file based on at least one of the following factors: recency, editorial popularity, clickthru popularity, favorites metadata, or favorites collaborative filtering. The file may be organized based on the assigned scores to provide users with more accurate search results. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of displaying information on a visual device. More specifically, the present invention relates to an apparatus for reducing the display intensity of a screen of a cathode ray tube.
2. Prior Art
In a typical display screen utilizing a cathode ray tube (CRT) to provide a visual display, an unchanging image on the screen will tend to burn that image into the CRT. The video image which results from a high-intensity beam striking the back face of the CRT screen cause the presentation of images on the front of the screen. However, when this high-intensity beam continues to provide an unchanging pattern on the screen for a prolonged period of time, the particular image is permantly "burned-in" on the screen. The burned-in image is quite noticeable even when the CRT is completely deactivated. Normally, this problem results when a video terminal is left unattended for a prolonged period of time, wherein a video pattern is unchanging during this unattended period.
To prevent this burn-in of the CRT, various "screen saver" functions have been implemented in video terminals in the prior art. A typical screen saver funtion implements a circuit for monitoring an interactive device, such as a keyboard. If no interaction has occured for a given period of time, the circuit interacts with the contrast control of the CRT and blanks the screen. Although the blanking function removes high-intensity video images from the CRT, it also leaves the video screen blank. Leaving the screen in the blank mode is disadvantageous because it is difficult to tell if the screen is on or off. Instead of proceeding to a blanking mode, another prior art method never permits the pattern to remain constant once the screen saver function is activated. In this instance colors are changed every few seconds, or a pattern is made to float across the screen randomly preventing any stationary image to remain on the screen.
It is appreciated then, that what is needed is a screen saver function which provides a continuous and unchanging video pattern which will not burn-in the CRT screen.
SUMMARY OF THE INVENTION
The present invention describes an apparatus for controlling a video display on a CRT screen such that it will not burn in the screen when the image in left unchanging for a prolonged period of time. The present invention implements a video digital-to-analog converter which has a dimming function to provide a reduced intensity display to the terminal. The present invention allows hardware dimming and blanking of a video display under software control. A right shift of two bits with a padding by zeroes causes an approximately 75% decrease in the intensity of the screen without significantly changing the existing image. The embodiment of the present invention is incorporated in a semiconductor device which is used to control the colors of the pixels of a video display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the elements of the present invention incorporated in to a semiconductor chip.
FIG. 2 is a graphic representation of a typical composite video signal.
FIG. 3 is a scematic diagram showing a dimming circuit of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention discloses an apparatus for providing a screen saver funtion in a video terminal. In the following description, numerous specific details are set forth such as the use of a specific bit pattern, specific replication of circuits, etc., in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known devices and control lines have not been described in detail in order not to unnecessarily obscure the present invention.
Referring to FIG. 1, a triple 8-bit video palette and digital-to-alalog converter (DAC) circuit embodying the present invention is shown. A data bus 12 is coupled to a control logic 11 and to a palette address register 13. Control logic 11 also accepts signals on lines 15, 16 and 17, as well as on processor control lines 18. Further, control logic 11 provides control signals to palette address register 13 on lines 14 and control signals to palette 19 on lines 23 and bus 24. Control logic 11 is also coupled to bypass multiplexer (MUX) 30 on bypass lines 31, to dim MUX 40 by line 41 and to delay circuit 35 by lines 36 and 37. Palette address register 13 is coupled to palette address decoder 26 which is then coupled to palette 19. Eight-bits of pixel information (P x 0-7) are coupled to palette address register 13 and to data MUX 32 on lines 27. A further 8-bits (P x 8-15) of pixel information are coupled to data MUX 32 on lines 28. Bypass MUX 30 accepts the output of data MUX 32 and the output of palette 19, and then couples one of these outputs to dim MUX 40. Dim MUX 40 provides an output to Red (R) decoder 42, Green (G) decoder 43 and Blue (B) decoder 44, wherein these decoder 42,43 and 44 outputs are coupled to R DAC 52, G DAC 53 and B DAC 54 respectively. R DAC 52, G DAC 53 and B DAC 54 receive a blanking signal from delay circuit 35 and a reference signal from reference generator 39. Delay circuit 35 also provides a synchronizing signal to G DAC 53. R, G and B analogue signals consistent with the RS-343A standard are outputted from R DAC 52, G DAC 53 and B DAC 54, respectively. Reference generator 39 is coupled to external devices (not shown) on lines 42 and 43.
Structurally, the various elements as described above are implemented on a single semiconductor chip 10 as shown by the rectangle enclosing the various blocks and lines. The semiconductor chip 10 of the present invention is packaged in a 44-pin surface mount package which generates an RS-343A compatible red, green and blue (R,G,B) video signals on lines 55, 56 and 57 and drives a doubly-terminated 75-ohm Coax directly, allowing for an easy interface to a color monitor. Although such a highly integrated device is disclosed, it is appreciated that such integration is not necessary to practice the present invention.
In operation, control logic 11 receives a blanking signal on line 15, a synchronizing (sync) signal on line 16 and a clocking signal on line 17, as well as being interfaced to a processor, such as a microprocessor on lines 18. Control logic 11, which also includes a register 20 for receiving data signals from bus 12, provides various control signals and sequences for controlling the other circuits within device 10. The control logic 11 also provides a sync signal and a blanking signal on lines 36 and 37 to delay circuit 35. Delay circuit 35 provides an appropriate synchronizing and blanking signals to the DACs 52-54 after providing proper pipeline delay. Delay circuit 35 also generates an external sync to synchronize the actual display on line 33.
Palette 19 of the present invention is a 256×24 random-accessmemory (RAM), which can store 256 color signals, wherein each color signal is 24 bits long. Color information is loaded into the pallette 19 by providing 8-bit color words on bus 12 to control logic 11. The color data is then transmitted on bus 24 from control logic 11 to palette 19. The necessary control signals are passed between control logic 11 and palette 19 on lines 23. A write signal on one of lines 23 permits the writing of colored data into palette 19 through bus 24. The addressing of palette 19 is provided by palette address register 13 and palette address decoder 26. The control logic 11 after receiving appropriate control signals will initialize palette address register 13. Palette address register 13 accepts 8-bit inputs and generates a 16-bit output to palette address decoder 26. Palette address decoder 26 then decodes the input to an 8-bit palette addressing signal to access palette 19. The 8 bit addressing signal from palette address decoder 26 accesses palette 19 for both read and write functions. When palette 19 is being loaded, a write signal on one of lines 23 and a sequencing address signal on bus 14 will load 256 colors into palette 19.
When palette 19 is to be accessed to provide color information to the display, the pixel information is provided as an 8-bit signal on lines 27. P x 0-7 signal is inputted to the pallet address register 13 and then fed to the palette address decoder 26. The 8 bit P x 0-7 signal selects one of the 256 addresses within palette 19. When pixel information is to be displayed, a read signal is generated on one of lines 23 from control logic 11. Palette 19 will then generate a 24-bit color signal as an output from palette 19 to bypass MUX 30. The color signal is then passed on to dim MUX 40 and then to the decoders 42-44.
Alternatively, P x 0-7 pixel information may be inputted directly to data MUX 32 which is then outputted to bypass MUX 30 as 24 bits of data consisting of three 8-bit words. The bypass MUX 30 is capable of multiplexing between one of two input signals; one from data MUX 32 and the other from palette 19 and selecting one of those outputs to dim MUX 40. Also, in addition, data MUX 32 is capable of receiving P x 8-15 pixel signals on lines 28 and combines them with 8-bits from P x 0-7 to provide a P x 0-15 signal. Further, data MUX 32 generates internal fill-in codes to generate an output signal which is 24 bits. Hence, data MUX 32 always generates 24 bits to bypass MUX 30. Therefore, bypass MUX 30 selects pixel data from information stored in palette 19, or directly passes pixel data presented on line 27 or both lines 27 and 28 mapped to 24 bits.
Bypass MUX 30 generates 24-bits to dim MUX 40. Dim MUX 40 separates the video signal to its R, G and B components for output to decoders 42-44. Dim MUX 40 also receives a dim signal on line 41 from control logic 11 to activate the dimmer function when desired.
The 8-bits to each of the decoders 42-44 are decoded and passed on to DACs 52-54. Each of the decoders 42-44 generates a mixed seqmented/binary weight signal to DACs 52-54. The 6 MSB's are segmented, the 2 LSB's are binary weighted. Since 24 bits are always inputted to DECODERS 42-44 2 24 color combinations are available on lines 55-57.
The preferred embodiment actually has three different modes of operation for the bypass MUX 30. In the first mode, when a gray-tone coloration is desired, 8-bits are passed from P x 0-7 to each of decoders 42-44 and on to its corresponding DACs 52-54. In the second mode, which is intended to support a 16-bit per pixel input, the 16 bits are split into R, G and B groups of 5,6 and 5 bits, respectively. The DATA MUX 32 supplies the padding to convert the 16 bits to the appropriate 24 bit combination. In the third mode, which also is intended as a support for 16-bits per pixel, the 16 bits are split into R, G and B groups of 6,6 and 4 bits respectively. The Data MUX 32 again supplies the padding to convert the 16 bits to the appropriate 24 bit combination. In the preferred embodiment, a sync signal is provided to G DAC 53 from delay circuit 35, although the sync signal may be applied to any of the color DACs. The reference generator requires an external reference resistor and a compensation capicitor on lines 42 and 43 to generate an internal reference signal to the DACs 52-54.
Referring to FIG. 2, a composite video signal 60 is shown. Video signal 60 has a horizontal sync pulse 61, a horizontal blanking pulse 62 and video portion 63. The peak portion 64 of the video signal 60 represents white, while the trough portion 65 represent the black. The signal levels in between the peak 64 and trough 65 represent the variations in the black and white shading and is called the DAC active range. The signal level (voltage level) of the horizontal blanking pulse 62 is at a still lower level in comparison to the voltage level of the black color. Therefore, when the display is under the blanking control, it is typically referred to as blacker-than-black, because the signal level represented by the horizontal blanking pulse 62 is much lower in magnitude than the voltage level represented by the black signal at portion 65. Ideally, what is desired is for the screen saver function to generate a voltage level which does not burn in the screen yet maintains the output in the active range.
Referring to FIG. 3, a circuit 70 which implements the dimming function of the present invention is shown. The circuit 70 is implemented in the dim mux 40 of FIG. 1. The circuit 70 is one of three implemented using 16 NMOS devices and an inverter. Under normal operation the dim signal on line 71 is high, activating transistors 80-87 to permit video signals VD0-VD7 to pass directly to the output which are labeled V0 OUT though V7 OUT. Therefore, video information from bypass MUX 30 of FIG. 1 are imputted to circuit 70 as three sets of VD0-VD7. Under normal operation, these bits are passed directly to decoders 42-44. It is understood that only one circuit 70 is shown to control 8-bits, but in reality three such circuits 70 are used to control three groupings of 8-bits, each for controlling all 24 bits from bypass mux 30. Each grouping of V0-V7 OUT bits are further manipulated in decoders 42-44 of FIG. 1, but V0-V7 OUT represent binary weighted values which translate to a voltage level for controlling the intensity of each of the R, G and B signals.
When dimming is desired the dim signal on line 71 goes low and deactivates transistors 80-87, but due to inverter 72, activates transistors 90-97. In the dim mode VD0 and VD1 are not used and signals VD2 through VD7 are downshifted two lines. Therefore, VD2 is now present on V0 OUT and respectively VD7 is now present on V5 OUT. A ground is placed on lines V6 and V7 OUT due to transistors 96 and 97 which are tied to electrical ground. Hence, the end result is a right shift with a zero fill occuring to the original video signal. In mathematical terms, this translates to an approximate decrease of 75% of the binary weight of the voltage level, resulting in an approximately equivalent reduction in the intensity level of the display screen.
The right shift with a zero fill operation reduces the intensity level of the CRT screen by reducing each of the R, G and B driving signals by approximately 75%. Because all three R, G and B driving signals are reduced equivalently, only the intensity is affected. The image which is present on the screen is still present in a "dimmed" mode and perceived by the eye as a dimmer image. This dim mode indicates to the operator that the screen is active, but prevents the burn-in of the image due to its low intensity.
The dim mode is activated by a novel approach of using software to control the dimming function. The operator may use the dimming funtion as part of his program in controlling the display. The software instruction is transferred to the control logic 11 of FIG. 1 by microprocessor control on lines 18 via the data bus 12, loading the instruction into register 20. The dimming function can be activated by a variety of prior art blanking activation methods as well.
Thus a software controllable hardware CRT dimmer is described. | An apparatus for controlling a video display on a viewing screen such that it will not burn in the screen when the image is left unchanged for a prolonged period of time. A software controlled dimming circuit implements a shifting operation to the digital signal when activated. The shifting results in a lowering of intensity of the screen, yet retaining the original image on the screen. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to furniture construction, in particular, it relates to tensioning fabric in furniture construction.
[0002] Furniture having strips of flexible material or entire sheets of flexible material stretched over a framework are popular. Some methods of stretching flexible sheets of material over chair frames are described in U.S. Pat. Nos. 4,371,142, 4,456,301, 4,592,126, 6,341,822 and 6,345,482.
SUMMARY OF THE INVENTION
[0003] The present invention includes a furniture construction and a method of placing a section of fabric in tension on the furniture construction. The section of fabric is placed in tension between two spaced apart rigid members, each of the rigid members having a slot extending along one side. A sufficiently rigid edge portion is provided on opposite sides of the section of fabric. Each sufficiently rigid edge portion is then inserted into the slot of each rigid member such that the fabric overlies an adjacent side surface of each rigid member. The edge portion of the fabric is sufficiently rigid to retain the fabric within the slot. The rigid members are then moved in opposing directions thereby placing the fabric in tension. The rigid members are then secured to the furniture construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is perspective view of the present invention.
[0005] FIG. 2 is an enlarged perspective view of a portion of the chair construction illustrated in FIG. 1 .
[0006] FIG. 3 a is a sectional view of rigid member with fabric attached thereto.
[0007] FIG. 3 b is a sectional view of an alternative embodiment of the rigid member with fabric attached thereof.
[0008] FIG. 4 is a plan view illustrating a method of placing the fabric section in tension.
DETAILED DESCRIPTION
[0009] A chair construction of the present invention is generally indicated at 10 in FIG. 1 . Like reference characters will be used to indicate like elements in the drawings. Although a chair construction is specifically illustrated, it is understood that the present invention is applicable to other furniture constructions. The present invention also includes a method of placing a section of fabric 12 in tension between two rigid seat members 14 and 16 . As specifically illustrated, the section of fabric 12 and the rigid seat members 14 and 16 form a seat portion 18 of the chair construction 10 . The method of the present invention is also used to form a back portion 34 of the chair construction. Although a single seat chair is illustrated, the method of the present invention may be used for chairs providing for more than single occupancy or which have more than one seat and back portion.
[0010] The chair construction 10 includes a framework 20 that can be made of plastic, aluminum or steel. The framework includes legs 22 , 24 , 26 and 28 . A front crossbrace 25 and a rear crossbrace 27 extend between and connect the legs 26 and 28 and the legs 22 and 24 , respectively. In the embodiment illustrated, the legs 26 and 28 have upper portions 30 and 32 which serve as arms and which are integrally conjoined behind the back portion 34 . The particular construction of the framework 20 is not especially important to the present invention, and is described herein as one exemplary type of framework for which the present invention is suitable.
[0011] To form the seat portion 18 , the rigid seat members 14 and 16 are provided with a downwardly facing slot 36 as best illustrated in FIGS. 2 and 3 . The slot 36 runs the length of the rigid members. The section of fabric 12 includes a semi-rigid or rigid edge portion 38 that extends along the length of opposing edge portions. The fabric section 12 overlies the seat member 16 along an outwardly facing side 31 adjacent to the slot 36 and extends over an upwardly facing side 41 , as illustrated in FIG. 3 . Although only the seat member 16 is specifically illustrated in FIG. 3 , the seat member 14 is similar as a mirror image in both construction and how the fabric section 12 overlies the seat member 14 .
[0012] An alternative embodiment of the seat member 16 is illustrated in FIG. 3 b. In FIG. 3 b, the fabric section 12 overlies a seat member 16 ′. The semi-rigid or rigid edge portion 38 is positioned in an upwardly facing slot 36 ′. The fabric 12 covers the edge portion 38 . Similarly, as with respect to member 16 , a mirror image member (not illustrated) of member 16 ′ receives a similar opposing edge portion 38 of the fabric 12 .
[0013] The semi-rigid or rigid edge portion 38 is made sufficiently rigid to secure the section of fabric 12 to the seat member 16 by engagement with the slot 36 . Preferably, the edge portion 38 is made of a section of plastic 40 that is attached to an edge portion 42 of the section of fabric 12 by a method that is well known such as sewing, gluing or thermo welding using ultrasonic or electronic means. For example, such rigid edge portions are provided to canvas tops for Jeep Wrangler vehicles made by Chrysler-Daimler to secure the canvas in certain places along the vehicle by engaging selectively positioned slots. It should be understood that other constructions and methods are included within the present invention to make the edge portion 38 sufficiently rigid to secure the fabric to either seat member 14 or 16 . By sufficiently rigid is meant that once the edge portion is positioned within the slot and the fabric is placed along the adjacent side 31 , the edge portion is retained within the slot since the edge portion cannot slide out due to its rigidity.
[0014] The edge portion 38 is also retained within slot 36 ′ of FIG. 3 b since the edge portion 38 cannot slide out due to its rigidity and that the tension on the fabric 12 is essentially perpendicular to the longitudinal plane of the slot.
[0015] The section of fabric 12 is made of a fabric normally used in the construction of outdoor furniture of a stretch fabric woven from an all-weather, vinyl-coated, flexible and elastic polyester yarn, such as PHIFERTEX® fabric made by Phifer Wire Products, Inc. of Tuscaloosa, Ala. An example of a stretchable fabric useful in this invention is described in U.S. patent application Ser. No. 10/369,444, entitled Chair Seat With Firm But Resilient Front Edge, filed on Feb. 19, 2003, which is herein incorporated by reference in its entirety.
[0016] The section of fabric 12 of the seat portion 18 is placed in tension by initially inserting the rigid edge portions 38 into the slots 36 of the rigid seat members 14 and 16 . In one example of the method of construction of the present invention, rigid seat members 14 and 16 each have two sets of apertures 46 and 47 with one set of aperture positioned near the front crossbrace and one set of apertures positioned near the rear crossbrace, as best illustrated in FIGS. 2 and 4 .
[0017] The apertures 46 and 47 are engaged by spreader tools 48 and 50 . Referring to FIG. 4 , the spreader tool 50 is illustrated with respect to the fabric 12 , and in relation to the front crossbrace 25 . Both spreader tools 48 and 50 are essentially the same, and therefore only spreader tool 50 will be described. The spreader tool 50 includes a pneumatic or hydraulic cylinder 52 which provides a force to move the seat members 14 and 16 in the direction of arrows 54 . The spreader tool 50 at each end includes pins 56 and 58 which engage apertures 46 and 47 of the rigid seat members 14 and 16 , respectively. Each pin 56 and 58 engages both the apertures 46 and 47 to prevent the seat members 14 and 16 from rotating about their axis when the section of fabric is placed in tension. Both spreader tools 48 and 50 are used to move the seat members 14 and 16 away from each other to place the section of fabric 12 in tension.
[0018] To retain the seat members 14 and 16 in position on the frame 20 , the front crossbrace 25 includes retainer tabs 64 and 66 . Similarly, the rear crossbrace 27 includes similar retainer tabs, only one of which is shown ( 68 ). The retainer tabs of the front and rear crossbraces are positioned from each other at a distance which matches a selected distance which seat members 14 and 16 are to be spread apart for the selected tension of the section of fabric 12 .
[0019] The spreader tools 48 and 50 spread the seat members 14 and 16 sufficiently far enough so that inside faces 60 and 62 of the seat members 14 and 16 extend beyond the retaining tabs 64 and 66 . The retaining tabs are preferably permanently secured to the respective crossbraces such as by welding.
[0020] Once the seat members 14 and 16 are positioned beyond the retaining tabs of the front and rear crossbraces, the spreader tools 48 and 50 may be drawn in and the pins disengaged from apertures 46 and 47 . Just prior to the disengagement of the spreader tools or directly thereafter, the seat members 14 and 16 are secured to the retaining tabs by screws 70 and 72 which extend through apertures 74 and 75 and into the seat members 14 and 16 . The seat members 14 and 16 are similarly attached to the retaining tabs of the rear crossbrace 27 . The screws 70 and 72 are exemplary of fasteners that may be used to secure the seat members 14 and 16 in position. Other fasteners or other fastening systems such as adhesives or welding are included within the present invention. Detachable fasteners such as screws have the advantage that the section of fabric may be easily replaced by detaching the seat members 14 and 16 from the frame 20 .
[0021] The back portion 34 is similarly constructed. The back portion 34 is also made of a section of fabric 76 that is in tension between back rigid members 78 and 80 , as best illustrated in FIG. 1 . The back members 78 and 80 are similar in construction and have the same cross-section as the seat members 14 and 16 illustrated in FIG. 3 a. The section of fabric 76 also includes rigid end portions similar to the edge portions of fabric 12 that are placed within the slots of the back members 78 and 80 . The slots of back members 78 and 80 may face rearwardly, or forwardly. If facing rearwardly, the back member 78 and 80 are of a similar construction as illustrated in FIG. 3 a. If they face forwardly, the back members 78 and 80 are of a cross-sectional construction similar to what is shown in FIG. 3 b. The section of fabric 76 is also placed into tension in a similar manner using spreader tools 48 and 50 . The back members 78 and 80 are spread sufficiently far apart to extend beyond retaining tabs 82 and 80 that extend from the rear crossbrace 27 and retaining tabs 84 and 85 which extend from arm sections 30 and 32 that extend behind the back portion 34 of the chair. The retaining tabs are preferably fixedly attached to the crossbrace and arm sections such as by welding.
[0022] Once the back members 78 and 80 are moved beyond the retaining tabs 81 , 84 and 82 , 85 , the back members 78 and 80 are attached to the retaining tabs, and the spreader tools are disengaged from the back members 78 and 80 . Screws (not illustrated) are used in the same manner as screws 70 and 72 to attach the back members 78 and 80 to the retaining tabs 81 , 82 , 84 and 85 .
[0023] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | A furniture construction and a method of placing a section of fabric in tension on the furniture construction includes providing a pair of rigid members each having a slot extending along one side. A rigid edge portion is provided on opposite sides of the section of fabric. Each rigid edge portion is then inserted into the slot of each rigid member such that the fabric overlies an adjacent side surface of each rigid member. The rigid members are then moved in opposing directions thereby place the fabric in tension. The edge portion of the fabric is sufficiently rigid to retain the fabric within the slot and thereby retain the fabric in tension. The rigid members are then secured to the furniture construction. | 0 |
TECHNICAL FIELD
This invention relates to a shock dampener for moving parts of a robotic manipulator, and, more particularly, to a rotator bearing shock dampener for the main bearing in the base of a robotic manipulator.
BACKGROUND ART
Most robotic manipulator structures include some type of base member which is often immovably connected to a mounting in a floor or similar structure, and a turret or turntable portion which rotates relative the base member to alter the position of the payload or working portion of the robotic manipulator. Quick starts and stops of such rotating turntable, as well as sudden changes in the effective loading of extendable robotic arms and the like, often transfer the impact of such movements in the form of sudden shocks and vibrations in the form of rocking vibrations and shocks to said turntable, and more particularly to the main bearing of the base. Additionally, external vibrations and shocks can be imposed on a robotic manipulator, such as by other equipment operating nearby. Due to the inherent compliances and clearances within the interacting parts at the interface of the turntable and the base (especially at the main bearing thereof), often a limited amount of displacement can be introduced into the system by such various shocks, vibrations, and jolts. In applications such as robotic manipulators where accurate and steady movement is often critical to successfully accomplishing the task at hand, even a relatively small amount of backlash or slack can be very harmful. If the amount of compliance in a system is relatively substantial, the robotic manipulator is much less reliable and accurate in its functions and, possibly, inappropriate for delicate operations. In modern applications which rely immensely on operations which require precise movements, such slack or backlash becomes increasingly more intolerable.
An example of a relatively simple robotic arm having a bearing support is shown in U.S. Pat. No. 4,546,233, which issued to H. Yasuoka on Oct. 8, 1985. In particular, this patent describes an arc-welding robot which includes a stationary table fixed to a floor, and having a rotary table mounted for rotation thereon by a pair of bearings. As shown in the drawings, the bearings are spaced apart longitudinally to support the rotary table in a rotatable manner on the stationary table. While the Yasuoka structure includes a tension spring to reduce the load bearing on the arm tilting motor, it does not include any structure intended to dampen the inherent shocks and jolts which the rotary table will convey to the stationary table during normal use.
Similarly, U.S. Pat. No. 4,392,776, issued to L. Y. Shum on July 12, 1983, describes a robotic manipulator structure including a base which rotatably supports a first swinging arm for rotation relative thereto. The first swinging arm is carried at its proximate end by a hollow shaft which is supported for rotation relative the base by a pair of spaced bearings. Like the Yasuoka structure, the Shum robotic manipulator structure utilizes the main rotator bearings to support a rotatable manipulator structure without any means for damping the inherent shocks and jolts which the robot's moveable arm and rotatable mechanism will inherently impose on the stationary base thereof.
Consequently, despite the universal knowledge in the industry that unwanted displacement or compliances in the moving parts of a robot are becoming increasingly more intolerable as the need for precision increases, there remain problems in effectively and efficiently eliminating such inherent displacement or compliances resulting from shocks, jolts and vibrations commonly encountered by rotator bearings in the base of such robotic manipulators.
DISCLOSURE OF THE INVENTION
It is an object of this invention to obviate the above-described problems.
It is another object of the present invention to provide a damping device for a rotator bearing of a robotic manipulator in a relatively simple, inexpensive and reliable manner.
It is yet another object of the present invention to provide a rotator bearing shock and vibration dampener for the base main bearing of a robotic manipulator which utilizes an oil film damping arrangement to effectively increase the dynamic stiffness of such manipulator.
In accordance with one aspect of the present invention, there is provided a rotator bearing shock and vibration dampener for the base main bearing of a robotic manipulator, with such shock and vibration dampener including a robotic manipulator base having a main bearing race formed therein, and an oil damp well space having a relatively thin, predetermined depth relative its surface area formed within the base adjacent the bearing race. The shock dampener further includes a main bearing for the robotic manipulator which is fitted within the bearing race, and a robotic manipulator turntable mounted for rotation relative the base and being supported by the main bearing. A predetermined volume of damping oil surrounds the main bearing in the base and fills the oil damp well space, whereby the damping oil normally resides in the well space, and the well space is formed with relatively limited inlets and outlets for the damping oil such that the oil tends to resist compression and displacement, thereby damping vibrations, mechanical shocks and jolts encountered by the robotic manipulator in use, and increasing the effective dynamic stiffness of the turntable relative to the base.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a top view, partially broken away, of the lower portion of a robotic manipulator including a base main bearing and a rotator bearing shock dampener of the subject invention; and
FIG. 2 is a cross sectional view of the lower portions of the robotic manipulator shown in FIG. 1, and taken along lines 2--2 thereof.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in detail, wherein like numerals indicate the same elements throughout the views, a top view of the lower portions of a robotic manipulator 10 is shown in the partially broken-away view of FIG. 1. In particular, a robotic manipulator base 12 is shown as including a drive gear assembly 40, which provides rotational input to the output driven gear 50, which serves to rotate the upper turret or turntable 14 of robotic manipulator 10 relative base 12. In particular, drive gear assembly 40 includes a main drive means 41 which receives rotational input from a rotational input means 60 (e.g. a servo-type motor) via rotational input transfer means 65. While rotational input transfer means 65 is shown as including a drive belt or chain 66, a drive shaft 67, drive transmission means 68 and bevel gear 69 to transfer such rotational input to main drive means 41, this structure is shown only as an example of the plethora of ways in which such rotation could be applied thereto. It is not critical how such rotational input is applied to main drive means 41.
As best illustrated in FIG. 2, rotational motion which is transferred from rotational input means 60 to main drive means 41 is, in turn, transferred to first drive gear 42 and second drive gear 43 integrally mounted on the lower distal end of main drive means 41. External gear teeth of first drive gear 42 mesh with corresponding gear teeth of transfer gear 44 (which can be a speed reduction gear), as shown in FIG. 2. Transfer gear 44 serves to transfer such rotational input from drive gear 42 to shaft 45 (upon which transfer gear 44 is mounted) and the integral rotator gear 46 at the upper end of shaft 45. Rotator gear 46 includes teeth which mesh with corresponding gear teeth of output driven gear 50 to thereby provide rotational movement to turret or turntable 14 relative base 12. Similarly, second drive gear 43 located above first drive gear 42 on main drive means 41 meshes with a second tranfer gear 47 (see FIG. 1) which transfers rotational input to a second shaft 48 and a second rotator gear 49 integrally connected to the upper end of shaft 48, which also meshes with output driven gear 50 to provide a dual drive system therefor. In this regard, it is contemplated that main drive means 41 can comprise two concentrically arranged shaft portions connected to first drive gear 42 and second drive gear 43, respectively, and connected together by means of a torsion elastic spring means located therebetween. It is further contemplated that the torsion elastic spring means can be preloaded with a predetermined amount of torque force such that first drive gear 42 and second drive gear 43 maintain constant torque force between the respective intermeshing teeth of their transfer gears, rotator gears, and the output driven gear 50. In this preloaded arrangement, first drive gear 42 and second drive gear 43 are simultaneously rotated by the single rotational input means 60 and its rotational input transfer means 65, as described above. This dual drive gear assembly is utilized to maintain such predetermined torque force at each gear interface throughout the system to eliminate backlash commonly encountered in robotic manipulator applications. This unique anti-backlash gear assembly is more fully described in the commonly owned, co-pending application entitled "Preloaded Anti-Backlash Gear Assembly," which was filed in the name of Edward J. Bailey on the same day as the present application, said application being hereby incorporated herein by reference. It should be noted that while such a dual drive gear assembly is preferred, the principles of the subject invention can equally be applied to a single or multiple drive gear system.
As best illustrated in FIG. 2, base 12 of robotic manipulator 10 is to be formed with a bearing race 25 adjacent its upper portion designed to provide adequate support for main rotator bearing 20 for rotatingly mounting turntable 14 to base 12. It is also contemplated that the lower outer portions of turntable 14 can be fitted with output driven gear 50. As shown in FIG. 2, main rotator bearing 20 is mounted in bearing race 25 between the outer periphery thereof and the inner periphery of output driven gear 50 which is attached to turntable 14. Output driven gear 50 includes external gear teeth about its outer periphery which are designed to correspond and mesh with the gear teeth of rotator gears 46 and 49 respectively, to provide rotational movement to turntable 14 relative base 12 in response to rotational input from input means 60 through drive gear assembly 40.
A closer look at the bearing race 25, bearing 20, and output driven gear 50 assembly of FIG. 2 further shows that formed adjacent such assembly are lower oil damp well space 30 and upper oil damp well space 31. In particular, oil damp well spaces 30 and 31 feature relatively small depth in relation to their surface area, and are located above and below main rotator bearing 20 and output driven gear 50 as mounted in robotic manipulator 10. Technically, a comparison of depth to surface area must be made by comparing the depth squared relative such surface area in order to keep the units of measurement compatible. Lower oil damp well space 30 is formed in base 12 below gear 50, while upper oil damp well space 31 is formed in turntable 14 above bearing race 25. The depth of these oil damp wells can vary for particular applications, but must be relatively thin when compared to the surface area over which such gap or space extends. In particular, these oil damp well spaces permit the maintenance of a thin oil film above bearing 20 and below output driven gear 50 in use. A resulting relatively wide but thin film of oil provides an oil film damper which can quite effectively dampen the inherent shocks, jolts, and vibrations at this turntable/base interface during normal robotic activities.
For example, it is contemplated that oil damp well spaces 30 and 31 might have a depth or thickness in a range of between about 0.003 inches and about 0.15 inches (e.g. about 0.076 millimeters and about 3.8 millimeters) for a surface area which is approximately one hundred and eighty times such depth (or about 18 square inches or 117 square centimeters). While these figures are simply provided as an example of the relative dimensions of oil damp well spaces 30 and 31, the exact numbers can vary according to the requirements of a particular application depending on variables such as oil viscosity, thickness of the well spaces, and surface area. It is critical, however, that the resulting oil films maintained within well spaces 30 and 31 be relatively thin in comparison with the surface area of such gaps to establish oppositely disposed oil films on the top of the bearing and on the bottom of the output driven gear. In use, because the oil held within oil damp well spaces 30 and 31 will have very limited inlet and outlet paths, upon imposition of shocks, jolts, and/or vibrations to bearing 20 and output driven gear 50 as a result of sudden movements or load variations or the like by the robotic manipulator and external vibrations and shocks imposed thereon, the oil within such damp well spaces cannot quickly move out of such spaces and inherently tends to resist compression, thereby effectively absorbing such energy input and providing additional dynamic stiffness to turntable 14 relative base 12. Because movement of the oil in to and out of the oil damp well spaces 30 and 31 will be restricted by the viscosity of the oil and the limited avenues of fluid communication between such well spaces and the larger reservoir of oil (not shown) in the base of a robot, these shock, jolt, and vibration forces will be dampened by the relatively slow moving oil.
It is contemplated that the limited avenues of movement of the oil to and from the oil damp well spaces 30 and 31 can comprise the inherent clearances within main rotator bearing 20 as mounted on bearing race 25 and the spaces between the gear teeth of output driven gear 50 of turntable 14. It is further contemplated that at least a portion of base 12 could be filled with gear oil to a level at least as high as the upper portion of upper oil well damp space 31 to provide a consistent source of oil to flow into and out of such well spaces. Such gear oil could also be utilized to lubricate drive gear assembly 40 as desired. In this regard, FIG. 2 illustrates an example of a seal 33 which might be of the O-ring type to provide sealing containment of the oil within base 12 at the turntable/base interface.
As mentioned above, the viscosity of the oil within the well spaces 30 and 31 in part determines the incremental amount of effective stiffness which the subject oil film damper provides to the robotic manipulator. In particular, higher viscosity oil would result in higher incremental effective stiffness in a given application. It is also contemplated that the depth of the oil damp well spaces can be varied, and the available avenues of entry and outlet of oil relative such well spaces could also be adjusted as desired. Obviously, a narrower well space and/or more restricted avenues of inlet and outlet of oil from such oil spaces would effectively increase the resulting stiffness. As an example, oil damp well spaces having a thickness and surface area within the ranges described above were successfully utilized and substantially increased the stiffness of a turntable 14 relative a base 12, wherein the output driven gear 50 had an approximate outside diameter of about 12 inches (or about 305 millimeters), and wherein the oil utilized was common SAE 90 weight gear oil.
In use, as turntable 14 is rotated about base 12, and as various other robotic manipulator parts are moved and achieve various tasks, various shocks, jolts and vibrations are commonly transferred from turntable 14 to base 12. In a robotic manipulator 10 having the oil film damping means shown and described herein, these unwanted forces tend to compress the oil within oil damp well spaces 30 and 31, respectively. As oil is substantially incompressible, such compressive forces act to squeeze the oil alternately in to and out of such well spaces. As described above, there are limited avenues of access relative such well spaces, and, therefore, the oil cannot move quickly enough to accommodate these compressive forces. Consequently, the slow moving oil acts to dampen or absorb such vibrations and forces as it is forced through the limited avenues of access of the respective well spaces. As a result, the oil damp well spaces serve to provide a dynamic damping ring above the inner race of the bearing and output below the outer race of the bearing and driven gear of the robotic manipulator improving the effective dynamic stiffness of the turntable 14 relative base 12 and greatly reducing unwanted displacement or compliance which can often be precipitated by such vibrations and the like. It should be noted that oil film dampers made in accordance herewith can be designed quite easily for custom applications whereby the controlled area of the oil film damp well spaces can be adjusted relative the depth of such spaces, as well as in light of the oil viscosity to be utilized, and the avenues of inlet and outlet for such oil relative such well spaces. Such oil film dampers are quite effective in substantially increasing the effective dynamic stiffness of a robotic turntable relative its base in a relatively simple and economic manner.
Having shown and described the preferred embodiment of the present invention, further adaptions of the oil film damper structure can be accomplished by appropriate modification of such structure by one of ordinary skill in the art without departing from the scope of the present invention. For example, the subject oil film damper structure could be utilized in any rotator bearing location in a robotic manipulator having a base portion with a bearing race formed therein, and a turntable portion mounted for rotation relative such base, where routine shocks and vibrations negatively impact on the effective stiffness of the rotating part relative its base. While the base portion may be an actual base member of a robotic manipulator, as illustrated in the figures, it should be noted that the term "base" is used herein to connote any portion of a robotic manipulator which provides a rotator bearing attachment of a moving part (i.e. a turntable portion) for rotation relative thereto. Accordingly, the scope of the present invention should be considered in terms of the following claims, it is understood not to be limited to the details of structure and operation shown and described in the specification and drawings. | There is provided a rotator bearing shock and vibration dampener for the rotator bearing of a robotic manipulator, with such shock dampener including a stationary robot base and a rotary turntable, and a large rotary turntable bearing having its inner race bolted to the stationary base and its outer race bolted to the rotary turntable. An oil damp well space having a relatively thin, predetermined depth squared relative its surface area is formed in the base below the outer race and in the turntable above the inner race. A predetermined volume of damping oil is located adjacent the turntable bearing in the base and fills the oil damp well space, whereby the damping oil normally resides in the well space to provide an oil film therewithin. The well space is formed with relatively limited inlets and outlets for the damping oil such that the oil film tends to resist compression and displacement, thereby damping vibrations, mechanical shocks and jolts encountered by the robotic manipulator in use, and increasing the effective dynamic stiffness of the turntable relative to the base. | 5 |
BACKGROUND OF THE INVENTION
Various multi-pane primary window structures and storm window arrangements based on the thermal insulation achieved from a dead air space or spaces are known in the prior art. Prior U.S. Pat. No. 3,925,945 discloses the concept of venting a dead air space in a window unit to the ambient atmosphere during the summer and to an interior building space during winter. Such venting in the prior patent is accomplished by bodily pivoting or reversing the entire window frame in its opening in a building wall.
The present invention seeks to greatly improve on the known prior art by providing in a window of any necessary size or in a plurality of windows an automatic temperature-responsive damper system which under certain conditions will close and seal a solar plenum formed in each window unit between the spaced window panels thereof; and under other conditions will vent the plenum to the outside ambient atmosphere to dissipate heat, as in the summertime, or will vent the plenum to an inside room or building space to heat the latter by natural convection or by forced draft means, in some cases.
Various types of solar screens associated with windows are also known in the prior art. Such screens have the ability to intercept and absorb up to sixty percent of the sun's ray energy falling on a window. During summer, these solar screens create a serious problem in the dissipation of the heat energy absorbed by the solar screen or trapped between it and an adjacent glass pane or panel. During the winter, this same useful heat energy is wasted in known prior art devices.
Accordingly, a further important objective of this invention is to utilize a solar screen in conjunction with the window structure and its automatic damper system in such a way that the solar energy absorbed by the screen during summer will be efficiently dissipated without excessively heating the interior building space, and during the winter will not be wasted but rather will be utilized as part of a convection system to supplement the heating of an interior building space.
In its essential elements, the present invention comprises a window which can serve as a solar heater, passive or active, a solar screen and a storm window. The invention may be embodied in many different types of windows, small or large, as well as in floor-to-ceiling glass panels commonly found in large buildings.
In summer, the window unit acts as a solar screen rejecting the sun's energy to the outside. During the night, the window like any multi-panel type having a dead air space minimizes loss of interior cooling.
In winter, the window unit serves as a solar heater of interior building spaces, and during the night acts as a storm window minimizing conduction and radiation of heat to the outside.
Other features and advantages of the invention will become apparent during the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary elevational view of a building equipped with windows embodying the present invention.
FIG. 2 is a fragmentary vertical section through one window unit taken on line 2--2 of FIG. 1.
FIG. 3 is a similar section taken through a bay between adjacent window units on line 3--3 of FIG. 1.
FIG. 4 is a fragmentary vertical section taken on line 4--4 of FIG. 3 in a plane at right angles to the planes of FIGS. 2 and 3.
FIGS. 5 and 6 are diagrammatic views showing the operation of thermally sensitive window damper operating means.
FIG. 7 is a fragmentary vertical section, similar to FIG. 2, according to a modification of the invention.
DETAILED DESCRIPTION
Referring to the drawings in detail, wherein like numerals designate like parts, the numeral 10 in FIG. 1 designates typical paired side-by-side window units in accordance with the invention separated by a bay 12 having a pair of isolated chambers 12a and 12b separated by a divider wall 12c, FIGS. 3 and 4. The chamber 12b of the bay 12 is vented to the outside ambient through louver slots 14, or in certain installations through louver slots 14a to inside building space temperature. Each window unit 10 at its bottom and top is provided with an outside air inlet 16, or slot, and an air outlet 18, to be further discussed.
As shown in FIG. 2, each window unit 10 also possesses at its bottom and top an inside air inlet 20 and an air outlet 22 at the elevations of the inlet and outlet 16 and 18. In the operation of each window unit, to be fully described, air flow from the outside or from the inside through a solar plenum 24 and returning to the outside or inside is regulated by dampers 26a and 26b of modified T cross section. Leakage around these dampers at the bottom and top of each window frame 28 is prevented by channel seals 30a and 30b, FIG. 2. Leakage between the solar plenum 24 and dampers 26a and 26b is prevented by pairs of strip seals 32a and 32b at the bottom and top of the plenum where it can communicate either with the passages 16 and 18, or the passages 20 and 22, under certain conditions. In FIG. 2, the dampers 26a and 26b are shown in their middle positions completely closing the solar plenum 24 to create a dead air space. In phantom lines in FIG. 2, the dampers are shown positioned at 34a and 34b to allow interior air to enter the plenum 24 from inlet 20 and to leave the plenum through outlet 22. Similarly, at 36a and 36b, the dampers are positioned to allow outside air to enter the plenum 24 through inlet 16 and to leave the plenum and return to the outside through outlet 18. At no time do the dampers 26a and 26b allow outside air to flow to the inside building space through the plenum or directly through passages 18-22 or 16-20. In the operation of the invention, the dampers 26a and 26b move in unison under control of thermally sensitive means, to be described.
The solar plenum or spaces 24 is defined by an outside storm window panel 38 fixed in the window frame and conventionally sealed and by a removable inside window panel 40 having an integrated frame 42 equipped with a seal 44 which abuts a fixed angle member 46 on the window frame. Removal of the inside window panel 40 allows cleaning of the interior of the outside panel 38, cleaning of the panel 40 and cleaning and servicing of a solar screen 48 within the plenum 24.
The solar screen 48 per se is conventional, being formed of black fiberglass mesh or the like. It extends diagonally across the plenum 24 from the upper outside corner thereof to the lower inside corner of the plenum, FIG. 2. The solar screen 48 is retained by splines 50 within a pair of spline retainer rails 52 held removably in sill mounts 54 under the biasing influence of leaf srings 56.
As shown in FIGS. 3 and 4, the bay 12 between window units 10 houses the thermally sensitive mechanism which controls the positioning of the dampers 26a and 26b. Referring to these figures, this mechanism comprises within the isolated bay chamber 12b a damper directional control cylinder 58 exposed to the ambient outside atmosphere through the louver slots 14, or in certain installations exposed to inside building air space ambient through the lower slots 14a, shown in dotted lines in FIG. 3, and within the chamber 12a a damper actuating cylinder 60 exposed to air in the plenum 24 through an opening 62 in the bay chamber side wall for this purpose. The two cylinders 58 and 60 contain thermally sensitive material causing two telescoping sections 58a-58b and 60a-60b of each cylinder to expand axially in response to a temperature increase. Surrounding retractile springs 64 on the two cylinders bias them to retracted positions shown in full lines in FIGS. 3 and 4. In such retracted positions, the dampers 26a and 26b are in their immediate closed positions relative to the plenum 24, FIG. 2. The relatively slight expansive axial movement of the cylinder 58 is indicated in phantom lines in FIG. 3, as where this cylinder is responding to an increase in temperature in the bay chamber 12b.
The thermally sensitive cylinders 58 and 60 are conventional devices and a manufacturing source for the cylinders is Dalen Products, Inc., 201 Sherlake Drive, Knoxville, Tenn. 37922. Other equivalent thermally sensitive actuator devices can be employed. The Dalen cylinder is disclosed in U.S. Pat. No. 4,155,504.
The base of damper directional cylinder 58 is attached to a bracket 66 fixed to the bottom wall 68 of chamber 12b. This cylinder may sense the outside ambient temperature due to its proximity to the vent slots 14. The temperature at which the cylinder 58 expands depends upon the particular type of window insulation, but a typical expansion initiation temperature is in the range of 60°-65° F. The damper directional cylinder 58 transmits motion to the damper actuator cylinder 60 through a hard link 70 having one end fixed to cylinder section 58b and having its opposite end attached at 72 to an offset or eccentric mount 74. Damper actuator cylinder 60 is supported by a bracket 76 fixed to a side wall of bay 12 whereby the cylinder 60 can rotate about an axis 78, FIGS. 3 and 4, when damper directional cylinder 58 extends or expands axially. Actuator cylinder 60 has a yoke 80 and a pin 82 fixed to its extendable section 60b. Pin 82 passes through an opening 84 in a cam lever 86. The cam lever 86 is rotatably held in a fixed bracket 88 attached to the side wall of bay 12 through a pivot pin 90, and maintained centered relative to bracket 88 by a centering spring 92.
The other end of cam lever 86 away from the opening 84 is attached via a slot and pin 94 to a dual leg damper lever 96 which is fixed on a rocker shaft 98 of the damper 26b. One leg of dual leg damper lever 96, FIG. 4, is attached at 100 to a push rod 102 which extends to a damper lever 104 fixed on the rocker shaft 106 of damper 26a through a connecting shaft 108, FIG. 4.
The proximity of damper actuator cylinder 60 to opening 62 enables the cylinder 60 to sense the prevailing temperature in plenum 24. The temperature at which the cylinder 60 will be extended depends upon the type of installation, but a typical temperature range which will initiate extension or expansion of cylinder 60 is 85°-90° F.
Damper actuator cylinder 60 transmits its motion to cam lever 86 rotating it either clockwise or counterclockwise on its pivot 90 depending upon the position of damper directional cylinder 58. Counterclockwise rotation of cam lever 86 will, through levers 96 and 104 and rod 102, move dampers 26a and 26b to their inside air flow positions 34a-34b, FIG. 2. Similarly, clockwise rotation of cam lever 86 will move dampers 26a and 26b to their outside air flow positions 36a-36b, FIG. 2.
In certain structures, such as office buildings, where the windows face south, the inside building air space often overheats on days with bright sun and low outside temperatures, due to sunlight heating through the windows. In such a situation the isolated bay chamber 12b instead of being placed in communication with outside ambient through the louver slots 14 is placed in communication with inside building ambient or air space temperature through the louver slots 14a, as shown in dotted lines in FIG. 3. Damper directional control cylinder 58 in such an arrangement is then exposed to and controlled by inside air temperature.
SUMMARY OF OPERATION
FIGS. 2, 3 and 4 show the window with the two cylinders 58 and 60 full retracted and the dampers 26a and 26b closing and sealing the solar plenum 24 which is now a dead air space. The damper directional cylinder 58 being exposed to outside ambient or inside building space air temperature, will be retracted whenever this temperature is typically below 60° F., FIG. 5. Damper actuation cylinder 60, being exposed to the temperature in plenum 24, will be retracted whenever this temperature is typically below 85° F., FIG. 3. Whenever the sun is shining, the temperature in the plenum 24 will be well above this temperature; therefore, the retracted condition of cylinder 60 will occur on cool overcast days or at night. On cool or winter days with the sun shining, directional cylinder 58 will remain retracted, when it is vented through louvers 14 to outside air, but actuation cylinder 60 will extend, FIG. 5. This extension will cause cam lever 86 to rotate counterclockwise, FIG. 5, moving dampers 26a, 26b to the inside air flow positions 34a, 34b, whereby inside air can circulate freely by natural convection through inlet 20, plenum 24 and outlet 22 to the inside building space, thus allowing air from the plenum 24 which has been heated by solar radiation with the assistance of screen 48 to enter and heat the inside building space.
On cool or winter days with the sun shining in building installations previously described, that have substantial glass facing south and thus have a tendency to overheat inside, directional cylinder 58 is vented to inside temperatures through louvers 14a, and will extend when inside air is greater than designed temperatures. This extension will rotate actuation cylinder 60 counterclockwise about pivot axis 78, and with damper actuation cylinder 60 extended due to high temperature in the plenum 24, the dampers will be in the outside air flow positions 36a, 36b, FIG. 6, to dissipate heat trapped in the plenum 24 to the outside atmosphere.
On warm days, above 65° F., with outside louvers 14, or when inside building space temperature is greater than designed building temperatures, with inside louvers 14a, damper directional cylinder 58 will extend, rotating actuation cylinder 60 counterclockwise, FIG. 6, about pivot axis 78, moving yoke 80 and pin 82 to the left side of cam lever 86. Centering spring 92 at this time maintains the position of cam lever 86.
When the sun heats up the solar screen 48 and hence the plenum 24, actuation cylinder 60 will extend and rotate cam lever 86 clockwise, FIG. 6, moving dampers 26a, 26b to their outside air flow positions 36a, 36b. Outside air can now flow through inlet 16 and plenum 24 and through outlet 18 in a continuous circuit, thus allowing heat trapped by the solar screen 48 in plenum 24 to be dissipated by dumping it to the outside atmosphere.
A unique feature of the cam lever 86 is that it allows the dampers 26a and 26b to move directly from the inside flow position 34a, 34b, FIG. 5, to the outside flow position 36a, 36b, FIG. 6, or vice versa. For example, actuation cylinder 60 can extend rotating cam lever 86 counterclockwise, FIG. 5, thus rotating dampers 26a, 26b to their inside air flow positions 34a, 34b. Then, if directional cylinder 58 extends, due to a rise in the outside temperature, or a rise in inside building space temperature above designed temperatures, it would rotate actuation cylinder 60 causing cam lever 86 to rotate clockwise on its pivot 90 from its extreme counterclockwise position to its extreme clockwise position, thus rotating dampers 26a, 26b directly from the inside air flow position of FIG. 5 to the outside air flow position of FIG. 6.
It can be seen that the two cylinders each have two operative positions creating four combinations. The conditions which initiate the four positions of the two cylinders 58 and 60 and the corresponding damper positions explained above are as follows when cylinder 58 is controlled by outside ambient:
______________________________________ Actuation Cyl. 60 Retracted Extended______________________________________ Temp: Out < 60°, Temp: Out <60°, (24) < 85° (24) > 90° Retr. Cond: Night or Cloudy Cond: Sunny and Cool and CoolDirect. Dampers: Closed Dampers: Inside FlowCyl. 58 Temp: Out > 65°, Temp: Out >65°, (24) < 85° (24) >90° Ext. Cond: Night or Cloudy Cond: Sunny and Warm and Warm Dampers: Closed Dampers: Outside Flow______________________________________
To remove the solar screen 48 for cleaning, the interior window 40 is removed and the leaf springs 56 are then compressed to allow removal of the rails 52 from their mounts 54 whereby the solar screen can be removed from the window.
FIG. 7 of the drawings shows an alternate embodiment of the invention which is identical to the described embodiment except that the exterior and interior windows 38 and 40 are replaced by double pane windows 110 and 112, each having a closed internal space 114 which can be filled with an inert gas, such as GN 2 at least in the interior window 112. In the summer, when hot air from the plenum 24 is being dumped to the outside, this double pane window arrangement will insulate the space 24 from the air conditioned interior room space. In cold weather, the double pane arrangement will provide additional dead air spaces reducing heat losses.
In some cases, a manual override arrangement for the automatic dampers 26a, 26b can be provided. A suitable blower, not shown, can be utilized to promote movement of air through the plenum 24. In such cases, where electricity is used to power a blower, the dampers could be actuated by thermostat controlled solenoid actuators to maintain the desired room temperature.
A suitable plenum could be provided at the top of the window units to transport warm air from the solar plenum 24 into existing building ductwork.
The described window provides distinct advantages over the prior art at any time of the year, day or night, as follows:
Summer Day--Solar screen prevents 75% of solar energy from entering room interior. The 60% absorbed (15% reflected) is removed from vicinity of window reducing loss to interior via conduction through glass. This is further enhanced via a dual inner pane.
Summer Night--Dead air space created by closed dampers insulates, reducing loss of cooling. This is further enhanced via a dual inner pane.
Winter Day--Solar screen absorbs 60% of incident solar energy. This heats air in window unit which is circulated through interior room for heating when the direction cylinder 58 is controlled by outside ambient, but is dumped to the outside atmosphere when the direction cylinder is controlled by inside air temperature.
Winter Night--Dead air space created by closed dampers insulates, reducing loss of heating. This is further enhanced via a dual inner pane. Solar screen reduces radiant energy loss from warm interior objects.
The structure of the invention is very versatile. For instance, inside window panel 40 may be a double hung window which can be raised and lowered to provide air circulation to the inside in lieu of providing inside air inlet 20 and inside air outlet 22, and outside storm window panel 38 may be regular storm window panel with the dampers 26a and 26b arranged at the bottom and the top of the storm window panel to vent the plenum 24 formed between the double hung window and the storm window only to the outside atmosphere. The pair of dampers at the opposite ends of the plenum 24 in such an arrangement are movable between a closed position in which the opposite ends of the plenum 24 are sealed, and an open position in which the opposite ends of the plenum are placed in communication with the outside atmosphere. The damper actuator 60 in such an installation is immovably connected in the position shown in FIG. 6 and is in communication with the temperature in the plenum 24. No damper direction control cylinder 58 is required in such an arrangement and it is for this reason that damper actuator cylinder 60 is immovably connected in the position shown in FIG. 6 so as to rotate cam lever 86, or a lever similar thereto, from a position as shown in FIG. 3 when it is in retracted position and the dampers are sealing opposite ends of the plenum 24, clockwise to the position shown in FIG. 6 where the dampers open opposite ends of the plenum in communication with the outside atmosphere. This simplier and more economical construction may also be incorporated into a window unit for office buildings and the like, which have an inside window panel 40 and an outside storm window panel 38 similar to those as illustrated in the drawings with only air passages 16 and 18 to the outside and without the air passages 20 and 22 to the inside, whereby the dampers 26a and 26b controlled only by a damper actuator 60 are movable between positions closing the opposite ends of the plenum 24 as shown in FIG. 2 to positions such as 36a and 36b opening opposite ends of the plenum to the outside atmosphere to dump the hot air in the plenum to the outside.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof but it is recognized that various modifications are possible within the scope of the invention claimed. | Spaced exterior and interior windows define a solar plenum having communication with one isolated chamber of an adjacent dual chamber bay, the second chamber of which is in communication with the outside ambient or the inside building space air. Dampers for the solar plenum are automatically operated by thermally sensitive devices in the two isolated bay chambers, one of the devices controlling the direction of damper movement and the other device controlling damper actuation. The two dampers can completely close the solar plenum or vent it to the outside ambient for dissipating heat or to an interior space requiring solar heating. A solar screen in the plenum increases the thermal efficiency of the window arrangement. In a modified form, only one thermally sensitive device is provided which is in communication with the solar plenum and is connected to operate the two dampers to either completely close the solar plenum or vent it to the outside. | 5 |
RELATED APPLICATIONS
This application claims the benefit of, and priority to, both of the following two commonly-invented U.S. Provisional Applications: (1) Ser. No. 61/683,271, filed Aug. 15, 2012; and (2) Ser. No. 61/781,617, filed Mar. 14, 2013.
FIELD OF THE INVENTION
This disclosure is directed generally to technology useful in measurement-while-drilling (“MWD”) applications in the oil and gas exploration field, and more specifically to isolation technology in electromagnetic (“EM”) telemetry.
BACKGROUND OF THE INVENTION
Ultra-low frequency (ULF) electromagnetic (EM) waves are the preferred transmission mechanism for wireless subterranean telemetry applications due to the ULF wave's ability to propagate long distances through the Earth's strata. In a typical subterranean telemetry application, the desired telemetry information is digitally encoded into data packets and sent as modulated “bursts” of ULF carrier waves. Transmission of the carrier waves is physically facilitated by injecting a modulated current into the Earth media using a power amplifier to create a time-varying voltage potential between two transmit electrodes coupled to the Earth media. The electrodes are spaced such that the induced current traverses a section of the Earth media creating associated electric and magnetic field energy which radiates as time-varying wave fronts through the Earth media.
According to a conventional EM telemetry system, a lower portion of drill string is typically isolated electrically from the upper portion, so that the electrically-isolated lower portion may act as an antenna to transmit or receive ULF carrier waves to or from the surface through the Earth's strata. Transmission and reception by the antenna is enabled by circuitry within a transceiver located in the lower drill string portion below the point of electrical isolation. The transceiver is conventionally deployed in an antenna sub located just below the point of electrical isolation. In receive mode, the transceiver is connected to the lower drill string portion acting as an antenna that is electrically isolated from the surface. The transceiver may thus receive EM waves propagated from the surface through the Earth's strata. In transmit mode, the transceiver's tendency is to want to transmit using the entire drill string as an antenna. However, EM waves propagated by the transceiver are forced to “jump” the point of electrical isolation by passing through the surrounding Earth media. In so doing, the EM waves are thus forced to propagate through the Earth's media, where they may be received by the surface antennae. The EM system may therefore enable tools on the drill string to intercommunicate with the surface via encoded data packets modulated onto the transceived carrier waves.
In order for the lower drill string portion configured as an antenna to work well, the lower portion should ideally be electrically isolated from the upper portion as completely as possible. Any loss in complete electrical isolation will cause the lower drill string to start to lose its character as an antenna, reducing the effectiveness of the EM system in communicating via the Earth's strata. This need for as complete an electrical isolation as possible is magnified in view of the “reality” of the high impedance of the Earth's strata through which the carrier waves must pass in normal operational mode. In order to encourage robust wave propagation through the Earth's strata (and deter wave propagation losses to ground via the upper portion of the drill string), the impedance of the electrical isolation must be correspondingly even higher. It will be appreciated, however, that in practice, complete electrical isolation is rarely achievable. Most operational isolations will be “lossy” to some degree. A goal of electrical isolation of the drill string in EM telemetry is thus to minimize “lossiness” to as close to “no losses” as possible.
A further “reality” is that the EM waves transmitted by the transceiver on the drill string are likely to be weak in comparison to their counterparts transmitted from the surface. Local power available to a transceiver on a tool string is limited. Thus, any wave propagation loss via poor isolation between upper and lower portions of the drill string is likely to cause a magnified reduction in effectiveness of the tool string transceiver's transmissions, as compared to surface transmissions.
Electrical isolation of the upper and lower portions of the drill string is frequently enabled by placement of “gap sub” technology in the drill string at the point at which isolation is desired. The gap sub technology provides isolating structure to prevent, as completely as possible, any electrical conductivity through the drill string between the portions of the drill string above and below the gap sub technology.
This disclosure uses the term “gap sub technology” in the previous paragraph because in alternative deployments, the electrical isolation of the upper and lower portions of the drill string may be achieved using differing arrangements. For example, electrical isolation may be enabled by deploying a single integrated electrical break in one or more locations on the drill string, where such electrical break(s) are integrated and continuous across the tubular drill collar and the tooling within the drill collar. In other arrangements, electrical isolation may be enabled via separate but cooperating electrical breaks: one (or more) electrical break(s) on the tubular drill collar, plus one (or more) separate electrical break(s) within the tooling structure deployed inside the collar. This disclosure pertains to the latter (separate but cooperating) arrangement, and specifically to electrical isolation of the drill collar itself.
By way of further explanation, the drill string often, at and around the desired point of isolation, comprises operational downhole tool structure deployed inside a hollow cylindrical outer collar. The collar generally refers to a string of concatenated hollow tubulars made from non-magnetic material, usually stainless steel. In such a deployment, it is often advantageous to make separate but cooperating physical electrical breaks in both the tooling and in the collar itself in order to achieve overall electrical isolation of the entire drill string.
Inside the collar, an “internal gap” is provided, usually positioned just above the transceiver tooling. The internal gap electrically isolates the drill collar internals below the internal gap from the drill collar internals above the internal gap. As noted, this disclosure is not directed to the internal gap.
On the collar itself, a “gap sub” is provided, comprising a hollow tubular inserted in the concatenation of hollow tubulars that comprise the collar. The concatenated connections of the collar are conventionally pin and box threaded connections, and the collar itself is conventionally a non-magnetic material (usually stainless steel). The gap sub is thus conventionally a non-magnetic tubular with pin and box connections at either end, configured to be inserted at a desired position in a concatenated string of similarly-connected non-magnetic drill collar tubulars. It will be appreciated that the collar, in and of itself, is a portion of the overall drill string. Functionally, therefore, the gap sub electrically isolates the portions of the drill collar (and therefore, by extension, the entire drill string) above and below the gap sub.
This disclosure is directed to an improved gap sub, providing excellent (almost complete) electrical isolation of the non-magnetic collar above and below the gap sub. The improved gap sub has further demonstrated excellent performance in operating conditions historically known to cause the isolating structure of prior art gap subs to break down or fail, causing unacceptable loss of isolation (and corresponding loss in EM telemetry) during live drilling operations.
SUMMARY OF THE INVENTION
The present invention addresses one or more of the above-described drawbacks of the prior art. In preferred embodiments, a gap sub is provided in which the improvement comprises generally an isolating ring made out of conductive material. In a preferred embodiment, the conductive material is a non-magnetic material such as stainless steel. The gap sub comprises at least one, and in a preferred embodiment, two electrically-isolating threaded joints in a non-magnetic tubular collar. The threads of the joints are isolated by a non-conductive coating, which may be deployed on the outside of the pin threads in accordance with the prior art. The shoulders of the joints are separated by the disclosed new isolating ring, wherein the ring is coated with non-conductive material on (1) at least one, and advantageously both, of its upper and lower faces, and (2) its interior surface. An annular recess in the collar prevents electrical contact between collar sections nearby the ring either side of each threaded joint. In the preferred embodiment, the non-conductive coating is a ceramic coating. The coating itself and its method of deployment may be in accordance with the prior art. The combination of (1) the non-conductive coating ring isolating the shoulders of the joint, and (2) the non-conductive coating between mating threads on the joint enables a robust electrical isolation either side of each threaded joint.
It is therefore a technical advantage of the disclosed gap sub to provide excellent (almost complete) drill collar isolation either side of the above-described electrically isolating threaded joints. As noted, when one, and advantageously two, of the above described threaded joints are deployed, the combination of (1) the non-conductive coating ring isolating the shoulders of the joint, and (2) the non-conductive coating between mating threads on the joint, enables a robust electrical isolation either side of the joint. As a result, optimized EM wave propagation is provided back and forth through the Earth's strata between the lower drill string (i.e. below the gap sub) and the surface.
A further technical advantage of the disclosed gap sub is to provide sustained electrical isolation either side of the above-disclosed threaded joints in operating conditions. Modern directional drilling operations require the drill string to undergo bending loads as the borehole changes direction. Historically, such bending loads have been known to crack or fracture electrically isolating coatings deployed on previous gap subs, causing loss in isolation. However, the non-conductive coatings as configured on the new gap sub disclosed herein (and particularly on the coated non-magnetic ring) have been shown to be very robust, even when the gap sub is undergoing high operational bending loads.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1A illustrates, in perspective view, a presently preferred embodiment of an assembled drill collar gap sub in accordance with the present disclosure;
FIG. 1B illustrates, again in perspective view, the gap sub of FIG. 1A in disassembled form; and
FIG. 2 illustrates, in cross-section view, isolating pin connection 107 (as indicated on FIG. 1B ) in detail, in further cooperation with isolating ring 106 .
DETAILED DESCRIPTION
FIGS. 1A and 1B illustrate, in assembled and disassembled views respectively, a presently preferred embodiment of a tubular drill collar gap sub 100 . In FIG. 1A , gap sub 100 comprises pin end portion 101 and box end portion 102 separating isolating portion 105 . Isolating rings 106 are provided at either end of isolating portion 105 . One isolating ring 106 is included in each of two threaded isolating joints 120 (one threaded isolating joint 120 between pin end portion 101 and isolating portion 105 , the other threaded isolating joint 120 between isolating portion 105 and box end portion 102 ). All the components illustrated on FIG. 1A (pin end portion 101 , isolating portion 105 , box end portion 102 and isolating rings 106 ) are made from a non-magnetic material such as stainless steel.
It will be appreciated that gap sub 100 , fully assembled as depicted in FIG. 1A , is disposed to be inserted into the drill string. More, precisely, as described earlier in this disclosure, fully assembled gap sub 100 may be inserted into a concatenated string of non-magnetic drill collar tubulars. With further reference to FIG. 1A , conventional pin connection 103 and box connection 104 (hidden from view on FIG. 1A ) at either end of fully assembled gap sub 100 enable such insertion into the concatenated string of drill collar tubulars. When inserted into the drill collar string, gap sub 100 provides electrical isolation within the drill collar either side of gap sub 100 . The concatenated string of non-magnetic drill collar tubulars is in turn connected at either end to other (upper and lower) portions of the entire drill string. Gap sub 100 thus provides electrical isolation in the drill collar between the upper and lower portions of the entire drill string.
As noted, FIG. 1B illustrates gap sub 100 from FIG. 1A in disassembled form. All the items called out by part number on FIG. 1A are illustrated on FIG. 1B by the same part number. Disassembly of gap sub 100 as shown in FIG. 1B allows further illustration of the threaded isolating joints 120 (identified on FIG. 1A ) at each end of isolating portion 105 . FIG. 1B shows isolating portion 105 including isolating pin connections 107 at each end, each isolating pin connection 107 configured to be received into a mating isolating box connection 108 on pin end portion 101 and box end portion 102 respectively. FIG. 1B also depicts isolating rings 106 inserted into the threaded isolating joints between isolating portion 105 and pin end portion 101 , and between isolating portion 105 and box end portion 102 .
FIG. 2 illustrates isolating pin connection 107 from FIG. 1B in more detail, per the view indicated on FIG. 1B . It will be understood, however, that although FIG. 2 illustrates isolating pin connection 107 near box end portion 102 (per FIG. 1B ), the details illustrated on FIG. 2 are functionally and structurally the same for isolating pin connection 107 near pin end portion 101 (also per FIG. 1B ).
Referring now to FIG. 2 , isolating pin connection 107 comprises male threads 112 at the end thereof. Male threads 112 are coated (functionally depicted as item C on FIG. 2 ) with a non-conductive coating as is known in the art. In a presently preferred embodiment, the non-conductive coating is a ceramic coating. Further, as is known in the art, male threads 112 are sized, shaped and configured so that once coated with the non-conductive coating, the coated male threads 12 mate with corresponding female threads on isolating box connection 108 on box end portion 102 (items 108 and 102 not shown on FIG. 2 for clarity, but depicted on FIG. 1B ).
FIG. 2 also depicts isolating ring 106 disposed to be received into ring cutout 110 on isolation portion 105 (item 110 described in more detail immediately below). Although not illustrated on FIG. 2 , it will be understood that isolating ring 106 receives a non-conductive coating on face surfaces 106 F1 and 106 F2 , and on interior surface 106 I . In a preferred embodiment, the non-conductive coating on isolating ring 106 is a ceramic coating. It should be noted that testing has revealed that coating the entire isolating ring (i.e. on the exterior ring surface as well as on face surfaces 106 F1 and 106 F2 , and interior surface 106 I ) is not particularly advantageous. It has been found that under operating conditions, the coating on the exterior ring surface chips and cracks quite quickly. These chips and cracks propagate and extend into the coating on the face surfaces 106 F1 and 106 F2 , causing premature breakdown in electrical isolation. It has been observed that the coating on face surfaces 106 F1 and 106 F2 performs much better when there is no coating on the exterior ring surface.
With further reference to FIG. 2 , isolating pin connection 107 also comprises a shoulder 109 at the point at which isolating portion 105 transitions into male threads 112 . Shoulder 109 is separated from male threads 112 by ring cutout 110 and recess 111 . Ring cutout 110 is sized and shaped to receive isolating ring 106 after a non-conductive coating has been applied to isolating ring 106 , as described immediately above. Recess 111 is positioned, sized and contoured so that when isolating ring 106 is received into ring cutout 110 , and when male threads 112 are operationally engaged on corresponding female threads on isolating box connection 108 (item 108 omitted for clarity on FIG. 2 ), there is no physical (or electrical) contact between isolating portion 105 and box end portion 102 (item 102 omitted for clarity) except via threaded engagement of male threads 112 or via contact through isolating ring 106 .
Functionally complete isolation is thus achieved. Since male threads 112 have a non-conductive coating, electrical isolation across threaded engagement of male threads 112 is enabled. Moreover, since isolating ring 106 also has a non-conductive coating, electrical isolation across shoulder 109 is also enabled. As noted above, recess 111 prevents any other physical (or electrical) contact between isolating portion 105 and box end portion 102 (item 102 shown on FIG. 1B but omitted for clarity on FIG. 2 ).
Field testing has shown operational drill collar gap subs designed in accordance with this disclosure have shown excellent (almost complete) isolation in normal directional drilling service. Isolating ring 106 (per FIG. 1B ) has the compressive strength and durability of a non-magnetic metal while still providing electrical isolation via its coating. As such, it is theorized that this hybrid nature of isolating ring 106 's properties enables superior performance.
Field testing has further shown that gap subs designed in accordance with this disclosure also show good isolation performance (and limited damage to non-conductive coatings) even when placed under high bending loads associated with elevated build rates. For example, one test was designed to simulate placing the gap sub downhole and subjecting it to approximately 140 continuous hours at a maximum operating bending stress that might be expected during directional drilling. In this test, bending stress was exerted on the gap sub equivalent to a simulated build of a 12° dogleg. This bending stress was imparted to the gap sub 25.2 times per second over a 6 hour period. Electrical isolation remained substantially complete and unchanged throughout the entire test.
The following paragraphs describe further alternative embodiments which, although not illustrated, are considered within the scope of this disclosure and the inventive material described herein.
It will be seen on FIG. 1B that an isolating pin connection 107 is provided on each end of isolating portion 105 . This is to simplify manufacturing. It is understood in the art that it is easier to deploy robust and precise non-conductive thread coatings on male threads on a pin end than on female threads in a box end. Thus, by providing an isolating pin connection on each end of isolating portion 105 , only one tubular (isolation portion 105 ) need be handled to receive a non-conductive coating for two isolating thread joints. Absent manufacturing economy and convenience, however, other embodiments may deploy isolating pin connection 107 on pin end portion 101 and/or box end portion 102 with equivalent enabling effect.
As noted, the presently preferred non-conductive coating on male threads 112 and isolating ring 106 (per FIG. 2 ) is a ceramic coating. This is because a ceramic coating has demonstrated good performance in gap subs designed in accordance with this disclosure. However, the disclosure is not limited in this regard. Other non-conductive coatings (such as, for example, plastics, fiberglass or composites) could be used with equivalent enabling effect.
The presently preferred embodiment described in this disclosure illustrates gap sub 100 with two threaded isolation joints 120 (per FIG. 1A ). Nothing in this disclosure should be interpreted to limit the disclosure to two isolation joints, however. Other embodiments of gap sub 100 may deploy only one isolation joint, or more than two isolation joints, depending on user and service requirements. In embodiments where there is to be only threaded one isolation joint 120 , it will be appreciated that, with further reference to FIGS. 1A and 1B , box end portion 102 may be eliminated, and isolating pin connection 107 near box end portion 102 may be substituted for a conventional box connection. In embodiments where there are to be more than two threaded isolation joints 120 , additional isolating portions 105 may be deployed between pin end portion 101 and box end portion 102 , with associated additional structure per FIG. 2 deployed on such additional isolating portions 105 .
It will be appreciated that throughout this disclosure, pin and box connections have been called out and identified according to a presently preferred embodiment. Nothing herein should be interpreted, however, to limit this disclosure to require a pin connection or a box connection at a particular location. It will be understood that pin connections and box connections may be deployed interchangeably on parts that thread together.
This disclosure has described a gap sub that is made entirely of a non-magnetic material (such as stainless steel) in a presently preferred embodiment. However, the scope of this disclosure is not limited to non-magnetic material. It will be appreciated that parts (or all) of the gap sub may alternatively be made of other serviceable materials (including magnetic materials such as carbon steel) with equivalent enabling effect.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. | A gap sub comprises at least one electrically isolating threaded joint in a conductive tubular collar. The threads of the joints are isolated by a non-conductive coating. The shoulders of the joints are separated by an isolating ring. Annular faces on the ring make contact with the shoulders in the joints. The ring is made of conductive material with a non-conductive coating deployed on (1) at least one of the ring's annular faces, and (2) the interior surface of the ring. An annular recess in the collar prevents electrical contact between collar sections nearby the ring on either side of at least one threaded joint. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to: German Patent Application No. 102009031964.6, filed on Jul. 6, 2009; and to German Patent Application No. 102009033785.7, filed Jul. 3, 2009; and to German Patent Application No. 102009016715.3, filed Apr. 9, 2009. German Patent Application No. 102009033785.7, filed Jul. 3, 2009, claims the benefit of German Patent Application No. 102009016715.3, filed Apr. 9, 2009.
BACKGROUND
[0002] The invention relates to an apparatus for accommodating different exchangeable contents and/or containers.
[0003] When participating in outdoor activities, such as for hiking or cycling, injuries may easily occur. Such injuries may require the use of disinfection agents and liquid patches that ordinarily are carried separately.
SUMMARY
[0004] The present invention relates to an apparatus for accommodating different exchangeable contents and/or containers and comprises at least two separated and closable internal spaces. The internal spaces are arranged on a common longitudinal axis and are closed by functional lids. The functional lids are arranged on the ends of the apparatus and have openings through which the different media may escape from the containers. The openings are closed by additional covers.
[0005] The exchangeable containers may be, for example, spraying bottles which contain media that can be sprayed.
[0006] The mentioned spraying bottles may include, for example, disinfection agents, means for attending to lesions or cleaning same and sprayed patches as well as cooling agents. The apparatus may thus be used as an emergency set in case of injuries.
[0007] To promote simple handling, the apparatus is formed as a simple handle that can be used with one hand, wherein the cover may, fore example, be lifted at a flap by means of the thumb in order to release the functional lid. The functional lid may also enable actuation of the spray pin of the spraying bottle in order to spray the medium.
[0008] To promote versatility, different adapter possibilities are provided. Hence, it is possible to carry the device around a belt or to attach it to a bicycle. The apparatus can be used, for example, outdoors, such as for hiking or cycling, where injuries may easily occur that require the use of disinfection agents and liquid patches. The apparatus is small, can be handled easily and is therefore easily portable. Many other possibilities of use with different media are feasible, such as for animals or also for craftspeople.
[0009] In some embodiments, the apparatus for accommodating different exchangeable containers comprises a handle which comprises at least two separated and closable internal spaces which are arranged on a common longitudinal axis. Each internal space is closed by a respective functional lid.
[0010] Preferably, the at least one functional lid comprises an opening through which the medium within the containers may escape.
[0011] A further advantage is that the functional lid comprises a lid insert which actuates the spray pin of, for example, an aerosol can upon being actuated, such that the medium can escape and may be metered.
[0012] In some embodiments, the at least one functional lid can be closed by a cover, such that the opening is protected against things like dirt or damage. In this case, the functional lid is movably connected to the cover, such as by an integral hinge.
[0013] In certain embodiments, the handle comprises an adapter receptacle at which an adapter can be attached.
[0014] In some such embodiments, the adapter comprises a further receptacle.
[0015] In other embodiments, the present invention relates to an emergency set for accommodating different exchangeable contents and comprises a handle having three separated and closable internal spaces. The internal spaces are arranged on a common longitudinal axis. The center internal space can be opened and closed by a fastener. This fastener may be formed, for example, as a screw plug or a clip.
[0016] The exchangeable contents may be different combinations of means for first aid in case of accidents and for injuries. For example, two spraying bottles including disinfection agents or liquid patches can be combined with a safety vest or a gauze bandage.
[0017] A further possibility includes various combinations of contents and containers. For example, an emergency set and a further knapsack can be attached to bicycles by means of an adapter near a drinking bottle.
[0018] It should be appreciated that the fields of application with respect to emergency sets are many, and are mentioned herein only as examples.
[0019] In some embodiments, the emergency set may contain different exchangeable contents and comprises a handle having three separated and closable internal spaces which are arranged on a common longitudinal axis, wherein the handle can be opened and closed at its center internal space by a fastener.
[0020] In some embodiments, the fastener is provided as a thread.
[0021] In other embodiments, the fastener is provided as a clip.
[0022] In some embodiments, a safety vest is included in the center internal space.
[0023] In other embodiments, a gauze bandage is included in the center internal space.
[0024] In some embodiments, the adapter may accommodate an emergency set as well as at least one additional knapsack.
[0025] In other embodiments, the adapter may accommodate an emergency set, a knapsack as well as a drinking bottle.
[0026] According to some embodiments, the present invention relates to an apparatus for accommodating different exchangeable containers and comprises at least two separated and closable internal spaces. The internal spaces are arranged in a kind of accommodating body which may be compared to the cylinder of a revolver. In this case, the internal spaces may also be arranged in duplicate. In such an embodiment, respectively two internal spaces are arranged on a common longitudinal axis. This embodiment would be comparable to a double cylinder. Each internal space is separately closed by a functional lid. The functional lids are disposed on the ends of the internal spaces and have openings through which the different media may escape from the containers. The openings are closed by additional covers to avoid contamination.
[0027] The exchangeable containers may be spraying bottles containing media which can be sprayed. The covers are so-called functional lids. The two-part functional lid, for example, enables the actuation of the spray pin of the spraying bottle to spray the medium and also functions to close the opening of the spray pin.
[0028] In order to be able to use the apparatus in various ways, different configurations are provided. It is possible to fill the apparatus differently, depending on the purpose of use. The handling may also be adapted through the use of suitable attachment or carrying means.
[0029] The emergency set box may be extended such that the shape and the arrangement of the internal spaces can be designed as desired. For example, a double cylinder shape also is provided, in which internal spaces having functional lids are arranged on both ends.
[0030] The emergency set box can be used e.g. outdoors, such as for hiking or cycling. In these cases, injuries may easily occur, which require the use of disinfection agents and liquid patches. In addition, the emergency set box may also accommodate a safety vest for cyclists. Many other uses are possible, and these examples should not be regarded as limiting. The apparatus is small, can be handled easily and is therefore easily portable. Many other uses with different media are feasible, such as for animals or also for craftspeople.
[0031] One advantage is that the emergency set box for accommodating different exchangeable containers is made of a base body comprising at least two separated and closable internal spaces which are arranged side-by-side and are respectively closed by a functional lid.
[0032] In one embodiment, the functional lid comprises at least one opening through which the medium inside the containers can escape.
[0033] In another embodiment, the functional lid comprises a cover.
[0034] In another embodiment, the at least one internal space may accommodate components of an emergency kit.
[0035] In a further embodiment, the internal spaces of the base body are arranged about a common axis.
[0036] In a still further embodiment, the base body forms a triangle.
[0037] In a still further embodiment, the base body forms a circle.
[0038] In one variation, the base body is doubled by providing a second base body facing opposite a first base body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the drawings, the subject-matter of the invention is shown schematically and is described in the following detailed description with reference to the figures, wherein like components have like reference numerals.
[0040] FIG. 1 a is a plan view of the apparatus.
[0041] FIG. 1 b is a sectional view taken along line A-A of FIG. 1 a.
[0042] FIG. 2 is an isometric exploded view of the apparatus of FIG. 1 a.
[0043] FIG. 3 a is an isometric exploded view of an emergency set.
[0044] FIG. 3 b is a sectional view of the emergency set of FIG. 3 a.
[0045] FIG. 4 is a sectional view of a knapsack.
[0046] FIG. 5 is a further isometric view of the emergency set.
[0047] FIG. 6 is an isometric exploded view of a further embodiment of the apparatus in the form of an emergency set box.
[0048] FIG. 7 is a sectional view of the emergency set box.
[0049] FIG. 8 illustrates a triangle shaped base body for the inventive emergency set box
[0050] FIG. 9 illustrates a circular shaped base body for the inventive emergency set box.
[0051] FIG. 10 is a perspective view of a further embodiment of the apparatus in the form of an emergency set box.
[0052] FIG. 11 is a sectional view of the embodiment illustrated in FIG. 10 .
[0053] FIG. 12 illustrates detail B of FIG. 11 in an enlarged view.
[0054] FIGS. 13 to 15 show illustrations, analogous to FIGS. 10 to 12 , of a further embodiment of the apparatus.
[0055] FIGS. 16 to 18 show illustrations, analogous to FIGS. 10 to 12 , of a further alternative embodiment of the apparatus.
DETAILED DESCRIPTION
[0056] FIG. 1 a shows an overall view of an apparatus for accommodating different exchangeable contents and/or containers 1 . The apparatus 1 defines a longitudinal axis 2 b and is attached to a pipe 6 by means of an adapter 5 . The pipe 6 is, for example, part of a bicycle frame. The adapter 5 comprises a further receptacle 5 a which surrounds the pipe 6 together with an additional part 5 b. The other side of the adapter 5 partially encompasses a handle 2 at an adapter receptacle 2 c . Therewith, the apparatus 1 is secured against axial and radial displacement. Functional lids 3 are shown at both ends of the apparatus 1 , which lids close internal spaces 2 a accommodating containers 4 . (See FIG. 1 b )
[0057] FIG. 1 b shows an overall view of the apparatus 1 in a section A-A. In this sectional view, the internal spaces 2 a are shown, which accommodate the containers 4 including media (not shown). The functional lids 3 are closed by respective covers 3 c. The handle 2 is supported by the adapter 5 .
[0058] FIG. 2 shows an isometric exploded view of the apparatus 1 . The containers 4 are inserted into the internal spaces 2 a of the handle 2 . The functional lids 4 close the internal spaces 2 a. The adapter 5 , together with the further receptacle 5 a, is positioned at the pipe 6 and attached with the additional part 5 b. The apparatus 1 is then inserted into the adapter 5 at the adapter receptacle 2 c.
[0059] FIG. 3 a shows an isometric exploded view of an emergency set 1 ′. The emergency set 1 ′ is attached at the pipe 6 ′ of, for example, a bicycle by means of the adapter 5 ′. The handle 2 ′ can be divided at the level of the center internal space 2 a ′ and is opened or closed by a fastener 3 f ′. The outer internal spaces accommodate containers 4 ′, in this case spraying bottles, which are actuated by the functional lid 3 ′.
[0060] FIG. 3 b shows a sectional view of the emergency set 1 ′. In this illustration, the center internal space 2 a ′ accommodates a safety vest 7 ′. Spraying bottles are disposed in the two outer internal spaces 2 a′.
[0061] FIG. 4 shows a sectional view of a knapsack 10 ′. Herein, it is shown how the internal spaces 2 a ′ are closed by a simple lid 3 ′. In the internal spaces 2 a ′, respectively a safety vest 7 ′ and a gauze bandage 8 ′ are disposed.
[0062] FIG. 5 shows an isometric illustration of the emergency set 1 ′. In this view, a possible arrangement on a bicycle is shown. The adapter 5 ′ enables the accommodation of a drinking bottle 9 ′, an emergency set 1 ′ and a knapsack 10 ′.
[0063] FIG. 6 shows an isometric exploded view of an emergency set box 11 . The shown emergency set box 11 comprises three internal spaces 12 a. Three containers 14 are depicted, as they can be accommodated in these internal spaces 12 a. A functional lid 13 comprises openings 13 a through which the medium 14 a (see FIG. 7 ) may escape from the containers 14 . The cover 13 b serves as a protection against contamination and is shown above the openings 13 a.
[0064] FIG. 7 shows a sectional view of the emergency set box 11 . A possible arrangement is shown herein. The containers 14 are located in the internal spaces 12 a.
[0065] The spray pins 14 b of the containers 14 are arranged under the functional lid 13 , such that the medium 14 a may escape through the openings 13 a when the functional lid 13 is actuated. The cover 13 b closes the emergency set box 11 and protects it against contamination.
[0066] FIG. 8 shows a triangle shaped base body 12 of the inventive emergency set box 11 . In this illustration, a possible shape of the base body is shown.
[0067] FIG. 9 shows a circular shaped base body 12 of the inventive emergency set box 11 . In this illustration, a further possible shape of the base body 12 is shown.
[0068] FIG. 10 is a perspective view of a further embodiment of the apparatus 1 , one cover 3 c of which is shown in an open state.
[0069] FIG. 11 shows a sectional view of this embodiment of the apparatus 1 , in which components corresponding to those of the preceding embodiments are designated with the same reference numerals. Accordingly, the apparatus 1 comprises a handle or a housing 2 which comprises, in this example, three housing parts 20 , 21 , 22 with respective internal spaces 20 ′, 21 ′ and 22 ′. The housing parts 20 and 21 are detachably connected through suitable connecting means 23 , and the housing parts 21 and 22 are detachably connected through suitable connecting means 24 . Examples for such connecting means are screw fittings, plug sockets or also bayonet couplings.
[0070] In the two internal spaces 20 ′ and 22 ′, containers for spraying agents, such as spray patches or cooling agents, are respectively arranged, which may also be referred to as cartridges.
[0071] The portion of the housing 2 surrounded with a circle B in FIG. 11 is shown enlarged in FIG. 12 . From this illustration, it is shown that the functional lid 3 is provided with an opening 3 a, wherein the functional lid 3 receives the spray pin 4 b of the container 4 in a center recess 3 f. As is made clear by FIG. 12 , the spray pin 4 b and its opening as well as the opening 3 a are located on the longitudinal axis 2 b of the housing 2 , such that a spraying direction of the medium within the container 4 is aligned with respect to the longitudinal axis 2 b when the functional lid 3 is actuated.
[0072] Further, the illustration of FIG. 12 makes clear that the lid or the cover 3 c is pivotally connected to the housing 2 through a clip connection. Said clip connection comprises a bridge 16 fixed at the housing 2 and a fork-shaped bridge receptacle 15 attached at the lid 3 c, which may be clipped onto the bridge 16 due to its elastic properties.
[0073] FIG. 13 shows a perspective view of a further embodiment of the inventive apparatus similar to FIG. 10 , except that the cover or lid 3 c of the embodiment of FIG. 10 is connected to the housing 2 through an integral hinge 3 e.
[0074] FIG. 14 clarifies the structure illustrated in FIG. 11 , wherein in this case only one cartridge 4 is arranged in the right-hand internal space 22 ′.
[0075] FIG. 15 in turn shows an enlarged illustration of detail C of FIG. 14 .
[0076] From this illustration, it becomes clear that the embodiment according to FIGS. 13 to 15 enables a redirection of the spraying direction about 90° with respect to the longitudinal axis 2 b. For this purpose, the cartridge or the container 4 comprises a lid 17 in which two spraying agent channels 18 and 19 , arranged at right angles with each other, are provided. The spray pin 4 b engages with the spraying agent channel 18 such that, upon actuation of the lid 17 , the fluid jet escaping from the container 4 is redirected by 90° through the channels 18 and 19 . The jet is ejected through a recess 120 in the housing 2 , which is visible in FIG. 13 .
[0077] In FIGS. 16 to 18 , a further embodiment is shown, in which again all components corresponding to those of the preceding embodiments are designated with the same reference numerals.
[0078] Also in this embodiment, a redirection of the spraying direction by 90° with respect to the longitudinal axis 2 b is provided. In this embodiment, two spraying agent channels 25 and 26 , arranged at right angles with each other, are provided in the functional lid 3 for this purpose. In this case, the spray pin 4 b engages with the spraying agent channel 25 . If the functional lid 3 is actuated, e.g. by pressing onto its upper side, the spraying agent escapes through the spray pin 4 b and is redirected through the perpendicularly arranged channels 25 and 26 and is ejected through the opening 27 of the spraying agent channel 26 .
[0079] The invention was described with reference to a specific embodiment. It is, however, apparent that amendments and variations can be carried out without leaving the protective scope of the following claims. In this context, it has to be pointed out that all aforementioned embodiments and individual features can be combined with each other as desired.
[0080] In addition to the above written disclosure of the invention, it is explicitly referred to the drawings in FIGS. 1 to 18 for a completion thereof, with reference to the following list of Reference Numerals:
1 apparatus 2 handle/housing 2 a internal space 2 b longitudinal axis 2 c adapter receptacle 3 functional lid 3 a opening 3 b lid insert 3 d flap 3 e integral hinge 3 f recess 4 container/cartridge 4 a medium 4 b spray pin 5 adapter 5 a further receptacle 5 b additional part 6 pipe 1 ′ emergency set 2 ′ handle 2 a ′ internal space 2 b ′ longitudinal axis 2 c ′ adapter receptacle 3 ′ functional lid 3 a ′ opening 3 b ′ lid insert 3 d ′ flap 3 e ′ integral hinge 3 f ′ fastener 4 ′ container 4 a ′ medium 3 b ′ spray pin 5 ′ adapter 5 a ′ further receptacle 5 b ′ additional part 6 ′ pipe 7 ′ safety vest 8 ′ gauze bandage 9 ′ drinking bottle 10 ′ knapsack 11 emergency set box 12 base body 12 a internal space 12 b bottom 13 functional lid 13 a opening 13 b cover 14 container 14 a medium 14 b spray pin 14 c emergency equipment 15 fork-shaped bridge receptacle 16 bridge 17 lid 18 , 19 spraying agent channels/passages 20 , 21 , 22 housing part 20 ′, 21 ′, 22 ′ internal spaces 23 , 24 connecting means 25 , 26 spraying agent channels/passages | An apparatus for accommodating different exchangeable containers comprising at least two separated and closable internal spaces arranged on a common longitudinal axis. The apparatus is characterized in that the internal spaces are respectively closed by a functional lid. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 09/983,054, filed Oct. 16, 2001, which is a continuation-in-part application of U.S. application Ser. No. 09/422,397, filed on Oct. 21, 1999, issued as U.S. Pat. No. 6,303,645 on Oct. 16, 2001, which is a continuation-in-part application of U.S. application Ser. No. 09/316,870, filed on May 21, 1999, issued as U.S. Pat. No. 6,271,390 on Aug. 7, 2001, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/086,494, filed on May 21, 1998.
BACKGROUND OF THE INVENTION
[0002] This invention relates to small molecule inhibitors of the IgE response to allergens that are useful in the treatment of allergy and/or asthma or any diseases where IgE is pathogenic.
[0003] An estimated 10 million persons in the United States have asthma, about 5% of the population. The estimated cost of asthma in the United States exceeds $6 billion. About 25% of patients with asthma who seek emergency care require hospitalization, and the largest single direct medical expenditure for asthma has been inpatient hospital services (emergency care), at a cost of greater than $1.6 billion. The cost for prescription medications, which increased 54% between 1985 and 1990, was close behind at $1.1 billion (Kelly, Pharmacotherapy 12:13S-21S (1997)).
[0004] According to the National Ambulatory Medical Care Survey, asthma accounts for 1% of all ambulatory care visits, and the disease continues to be a significant cause of missed school days in children. Despite improved understanding of the disease process and better drugs, asthma morbidity and mortality continue to rise in this country and worldwide (U.S. Department of Health and Human Services; 1991, publication no. 91-3042). Thus, asthma constitutes a significant public health problem.
[0005] The pathophysiologic processes that attend the onset of an asthmatic episode can be broken down into essentially two phases, both marked by bronchoconstriction, that causes wheezing, chest tightness, and dyspnea. The first, early phase asthmatic response is triggered by allergens, irritants, or exercise. Allergens cross-link immunoglobulin E (IgE) molecules bound to receptors on mast cells, causing them to release a number of pre-formed inflammatory mediators, including histamine. Additional triggers include the osmotic changes in airway tissues following exercise or the inhalation of cold, dry air. The second, late phase response that follows is characterized by infiltration of activated eosinophils and other inflammatory cells into airway tissues, epithelial desquamonon, and by the presence of highly viscous mucus within the airways. The damage caused by this inflammatory response leaves the airways “primed” or sensitized, such that smaller triggers are required to elicit subsequent asthma symptoms.
[0006] A number of drugs are available for the palliative treatment of asthma; however, their efficacies vary markedly. Short-acting β 2 -adrenergic agonists, terbutaline and albuterol, long the mainstay of asthma treatment, act primarily during the early phase as bronchodilators. The newer long-acting β 2 -agonists, salmeterol and formoterol, may reduce the bronchoconstrictive component of the late response. However, because the β 2 -agonists do not possess significant antiinflammatory activity, they have no effect on bronchial hyperreactivity.
[0007] Numerous other drugs target specific aspects of the early or late asthmatic responses. For example, antihistamines, like loratadine, inhibit early histamine-mediated inflammatory responses. Some of the newer antihistamines, such as azelastine and ketotifen, may have both antiinflammatory and weak bronchodilatory effects, but they currently do not have any established efficacy in asthma treatment. Phosphodiesterase inhibitors, like theophylline/xanthines, may attenuate late inflammatory responses, but there is no evidence that these compounds decrease bronchial hyperreactivity. Anticholinergics, like ipratopium bromide, which are used in cases of acute asthma to inhibit severe bronchoconstriction, have no effect on early or late phase inflammation, no effect on bronchial hyperreactivity, and therefore, essentially no role in chronic therapy.
[0008] The corticosteroid drugs, like budesonide, are the most potent antiinflammatory agents. Inflammatory mediator release inhibitors, like cromolyn and nedocromil, act by stabilizing mast cells and thereby inhibiting the late phase inflammatory response to allergen. Thus, cromolyn and nedocromil, as well as the corticosteroids, all reduce bronchial hyperreactivity by minimizing the sensitizing effect of inflammatory damage to the airways. Unfortunately, these antiinflammatory agents do not produce bronchodilation.
[0009] Several new agents are currently being developed that inhibit specific aspects of asthmatic inflammation. For instance, leukotriene receptor antagonists (ICI-204, 219, accolate), specifically inhibit leukotriene-mediated actions. The leukotrienes have been implicated in the production of both airway inflammation and bronchoconstriction.
[0010] Thus, while numerous drugs are currently available for the treatment of asthma, these compounds are primarily palliative and/or have significant side effects. Consequently, new therapeutic approaches which target the underlying cause rather than the cascade of symptoms would be highly desirable. Asthma and allergy share a common dependence on IgE-mediated events. Indeed, it is known that excess IgE production is the underlying cause of allergies in general and allergic asthma in particular (Duplantier and Cheng, Ann. Rep. Med. Chem. 29:73-81 (1994)). Thus, compounds that lower IgE levels may be effective in treating the underlying cause of asthma and allergy.
[0011] None of the current therapies eliminate the excess circulating IgE. The hypothesis that lowering plasma IgE may reduce the allergic response, was confirmed by recent clinical results with chimeric anti-IgE antibody, CGP-51901, and recombinant humanized monoclonal antibody, rhuMAB-E25. Indeed, three companies, Tanox Biosystems, Inc., Genentech Inc. and Novartis AG are collaborating in the development of a humanized anti-IgE antibody (BioWorld® Today, Feb. 26, 1997, p. 2) which will treat allergy and asthma by neutralizing excess IgE. Tanox has already successfully tested the anti-IgE antibody, CGP-51901, which reduced the severity and duration of nasal symptoms of allergic rhinitis in a 155-patient Phase II trial (Scrip #2080, Nov. 24, 1995, p.26). Genentech recently disclosed positive results from a 536 patient phase-II/II trials of its recombinant humanized monoclonal antibody, rhuMAB-E25 (BioWorld® Today, Nov. 10, 1998, p. 1). The antibody, rhuMAB-E25, administered by injection (highest dose 300 mg every 2 to 4 weeks as needed) provided a 50% reduction in the number of days a patient required additional “rescue” medicines (antihistimines and decongestants), compared to placebo. An NDA filing for this product is projected to be in the year 2000. The positive results from anti-IgE antibody trials suggest that therapeutic strategies aimed at IgE down-regulation may be effective.
SUMMARY OF THE INVENTION
[0012] The present invention discloses a family of related compounds for use in the treatment of a condition associated with an excess IgE level. The benzimidazole inhibitors of IgE in accordance with the present invention are represented by the generic formula:
wherein X and Y are independently selected from the group consisting of H, alkyl, alkoxy, aryl, substituted aryl, hydroxy, halogen, amino, alkylamino, nitro, cyano, CF 3 , OCF 3 , CONH 2 , CONHR and NHCOR 1 ; wherein R is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , CH 2 Ph, CH 2 C 6 H 4 —F(p-), COCH 3 , CO 2 CH 2 CH 3 , aminoalkyl and dialkylaminoalkyl; and wherein R 1 and R 2 are independently selected from the group consisting of H, aryl, heteroaryl, thiophene, pyridyl, thiazolyl, isoxazolyl, oxazolyl, pyrimidinyl, substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, cycloaryl, cycloheteroaryl, quinolinyl, isoquinolinyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, multi-ring cycloaryl, multi-ring cycloheteroaryl, benzyl, heteroaryl-methyl, substituted benzyl, substituted heteroaryl-methyl alkyl, dialkylaminoalkyl, cycloalkyl, cycloalkyl containing 1-3 heteroatoms, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, multi-ring cycloalkyl, multiring cycloalkyl containing 1-3 heteroatoms, fused-ring aliphatic, fused-ring aliphatic containing 1-3 heteroatoms, cyclopropyl, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, cyclopentyl, pyrrole, piperidine, substituted cyclopentyl, cyclohexyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, substituted adamantyl and the like, wherein at least one of R 1 and R 2 are aromatic groups or heteroaromatic groups.
[0016] The substituents on said substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, substituted benzyl, substituted heteroaryl-methyl alkyl, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, substituted cyclopentyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, and substituted adamantyl are independently selected from the group consisting of alkyl, aryl, CF 3 , CH 3 , OCH 3 , OH, CN, CONH 2 , CONHR, CONR1R2, COOR and COOH.
[0017] In accordance with another aspect of the invention, there is disclosed a composition for use in the treatment of an allergic condition comprising the benzimidazole inhibitor of IgE disclosed above and at least one additional active ingredient, combined in a pharmaceutically acceptable diluent. The additional active ingredients may be selected from the group consisting of short-acting β 2 -adrenergic agonists, like terbutaline and albuterol, long-acting β 2 -adrenergic agonists, like salmeterol and formoterol, antihistamines, like loratadine, azelastine and ketotifen, phosphodiesterase inhibitors, anticholinergic agents, corticosteroids, inflammatory mediator release inhibitors and leukotriene receptor antagonists.
[0018] In accordance with another aspect of the invention, there is disclosed a family of symmetric and asymmetric diacyl and monoacyl benzimidazole compounds for use in the treatment of an allergic condition comprising the following species:
[0019] In accordance with another aspect of the present invention, there is disclosed a method for the preparation of a medicament for treatment of a condition associated with an excess IgE level. The compound has the formula:
[0020] X and Y are independently selected from the group consisting of H, alkyl, alkoxy, aryl, substituted aryl, hydroxy, halogen, amino, alkylamino, nitro, cyano, CF 3 , OCF 3 , CONH 2 , CONHR and NHCOR 1 . R is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , CH 2 Ph, and CH 2 C 6 H 4 —F(p-). R 1 and R 2 are independently selected from the group consisting of H, aryl, heteroaryl, thiophene, pyridyl, thiazolyl, isoxazolyl, oxazolyl, pyrimidinyl, substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, cycloaryl, cycloheteroaryl, quinolinyl, isoquinolinyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, multi-ring cycloaryl, multi-ring cycloheteroaryl, benzyl, heteroaryl-methyl, substituted benzyl, substituted heteroaryl-methyl alkyl, dialkyl, aminoalkyl, cycloalkyl, cycloalkyl containing 1-3 heteroatoms, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, multi-ring cycloalkyl, multiring cycloalkyl containing 1-3 heteroatoms, fused-ring aliphatic, fused-ring aliphatic containing 1-3 heteroatoms, cyclopropyl, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, cyclopentyl, pyrrole, piperidine, substituted cyclopentyl, cyclohexyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalknyl, adamantyl, substituted adamantyl and the like, and wherein at least one of R 1 and R 2 are aromatic groups or heteroaromatic groups. The R 1 and R 2 substitutions are independently selected from the group consisting of alkyl, aryl, CF 3 , CH 3 , OCH 3 , OH, CN, CONH 2 , CONHR, CONR1R2, COOR and COOH.
[0021] In accordance with another aspect of the present invention, there is disclosed a method of treating a mammal having a condition associated with an excess IgE level. The method comprises administering to the mammal an amount of a compound sufficient to reduced IgE levels in the mammal. The compound has the formula:
wherein X and Y are independently selected from the group consisting of H, alkyl, alkoxy, aryl, substituted aryl, hydroxy, halogen, amino, alkylamino, nitro, cyano, CF 3 , OCF 3 . CONH 2 , CONHR and NHCOR 1 ; wherein R is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , CH 2 Ph, CH 2 C 6 H 4 —F(p-), COCH 3 , CO 2 CH 2 CH 3 , aminoalkyl and dialkylaminoalkyl; and wherein R 1 and R 2 are independently selected from the group consisting of H, aryl, heteroaryl, thiophene, pyridyl, thiazolyl, isoxazolyl, oxazolyl, pyrimidinyl, substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, cycloaryl, cycloheteroaryl, quinolinyl, isoquinolinyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, multi-ring cycloaryl, multi-ring cycloheteroaryl, benzyl, heteroaryl-methyl, substituted benzyl, substituted heteroaryl-methyl alkyl, dialkylaminoalkyl, cycloalkyl, cycloalkyl containing 1-3 heteroatoms, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, multi-ring cycloalkyl, multiring cycloalkyl containing 1-3 heteroatoms, fused-ring aliphatic, fused-ring aliphatic containing 1-3 heteroatoms, cyclopropyl, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, cyclopentyl, pyrrole, piperidine, substituted cyclopentyl, cyclohexyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, substituted adamantyl and the like, wherein at least one of R 1 and R 2 are aromatic groups or heteroaromatic groups.
[0025] The substituents on said substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, substituted benzyl, substituted heteroaryl-methyl alkyl, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, substituted cyclopentyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, and substituted adamantyl are independently selected from the group consisting of alkyl, aryl, CF 3 , CH 3 , OCH 3 , OH, CN, CONH 2 , CONHR, CONR1R2, COOR and COOH.
[0026] In a variation of the above-disclosed method, at least one additional active ingredient may be administered in conjunction with the administration of the compound. The additional active ingredient may be combined with said compound in a pharmaceutically acceptable diluent and co-administered to the mammal. The additional active ingredient may be a short-acting β 2 -adrenergic agonist selected from the group consisting of terbutaline and albuterol. In a variation, the additional active ingredient may be a long-acting β 2 -adrenergic agonist selected from the group consisting of salmeterol and formoterol or an antihistamine selected from the group consisting of loratadine, azelastine and ketotifen. In another variation, the additional active ingredient may be a phosphodiesterase inhibitor, an anticholinergic agent, a corticosteroid, an inflammatory mediator release inhibitor or a leukotriene receptor antagonist.
[0027] The compound is preferably administered at a dose of about 0.01 mg to about 100 mg per kg body weight per day in divided doses of said compound for at least two consecutive days at regular periodic intervals.
[0028] Other variations within the scope of the present invention may be more fully understood with reference to the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The present invention is directed to small molecule inhibitors of IgE (synthesis and/or release) which are useful in the treatment of allergy and/or asthma or any diseases where IgE is pathogenic. The particular compounds disclosed herein were identified by their ability to suppress IgE levels in both ex vivo and in vivo assays. Development and optimization of clinical treatment regimens can be monitored by those of skill in the art by reference to the ex vivo and in vivo assays described below.
[heading-0030] Ex Vivo Assay
[0031] This assay begins with in vivo antigen priming and measures secondary antibody responses in vitro. The basic protocol was documented and optimized for a range of parameters including: antigen dose for priming and time span following priming, number of cells cultured in vitro, antigen concentrations for eliciting secondary IgE (and other Ig's) response in vitro, fetal bovine serum (FBS) batch that will permit optimal IgE response in vitro, the importance of primed CD4+ T cells and hapten-specific B cells, and specificity of the ELISA assay for IgE (Marcelletti and Katz, Cellular Immunology 135:471-489 (1991); incorporated herein by reference).
[0032] The actual protocol utilized for this project was adapted for a more high throughput analyses. BALB/cByj mice were immunized i.p. with 10 μg DNP-KLH adsorbed onto 4 mg alum and sacrificed after 15 days. Spleens were excised and homogenized in a tissue grinder, washed twice, and maintained in DMEM supplemented with 10% FBS, 100 U/ml penicillin, 100 μg/ml streptomycin and 0.0005% 2-mercaptoethanol. Spleen cell cultures were established (2-3 million cells/ml, 0.2 ml/well in quadruplicate, 96-well plates) in the presence or absence of DNP-KLH (10 ng/ml). Test compounds (2 μg/ml and 50 ng/ml) were added to the spleen cell cultures containing antigen and incubated at 37° C. for 8 days in an atmosphere of 10% CO 2 .
[0033] Culture supernatants were collected after 8 days and Ig's were measured by a modification of the specific isotype-selective ELISA assay described by Marcelletti and Katz (Supra). The assay was modified to facilitate high throughput. ELISA plates were prepared by coating with DNP-KLH overnight. After blocking with bovine serum albumin (BSA), an aliquot of each culture supernatant was diluted (1:4 in phosphate buffered saline (PBS) with BSA, sodium azide and Tween 20), added to the ELISA plates, and incubated overnight in a humidified box at 40 C. IgE levels were quantitated following successive incubations with biotinylated-goat antimouse IgE (b-GAME), AP-streptavidin and substrate.
[0034] Antigen-specific IgG1 was measured similarly, except that culture supernatants were diluted 200-fold and biotinylated-goat antimouse IgG1 (b-GAMG1) was substituted for B-GAME. IgG2a was measured in ELISA plates that were coated with DNP-KLH following a 1:20 dilution of culture supernatants and incubation with biotinylated-goat antimouse IgG2a (b-GAMG2a). Quantitation of each isotype was determined by comparison to a standard curve. The level of detectability of all antibody was about 200-400 μg/ml and there was less than 0.001% cross-reactivity with any other Ig isotype in the ELISA for IgE.
[heading-0035] In Vivo Assay
[0036] Compounds found to be active in the ex vivo assay (above) were further tested for their activity in suppressing IgE responses in vivo. Mice receiving low-dose radiation prior to immunization with a carrier exhibited an enhanced IgE response to sensitization with antigen 7 days later. Administration of the test compounds immediately prior to and after antigen sensitization, measured the ability of that drug to suppress the IgE response. The levels of IgE, IgG1 and IgG2a in serum were compared.
[0037] Female BALB/cByj mice were irradiated with 250 rads 7 hours after initiation of the daily light cycle. Two hours later, the mice were immunized i.p. with 2 μg of KLH in 4 mg alum. Two to seven consecutive days of drug injections were initiated 6 days later on either a once or twice daily basis. Typically, i.p. injections and oral gavages were administered as suspensions (150 μl/injection) in saline with 10% ethanol and 0.25% methylcellulose. Each treatment group was composed of 5-6 mice. On the second day of drug administration, 2 μg of DNP-KLH was administered i.p. in 4 mg alum, immediately following the morning injection of drug. Mice were bled 7-21 days following DNP-KLH challenge.
[0038] Antigen-specific IgE, IgG1 and IgG2a antibodies were measured by ELISA. Periorbital bleeds were centrifuged at 14,000 rpm for 10 min, the supernatants were diluted 5-fold in saline, and centrifuged again. Antibody concentrations of each bleed were determined by ELISA of four dilutions (in triplicate) and compared to a standard curve: anti-DNP IgE (1:100 to 1:800), anti-DNP IgG2a (1:100 to 1:800), and anti-DNP IgG1 (1:1600 to 1:12800).
[heading-0039] Benzimidazole Inhibitors of IgE
[0040] Several species embraced by the following generic formula were synthesized and evaluated for their effectiveness in down-regulating IgE in the ex vivo and in vivo assays.
wherein X and Y are independently selected from the group consisting of H, alkyl, alkoxy, aryl, substituted aryl, hydroxy, halogen, amino, alkylamino, nitro, cyano, CF 3 , OCF 3 . CONH 2 , CONHR and NHCOR 1 ; wherein R is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , CH 2 Ph, CH 2 C 6 H 4 —F(p-), COCH 3 , CO 2 CH 2 CH 3 , aminoalkyl and dialkylaminoalkyl; and wherein R 1 and R 2 are independently selected from the group consisting of H, aryl, heteroaryl, thiophene, pyridyl, thiazolyl, isoxazolyl, oxazolyl, pyrimidinyl, substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, cycloaryl, cycloheteroaryl, quinolinyl, isoquinolinyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, multi-ring cycloaryl, multi-ring cycloheteroaryl, benzyl, heteroaryl-methyl, substituted benzyl, substituted heteroaryl-methyl alkyl, dialkylaminoalkyl, cycloalkyl, cycloalkyl containing 1-3 heteroatoms, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, multi-ring cycloalkyl, multiring cycloalkyl containing 1-3 heteroatoms, fused-ring aliphatic, fused-ring aliphatic containing 1-3 heteroatoms, cyclopropyl, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, cyclopentyl, pyrrole, piperidine, substituted cyclopentyl, cyclohexyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, substituted adamantyl and the like, wherein at least one of R 1 and R 2 are aromatic groups or heteroaromatic groups.
[0044] The substituents on said substituted aryl, substituted heteroaryl, substituted thiophene, substituted pyridyl, substituted thiazolyl, substituted isoxazolyl, substituted oxazolyl, substituted cycloaryl, substituted cycloheteroaryl, substituted quinolinyl, substituted isoqunolinyl, substituted benzyl, substituted heteroaryl-methyl alkyl, substituted cycloalkyl, substitute cycloalkyl containing 1-3 heteroatoms, substituted cyclopropyl, cyclobutyl, substituted cyclobutyl, substituted cyclopentyl, substituted cyclohexyl, cycloheptyl, substituted cycloheptyl, bicycloheptyl, substituted pyrrole, substituted piperidine, bicyclooctyl, bicyclononyl, substituted bicycloalkenyl, adamantyl, and substituted adamantyl are independently selected from the group consisting of alkyl, aryl, CF 3 , CH 3 , OCH 3 , OH, CN, CONH 2 , CONHR, CONR1R2, COOR and COOH.
[heading-0045] Synthesis of the Combinatorial Library
[0046] The diacyl benzimidazole compounds of the present invention were prepared using the following synthesis reactions, wherein the desired acid chlorides are selected from the R1 and R2 groups provided in the Table.
[0047] Synthesis of 3: 4-Nitro-1,2-phenylenediamine (10 g, 65.3 mmol) and 4-aminobenzoic acid (8.95 g, 65.3 mmol) were taken in a round bottomed flask and phosphorus oxychloride (95 ml) was added slowly. The reaction mixture was allowed to stir under reflux conditions. After 18 h, the reaction was allowed to cool and then poured slowly into an ice water mixture in an Erlenmeyer flask with vigorous stirring. Greenish yellow precipitate fell out which was then filtered and washed with copious amounts of water. The residue was then dried to obtain 16.9 g of crude desired product. Mass spectrum analysis (positive ion) indicated presence of 3.
[0048] Synthesis of 4: Benzimidazole 3 (800 mg, 3.14 mmol) was dissolved in dry pyridine (5 ml) in a scintillation vial and the desired acid chlorides (1.1 eq) were added slowly. The reactions were carried out in an oven at 60C. After 16 h, the reaction was cooled to RT and DI water was added. Precipitation took place, which was filtered off, washed with water and air dried. The aqueous layer was extracted with EtOAc (6×50 ml), dried over anhydrous Na 2 SO 4 and the solvent was removed in vacuo to result in a colored solid. By positive ion MS the desired monoacylated product was found to be present in the initial precipitate as well as in the organic layer. Hence the solid residues obtained were combined and used as such for the reduction step.
[0049] Reduction of 4: Crude monoacylated nitro benzimidazole 4 (1.22 g, 3.40 mmol) was dissolved in MeOH (20 ml) and minimum amount of THF was added for complete dissolution to occur. Catalytic amount of 10% Pd on C was added and the solution was degassed and allowed to stir at 3.4 atm pressure under H 2 atmosphere for 4 h. Upon completion of reaction as observed via TLC, the reaction mixture was filtered through celite and the solvent was removed under reduced pressure to afford 979 mg of crude residue.
[heading-0050] General Organic Analyses
[0051] HPLC/MS data was obtained using a Gilson semi-prep HPLC with a Gilson 170 Diode Array UV detector and PE Sciex API 100LC MS based detector. A Waters 600E with a Waters 490E UV detector was also used for recording HPLC data. The compounds were eluted with a gradient of CH 3 CN (with 0.0035% TFA) and H 2 O (with 0.01% TFA). Both HPLC instruments used Advantage C18 60A 5 μ50 mm×4.6 mm columns from Thomson Instrument Company. Mass spectra were obtained by direct injection and electrospray ionization on a PE Sciex API 100LC MS based detector. Thin layer chromatography was performed using Merck 60F-254 aluminum backed precoated plates. Flash chromatography was carried out on Merck silica gel 60 (230-400 mesh) purchased from EM Scientific.
[heading-0052] Syntheses of Symmetrical Diamides
[0053] The symmetrical diacyl benzimidazole compounds of the present invention were generally prepared from 2-(4-aminophenyl)-5-aminobenzimidazole, which was obtained by reduction of 2-(4-nitrophenyl)-6-nitrobenzimidazole.
[0054] 2-(4-nitrophenyl)-6-nitrobenzimidazole
[0055] The dinitro benzimidazole was prepared as follows: a mixture of 4-nitrophenylenediamine (6.4 g, 41.83 mmol) and 4-nitrobenzoic acid (7.86 g, 47 mmol) was dissolved in POCl 3 (250 ml) and heated to reflux for 2 h. The reaction mixture was cooled, poured on to ice, and stirred for 30 min. The resulting solid was filtered and washed with methanol and sodium bicarbonate to remove unreacted acid and allowed to dry overnight to give the desired product as a brown solid (5.8 g). The product was characterized by electrospray mass spectroscopy (mp>300° C.).
[0056] 2-(4-Aminophenyl)-5-aminobenzimidazole was prepared by suspending the above solid (75 g) in THF (75 ml), to which was added Pd-C (10% Pd by weight). The flask was purged with hydrogen and stirred under a balloon of hydrogen over night. TLC and MS showed starting material was still present so the reaction was allowed to continue over the weekend. TLC indicated complete reaction, the reaction was filtered through celite and washed with methanol. The solvent was removed under reduced pressure to give a dark brown solid (0.37 g) that was used without further purification.
[0057] 2-(4-aminophenyl)-5-aminobenzimidazole
[0058] Alternatively, the 2-(4-aminophenyl)-5-aminobenzimidazole was prepared by the following reduction: 2-(4-nitrophenyl)-6-nitrobenzimidazole (8.9 g, 31 mmole) was suspended in concentrated HCl (100 ml) to which was added stannous chloride (42.3 g 180 mmole). The reaction mixture was heated to reflux for 5 hrs. The mixture was cooled to RT and the HCl salt of the desired product was precipitated by the addition of ethanol. The resulting solid was filtered, re-dissolved in water and the solution made basic by the addition of concentrated ammonium hydroxide. The resulting precipitate was filtered and dried overnight under vacuum to yield the desired product as a gray solid (6.023 g, 26.9 mmole, 87%). The product characterized by electrospray mass spectroscopy and HPLC (mp. 222-227° C.).
[0059] 2-(4-Aminophenyl)-5-methoxy benzimidazole was synthesized from 2-(4-nitrophenyl)-5-methoxy benzimidazole, which was prepared as follows: 1,2-diamino-4-methoxybenzene (1.26 g, 10.0 mmole was mixed with 4-nitrobenzoic acid (1.67 g, 9.8 mmole) and dissolved in POCl 3 (10 ml) and heated to reflux for 2.5 hours. The reaction mixture was cooled and cautiously poured onto ice. The resulting solid was filtered, washed with NaHCO 3 and used without further purification.
[0060] 2-(4-nitrophenyl)-5-methoxy benzimidazole
[0061] 2-(4-Aminophenyl)-5-methoxy benzimidazole was prepared by dissolving 1 g of the above nitrobenzimidazole in 30% Na 2 S9H 2 O (20 ml) with stirring at RT for 21 h. The reaction mixture was diluted with water and extracted with EtOAc. The combined organic extracts were dried over sodium sulfate and concentrated under vacuum. The product was characterized by mass spectroscopy.
[0062] 2-(4-aminophenyl)-5-methoxy benzimidazole
[0063] 2-(4-Aminophenyl)-5,6-dichloro benzimidazole was synthesized from 2-(4-nitrophenyl)-5,6-dichloro benzimidazole, which was prepared as follows: 1,2-diamino-4,5-dichlorobenzene (1.68 g, 10.0 mmole) was mixed with 4-nitrobenzoic acid (1.58 g, 9.3 mmole), dissolved in POCl 3 (10 ml), and heated to reflux for 2.5 hours. The reaction mixture was cooled and cautiously poured onto ice. The resulting solid was filtered, washed with NaHCO 3 and used without further purification.
[0064] 2-(4-nitrophenyl)-5,6-dichloro benzimidazole
[0065] 2-(4-Aminophenyl)-5,6-dichloro benzimidazole was prepared by dissolving 1 g of the above nitrobenzimidazole in 30% Na 2 S9H 2 O (20 ml) with stirring at RT for 21 h. The reaction mixture was diluted with water and extracted with EtOAc. The combined organic extracts were dried over sodium sulfate and concentrated under vacuum. The product was characterized by mass spectroscopy.
[0066] 2-(4-Aminophenyl)-5,6-dichloro benzimidazole
[0067] 2-(4-aminophenyl)-7-methyl benzimidazole was synthesized from 2-(4-nitrophenyl)-7-methyl benzimidazole, which was prepared by mixing 1,2-diamino-3-methylbenzene (1.24 g, 10.0 mmole) with 4-nitrobenzoic acid (1.69 g, 9.8 mmole), dissolved in POCl 3 (10 ml), and heated to reflux for 2.5 hours. The reaction mixture was cooled and cautiously poured onto ice. The resulting solid was filtered, washed with NaHCO 3 and used without further purification.
[0068] 2-(4-nitrophenyl)-7-methyl benzimidazole
[0069] 2-(4-Aminophenyl)-7-methyl benzimidazole was synthesized by dissolving 1 g of the above nitrobenzimidazole in 30% Na 2 S-9H 2 O (20 ml) with stirring at RT for 4.5 h. The reaction mixture was diluted with water and extracted with EtOAc. The combined organic extracts were dried over sodium sulfate and concentrated under vacuum. The product was characterized by mass spectroscopy.
[0070] 2-(4-aminophenyl)-7-methyl benzimidazole
[0071] 2-(4-Aminophenyl)-6-methyl benzimidazole was synthesized from 2-(4-nitrophenyl)-6-methyl benzimidazole, which was prepared by mixing 1,2-diamino-4-methylbenzene (1.24 g, 9.8 mmole) with 4-nitrobenzoic acid (1.6 g, 9.9 mmole) and dissolved in POCl 3 (10 ml) and heated to reflux for 2.5 hours. The reaction mixture was cooled and cautiously poured onto ice. The resulting solid was filtered, washed with NaHCO 3 and used without further purification.
[0072] 2-(4-nitrophenyl)-6-methyl benzimidazole
[0073] 2-(4-Aminophenyl)-6-methyl benzimidazole was synthesized by dissolving 1 g of the above nitrobenzimidazole in 30% Na2S.9H 2 O (20 ml) with stirring at RT for 4.5 h. The reaction mixture was diluted with water and extracted with EtOAc. The combined organic extracts were dried over sodium sulfate and concentrated under vacuum. The product was characterized by mass spectroscopy.
[0074] 2-(4-aminophenyl)-6-methyl benzimidazole
[0075] 2-(4-Aminophenyl)-5,6-dimethyl benzimidazole was synthesized from 2-(4-nitrophenyl)-5,6-dimethyl benzimidazole, which was prepared by mixing 1,2-diamino-4,5-dimethylbenzene (1.38 g, 10.1 mmole) with 4-nitrobenzoic acid (1.69 g, 9.9 mmole) and dissolved in POCl 3 (10 ml) and heated to reflux for 2.5 hours. The reaction mixture was cooled and cautiously poured onto ice. The resulting solid was filtered, washed with NaHCO 3 and used without further purification.
[0076] 2-(4-nitrophenyl)-5,6-dimethyl benzimidazole
[0077] 2-(4-Aminophenyl)-5,6-dimethyl benzimidazole was synthesized by dissolving 1 g of the above nitrobenzimidazole (31.1) in 30% Na 2 S-9H 2 O (20 ml) with stirring at RT for 4.5 h. The reaction mixture was diluted with water and extracted with EtOAc. The combined organic extracts were dried over sodium sulfate and concentrated under vacuum. The product was characterized by mass spectroscopy.
[0078] 2-(4-aminophenyl)-5,6-dimethyl benzimidazole
[0079] The subsequent preparation of symmetrical diamides was accomplished by one of the following methods:
[0080] Method A: 2-(4-Aminophenyl)-6-aminobenzimidazole (1 mmole) was suspended in THF (5 ml) to which was added DIEA (2.5 mmole) and mixture cooled to −78° C. To the above cooled mixture was added the acid chloride (2.5 mmole) and let warm to RT overnight. Water (2 ml) is added to the reaction and extracted with EtOAc. The combined organic extracts were combined washed with NaHCO 3 (aq.) and concentrated under reduced pressure. The resulting residue was purified on silica gel (hexanes/EtOAc or MeOH/CH 2 Cl 2 ) or reverse phase HPLC (CH 3 CN/H 2 O).
[0081] Method B: 2-(4-Aminophenyl)-6-aminobenzimidazole (1 mmole) and DMAP (cat.) was dissolved in pyridine (5 ml). To the above solution was added the acid chloride (2.5 mmole) and the reaction stirred overnight at 600 C. The reaction was cooled to room temperature and water added to precipitate the product. The resulting solid was collected by filtration with the solid being washed by hexanes and water and NaHCO 3 (aq.). The resulting residue was purified on silica gel (hexanes/EtOAc or MeOH/CH 2 Cl 2 ) or reverse phase HPLC (CH 3 CN/H 2 O).
[0082] Method C: 2-(4-Aminophenyl)-6-aminobenzimidazole (1 mmole) was suspended in THF (10 ml) to which was added K 2 CO 3 (2.5 mmole) in water (0.5 ml). and mixture cooled to −78° C. To the above cooled mixture was added the acid chloride (2.5 mmole) and let warm to RT overnight. Water (10 ml) was added to the reaction and extracted with EtOAc. The combined organic extracts were combined washed with NaHCO 3 (aq.) and concentrated under reduced pressure. The resulting residue was purified on silica gel (hexanes/EtOAc or MeOH/CH 2 Cl 2 ) or reverse phase HPLC (CH 3 CN/H 2 O).
[0083] Method D: The carboxylic acid (2.2 mmole), EDC (2.2 mmole) and DMAP (cat.) was dissolved in hot pyridine. To the above solution was added 2-(4-aminophenyl)-6-aminobenzimidazole (1 mmole) and heated to 60° C. overnight. The cooled reaction mixture was partitioned between water and EtOAc. The organic layer was washed with NaHCO 3 , dried over Na 2 SO 4 and concentrated under vacuum. The resulting residue was purified on silica gel (hexanes/EtOAc or MeOH/CH 2 Cl 2 ) or reverse phase HPLC (CH 3 CN/H 2 O).
[heading-0084] Benzimidazole Species
[0085] The following species encompassed within the disclosed generic formula were synthesized and tested for their ability to suppress IgE. The species are presented below.
Suppression of IgE Response
[0087] The inhibitory activity of the small molecules of the present invention were assayed using both the ex vivo and in vivo assays as described above. All of the compounds presented above were active in suppressing the IgE response. In the ex vivo assay, compounds in genuses I-XI produced 50% inhibition at concentrations ranging from 1 pM to 100 μM. In the in vivo assay, the compounds were effective at concentrations ranging from less than about 0.01 mg/kg/day to about 100 mg/kg/day, when administered in divided doses (e.g., two to four times daily) for at least two to seven consecutive days. Thus, the small molecule inhibitors of the present invention are disclosed as being useful in lowering the antigen-induced increase in IgE concentration, and consequently, in the treatment of IgE-dependent processes such as allergies in general and allergic asthma in particular.
[heading-0088] Treatment Regimens
[0089] The amount of the IgE inhibitor compound which may be effective in treating a particular allergy or condition will depend on the nature of the disorder, and can be determined by standard clinical techniques. The precise dose to be employed in a given situation will also depend on the choice of compound and the seriousness of the condition, and should be decided according to the judgment of the practitioner and each patient's circumstances. Appropriate dosages can be determined and adjusted by the practitioner based on dose response relationships between the patient's IgE levels as well as standard indices of pulmonary and hemodynamic changes. Moreover, those skilled in the art will appreciate that dose ranges can be determined without undue experimentation by following the protocol(s) disclosed herein for ex vivo and in vivo screening (See for example Hasegawa et al., J. Med. Chem. 40: 395-407 (1997) and Ohmori et al., Int. J. Immunopharmacol. 15:573-579 (1993); employing similar ex vivo and in vivo assays for determining dose-response relationships for IgE suppression by naphthalene derivatives; incorporated herein by reference).
[0090] Initially, suitable dosages of the compounds will generally range from about 0.001 mg to about 300 mg per kg body weight per day in divided doses, more preferably, between about 0.01 mg and 100 mg per kg body weight per day in divided doses. The compounds are preferably administered systemically as pharmaceutical formulations appropriate to such routes as oral, aerosol, intravenous, subcutaneously, or by any other route which may be effective in providing systemic dosing of the active compound. The compositions of pharmaceutical formulations are well known in the art. The treatment regimen preferably involves periodic administration. Moreover, long-term therapy may be indicated where allergic reactions appear to be triggered by continuous exposure to the allergen(s). Daily or twice daily administration has been effective in suppressing the IgE response to a single antigen challenge in animals when carried out continuously from a period of two to seven consecutive days. Thus, in a preferred embodiment, the compound is administered for at least two consecutive days at regular periodic intervals. However, the treatment regimen, including frequency of dosing and duration of treatment may be determined by the skilled practitioner, and modified as needed to provide optimal IgE down-regulation, depending on nature of the allergen, the dose, frequency, and duration of the allergen exposure, and the standard clinical indices.
[0091] In one embodiment of the present invention, an IgE-suppressing compound may be administered in conjunction with one or more of the other small molecule inhibitors disclosed, in order to produce optimal down-regulation of the patient's IgE response. Further, it is envisioned that one or more of the compounds of the present invention may be administered in combination with other drugs already known or later discovered for treatment of the underlying cause as well as the acute symptoms of allergy or asthma. Such combination therapies envisioned within the scope of the present invention include mixing of one or more of the small molecule IgE-inhibitors together with one or more additional ingredients, known to be effective in reducing at least one symptom of the disease condition. In a variation, the small molecule IgE-inhibitors herein disclosed may be administered separately from the additional drugs, but during the same course of the disease condition, wherein both the IgE-inhibitor(s) and the palliative compounds are administered in accordance with their independent effective treatment regimens.
[0092] While a number of preferred embodiments of the invention and variations thereof have been described in detail, other modifications and methods of use will be readily apparent to those of skill in the art. Accordingly, it should be understood that various applications, modifications and substitutions may be made of equivalents without departing from the spirit of the invention or the scope of the claims. | This invention relates to a family of benzimidazole analogs, which are inhibitors of the IgE response to allergens. These compounds are useful in the treatment of allergy, asthma, or any diseases where IgE is pathogenic. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to conveyors and more particularly to a class of conveyors called Triple-Strand or Triple-Strand roller chain type conveyors wherein the generally loaded pallets are conveyed in one direction on the top of the conveyor and thereafter the empty pallets are returned along the bottom of the conveyor, thereby eliminating the requirement for a separate return conveyor.
In the prior art the pallet has been conveyed in close contact with the chain around the end sprockets. The control of the pallet through the transition is difficult unless close tolerances, high chain tension, and accurate guide surfaces are maintained. Otherwise, the pallets tend to flop, slip or break around the turns creating high forces on the chains and associated drive equipment.
The foregoing illustrates limitations known to exist in present devices and methods. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention this is accomplished by providing a triple-strand roller chain conveyor comprising roller means attached to a transferred conveyor pallet for the purposes of controlling the conveyor end pallet rollover transition; means associated with the ends of the conveyor for receiving the roller means including cam means for guiding the rollers through the transition; and resilient means for driving, guiding, and resiliently loading the roller means against said cam means through the transition.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a plan view of a typical triple-strand conveyor;
FIG. 2 is a side elevation of the conveyor of FIG. 1;
FIG. 3 is an end elevation of the conveyor of FIG. 1;
FIG. 4 is a partial side elevation of the head shaft area of a conveyor according to the present invention;
FIG. 5 is a partial cross section of the tail shaft portion of a conveyor according to the present invention;
FIG. 6 is a partial end elevation of the head shaft area of a conveyor according to the present invention;
FIG. 7 is a partial end elevation of the tail shaft portion of a conveyor according to the present invention;
FIG. 8 is a schematic of the pallet guide in the head shaft area of the present invention; and
FIG. 9 is a schematic of an alternate embodiment of the guide according to the present invention in the tail shaft area.
DETAILED DESCRIPTION
Referring to FIGS. 1, 2, and 3, a conveyor is shown of the triple-strand type generally referred to by reference numeral 1.
In general, the conveyor is comprised of a plurality of supports 28 which position the conveyor relative to, for example, a production floor. A conveyor frame is shown positioned on the supports 28 and in general comprises two top rails 4 and two bottom rails 4' spaced apart at a convenient width and height to form the supporting structure for the triple-strand conveyor chain 25 (best seen in FIG. 2).
A head shaft 23 and a tail shaft 22 are conveniently supported within the frame near the ends. The head shaft is provided with a pair of matched double sprockets 7 and the tail shaft 22 is provided with a pair of matched double sprockets 7' which drives the triple-strand chain 25. The sprocket 23 is in turn driven by a drive chain 16 which in turn is driven by the gear reducer 3 and motor 2.
In the transfer direction indicated by the arrow designated T a plurality of pallets 5 coact with the transfer chain which guidingly drives the pallets in the direction of transfer, the pallets being carried along by the triple-strand chain as will be more particularly described later.
Referring now to FIG. 4, the partial head shaft end elevation shows a pallet 5 being transferred into the head shaft area as will be more fully described later. The pallet is being carried along by the triple-strand roller chain 25. A cam roller 10 is shown attached to a bottom pad plate 9 which is part of a rail bracket 8, as best seen in FIG. 6. This bracket is attached to the pallet 5.
It should be understood that one or two such cam rollers are mounted o each side of the pallet 5 as designated by the duplicate prime numbers. A C-shaped cam plate 35 is shown. This receives the cam roller 10 as the pallet is transferred to the end of the conveyor, which in combination with a resilient roller 45 and bottom pad plate 9 drive the pallet around the end of the conveyor.
Referring to FIGS. 4 and 6, it should be appreciated by one skilled in the art that the double sprocket 7 on one side of the head shaft 23, and a duplicate double sprocket, not shown for clarity, on the opposite of the head shaft 23, engage the triple-strand roller chain 25 and as the head shaft 23 is driven in rotation the triple-strand roller conveyor chain is in turn driven around the sprocket and thence along the conveyor length.
A plurality of chain guides 29 and 29' generally support the triple-strand chain in a cantilevered fashion. Similar guides 49 and 49' support the roller chain in cantilevered fashion during its return travel.
The pallet 5 is shown supported on a pallet top rail 12 on the inner cantilevered end of the roller chain. During the return the pallet is supported on the inward end of the ca levered roller chain by the pallet bottom rail 9. The duplicate prime numbered elements are shown for the opposite side of the conveyor.
Generally, in the prior art, the pallet is provided with a close fitting guide which intimately contacts the roller chain through the transition from the top to the bottom portion. In order for these to function properly the chain must be maintained in proper tension and the guides must be accurately machined to reflect the radius of the turn. Otherwise considerable flop or slip is experienced as the pallet goes over and/or up the end of the conveyor. The resulting forces can create an annoying and potentially damaging instantaneous chain loading.
According to the present invention, the pallet bottom pad 9 is provided with a cam roller 10 or two cam rollers 20 which engage cam plate 35 and resilient tire 45 at the end of the conveyor in the head shaft 23 area and oppositely cam plate 30 and a resilient tire 15 in the tail shaft 22 area. As best seen in FIG. 5, the cam roller 20 in the tail shaft area is forced against the cam 30 by the bottom pad 9' being squeezed by the tire 15.
As seen in FIG. 4, a single cam roller per side may be provided on the pallet 5 to engage the cam plate 30 or 35 and the bottom pad 9 engages the resilient tire roller 15 or 45 at each end of the conveyor. In the case of a single cam roller, the pallet bottom pad 9 engages the resilient tire 15, 45 at each end of the conveyor and resiliently restrains the pallet during the rollover turn. This substantially cushions the flopping force experienced and in fact the conveyor pallet is lifted slightly out of contact with the triple-strand chain during the rollover function. This permits the chain to have a greater tolerance in tension and removes the force generated in the pallet flopping over the end of the conveyor from the chain. A single roller has been found satisfactory for use with relatively light pallets.
As shown in FIG. 5, a double cam roller 20 may be provided to provide better control for the pallet around the turn. This further reduces the tendency of the pallet to flop as it goes around the turn.
The operation of the roller cam 10, 20 may best be understood by referring to FIGS. 8 and 9.
FIG. 8 shows a single cam roller 10a attached to a conveyor pallet 5 on the pallet pad 9 showing the progression of the roller as indicated by the phantom line progression of the rollers 10b, 10c, 10d, and 10e through the turn.
It should be understood by one skilled in the art that the cam plates 30 and 35 may be positioned by means of a cam bracket 6 or 6' at the respective ends of the conveyor. The cam plate 35 is chosen to generally raise the pallet clear of the roller chain during the initial portion of the turn and thereafter having completed the rotation gently redeposit the pallet on the roller chain on the bottom portion of the conveyor.
The cam plate 30 similarly gently lifts the pallet as it approaches the end of the conveyor, permits rollover and gently redeposits the pallet on the top of the roller chain 25 on the top portion of the conveyor. This is best seen in FIG. 9.
The distance between the cam plate 30,35 surface and the bottom pad 9, is greater than the distance between the cam plate surface 30,35 and the resilient tires 15,45.
The resilient tires 15 and 45 are compressed by the bottom pad 9 as the cam rollers go against the cam plate at each respective end. The resilient nature of the tires permits them to grip the bottom pad and the tire is squashed by the bottom pad as the roller contacts the cam. This provides the required drive of the pallet through the turn without chain contact and resiliently controls the flop or slip of the conveyor pallet as it goes through the end transition.
FIG. 8 depicts a single roller cam 10 and FIG. 9 depicts a double roller cam 20. It should be understood that this is for purpose of convenience and that either one or two rollers is provided for each side of the pallet. The function at both ends is similar for one or two rollers. Thus, in this invention we have eliminated the critical shaped pieces and the need for chain tensioning devices in the present invention.
In summary, according to the present invention, two bottom pads are mounted to the bottom of the pallet, one on each side. Mounted to the side of each bottom pad are one or two cam follower bearings as described. Two resilient tires are mounted on each conveyor shaft (head drive shaft and tail or takeup shaft), one on each side near the sprocket. Along the side of each conveyor sprocket is mounted a cam plate. As the pallet approaches the end of the conveyor the cam follower enters the cam plate area. The pallet bottom pads engage the resilient tires and force the cam followers against the cam plate driving the pallet around the end of the conveyor a the tire 15 is mounted to and rotates with the conveyor shafts.
On the adjustable takeup shaft at the tail end of the conveyor the cam plate is mounted on the shaft with sleeve bearings or the like and therefore any linear adjustment made to the conveyor takeup shaft (tail shaft) automatically includes the cam plate. | A triple-strand conveyor is provided with guiding rollers on the pallet which coact with a resilient driving roller and a cam plate guide to provide positive control of the pallet during rollover at the conveyor ends from the top to bottom positions and vice versa. The combination of positive drive and resilient control reduces the chain forces associated with rollover and minimizes the need for constant readjustment of the chain tension during operation. The rollers eliminate chain contact during the rollover function thereby eliminating the need for elaborate chain contact and guide devices associated with the prior art. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application hereby incorporates the following United Stated Patent Applications by reference in their entirety:
Attorney Docket Number Express Mail L.N./U.S.P.N. Filing Date LSI 01-390 EV 013 245 452 US Nov. 20, 2001 LSI 01-488 EV 013 245 396 US Oct. 30, 2001 LSI 01-489 LV 013 245 404 US Oct. 30, 2001 LSI 01-490 LV 013 245 418 US Oct. 30, 2001 LSI 01-524 EV 013 245 316 US Dec. 27, 2001 LSI 01-695 09/842,335 Apr. 25, 2001 LSI 01-828 EV 013 244 973 US Dec. 27, 2001
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of integrated circuit design, and particularly to a system and method for coevolutionary circuit design.
BACKGROUND OF THE INVENTION
[0003] Integrated circuits are becoming more pervasive in most every aspect of life. Because of the wide range of uses of integrated circuits, there is also a corresponding wide range of circuits designed in a manner to provide the desired functionality in an optimized manner.
[0004] Additionally, more and more functions are being included within each integrated circuit. While providing a semiconductor device that includes a greater range of functions supported by the device, inclusion of this range further complicates the design and increases the complexity of the manufacturing process. Such complications further increase the complexity of methodologies needed to utilize this complex functionality.
[0005] Further, traditional methods of designing an integrated circuit may not be able to address the every increasing range of device needs as well as the additional complexity required in each device to provide the device requirements. For instance, an integrated circuit may be desired of such complexity that traditional design methods and systems are not able to provide the behaviors desired, such as consistent availability of the functionality, verifiable, predictable, high yielding, and the like.
[0006] Therefore, it would be desirable to provide a system and method for designing an integrated circuit utilizing coevolutionary aspects to drive both design of the integrated circuit and the methodologies needed to utilize the design in a unified manner.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention is directed to a system and method for coevolutionary circuit design. In a first aspect of the present invention, a system suitable for providing integrated circuit design includes a memory suitable for storing a first set of instructions and a second set of instructions and a processor communicatively coupled to the memory. The processor is suitable for performing the first set of instructions and the second set of instructions. The first set of instructions is suitable for configuring a processor to provide an integrated circuit development environment in which a support methodology for an integrated circuit is created. The second set of instructions is suitable for configuring a processor to provide tools for implementing a platform architecture of an integrated circuit in which the platform architecture supplies a structure of the integrated circuit. The first set of instructions and the second set of instructions are linked through at least one formalism so that at least one of an action taken utilizing the platform architecture influences the support methodology and an action taken utilizing the support methodology influences the platform architecture.
[0008] In a second aspect of the present invention, a method of designing an integrated circuit includes receiving functional specifications and constraints of an integrated circuit and interacting with a system configured to provide an environment for deriving a support methodology for an integrated circuit having the received functional specifications. The interaction with the support methodology for the integrated circuit influences an environment for designing a platform architecture for the integrated circuit.
[0009] In a third aspect of the present invention, a method of designing an integrated circuit includes receiving functional specifications and constraints of an integrated circuit and interacting with a system configured to provide an environment for deriving a platform architecture for an integrated circuit having the received functional specifications. The interaction with the platform architecture for the integrated circuit influences an environment for designing a support methodology for the integrated circuit.
[0010] It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
[0012] [0012]FIG. 1 is an illustration of an embodiment of the present invention wherein a coevolutionary relationship between a support methodology and physical silicon structures is shown; and
[0013] [0013]FIG. 2 is an illustration of an embodiment of the present invention wherein a relationship between a support methodology and physical silicon structure as implemented through use of a neural network and genetic programming is shown.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
[0015] Referring generally now to FIGS. 1 through 2, exemplary embodiments of the present invention are shown. Methodology and metamethodology and the relationship to platform architecture, and the form that this has taken mostly has been in advanced platform architecture, such as reconfigurable processors, embedded programmable logic cores, relationship between these two things that includes the incorporation of nonvolatile writable memory, embedded software techniques, a scalable interconnect, such as an interconnect with isochronous properties, and the like.
[0016] When a platform incorporating these aspects is provided, especially in a sea of platforms architecture, two things are apparent. One is that the enormous complexity and the degrees of freedom that this architecture opens up are such that it may not be possible to effectively or productively exploit this richness of capability, flexibility and power without having an advanced methodology that incorporates the features and a much deeper understanding of how to manipulate this potential.
[0017] In an aspect of the present invention, algebraic techniques are provided as implemented by a system for mapping between these spaces so that algebras for mapping into complex hardware spaces, performing verification and the like may be utilized for integrated circuit development and design. Additionally, a platform architecture may be provided to handle problems with complexity and advanced deep submicron aspects. To utilize the advanced platform architecture, a methodology, such as a metamethodology, for instance metastreaming and the like, may be provided.
[0018] Additionally, coevolutionary aspects are provided for implementation in the design process. The coevolutionary aspect of the present invention may proceed a step further, whereas previously the platform architecture and support methodology were treated as essentially independent, such as concocting a platform architecture or features in it, and then deriving some kind of methodology to support it. By utilizing the present invention, a system may be employed that treats these two spaces as neutrally interacting in a way that will be referred to as coevolutionary.
[0019] Coevolution may be developed formally and described mathematically. For instance, in biology, coevolution may be applied so that in a given ecosystem or a pair of ecosystems, two species may be so intertwined that the species evolve in conjunction with one another, so that mutual interactions during evolution influence each species' adaptive properties.
[0020] By utilizing the present invention, coevolution may be implemented through formalisms provided to take advantage of mutual interactions to allow algorithms, graphical-user interfaces and data structures to be determined on the development side. The development side may then, in turn, influence the silicon structures and protocols and device types that are actually optimal to implement the structure, given that a class of components operating on the development side in the silicon is available.
[0021] In other words, the present invention provides a global optimization that applies across both the development side and structure. Thus, a coevolutionary system and method is provided which may utilize from an algebraic point of view, coevolutionary theory to allow these two aspects to be united and drive them, as it were, as a single system.
[0022] For instance, an astronomically increasing computer capability is being driven by microprocessors at ever decreasing prices, such as a 64-bit, two and a half gigahertz microprocessor, costing at most a few hundred dollars, is rapidly declining to a few dozens of dollars. Thus, enormous processing power is available on the design side.
[0023] An optimal way of allocating a total task of designing efficient silicon, between the cost effectiveness of this design-side efficiency and the particular classes of structures that are desired of the physical silicon, may be derived by employing this coevolutionary system.
[0024] Thus, the cost effectiveness of the design-side efficiency may be capable of altering the cost effectiveness of the actual deployment of silicon in the field, such as for use in cell phones, DVD players, in enterprise solutions, information handling systems, information handling system components such as computers and disk drives, satellites, biometric systems and the like as contemplated by a person of ordinary skill in the art.
[0025] The coevolutionary relationship, such as between these two aspects, may be implemented in a system in which physical silicon structures are provided with a design environment that is geared toward this economy of scale that is operating on the design side, unified in a comprehensive view.
[0026] One method that may be utilized by a system of the present invention to describe the interactions between the two systems is algebraically. There are a variety of theories that may be employed without departing from the spirit and scope of the present invention, such as a “differential game”.
[0027] Differential games are a body of theory that is based on variational principles with a calculus of variations. For instance, classical optimal control theory may deal with a determination of an optimal control that optimizes principle subjects to dynamic constraints expressing evolution of a system state under the influence of control variables. If this is extended to the case of multiple design constraints with different and sometimes conflicting optimization criteria, which may be described through a payoff function, differential games may be employed to reach this coevolution and optimization of both the design side and the physical side, even with conflicting constraints.
[0028] Zero-sum differential games, also called differential games of pursuit, are a part of differential games. One such example is the “Homicidal Chauffeur”. In this canonical differential game, it asks the question, if a chauffeur in a car is in a parking lot and the employer enters the parking lot, the employer has a certain number of degrees of freedom of motion. If the chauffeur is bent on pursuing the employer, what are the optimal strategies? To jointly calculate optimal strategies, various factors may be taken into account, such as weight, acceleration, steering and the like of the car and the maneuverability, flexibility and so on and so forth of the employer, to determine respective optimal pursuit and evasion strategies. Thus, differential games may be used for the analysis of very complex problems of pursuit and evasion, and the like to describe optimal strategies and control.
[0029] The previous example may be thought of as a metaphor for the classes of behavior listed in the illustration depicted in FIG. 1. The silicon devices and structures may be thought of as the employer, and the structures are being pursued with the objective of optimizing the pursuit of structures in a cost-effective and constantly-reduced cost design environments in software.
[0030] The mathematics employed in the analysis, such as used in fire-control problems and related to the differential games are relevant, and such as traditional and well understood dynamic programming in which simultaneously varying classes of phenomena are studied to arrive at optimal resolutions of strategies for pursuing them. By applying this theory as discussed to the two very different classes of the present system, optimization and design may be implemented utilizing a coevolutionary structure in a new and useful manner.
[0031] Additionally, neural networks on the design side, such as a type of counterpropagation network on the design side, and species of genetic programming on the device side may be employed by the present invention. For instance, work was done by Adrian Thompson in which a chip was able to define itself optimal for the solution of a particular problem. In the case of Thompson, the problem was to have a chip evolve itself to become a highly-reliable tone discriminator capable of discriminating with 100 percent accuracy between one kilohertz and ten kilohertz tones in random bursts. A genetic program was written and given to an FPGA which allowed the FPGA to converge and set a few thousand generations on a successful configuration that would permit the chip to make this discrimination.
[0032] Thus, counterpropagation networks and neural networks, such as networks including a Grosberg layer, may be applied to guide the application of genetic programming for the purpose of deriving optimal uses of silicon on the design side.
[0033] For instance, an example of the class of coevolutionary relationship between the design side and the silicon side through time as contemplated by the present invention may include a suitable genetic algorithm guiding the unfolding of the actual structures employed and related to a design environment in which the operator, i.e. the designer, was guiding the training of a neural network.
[0034] As the complexity of the integrated circuits increase, it may also be desirable to employ heuristics and capabilities on the design side that extend understanding. Ultimately, by providing this type of relationship, it may not be necessary to know how the particular device that is derived from the process works. For example, it is not known how the device derived from Thompson's program works, except at a generalized level.
[0035] For instance, the complexity may become so great that only a very general understanding of how the integrated circuit actually operates is possible. In such an instance, a systematic support and heuristic support on the design side for governing the emergence of these extremely complex structures may be desirable. Thus, it is likely that the complexity of the integrated circuits that are being provided will drive the design and implementation process in that direction.
[0036] Therefore, the question of how to produce complex behaviors and the like over here, but also the question of how to regulate the emergence of those behaviors so that the behaviors are rendered highly available, verifiable, predictable, high yielding, and the like, so that the behaviors have properties that are desirable in a manufacturing environment needs to be addressed. By providing this coevolutionary relationship, as this enormous complexity emerges on the hardware side, these complex guidance systems, as it were, on the design side may also be developed through the linked formalisms of the coevolutionary relationship.
[0037] Further, dynamic programming may also be implemented through use of genetic programming and cybernetics of this dynamic programming relationship between the design side and the device side, as shown in the embodiment 200 illustrated in FIG. 2. For instance, a metastream environment may be provided, for example, with a graphical user interface, with which a human being will interact.
[0038] A set of algorithms as implemented by the system is also provided. The inputs may include functional specs and constraints, i.e. in terms of silicon process, gate count, power, area and the like as contemplated by a person of ordinary skill in the art.
[0039] For instance, a customer may provide such functional specs and constraints. For example, a customer engagement model may be provided that allows the system to receive and set parameters along those lines, and then apply the parameters on a model of the platform at which the parameters are directed on the device side. For instance, a platform in the sense, such as a sea of platforms architecture with certain capabilities, applied to an environment including embedded arrays, and the like as contemplated by a person of ordinary skill in the art. Additionally, the environment of the present invention may be applied where a sea of platforms architecture ramifies the complexity dealt with so that direct interaction by a designer is difficult. Thus, a level of abstraction provided by the present invention may provide the tools needed by a designer to interact with these complex environments. For instance, low levels on the design side and low levels on the physical side may interact directly, and be manipulated through a system of the present invention at a level of abstraction contemplatable by a designer in an easy manner.
[0040] Additional areas are contemplated by the present invention without departing from the spirit and scope thereof. For instance, one of the areas in which this kind of coevolutionary relationship is applicable is between software development and embedded software where the real-time multithreaded software running on the device side may require this extremely intelligent environment to specify the functionality and development.
[0041] Further, a second analogous coevolutionary relationship between an interconnect as, for example, in a scalable isocranus interconnect, such as the interconnect described in U.S. Pat. Application No. EV 013 245 396 US, filed Oct. 20, 2001, titled INTERSCALABLE INTERCONNECT, which is hereby incorporated by reference in its entirety, the interconnect characteristics on the one hand and the IP that the interconnect ties together. These two aspects interact mutually and may be thought of as enjoying a coevolutionary relationship because the characteristics of the interconnect and its protocol on the one hand will influence the characteristics of the IP that it is actually hooking up and vice versa.
[0042] In an embodiment of the present invention, an intelligent compiler is provided which is guided according to the same kinds of principles described earlier, which is interacting with complex environment, such as realtime embedded multithreaded software implemented through processors running on the device itself, including information handling systems, heterogenous processor types, extensible cores, DSP processors, perhaps traditional processors, tower PCs, and the like, whose software is actually specified by intelligent algorithms and intelligent compilers that operate on the design side.
[0043] The present invention may be implemented through the use of underlying algorithms that permit the compilers to emit the correct instruction streams for the multiples of processors on the design side, which currently is being essentially handled manually by the designers. Thus, the present invention supports a kind of coevolutionary relationship between the structures that are actually put into the chip and the environment in which the structures are specified by the designer. In this way, integrated circuits may be supplied that are so complex that the end result is not something that any human being ever fully comprehends.
[0044] The present invention may implement classes of algebras suitable for describing a coevolutionary relationship in a design environment for designing an integrated circuit and system employing integrated circuits. For instance, different algebras may be employed, such as L systems, church algebras and the like, in this mutually-interacting coevolutionary framework. The present invention provides independent but tightly-linked bodies of technology on the design side and on the device side that enjoy this kind of symbiotic algebraic coevolutionary explicit linkage with one another.
[0045] In exemplary embodiments, the methods disclosed may be implemented as sets of instructions or software readable by a device. Further, it is understood that the specific order or hierarchy of steps in the methods disclosed are examples of exemplary approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged while remaining within the scope of the present invention. The accompanying method claims present elements of the various steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented.
[0046] Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. One of the embodiments of the invention can be implemented as sets of instructions resident in the memory of one or more information handling systems, which may include memory for storing a program of instructions and a processor for performing the program of instruction, wherein the program of instructions configures the processor and information handling system. Until required by the information handling system, the set of instructions may be stored in another readable memory device, for example in a hard disk drive or in a removable medium such as an optical disc for utilization in a CD-ROM drive and/or digital video disc (DVD) drive, a compact disc such as a compact disc-rewriteable (CD-RW), compact disc-recordable and erasable; a floppy disk for utilization in a floppy disk drive; a floppy/optical disc for utilization in a floppy/optical drive; a memory card such as a memory stick, personal computer memory card for utilization in a personal computer card slot, and the like. Further, the set of instructions can be stored in the memory of an information handling system and transmitted over a local area network or a wide area network, such as the Internet, when desired by the user.
[0047] Additionally, the instructions may be transmitted over a network in the form of an applet that is interpreted or compiled after transmission to the computer system rather than prior to transmission. One skilled in the art would appreciate that the physical storage of the sets of instructions or applets physically changes the medium upon which it is stored electrically, magnetically, chemically, physically, optically or holographically so that the medium carries computer readable information.
[0048] It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the forgoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | The present invention is directed to a system and method for coevolutionary circuit design. A system suitable for providing integrated circuit design may include a memory suitable for storing a first set of instructions and a second set of instructions and a processor communicatively coupled to the memory. The processor is suitable for performing the first set of instructions and the second set of instructions. The first set of instructions is suitable for configuring a processor to provide an integrated circuit development environment in which a support methodology for an integrated circuit is created. The second set of instructions is suitable for configuring a processor to provide tools for implementing a platform architecture of an integrated circuit in which the platform architecture supplies a structure of the integrated circuit. The first set of instructions and the second set of instructions are linked through at least one formalism so that at least one of an action taken utilizing the platform architecture influences the support methodology and an action taken utilizing the support methodology influences the platform architecture. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a jumping rope. The existing jumping rope on the market is a kind of fixed length once a specific length is made. For a growing child with changing height, it is quite often to buy a new jumping rope in order to get a longer length. Even so, a jumping rope of fixed length can not be used by other people having different heights. When the rope is to be held by two people instead of one for group playing, it also needs a much longer length.
Therefore, to save money and allow all people to join the play to have fun, an all-occasion jumping rope is invented to adjust the length to meet the requirements of different heights of all people, such as family members with growing children, schoolmates, classmates and neighbors.
DESCRIPTION OF THE DRAWING
The objects, characteristics and advantages of this invention will be more fully understood from the accompanying drawings, in which:
FIG. 1 is a front view of the most preferred embodiment of all-occasion jumping rope,
FIG. 2 is an enlarged view of one of the end portions of FIG. 1,
FIG. 3 is a top view of FIG. 2,
FIG. 4 is an enlarged view of the middle portion of FIG. 1,
FIG. 5 is a second preferred embodiment of rope similar to FIG. 4,
FIG. 6 is a third preferred embodiment of rope similar to FIG. 4,
FIG. 7 is a fourth preferred embodiment of rope similar to FIG. 4,
FIG. 8 is another embodiment of holder of all-occasion jumping rope, and
FIG. 9 is the side view of FIG. 8.
DESCRIPTION OF THE INVENTION
Now, referring to FIG. 1 there is shown an all-occasion jumping rope 10 of the most preferred embodiment. The rope 10 consists of two handles 20, two holders 30, a rope 40 and a string 50 passing through the rope 40. The string 50 is attached at both ends to two holders 30 by knots or ties. Each holder 30 is free rotatable inside handle 20, so that any rotational twist on rope 40 will not transfer to handles 20. This is similar to the universal joints of a key chain which is free rotatable at all joints. The rope 40 may be attached at both ends to two holders 30, or placed between two holders 30. By changing the length of string 50, such as winding or un-winding on one or both holders 30, the pitches of the corresponding points of the corrugation of the rope 40 will be increased or decreased, thus change the length of jumping rope 10 between both ends of two holders 30. Item 16 is a shorter length of rope 10. Item 18 is a longer length of rope 10.
FIG. 2 shows details of handle 20 which consists of a tube 21 with one open end 24, and with another close end 25 having a hole 22.
The holder 30 consists of a tube 31 with a hole 32, and a body 35 which has holes 34 and 36, and notches 51, 52 and 53. The holder 30 is free rotatable inside handle 20. The rope 40 may end at lower surface 33 of holder 30 with or without a knot, or end at upper surface 37 with or without a knot or tie. The rope 40 may also be tied at holes 34 and 36. The string 50 comes out of rope 40 at lower surface 33 or upper surface 37 in front of any knot or tie of rope 40, passing through hole 36 and winding onto notches 51 and 52 for large amount of length adjustment, and notches 52 and 53 for small amount of length adjustment.
By pushing the lower surface 33 upward, the holder 30 comes out of handle 20 so that it is possible to winding or un-winding the string 50 to change the length of rope 40, and then, put it back into its original position ready for playing. The string 50 with rope 40 is attached, by a tie, to both holders 30 on notches 51 and 52 but the winding of string 50 may be on one or both holders 30. Of course, the length of tube 31 should be long enough to allow the holder 30 to be pushed out long enough to convenient the operation of winding or un-winding. Or the maximum width or height of rope 40 in its shortest length must be smaller than the hole 22 on handle 20. The outside contour of handle 20 may varies to fit the hand grip.
FIG. 3 shows handle 20 with holder 30 inside. The tube 31 of holder 30 will rotate freely in hole 22 of handle 20. The hole 32 allows string 50 with or without rope 40 to pass through. The notch 53 on body 35 of holder 30 is provided for the winding of string 50. The view is incomplete for the purpose of clarity.
FIG. 4 shows details of the first preferred embodiment 41 of rope 40 with string 50, which are all flexible. There are a plurality of small holes 11 on rope 41 for string 50 to pass through.
FIGS. 5 and 5A show details of the second preferred embodiment 42 of rope 40 with string 50. The rope 42 consists of a plurality of O-rings. There are two small holes 12 on each O-ring of rope 42 for string 50 to pass through. Those rings may also be made in long series, into a chain.
FIG. 6 shows details of the third preferred embodiment 43 of rope 40 with string 50. The rope 43 may be a braided nylon rope or string or the like having string 50 passing through its hole 13 in the middle. The rope 43 of braided nylon is shortened by having the braided nylon fibers jamed together more closely. This "wrinkled" or "corrugated" rope 43 is still good for use. Also, the rope 43 may have a knot above upper surface 37 of holder 30 in FIG. 2, or have a second knot under lower surface 33, or even tied through holes 34 and 36 of holder 30.
FIG. 7 shows details of the fourth preferred embodiment 44 of rope 40 with string 50. The rope 44 may be a coiled nylon rope with or without a spring steel as a core. The string 50 passes through the center 14 of coiled rope 44.
For FIG. 4 through FIG. 7 included, a change in length of string 50 will change the length of rope 40 to meet the requirement. The pitch between two corresponding points which are not shown for clarity, decreases when string 50 is shortened. Due to some spring effect, those pitches increase when string 50 is longer. The height or width which is not shown for clarity, at both end portions of rope 40 must be smaller than the hole 22 of handle 20 when the rope 40 is in its minimum length, so that the holder 30 with rope 40 can be pushed out of handle 20 for winding or un-winding.
FIG. 8 and FIG. 9 show another way to adjust the length of string 50. The holder 60 has similar features as the one shown on FIG. 2. The holder 60 has a tube 61 with a long hole 62, a body 65 with holes 64 and 66, a post 67 with a hole 68 and a post 69 with a hole 70, holes 76 and 88 as hinge points, and block 71 with a long hole 72.
A roller 72 is rotatably mounted within the hole 88 on holder 60. The roller 72 has two disc 84 and 85 with a plurality of key slots 82 on at least one disk, and a neck 83 for the winding of string 50. A post 86 on roller 72 has a hole 87 for a coil spring 96 of tension type or compression type to attach to. The other end of spring 96 is attached to a hole 68 on the post 67 of holder 60.
The block 71 which is a portion of holder 60 has a long hole 79 in the middle to guide a slidable bar 92. A lever 75 rotatably mounted within hole 76 has its one end 93 passing through a slot 94 of bar 92. A tension spring 97 is attached on hole 77 of lever 75 and hole 70 of post 69. A press on a knob 98 of lever 75 lifts bar 92 to disengage from key slot 82. Thus, allows the adjustment of the length of spring 50 by winding or un-winding from roller 72. The operation of winding is accomplished by the help of spring force of coil spring 96 while pressing on knob 98 of lever 75. The operation of un-winding is accomplished by stepping the rope 40 onto the ground and lifting the handle upward while pressing on knob 98 of lever 75. The views are incomplete for the purpose of clarity.
FIG. 9 is a side view of FIG. 8. Those major parts are as shown.
To adjust the length of the flexible spring 50 it is possible to use any kinds of combination of gears having different gear ratios, spring and stop knob. However, for a simple implement with once-a-while adjustment, it is more feasible to use the device shown on FIG. 2, or one in FIG. 2 and a second one on FIG. 8. Of course, it is still feasible to use only the device shown on FIG. 8.
For string 50 to be able to slide inside the rope 40 for adjustment in length, the string 50 must comes out of rope 40 in front of any knot or tie of rope 40.
The descriptions and illustrations mentioned above are those of the most preferred embodiments of this invention and no unnecessary limitations should be understood therefrom as modification will be obvious to those skilled in the art. | An all-occasion jumping rope comprises two handles, two freely rotatable holders inside the handles, a flexible rope, a flexible string free slidable inside the rope, a structure to hold the flexible rope to allow the twisting of rope to transfer to the free rotatable ends and structure to adjust the length of the string to change the length of the rope so that all people of different height including growing children can use it all the time without buying a new rope of longer length. | 8 |
RELATED APPLICATION
This application is a continuation-in-part patent application of U.S. patent application Ser. No. 709,314, filed July 28, 1976, entitled SAFETY INTERLOCK SYSTEM, now abandoned.
BACKGROUND OF THE INVENTION
1. Purpose of the Invention
This invention relates in general to certain new and useful improvements in lock release mechanisms utilizable in vehicles for preventing theft, and, more particularly, to lock release mechanisms which are operated in conjunction with safety interlock systems designed to prevent theft or other unauthorized removal of automotive vehicles and like apparatus.
2. Brief Description of the Prior Art
In recent years, theft of automotive vehicles has become quite prevalent and, in fact, has given rise to large-scale businesses based on stealing and resale of such automotive vehicles. In order to obviate this problem, various manufacturers of automotive vehicles and, in addition, various suppliers of safety systems and theft-prevention systems and the like have proposed alarm systems for use in these vehicles which advise of the potential theft or otherwise unauthorized removal of the vehicle. These alarm systems generally rely upon electronic sound alarms which are generated upon unauthorized attempts of removal. However, one skilled in these particular alarm systems is capable of short-circuiting the alarm system or otherwise removing the vehicle in such manner as to obviate the generation of the alarm signal.
There have been many proposals for safety interlock systems which employ encoded switching systems which must be actuated prior to operation of the vehicle. These encoded switch systems operate as a combination switch which is designed to prevent operation of the engine of the vehicle until such time as a proper electrical signal has been introduced into the switching system in order to energize the same. The signal is an enabling signal which is generated when a plurality of switches has been actuated in proper sequence. These switching systems are designed to control the various operable components of the vehicle and particularly the electrically operable components such as, for example, the starter solenoid of the vehicle. Thus, when the preestablished code is introduced into the system, the starter solenoid is enabled.
One of the primary disadvantages of these safety interlock systems resides in the fact that a typical automotive thief may open the hood of the vehicle in order to disenable the safety interlock system. Otherwise, if the thief is unable to disenable the safety interlock system, the thief can typically obviate or bypass the safety interlock system and thereby steal the vehicle.
Most automotive vehicles presently employ some form of hood lock mechanism such as the hood lock mechanism which may be opened from the exterior of the vehicle. In other types of automotive vehicles, the hood lock can only be opened from the interior of the vehicle, such as in the passenger compartment. In the event that the doors of the vehicle leading into the passenger compartment were not locked, then a thief would have easy access to open the hood lock release and thereby the compartment to disenable any safety interlock system. In addition, the thief may otherwise easily steal any of the components forming part of the engine system of the vehicle or the entire vehicle itself.
There have also been several proposed lock release mechanisms operable with the lock device included with the vehicle. These lock release mechanisms included a lock which operated the locking device of the vehicle on the hood leading into the engine compartment when the engine was started.
The typical type of electrically operable lock release mechanism which operates the hood lock comprises a housing having a pair of spaced apart walls with a locking pin extending out of one of the walls. A wedge or plunger is introduced into the space between these walls and when the pin was retracted, the wedge would be fully inserted into the space and thereby locked when the pin was released to engage an upper surface on the wedge. Thus, when a solenoid was energized pursuant to starting of the ignition of the vehicle, the pin would be retracted and, in this way, the wedge could be removed. Nevertheless, if the solenoid was not properly energized pursuant to the energization of the ignition system of the vehicle, the pin remained in its locking position, thereby permitting removal of the wedge which was, in turn, connected to the hood of the vehicle.
The primary disadvantage of this type of electrically energizable hood release mechanism resided in the fact that it is difficult to align the wedge or plunger with the pin. It can be observed that it is difficult to align the plunger with the pin when the hood was closed primarily due to the fact that the plunger moved through an arc with the closing of the hood. Thus, the mechanics installing the device could not properly align the plunger with the opening between the two walls when the hood was almost in the closed position. The difficulty of aligning the plunger with the opening also was increased due to the fact that it was often difficult to find a proper location in which to install the plunger so that it could be dropped into the opening in proper alignment. Another one of the disadvantages of this type of device is that if the hood was sprung due to an automobile accident or other condition, the hood could not be closed, and if one attempted to close the hood when the plunger was not in proper alignment, it would tend to jam the entire device and even result in damage to the lock release mechanism.
Due to the difficulties of properly installing these prior art lock release mechanisms, it has been found that the hood lock release device cannot be properly opened if the hood lock release mechanism is not properly mounted.
OBJECTS OF THE INVENTION
It is, therefore, the primary object of the present invention to provide a lock release mechanism which is used with a lock device for use in powered vehicles and the like, and which permits releasing of the lock release mechanism by introduction of an electrical signal which operates the hood lock release mechanism.
It is another object of the present invention to provide a hood lock release mechanism of the type stated which is easily installed and does not require precise alignment of a plunger with respect to the lock mechanism.
It is a further object of the present invention to provide a hood lock release mechanism of the type stated which operates in conjunction with a safety interlock system such that the hood lock release mechanism can only be operated when a preselected code is introduced in proper sequence through manual actuation of a plurality of input switches.
It is an additional object of the present invention to provide a method of operating a hood lock release mechanism in such manner that the hood lock release mechanism can only permit opening of a hood lock when a proper preselected code is introduced in proper sequence and which thereby obviates unauthorized removal of any device upon which the locking release mechanism is utilized.
It is also an object of the present invention to provide a unique electrical circuit which operates the hood lock release mechanism of the present invention in such manner that only the authorizer users of the vehicle can open the hood of the vehicle leading into the engine compartment.
With the above and other objects in view, my invention resides in the novel features of form, construction, arrangement and combination of parts presently described and pointed out in the claims.
SUMMARY OF THE INVENTION
The invention relates to a system for controlling automotive vehicles and like vehicles and, particularly, for controlling the action of a conventional lock on a vehicle access means as well as the electrical system forming part of the engine of the vehicle. Thus, the invention, in one aspect, includes a circuit for controlling an electrically operable component forming part of the engine system of the vehicle and which also controls a lock release mechanism providing access into a portion of the vehicle.
The system for controlling a lock on the vehicle comprises a safety interlock circuit having a plurality of manually operable switches which generate an enabling signal when certain of the switches have been actuated in a proper sequence in accordance with a preestablished code. The system also comprises a manually actuable lock device on a vehicle access means. In this case, the lock device could form part of a conventional lock on the hood of an automotive vehicle. In addition, the system operates in conjunction with an electrically operable component forming part of the vehicle engine. This electrically operable component is operatively connected to the safety interlock circuit and is operable when the enabling signal has been generated. When the enabling signal has been generated, the lock release mechanism permits opening of the lock device. In addition, the lock release mechanism prevents opening of the lock device when the lock release mechanism is deenergized.
In a preferred aspect of the invention, a sensing means is operatively connected to the interlock circuit for holding the lock release mechanism in a position as it would be when energized even though generation of the enabling signal has ceased. This sensing means holds the lock release mechanism in this position until the access means, such as the hood of the vehicle, is closed. In this way, damage to the lock release mechanism is obviated. Moreover, the access means cannot be opened again until the enabling signal is generated through proper introduction of the preselected code by actuation of the plurality of switches.
The lock release mechanism is also actuable by a manually actuable member, such as a hood lock release member, located in the passenger compartment of the vehicle. This manually actuable member, such as the hood lock release handle, is operatively connected to the lock release mechanism of the present invention and permits the lock release mechanism to open after the lock release mechanism has been energized pursuant to the enabling signal.
The lock release mechanism comprises an outer housing having a first bore and a second bore angularly located with respect to the first bore and, preferably, perpendicularly located with respect to the first bore. A shiftable lock cooperating element is located within the first bore. This lock cooperating element has a pair of spaced apart heads defining a plunger receiving space therebetween, such that the plunger receiving space is capable of being located in alignment with the second bore.
A plunger is located within the second bore and is provided with a locking element capable of being shifted into a locking position in said plunger receiving space in order to prevent movement of the shiftable lock cooperating element. An electrically operable means is associated with the plunger for shifting the plunger out of the plunger receiving space in order to permit movement of the lock cooperating element upon energization of the electrically operable means.
The electrically operable means is preferably a conventional electrical solenoid. The means which biases the plunger is a coil spring which normally biases the plunger into the locking position but can be overcome by energization of the solenoid. Thus, the solenoid should generate sufficient electromagnetic coupling in order to pull the plunger to a position where the locking section is removed from the plunger receiving space. Moreover, the lock cooperating element is normally biased to a position where the plunger receiving space is aligned with the plunger. A compression spring is designed to bias the lock cooperating element to this position. In addition, a cable is normally connected to the lock cooperating element for manually pulling the plunger against the action of the compression spring which biases the plunger into the position where the plunger receiving space is aligned with the plunger. The cable is also operatively connected to the lock device such that pulling on the cable will open the lock device.
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 schematic view showing a conventional hood lock mechanism of an automotive vehicle operated in conjunction with the hood lock release mechanism of the present invention when in the opened position;
FIG. 2 is a schematic side elevational view, similar to FIG. 1, and showing a conventional hood lock operated by the hood lock release mechanism of the present invention when in the locked position;
FIG. 3 is a vertical fragmentary sectional view showing a portion of the prior art type of hood lock release mechanism;
FIG. 4 is a schematic side elevational view showing the method of connecting the hood lock release mechanism of the present invention to a hood lock of an automotive vehicle;
FIG. 5 is a vertical sectional view in longitudinal cross section showing the interior components of the hood lock release mechanism of the present invention;
FIG. 6 is an end elevational view of a hood lock release mechanism of the present invention taken along line 6--6 of FIG. 5;
FIG. 7 is a fragmentary vertical sectional view, somewhat similar to FIG. 6, and showing the hood lock release mechanism in the locked position; and
FIG. 8 is a schematic electrical view showing a portion of a safety interlock system which is utilized in connection with the hood lock release mechanism 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 safety lock release mechanism which is constructed in accordance with and embodies the present invention. This lock release mechanism is specifically designed to be utilized in connection with the hood release locks of automotive vehicles and like devices or other forms of locks in other portions of the vehicles.
The lock release mechanism of the present invention is generally designed to be used with safety interlock systems, and, particularly, that form of safety interlock system which is energized by introduction of a preselected code in proper sequence by a plurality of manually operable input switches. However, the lock release mechanism of the present invention can be used with a wide variety of safety interlock systems, but is more specifically adapted to be used with that safety interlock system described in my copending application Ser. No. 709,314, filed July 28, 1976, and in my copending application Ser. No. 866,287, filed contemporaneously herewith, now abandoned in favor of application Ser. No. 7,359 filed Jan. 29, 1979 and which matured into U.S. Pat. No. 4,233,642 dated Nov. 11, 1980.
The lock release mechanism in conjunction with the safety interlock system is specifically designed to prevent theft or other unauthorized removal of automotive vehicles. However, it should be understood that the lock release mechanism and the safety interlock system could be used in a wide variety of applications, including the unauthorized removal of other forms of vehicles, e.g. boats, airplanes and the like. In addition, the lock release mechanism could be used without the safety interlock system, or in addition, to the safety interlock system in order to prevent unauthorized tampering with other devices.
FIG. 1 illustrates a conventional hood lock 10 used in conjunction with the hood lock release mechanism A of the present invention, and, in this case, the conventional hood lock includes a pair of camming plates 12 and 14 which are often referred to as camming "discs". These camming discs cooperate to serve as a lock and are, therefore, often referred to as locking discs. The first camming disc 12 is being shown as pivoted on a pivot pin 16 with a first camming surface 18 and having a recess 20. The second camming disc 14 is pivoted on a pivot pin 22 and includes a camming surface 24 mating with the camming surface 18 and also includes a second recess 26. In the position as illustrated in FIG. 1, the lock mechanism is in the open position, such that the hood or other portion of the vehicle can be opened.
Referring now to FIG. 2, it can be observed that the conventional lock mechanism of the vehicle is in the locked position such that the hood or other portion of the vehicle could not be opened without releasing the same from the interior passenger compartment of the vehicle. In this case, it can be observed that the first and second camming discs 12 and 14, respectively, are rotated to a position such that a first finger 28 on the first camming disc extends into the recess 26 on the second disc 14. In like manner, a second finger 30 on the second camming disc 14 extends into the recess 20 on the first camming disc 12. In this way, the lock mechanism cannot be opened until the same is released through a release mechanism 32 in the passenger compartment of the vehicle.
Referring again to FIGS. 1 and 2, it can be observed that the release mechanism includes a handle 34 which is located in the passenger compartment of the vehicle and connected to the camming disc 12 by means of a cable 36. In the absence of the lock release mechanism A, the handle 34 can be pulled in order to shift the camming plates 12 and 14 from the position as illustrated in FIG. 2 to the position as illustrated in FIG. 1, thereby permitting opening of the hood of the vehicle. More specifically, it can be observed that the hood of the vehicle includes a locking pin 38 which is located in the recess 26 in the locked position, but which can be removed from the recess 26 when the camming discs 12 and 14 are shifted to the opened position as illustrated in FIG. 1 of the drawings. Thus, the lock mechanism as illustrated in FIGS. 1 and 2 can be operated without the lock release mechanism A as illustrated.
However, in the preferred aspect of the present invention, the lock mechanism A is included to prevent the opening of the hood lock 10 by being shifted from the closed position as illustrated in FIG. 2 to the opened position as illustrated in FIG. 1 without introduction of the preselected code as described above and as hereinafter described in more detail. Thus, if the proper preselected code has not been entered, the hood lock release mechanism A would not be energized to permit the shifting of the cam plates 12 and 14 in FIG. 2 to the opened position as illustrated in FIG. 1.
FIG. 3 illustrates a prior art lock release mechanism. These mechanisms were not used in conjunction with a safety interlock system, but merely operated by turning on the ignition of the vehicle. In this case, the prior art lock release mechanism, designated as 40, operates in connection with a conventional hood lock 10 in order to permit opening of the same, such that the camming discs 12 and 14 are shifted to the position as illustrated in FIG. 1 upon energization of the lock release mechanism as herein described. The prior art lock release mechanism 40 is comprised of an outer housing 42 having a pair of spaced apart opposed camming plates 44 and 46 and each of which are provided with opposed, upwardly presented and downwardly and inwardly converging camming surfaces 48. The camming surfaces 48 merge into relatively parallel spaced apart surfaces 50 located on the respective camming plates 44 and 46 and which in combination define a plunger opening 52. The spaced apart, relatively parallel surfaces 50 also merge into diverging, outwardly extending camming surfaces 53.
One of the camming plates 46 is provided with a locking pin 54 which extends toward the camming surface 50 in the manner as illustrated in FIG. 3. The locking pin 54 is normally biased into a locking position as illustrated in FIG. 3 so that it extends into the opening 52 by means of a coil spring 56. The coil spring fits within a recess 58 so as to bias the locking pin 54 to the outward position or locking position as illustrated in FIG. 3 of the drawings. The locking mechanism 40 is also provided with a solenoid 59 which contains a solenoid coil 60 and operable through a pair of conductors 62. When current is introduced into the coil 60, it is energized and thereby magnetically urges the locking pin 54 to the retracted position so that it is removed from the space 52. Deenergization of the coil 60 permits the locking pin 54 to be extended into the locking space 52 by action of the compression spring 56.
A locking plunger 64 operates in conjunction with the lock release mechanism 40 and is mounted on the interior surface of a hood 65, as illustrated in FIG. 3 of the drawings. The plunger 64 is comprised of a shank 66 and an enlarged locking head 68, the latter having camming surfaces 70 which merge into a relatively flat annular wall 72. In this way, the plunger 64 extends downwardly into the opening 52, and the camming faces 70 are capable of biasing the locking pin 54 inwardly against the action of the compression spring 56. After the plunger is shifted to its lowermost or seated position, the locking head will be below the level of the pin 54. In this latter position, the locking pin 54 will be extended outwardly by the action of the compression spring 56 so as to engage a shoulder 74 on the plunger, and thereby secure the hood 65 in a locked position.
This prior art mechanism has been found to be relatively ineffective in that the locking pin 54 must be retracted in the event that the hood 66 is shifted to the closed position. Otherwise, the camming surfaces 70 on the plunger 64 would engage the locking pin 54 and bend the same if force was applied to the hood 65. Even moreso, it was found necessary to properly align the plunger 64 with respect to the opening 52 in order to permit the plunger 64 to extend within the opening 52 even when the locking pin 54 was retracted. Otherwise, the misalignment would result in damage to the lock release mechanism 40 as well as improper operation.
The lock release mechanism A of the present invention is more fully illustrated in FIGS. 5-7 of the drawings. In this case, the lock release mechanism A of the present invention comprises an outer housing 90 which is capable of being located and physically mounted within the engine compartment of the vehicle and which operates in conjunction with the conventional hood lock mechanism 10. It should also be observed that the locking release mechanism A could be mounted in any portion of the vehicle including the trunk portion of the vehicle so as to prevent unauthorized opening of the trunk of the vehicle. In addition, the lock release mechanism A could be located in any other portion of the vehicle in order to prevent unauthorized entry of the vehicle, as for example, with respect to the doors of the vehicle leading into the passenger compartment of the vehicle or other portions of the vehicle.
The housing 90 is internally bored to provide a first horizontally located circular passage 92 in the manner as illustrated in FIG. 6 of the drawings. Shiftably located within the bore 92 is an elongate lock cooperating plug 94 comprised of a pair of spaced apart, locking heads 96 and 98. These two heads 96 and 98 are connected by a central shaft 99 defining an annular plunger receiving space 100 in the manner as illustrated in FIG. 5. Each of the head sections 96 and 98 are provided with a pair of relatively flat end 108, but which is capable of engaging a shoulder 110 on a tapered recess 112. The other head 98 is provided with a recess 114 sized to accommodate a swedge 116 which is used to secure the forward end of a release cable within the bore 92. The swedge 116 is locked in place by means of a transversely extending pin 117 often referred to as a "roll pin".
The plug 94 including the combined heads 96 and 98, along with the shaft 99, is biased toward the right-hand direction in the manner as illustrated in FIG. 5 by means of a compression spring 118 which is interposed between the left-hand end of the head 98 and a retaining plug 120 located at the left-hand end of the bore 92. In this case, it can be observed that the swedge 116 provides a means for securing the end of a cable 126 to permit actuation of the hood lock assembly in the vehicle. The swedge 116 is located coaxially within the bore 92, and the cable extends into a central bore 124 formed in the plug 120 in the manner as illustrated in FIG. 5. In this case, the cable 126 corresponds to a cable leading from the lock release mechanism A to the handle 34 in the manner as illustrated in FIGS. 1 and 2 of the drawings.
The lock release mechanism A also includes a plunger 128 which is operable by a solenoid 130 mounted on the housing 90, in the manner as illustrated in FIG. 5. The plunger 128 is vertically shiftable in a vertical bore 129 communicating with the bore 92. The solenoid 130 includes a conventional solenoid housing 132 along with a solenoid coil 134 located therein in a conventional manner. In this case, the solenoid 130 would be operated by energization of the solenoid coil 134 through a source of electrical current applied to the coil 134, in a manner to be hereinafter described, through conductors 136. The plunger 128 includes a locking head 138 which is capable of being extended into the annular space between the end walls 102 and 104 in the manner as illustrated in FIGS. 5 and 7 of the drawings.
The locking head 138 is connected to a plunger shaft 140 which extends through a sleeve 142 which is integral with the casing 132 and also through the coil 134 in the manner as illustrated in FIG. 5 of the drawings. Moreover, the locking head 138 is biased to the locking position, that is the position as illustrated in FIG. 7 of the drawings, by means of a compression spring 144 which is interposed between the locking head 138 and the sleeve 142. The spring 144 biases against the upper end of the locking head 138 and against a shoulder 146 formed on the lower end of the sleeve 142.
The plunger shaft 140 is secured within a recess 148 formed within the locking head 138 by means of a locking pin 150. In addition, the plunger shaft 140 has an upper end 152 extending within the area of the solenoid coil 134. In this way, when the solenoid coil 134 is energized, the upper end 152 will be electromagnetically biased upwardly, and hence the entire plunger 128 is biased upwardly to the unlocked position in the manner as illustrated in FIG. 5. However, when the coil 134 is deenergized, the plunger 128 is spring biased downwardly by means of the spring 144 into the locked position, in the manner as illustrated in FIG. 7. It can be observed that when in the locked position, the locking head 138 extends into the annular space 100 between the two end walls 102 and 104, thereby preventing any shiftable movement of the lock cooperating plug 94.
The housing 90 is also provided with a plurality of bolt-receiving apertures 154 for accommodating bolts in which to lock the lock releasing mechanism A to any convenient portion of the vehicle. These apertures could be designed to accommodate any form of fastener used to secure the lock release mechanism A to the desired portion of the vehicle, as for example a structural wall W, as shown in FIG. 6. In this case, the lock release mechanism A would be located in close proximity to the actual hood release lock in the vehicle.
It can be observed that when a preselected code is introduced into a safety interlock system in proper sequence, the electrical circuitry forming part of the safety interlock system will generate an enabling signal which is introduced into the coil 134 through the lead 136. As this occurs, the coil 134 becomes energized, thereby raising the plunger 128. When the plunger 128 is shifted to the upper position, as illustrated in FIG. 5, the operator of the vehicle can merely pull the handle 34 in the passenger compartment and which is connected to the cable 126. In this way, the lock cooperating plug 94 can be pulled rearwardly, that is to the left, reference being made to FIG. 5. As this occurs, the head 96 will partially block the passage for the plunger 128. Thus, even if the circuit is deenergized, the plunger 128 cannot shift downwardly so that the locking head 138 is introduced into the annular space 100 so long as the handle 34 is pulled to open the lock mechanism.
It can be observed that after the handle is released, and if the circuit is deenergized, the plunger 128 will be biased downwardly through the action of the compression spring 144 and into the annular space 100, thereby preventing further opening movement of the lock release mechanism until a proper code has again been introduced into the vehicle. It is also to be noticed that the hood mechanism or other portion of the vehicle can be closed even though the circuit is deenergized, due to the action of a sensor 162 hereinafter described, without creating any damage to the lock release mechanism, such that the fact that the annular space 100 will always be opened to and in alignment with the locking head 138.
FIG. 4 illustrates the connection of the lock release mechanism A with respect to a conventional lock mechanism 10 used in an automotive vehicle. In this case, it can be observed that the cable 36 extending from one of the camming discs 12 is coupled to the cable 126 by means of a clamp 160. Either one or both of these cables is then extended into the passenger compartment and connected to the hood release handle 34 in the manner as illustrated. Any suitable form of clamp 160 may be employed for this purpose, as for example, a simple hose clamp or the like.
The conductor 136 which is connected to the solenoid coil 134 is also connected to a suitable safety interlock circuit of the type illustrated in FIG. 8 of the drawings. Again, and as indicated above, the conductor 136 would be connected to the preferred type of safety interlock system as defined in the aforesaid patent applications. One of the unique aspects of the present invention is that a sensor 162 operating a switch or otherwise operating as a switch may be located on the hood or other portion of the vehicle which constitutes a closure member. The sensor 162 will sense the position of the hood in order to prevent damage to the lock release mechanism A. Thus, if the ignition is turned off, or otherwise the electrical circuitry forming part of the engine of the vehicle is deenergized, the solenoid 130 will still remain energized until such time as the hood is completely closed. In this way, the plunger will not be bent or otherwise destroyed.
With further consideration to the schematic electrical diagram illustrated in FIG. 8, which more specifically shows a typical form of safety interlock system, this safety interlock system is designed to introduce a proper electrical code in order to generate an enabling signal which, in turn, permits operation of the electrical system of the vehicle and also a release of the hood lock release mechanism. In this case, the electrical safety interlock system comprises a plurality of manually operable push-button switches 164 which are typically mounted on a pad located within the interior of the vehicle, such as the passenger compartment of the vehicle. The manually operable push-button switches 164 are designed to generate an electrical signal when operated in proper sequence and include a hold circuit 166 which is designed to override the system as may be desired.
The push-button switches 164 are connected to a plurality of latches 168 by means of a plurality of inputs into latches 168. The latches 168 are cross-coupled and are preferably comprised of a plurality of NAND-gates so as to create an output signal, such as an enabling signal, when each of the input switches are pressed in proper sequence. When each of the switches 164 are pressed in proper sequence, an enabling signal is generated over an output line 170 which is connected through a resistor 172 into an NPN transistor 174. The emitter of the NPN transistor 174 is connected through a coupling resistor 176 to a terminal 177 of an ignition switch through a diode 178. The diode 178 is grounded through a resistor 180 in the manner as illustrated in FIG. 8.
In addition, the emitter of the transistor 174 is connected through a diode 182 and a resistor 184 to a coil 186 which operates as a solenoid coil of a hood lock release mechanism. In this case, the coil 186 is equivalent to the solenoid coil 134 which will operate the hood lock release mechanism A in accordance with the present invention.
Thus, in accordance with the present invention, it can be observed that the proper introduction of the preselected code in proper orientation of the actuation of the input switches 164 will generate an enabling signal through the transistor 174 which will not only permit operation of the ignition 177, but it will also permit operation of the hood release mechanism. However, when the ignition is deenergized, the hold circuit 166 will permit energization of the coil 186 which operates the hood lock release mechanism by means of the sensor 162 in a conventional manner, and, more specifically, in the manner as illustrated in the copending patent application filed of even date hereof.
The switches 164 which form part of the safety interlock system may be conveniently mounted within a small casing located in a convenient location within the vehicle, as, for example, on the dashboard of the vehicle, as aforesaid. This casing would include a plurality of the manually operable push-button switches 164 which may be operated in proper sequence in order to generate an enabling signal. In addition, light emitting diodes may also be provided on the face plate (not shown) of the small casing to indicate that the switches of the system have been properly operated in sequence in order to permit energization of the vehicle engine and also to permit energization of the solenoid 186 to thereby enable access to the engine compartment of the vehicle.
The hood lock release mechanism of the present invention can be used in conjunction with a wide variety of conventional hood locks on automotive vehicles or other access means to the vehicle, as for example, the trunk lid and like access means. Moreover, the lock release mechanism can be mounted in any suitable location in close proximity to the access means of the vehicle and any form of conventional mounting means may be employed.
It has been found that the lock release mechanism of the present invention is highly reliable and cannot be damaged through inadvertence, and thereby obviates many of the deficiencies of the prior art hood lock release mechanisms.
Thus, there has been illustrated and described a unique lock release mechanism which may be used in conjunction with conventional vehicle locks and in which the mechanism may be operable with a safety interlock system and which meets 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 are deemed to be covered by the invention which is limited only by the following claims. | A lock release mechanism which is operable in conjunction with a locking device on an access means, such as a hood into a portion of a vehicle, preferably an automotive vehicle. The lock release mechanism comprises an outer housing having a shiftable locking element therein. The shiftable locking element is locked when a shiftable plunger, such as a wedge, is biased into locking position. The lock release mechanism also includes a solenoid which is energized to remove the plunger from the locking position. When the plunger is removed from its locking position, the lock device on the access means can be operated.
The lock release mechanism is preferably designed for use in vehicles of the type equipped with a safety interlock system and which is electrically operable pursuant to the introduction of a preselected code through a plurality of manually operable input switches. In most cases, the safety interlock system comprises a plurality of latches which are operated in preestablished sequence when a preestablished code of indicia is introduced through manual operation of the plurality of input switches. When the latches are operated pursuant to the introduction of the preestablished code, the lock release mechanism may be operated. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to U.S. Patent Application No. 61/859,075, entitled INTERNAL COMBUSTION ENGINE HAVING INDEPENDENTLY CONTROLLED VALVES AND A METHOD OF OPERATION, filed Jul. 26, 2014, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The invention relates generally to an internal combustion engine. More specifically, the invention relates to an internal combustion engine operating on a six stroke cycle.
[0004] 2. Description of Related Art
[0005] Internal combustion engines have typically operated on a 4 stroke cycle, comprised of intake, compression, combustion, and exhaust strokes. When the cycle repeats, the intake stroke directly follows the exhaust stroke in which the hot combustion gases are evacuated from the cylinder. The heat from the combustion gases raises the temperature of the cylinder wall, which in turn heats the air-fuel charge during the intake stroke. Excessive air intake temperature can lead to knocking. To prevent knocking, the compression ratio of a typical engine is limited to the range of 8 to 11, which also limits the efficiency of the engine.
[0006] Six stroke cycle engines have previously been disclosed that cool the cylinder and use the excess heat created by combustion to improve the operating efficiency of the engine. In U.S. Pat. No. 8,291,872 to Szybist, water is injected into the cylinder during the fourth stroke, when the combustion gases are typically exhausted. The water, which is heated by the combustion gases, is turned to steam and provides additional power during a fifth stroke. The sixth stroke exhausts the steam and combustion gases from the cylinder. Similarly, in U.S. Pat. No. 6,311,651 to Singh, water is injected during the fourth stroke of a six stroke cycle engine to improve engine efficiency, wherein the amount of water to be injected is calculated by determining the energy content of the cylinder.
[0007] The previous examples of six stroke cycle engines have relied on complicated water injection systems to improve overall engine efficiency. The invention of the present disclosure overcomes this problem by cooling the cylinder during fifth and sixth strokes without the need for water injection.
BRIEF SUMMARY OF INVENTION
[0008] The present invention relates generally to a six stroke cycle internal combustion engine. The first stroke is an intake stroke, in which fuel and air are drawn into the cylinder. During the second stroke, the contents of the cylinder are compressed. The third stroke is the combustion stroke where the air/fuel mixture is ignited. The fourth stroke exhausts the contents of the cylinder. The first four strokes are similar to those of a typical four stroke cycle engine. However, during a fifth stroke, air is drawn through an open intake valve. During this stroke, the fresh air absorbs heat from the piston and cylinder. In the sixth and final stroke, the heated air is expelled through an open exhaust valve. As the six stroke cycle repeats, the temperature of the cylinder is reduced compared to if the cycle repeated after the fourth stroke as in a typical four stroke cycle.
[0009] The opening and closing of the valves can be accomplished through mechanical or electrical means. Typical internal combustion engines use cams, pushrods, or rocker arms to accomplish this task. In a four cycle engine, each valve is being opened only once during each cycle. Thus, the cam has only one lobe and rotates once per engine cycle. In the six stroke cycle engine of the present invention, the valves open twice per cycle. To accomplish this, the cam has two lobes. The same result can be accomplished by attaching a solenoid to the valve stem. In this configuration, a controller determines when to open and close each valve.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS
[0010] FIGS. 1-7 depict a cylinder of an internal combustion engine during each of six strokes according to an embodiment of the present invention, with a legend identifying the gases and fuel present in the engine.
[0011] FIG. 8 depicts a cylinder of an internal combustion engine with independently controlled intake and exhaust valves.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In the preferred embodiment of the present invention, an internal combustion engine completes a six stroke cycle. The first four strokes are similar to that of a typical four stroke cycle engine. As shown in FIG. 1 , the first stroke is an intake stroke. During this stroke, intake valve 10 is in an open position. Fresh air from the air intake 16 is drawn into the cylinder as piston 15 moves away from the valves 10 and 11 . Also, the fuel injector 12 injects fuel into the cylinder 14 during this stroke. In FIG. 2 , the air/fuel mixture is compressed as the piston 15 moves in the opposite direction, towards valves 10 and 11 . FIG. 3 shows the combustion stroke, where spark plug 13 ignites the compressed air/fuel mixture. The combustion of the air/fuel mixture forces the piston 15 away from the top of the cylinder 14 . During the second and third strokes, both the intake valve 10 and the exhaust valve 11 remain closed. In the fourth stroke, as shown in FIG. 4 , the exhaust valve 11 opens and the combustion gases are expelled through the exhaust 17 .
[0013] FIG. 5 depicts the fifth stroke in which the intake valve 10 is in the open position and fresh air is drawn into the cylinder 14 as the piston 15 moves toward the bottom of the cylinder 14 . In a typical four stroke cycle engine, the next stroke after the exhaust stroke would be a new intake stroke in which both fuel and air would be drawn into the cylinder. However, in the preferred embodiment of the present invention, only air is drawn into the cylinder 14 during this stroke. This fresh air, which is close to the ambient air temperature surrounding the engine, is heated by the walls of the cylinder 14 and piston 15 , causing a decrease in the temperature of those components.
[0014] FIG. 6 shows the sixth and final stroke. In this stroke, the intake valve 10 is in a closed position and the exhaust valve 11 is in an open position. As the piston 15 moves towards the valves 10 and 11 , the fresh and heated air is forced out of the cylinder 14 through the exhaust 17 . Consequently, the temperature of the cylinder 14 , piston 15 , and other components defining the combustion chamber is lower than it was after the fourth stroke. When the cycle repeats, the air/fuel mixture drawn into the cylinder 14 will be heated to a lesser extent than without the fifth and sixth strokes. With a cooler air charge, the compression ratio of the engine can be increased to increase the overall efficiency of the engine. Other engine operation parameters can be adjusted as well to take advantage of the decreased air and fuel mixture temperature.
[0015] By exhausting fresh air into the exhaust 17 , unburnt fuel will have the opportunity to complete combustion. In addition, most modern car engines require an exhaust gas recirculation (EGR) system. The EGR system is designed to reduce the nitrous oxide emissions that are created at high temperatures in the exhaust 17 . In an EGR system, a portion of the exhaust gas is recirculated into the intake of the engine to displace combustible air. This has the effect of reducing combustion chamber temperatures. However, while reducing emissions, the EGR system further has the effect of reducing peak power output of the engine. The fifth and sixth strokes of the present invention cause a reduction in the temperature of the exhaust without the need for an EGR system.
[0016] A person having skill in the art will appreciate that various configurations of the engine components can be used in a six stroke cycle. For example, two valves or four valves can be used in the same manner as described in this disclosure. Moreover, the figures depict a cylinder 14 having direct injection, where the fuel injector 12 puts fuel directly into the cylinder 14 . The fuel injection 12 can alternatively be placed in the intake 16 to each cylinder. Also, the internal combustion engine of the present invention can run on gasoline, diesel, natural gas, or other fuels that have been used in traditional four stroke internal combustion engines.
[0017] To allow the intake 10 and exhaust 11 valves to open twice per cycle, a cam is provided with two lobes. In a typical four stroke cycle engine, the cam has only one lobe. Because the cam completes one rotation per cycle, the cam in the six stroke cycle engine of the present invention rotates 60 degrees per stroke. Referring to the figures, the intake valve 10 is open during the intake stroke, as shown in FIG. 1 . This open condition corresponds with a lobe of the cam contacting the valve stem or rocker arm, depending on the configuration of the engine. As the cam rotates 60 degrees during the next stroke, the lobe disengages and the intake valve 10 moves to the closed position. As the engine moves through the third and fourth strokes, the intake valve 10 remains closed and the cam has rotated an additional 120 degrees. In the fifth stroke, the cam rotates another 60 degrees and the second lobe of the cam engages the valve stem and the intake valve 10 moves to the open position, as shown in FIG. 5 . The intake valve 10 moves to the closed position as the cam rotates during the sixth stroke. Since the valve is open during the first and fifth strokes, the two lobes on the cam are correspondingly located at the zero degree and 240 degree positions. The cam for the exhaust valve works in the same manner, but the lobes are located at the 180 degree and 300 degree positions since the exhaust valve 11 is in the open position at during the fourth and sixth strokes.
[0018] In the alternative embodiment of the present invention, electronically controlled solenoids 20 are used as the actuation mechanism for the intake 10 and exhaust valves 11 of the engine. Each intake 10 and exhaust valve 11 has separate solenoids 20 so that the valve timing in each cylinder 14 can be controlled independent of other cylinders or engine rotation. The valve will be held in a normally closed position by a valve spring 18 , as shown in FIG. 8 . When an electrical signal is sent to the solenoid 20 by a controller 21 , the solenoid 20 depresses the valve, causing it the move to the open position.
[0019] In one embodiment of the present invention, the controller 21 is further electronically connected to sensors providing information such as throttle position, intake air temperature, and engine speed, among others. In other embodiments of the present invention, the controller 21 is part of the engine control unit. The controller 21 has the ability to vary the sequence of opening and closing of the valves 10 and 11 based on the needs of the engine.
[0020] The controller 21 further has the ability to control the duration of the time a valve is opened. For example, if a cylinder is running rich, the duration that the intake valve 10 is open can be decreased to limit the amount of fuel entering the cylinder for a port injected engine, similar to a choke operation on a carbureted engine. The timing of the valves can eliminate rich conditions that result in backfires and high carbon emissions. When undesired air/fuel mixtures are eliminated, fuel efficiency will be improved and the engine will have improved response to load changes.
[0021] With independent control of the valves and fuel delivery, the operation of the engine can be varied depending on engine load, engine conditions, sensor input, or external conditions. For example, in cold conditions, the engine can operate as a standard four stroke cycle engine until the cylinder 14 reach a temperature that requires further cooling. As another example, during highway cruising in which a relatively light load is placed on the engine, individual cylinders can have fuel cut-off and the valves 10 and 11 opened to reduce pumping losses, reducing the effective displacement of the engine. In this method of operation, in which certain cylinders are not receiving fuel, fuel economy can be increased. | The present invention relates generally to an internal combustion engine and a method of operating the engine on a six stroke cycle, in which the fifth and sixth strokes cool the engine to improve efficiency and reduce emissions. | 5 |
BACKGROUND ART
This invention concerns building construction and more particularly a precast building block module and method of constructing buildings utilizing the module. A common form of modern building construction is steel frame in which columns and beams of structural steel are assembled into a framework which supports the weight of the walls, floors and other components of the building, which are secured to the framework. Such construction is relatively expensive due to the high cost of structural steel and requires relatively expensive on site labor for the installation of the walls and ceiling panels to the steel framework.
In an effort to reduce the costs of construction for relatively low-rise buildings, i.e. 20 stories or less, reinforced concrete construction has also been commonly employed. In such construction, concrete forms are erected at the site, steel reinforcing rods placed in the forms, and concrete poured into these forms to create walls, load bearing columns, and floors of reinforced concrete. The interior and exterior facing panels are then secured to the reinforced concrete structure resulting in reinforced concrete structure. Concrete is much less expensive than steel as a structural material, and material costs are greatly reduced in this latter construction. However, on site labor is still quite extensive and thus this method still results in expensive construction. On site labor is carried out under uncontrolled site conditions, and the resultant scheduling problems resulting from the need for on time arrival of materials and various types of workers all escalate the cost of such labor over the costs of factory labor. For these reasons, fabrication of construction components can be carried at much lower costs in factory settings.
Other forms of construction have also been utilized, such as solid or hollow block walls, but this construction requires relatively intensive labor and also requires separate on site attaching of the exterior and interior panels.
In an effort to reduce the on site labor involved in reinforced concrete type construction, it has heretofore been proposed and implemented to utilize a special prefabricated form for pouring concrete as disclosed in U.S. Pat. No. 4,098,042. This patent describes a system for carrying out building construction by use of prefabrication sheet metal concrete forms to enable the reinforced concrete construction to be more rapidly carried out to greatly reduce the on site labor. However, considerable on site labor remains in the pouring of the concrete and in the installation of the interior and exterior facing panels as well as any required insulation.
Accordingly, it is an object of the present invention to provide a method of erecting and system of wall and floor structure, and a prefabricated building block module utilized therein which results in a reinforced concrete structure with a great reduction in on site labor.
It is still another object of the present invention to provide such method and module by which the on site labor in installing the wall insulation and the exterior and interior wall panels is greatly reduced.
Still another object of the present invention is to provide a building block module and system and method of wall and floor construction of reinforced concrete by which the extent of on site pouring of concrete is minimized.
It is still another object of the present invention to provide such a method and module for reinforced concrete construction in which the necessity for the on site erection of concrete forms is substantially eliminated.
DISCLOSURE OF THE INVENTION
These and other objects of the present invention are achieved by a method in which precast building block modules of precast reinforced concrete are erected into vertical walls which are integrated into a wall-floor system, whereby the walls support the building floors. The building block modules consist of generally rectangular hollow blocks of reinforced concrete, with generally beveled corners. Reinforcing bars or rods are cast within each of the sides, top and bottom of the module and extend into and through the spaces created by the beveling of the corners.
The spacing of the sides of the rectangular module is such as to correspond to the necessary column sizing and spacing for the particular building design. The modules are assembled into vertical walls aligned over each other and in end to end and side and top and bottom abutment. The beveled spaces enable the vertical and horizontal rods to be rerodded together with the spaces then filled with concrete to form solid columns of reinforced concrete construction through which continuous reinforcing extends. The building modules are also provided with integral or separately attached external panels which come into abutment to provide the building exterior face when the modules are assembled into the walls.
The building floors are poured or precast floor sections are assembled into position atop the building modules with the beveled tops each acting as arches transmitting the weight of the floor into the vertical columns formed by the module sides.
The sides of the modules are provided with tongue and grooves on opposite sides which are in mating relationship upon assembly of the modules into the walls. The modules are also provided with insulation material filling the hollow space within the interior of each module. In addition, interior wall panels may be assembled to each of the interior faces of the modules. All of the building block modules as well as attached exterior and interior wall panels are prefabricated at factory sites, such that the on site labor is greatly reduced to greatly reduce building labor costs, while providing the material cost reduction advantage of reinforced concrete construction.
The enablement of the rerod connection in the spaces provided by the beveled corners enables continuously extending vertical and horizontal reinforcing rods to provide continuous reinforcement of the columns and beams formed by the module top and sides. The connections at the ends of the reinforcing rods may be made by welding, twisting or otherwise connecting the ends of the reinforcing rods.
In a second embodiment, the reinforcing rods are provided with threaded connections, which cooperate with threaded coupling elements so as to draw together the individual modules into tight side and top and bottom abutment with each other and the floor sections.
The vertical reinforcing rods are coupled by a sleeve capturing a headed end on one of the reinforcing bars and threadedly engaging the other end of the other aligned reinforcing bar to facilitate positioning of each of the modules atop each other. The sleeve is slotted to enable subsequent installation of the sleeve over the headed end of one of the aligned reinforcing rods and movement into threaded engagement with the other end of the opposing reinforcing bar end. In this embodiment, precast floor sections are employed which are provided with horizontally extending internal spaces which accommodate turn-buckle assemblies each anchored at one end on transverse rods embedded in the floor section and extending through the floor spaces. The other end of each of the turn-buckles are anchored over a vertical rod extending out of each side of the module into the beveled space, which arrangement enables the floor and modules to be drawn tight together by rotation of the turnbuckle.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the building block module according to the present invention with an exploded fragmentary view of an edge seal assembled into the side space between adjacent module.
FIG. 2 is a top view of the module shown in FIG. 1.
FIG. 3 is a front elevational view of the module shown in FIG. 1.
FIG. 4 is a side elevational view of an assembly of the modules into a load bearing building wall-floor structure system.
FIG. 5 is a diagrammatic front elevational view of a series of modules assembled into a load bearing wall-floor structure.
FIG. 6 is an exterior elevational view of a series of modules of alternate form assembled into a wall-floor structure.
FIG. 7 is an enlarged interior elevational view of the wall-floor structure shown in FIG. 6.
FIG. 8 is a fragmentary enlarged side elevational view showing two vertical aligned building modules of the type shown in FIGS. 6 and 7 together with a portion of floor structure showing the details of the reinforcing bars connection.
FIG. 9 is an exploded perspective of the coupling component and reinforcing rod ends connecting the vertical reinforcing rods in the embodiment of FIGS. 6-9.
DETAILED DESCRIPTION
In the following detailed description, certain specific terminology will be employed for the sake of clarity and particular embodiments described in accordance with the requirements of 35 USC 112, but it should be understood that the same is not intended to be limiting and indeed should not be so construed.
Referring to the drawings, and particularly FIGS. 1-4, according to the concept of the present invention a plurality of precast reinforced concrete building block modules 10 are utilized which are assembled into load bearing walls of the building structure. According to accepted construction techniques for erecting reinforced concrete buildings, reinforced concrete columns are provided which extend to the full height of the building, the concrete columns having iron or steel reinforcing rods embedded therein. Such steel reinforcement bars must extend continuously through the full height of the column, according to accepted building practice.
In the normal procedure for achieving this the reinforcing rods are of length to extend above the height of the column after pouring of the concrete. The reinforcing rods for the next aligned column section are "rerodded" or joined to the protruding lengths of reinforcing rods. Each column section corresponds to a building story, such that each floor section is poured or assembled onto bond beams extending between the columns, such that the weight of each floor is born by the respective column section.
The bond beam similarly is provided with a continuously joined steel reinforcing rods extending throughout the lengths of the bond beam.
According to the concept of the present invention each of the prefabricated building modules 10 comprise a structure which acts as a pair of column sections as well as an adjacent connecting bond beam which transmits the load of the floor into the columns. A particular configuration of the building module 10 enables ready joining of the column sections into continuously reinforced vertical columns extending throughout the full height of the building.
Each building module 10 includes a generally rectangular precast reinforced concrete member 12 having side sections 14 and 16 joined by a top section 18 and a bottom section 19. A central hollow 20 is formed by the surrounding rectangle top, sides and bottom.
Each of the corners of the rectangular precast concrete member 12 are generally beveled to formed spaces indicated at 22, 24, 26 and 28 in FIG. 1. The beveling of the bottom spaces 24 and 26 is more steeply vertical while the spaces 22 and 28 at the top are more horizontally inclined. Each of the sides 14 and 16, the joining top section 18 and bottom section 19 have sections of reinforcing rods 30 and 32 cast thereinto. The number and size of such rods is determined by the design of the particular building in question, as is the spacing of the sides 14 and 16, and the sizing of the various sections.
The reinforcing rods 30 in the side section 14 and 32 in the side section 16 have their upper ends extending through the bevel spaces 22 and 28 to protrude well beyond the upper surface of the top section 18. However, the reinforcing rod ends extending into the spaces 24 and 26 extend only as far as the bottom surface of the bottom section 19. The reinforcing rods 34 within the top section 18 extend out of the bevel spaces 24 and 26. This arrangement enables connections between the aligned opposing rod ends after assembly into a wall structure, as will be described below.
Each of the sides 14 and 16 are provided with complementary lengthwise extending mating contours provided for side engagement between adjacent building modules, i.e., side 14 is provided with a lengthwise groove 38 while side section 16 is provided with a lengthwise tongue 40.
Suitable seals are provided such as neoprene seal 42 of a complementary shape to be interposed between adjacent side sections in order to provide a weather tight joint.
The building block module may also be provided with either integral or attached exterior wall panels 44 which may also be of poured concrete. Such panels generally overlie the hollow rectangular member 12 and having an upper area extending above the upper surface of the top section 18, for a distance corresponding to the floor depth to accommodate its thickness. The top surface 46 is chamfered in order to provide a weather lap joint between overlying the bottom edge 48 of the next above exterior panel of the module 10 positioned directly above in the building structure. The bottom contour 48 is wedgeshaped in a complementary fashion for this purpose.
The module 10 may also be optionally provided with an interior wall panel 50 which also overlies the inside flanged face of the hollow rectangular member 12, the flange 13 extended over the bevel spaces 22, 24, 26 and 28 as shown. Panel 50 may be a section of drywall or other suitable interior facing material. Alternatively, the interior surfaces may simply be plastered after assembly of the modules 10 into the wall structure.
The hollow interior space 20 may also be filled with a mass of insulating material such as foamed plastic or other suitable insulating material when the module 10 is prefabricated. This may also be done after the building structure has been erected.
A vapor barrier indicated at 52 is provided overlying the hollow rectangular member 12 underneath the interior wall panel 50. Suitable cast in lifting eyes 52 may also be provided or to facilitate hoisting of each building module 10 into position which will also act as keys when embedded in a poured concrete flooring section.
According to FIGS. 4 and 5, the erected floor wall system is comprised of a series of building modules 10 assembled in side by side relationship with the tongue and grooves 38 and 40 in mating relationship, with each of the sides 14 and 16 aligned with the below positioned module 10 having corresponding sides 14 and 16.
The initial or first course of building modules 10 are of special configuration in order to be assembled to the foundation structure 56, which may be of poured concrete construction formed with core openings 58 which are spaced at the spacing S corresponding to the designed column spacing of the building structure. Thus the core openings 58 can be filled with high strength concrete and receive the bottom ends of reinforcing rods which, in this version of the building modules 10, extend below the bottom section 19.
Each of the building modules 10 in this procedure would be placed in edge abutting relationship and in alignment with each other with the appropriate seals 42 in place to form a wall. After placement of the first course, each of the building modules provide column sections comprising sides 14 and 16. The floor sections 60 are either assembled or poured in place such as to overlie the top beam 18. In this case the lifting eyes 52 act to tie in the floor to each building module 10.
The offset distance D is the dimension in which the exterior panel 44 extends above the top of the beam 18 or top side 18 corresponds to the depth of the floor 60. Of course it should be understood that in the event the floor 60 is poured on site, the necessary forms, supports, etc., must be erected if the floor 60 is of a precast configuration, necessary the fastening hardware must be employed in a manner known to those skilled in the art.
The spacing S noted in FIG. 5 equal to the distance between the columns, constituted by the sides 14 and 16 of course, will be determined by the design of the particular building as will be the sizes of the sides 14 and 16, top section 18, and the size and number of reinforcing rods 30 and 32.
After placement of floor 60, the next succeeding course of building modules 10 is assembled into position with each building module 10 aligned and having its sides 14 and 16 in direct alignment with the next below module sides 14 and 16.
This positions the upper ends of the reinforcing rods 30 and 32 protruding into the beveled spaces 26 and 30 so that they may be brought into overlapping relationship with the lower ends of the reinforcing rods 30 and 32 of the next above building module 10. The rods 30 and 32 then may be rerodded or joined as by wiring or welding as per conventional techniques. Access thereto for this purpose is afforded by the beveled spaces 24 and 26 of the upper modules 10.
Similarly cross reinforcing rods 32 and 36 extend into adjacent bevel spaces 22, 24, 26 and 28 enabling lapping of adjacent rods and rerodding of these. In this way the second course may be erected and the next floor if any assembled to the top of the next course of building modules 10. After assembly thereof, each of the beveled spaces 22, 24, 26 and 28 is then filled in with concrete or other similar material to provide continuous vertical columns consisting of the aligned sides 14 and 16 of each of the vertically aligned building modules 10. If insulation has not previously been filled into each of the void spaces 20, this may be foamed or otherwise installed after erection of the wall-floor structure, as well as the installing of suitable interior panels and vapor barriers, or the interior wall plastered.
It is noted that each module 10 is of a height equal to the building story and is therefore of variable width and size.
The lower section 19 not bearing the load of the floor weight is incorporated only to provide a relatively strong building module 10 which is able to be easily handled during the shipping and erection processes. It can be appreciated that the entire modules can be substantially completely prefabricated in a factory environment and thus minimize construction labor at the site, particularly if the exterior and interior panels and the insulation is incorporated in the prefabrication of the modules 10.
Also window openings may be relatively easily provided for by providing appropriate cutouts in the region of the central void space 20.
The resulting wall structure will be relatively weather type due to the sealing engagement between adjacent building modules and also the vertical and horizontal weather lap afforded by the mating of the exterior panels, which may also be caulked in conventional fashion.
It may be advantageous to provide means for drawing the modules 10 into tight engagement with the floor and the wall made up of the individual building modules 10. In FIGS. 7-9, an arrangement is depicted for causing prestress tensioning to be exerted on the reinforcing bars, and also in order to draw the panels into tight engagement with the flooring and with the adjacent building modules 10.
This arrangement is best seen in FIGS. 7 and 8. This includes a coupling 62 which mates with the aligned threaded ends of horizontal reinforcing rods 64 extending through the bottom section 19 of each member 12. In similar fashion, a coupling 66 mates with aligned and opposed threaded ends of reinforcing bars 68 extending through the top sections 18. The bevel spaces 23, 26, 22 and 28 provide the necessary access space for installation and tightening of the coupling 62 and 66.
The reinforcing rods 70 and 72 extending through each of the sides 14 and 16 of each module 10 are enabled to be drawn together and secured by means of a special fitting engaging headed lower ends 74 and 76 of each of the respective reinforcing bars 70 and 72 and the threaded upper ends 78 and 80 of the reinforcing bars 70 and 72 respectively. In the embodiment, the bars are sized so as to create a gap between the aligned and opposed upper and lower ends of the reinforcing bars upon installation of the building modules in their vertically aligned position.
After fitting each module 10 in position the special fitting 82 is slid over the threaded section 74 or 76 through a cut out or slot 84, and the threaded bore 86 moved into threaded engagement with the lower end of 78 or 80.
The exterior of the special fitting 82 is formed with wrenching flats 88 to enable the rotation of special fitting 82 to create tension on the reinforcing bars 78 and 72 to both prestress the reinforcing rods 70 and 72 and also to insure tight abutment of the adjoined floor section and each of the building modules 10.
The floor sections 90 of this configuration are of precast construction and include openings 92 which extend transversely to the building module 10. Such flooring construction is of a type known to those skilled in the art and includes steel reinforcing rod 94 in the lower regions of the floor to provide tension reinforcement. A turnbuckle fitting 96 is positioned in the core openings 92 adjacent each of the bevel spaces of building modules 10. The core openings 92 serve to accommodate these fittings. Each turnbuckle fitting 96 includes an anchoring eye 98 anchored on a transverse bar 100 extending through the floor section 90. The opposite end of the turnbuckle fitting 96 includes an anchoring eye 102 which is fit around a vertically extending bar 104 embedded into each of the side wall side sections 14 and 16, positioned offset both laterally and in and out from the reinforcing bars 70 and 72. The turnbuckle fitting also includes a turnbuckle nut section 108 protruding into the space 110 which is adjacent an end face 112 of the flooring section 90 in the exterior panel 44 of the building module. Access thereto is through the spaces 22, 26, 24 and 28 to enable wrenching of the turnbuckle nut 108.
Accordingly the reinforcing rod 70 and 72 may be prestressed and securely joined and tensioned by this arrangement and the horizontally extending reinforcing bars 64 prestressed which also causes the building modules 10 to be drawn into tight engagement with each other and with the flooring sections 90.
Accordingly, it can be seen that the on site labor required for erection is greatly reduced while producing a structure of reinforced concrete such as to reduce the material costs involved. The building modules 10 may include the external and internal finishing panels as well as insulation and vapor barrier to further reduce the on site labor and also increasing the speed with which the building may be erected to further reduce the cost of construction. | A method of construction is disclosed employing reinforced concrete building block modules which are assembled into load bearing walls. The modules are configured as hollow rectangles with each of the corners beveled and with reinforcing rods extending through each of the top, bottom and sides of the rectangle and into the bevel spaces. After assembling the modules into wall structures, the adjacent reinforcing rods are joined to each other and the bevel spaces filled in with concrete. The modules are optionally provided with attached or integrally formed exterior and/or interior facing panels and the hollow space within each module is adapted to be filled with foam insulation. In the resulting wall structure, the sides of each of the modules act as load bearing columns supporting the building floors, with the weight thereof transmitted into the columns by the top of each module acting as an arch. In an alternate form of the invention, the connection between reinforcing rods is provided by tensioning arrangements which also draw the block modules and floor together. | 4 |
TECHNICAL FIELD
This invention relates generally to fuel injection systems for engines and, in particular, diesel engine applications.
BACKGROUND
Practically all fuel systems for diesel engines employ high-pressure pumps, the output volume of which is made variable by varying the effective displacement of the pump. Injection pressures of these systems generally are dependent upon speed and fuel output. At lower engine speeds and fuel outputs injection pressure falls off producing less than an optimum fuel injection process for good combustion.
SUMMARY OF THE INVENTION
The common rail fuel system consists primarily of a high-pressure fixed displacement fuel pump, nozzles, a rail or rails having relatively constant pressure situated between the fuel pump and the nozzles, the necessary connecting fuel lines, and an electronic control system.
Electronic controls technology makes the system of this invention possible. A fixed displacement pump controls the fuel flow to the engine and increases the pressure and volume of the fuel as required for optimum combustion. Injection pressure is controlled by electronically controlled nozzles which determine the duration of injection. Injection pressure can be varied by varying the on time of the nozzle solenoid while the output of the pump is held constant.
The inlet valve of the high-pressure pump is a metering valve which is actuated by a solenoid. The electrical pulse to the solenoid is supplied by the electronic control system, which is also responsible for matching of the metered fuel volume to the fuel volume required for the engine operating conditions. The electronic control system determines the beginning and end of the electronic pulse sent to the solenoid stator which actuates the metering inlet valve. System characteristics determine the armature and valve assembly response. Correlation of the duration of the solenoid activation pulse to the fuel requirement of the engine is established by a fuel map developed through test and programmed into the controller.
The relative constant pressure supply fuel is boosted to injection pressure by the high-pressure fuel pump. Fuel volume is metered by the inlet valves. The inlet valve is actuated by a solenoid and opens shortly after the plunger begins the retraction stroke. Fuel at supply pressure flows in to fill the cavity produced by the retracting plunger. When the proper volume of fuel to supply one cylinder firing event for the load and speed conditions present at the time has been admitted to the pumping chamber, the inlet valve closes. Plunger travel during the time the inlet valve is held open determines the volume displaced by the plunger and, therefore, the volume of fuel admitted to the high-pressure chamber of the pump.
As the plunger continues to retract after closing of the inlet valve, a vacuum is created in the pumping chamber. Near the end of the plunger retraction stroke, the leakage return port is uncovered. The vacuum in the pumping chamber increases the pressure differential between the leakage system and the pumping chamber, improving fuel flow from the leakage system into the pumping chamber. Once equilibrium of the leakage system has been achieved, the volume of leakage system fuel which is held in the pumping chamber is equal to the leakage of the plunger and nozzle(s) during one pumping and retraction cycle of the plunger.
At the start of the pumping stroke, the leakage return port is uncovered. A check valve may be placed in the leakage return line to prevent fuel from escaping until the port is closed by the upward moving plunger. Otherwise the pump output will be reduced by the volume of fuel which escaped. Pressure will begin to increase in the pumping chamber as soon as the plunger begins to rise if a check valve is used. If no check valve is placed in the leakage return line to prevent fuel from flowing out of the leakage return port, pressure will begin to increase when the port is closed by the upward moving plunger. The rate of increase is a function of volume of fuel trapped in the pumping chamber and bulk modulus of the fuel. When the fuel inside the pumping chamber reaches a pressure adequate to overcome the force of rail pressure on the delivery valve, and any spring load, if a spring is used, the delivery valve opens and fuel flows from the pumping chamber into the rail. Fuel continues to flow from the pumping chamber into the rail until the plunger direction again reverses and the plunger begins to retract, increasing pumping chamber volume and reducing pressure in the pumping chamber. The rail pressure, assisted by the spring load, if present, closes the delivery valve.
Steady-state rail pressure and pump output are maintained by controlling the relative on duration of the fuel pump inlet solenoid and the nozzle solenoid signal duration, and are controlled by the ECM. During engine start-up, fuel pump inlet solenoid signal duration is maximized until rail pressure is attained. Once the engine is started, solenoid signal durations are adjusted by the ECM to maintain the desired speed as determined by throttle position.
Introduction of the fuel from the pumping chamber into the rail produces a short-term pressure increase in the rail. This pressure pulse is superimposed on the steady-state pressure maintained in the rail. Rail and connecting line design are intended to minimize the disturbance created by this pulse.
Pulses are created by the opening and closing of the injection valve in the nozzle. These pulses can be phased relative to the pulses generated by the pump by advancing or retarding the pump with respect to the nozzle to achieve the most favorable interaction between pump and nozzle pulses. Nozzle event timing is controlled only by combustion factors.
Rail pressure can be maintained relatively constant, varying only by the fluctuations due to the output pulses of the pump and the injection pulses. These fluctuations are small relative to injection pressure, being attenuated by the elasticity of the reservoir structure and volume of high-pressure fuel. Rail pressure is also independent of speed.
The common rail system of the invention provides the advantage that fuel at injection pressure is available at the nozzle immediately upon opening of the valve in the tip of the nozzle and the opportunity to maintain a more advantageous spray pattern throughout a wider engine speed and load range.
These and other features of the invention will be more fully understood from the following description of the preferred embodiment taken together with the accompany drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic showing the fuel system of the invention;
FIG. 2 is a sectional view showing the novel highpressure pump used in the system;
FIGS. 3A-G are sectional views illustrating the pump at six different sequential points in a cycle of operation;
FIG. 4 is a sectional view showing one of the injector nozzles of the common rail system, with the nozzle being shown in closed position;
FIG. 5 is a view similar to FIG. 4 with the nozzle shown in the open position under actuation by the nozzle solenoid; and
FIG. 6 is a graph illustrating the pressure at the spray hole entrance, shown at the various degrees of fuel pump cam rotation when the discharge of the various nozzles takes place and shows the slight variation in rail pressure during discharge.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown the common fuel rail system of the invention as applied to a six-cylinder diesel engine. The system includes an electronic control module 10 (ECM) which sends signals to an electronic distribution unit 12 (EDU). As is usual, the signals are of low voltage and low power and activate the electronic distribution unit which is connected to a 12-volt vehicle battery 14 by a conductor 16. The ECM has at least two electronic inputs, one input A which indicates crank shaft position as a timing reference. The other output B indicates throttle position as a load reference. Optional inputs are C--turbo boost, D--temperature of oil, E--coolant level, and F--oil pressure. The ECM also has a PROM 18 which is programmed by a fuel map developed by actual engine testing.
The system further includes a fuel-injection pump assembly which is supplied with fuel by a fuel supply pump 22 connected by a line 21 to a fuel tank 23. Pump assembly 20 includes two high-pressure fuel-injection pumps 24 and 26, with pump 24 supplying the high-pressure common fuel rail 28, while pump 26 supplies the high-pressure common fuel rail 30 through supply lines 32 and 34, respectively. Lines 36 and 38 supply fuel at constant pressure to the high-pressure fuel-injection pumps 24 and 26 from the supply pump 22. The high-pressure fuel rail 28 supplies fuel to the injection nozzles 40, 42 and 44 by way of lines 46, 48 and 50, while the high-pressure fuel rail 30 supplies injection nozzles 52, 54 and 56 by way of lines 58, 60 and 62, respectively.
Some leakage occurs at the nozzles which is captured by the nozzle leakage return lines 66, 68 and 70, which feed the nozzle leakage return line 72, while the nozzle leakage return lines 74, 76 and 78 feed the nozzle leakage return line 80. The pumps have solenoid valves 82 and 84, respectively, which connect through conductors 86 and 88, respectively, to the EDU and are operated by signals the ECM received by way of conductors 86' and 88', respectively. The injector nozzles have solenoids 100, 102, 104, 106, 108 and 110 which are operated by the EDU by conductors 112, 114, 116, 118, 120 and 122, respectively, which are in turn controlled by signals sent from the ECM by conductors 112', 114', 116', 118', 120' and 122', respectively.
FIG. 2 shows the details of construction of fixed displacement pump 24 which is identical to pump 26. Pump body 130 houses a pumping chamber 132 within which a pumping plunger 134 reciprocates between fixed top and bottom positions, as will be later described in reference to FIG. 3. Fuel is delivered to inlet port 135 of pump 24 by supply line 36. Flow of fuel into pumping ,chamber -32 is controlled by inlet valve 136 by fluctuations due to the output pulses of the pump. These fluctuations are small since they are attenuated by the elasticity of the rail structure and volume of high-press fuel. Rail pressure is independent of engine speed. Inlet valve 136 includes a stem 140 which mounts the armature 142 of solenoid 82. Armature is normally retracted within stator 144 by a compression spring 145, and is extensible upon energization of stator 144 via conductor 86 to open valve inlet port 135. The amount of fuel pumped by pump 24 is dependent upon the length of time solenoid 82 is energized and inlet valve 136 is open.
Fuel delivery from pump 24 is controlled by outlet valve 146 which opens to connect outlet passage 148 which is normally closed by a compression spring 150. Upon opening, valve 146 connects passage 148 with outlet port 152 to enable pressurized flow to delivery line 32.
Plunger 134 is reciprocated within chamber 132 by a rotating cam 154 between top and bottom positions, thus providing a constant volume pump. A bottom flange 156 is maintained in contact with cam 154 by a compression spring 158, confined between flange 156 and a pump body internal wall 160.
Leakage return line 80 is connected to a leakage fuel inlet port 162 in pump body 130 to deliver leakage fuel to a leakage accumulator chamber 164. Chamber 164 houses a piston 166 that is backed by a compression spring 168. Leakage fuel accumulated during a pumping cycle is delivered to chamber 132 through leakage chamber outlet passage 170, as will be later described. Any fuel leaking past plunger 134 during a cycle collects in a collector groove 172.
Operation of fuel pump 24 will now be described with reference to FIGS. 3A-3D which sequentially depict a pumping cycle.
Referring also to FIGS. 3A-3G, it is noted that the high-pressure pump shown in FIG. 2 is in the same position as the pump shown in FIG. 3A. In operation, the cycle starts when the plunger is just past top dead center (TDC) with the solenoid off and both the inlet valve 136 and outlet valve 146 are closed by respective springs 145 and 150.
As shown in FIG. 3B, as cam 154 enables spring 158 to begin retracting plunger 134, the inlet valve 136 is opened by the solenoid 82, permitting fuel to flow into the pumping chamber 132. Upon further rotation of the cam 154 and passage of a predetermined period of time, shown in FIG. 3C, the inlet valve 136 is closed by the solenoid 82, halting fuel flow to the pumping chamber 132. The length of time that inlet valve 136 is held open determines how much fuel is metered into the pumping chamber 132.
As shown in FIG. 3D, further cam rotation effects plunger retraction, with no additional fuel being metered into the pumping chamber. This creates a sub-atmospheric pressure, or partial vacuum, in chamber 132.
One feature of the invention is that fuel accumulated from nozzle and/or plunger leakage is returned to the high-pressure pump without passing through the primary metering valve 136. As the cam 154 reaches its bottom dead center (BDC) position (FIG. 3E), final retraction of the plunger 134 opens the passage 170 to connect the fuel leakage accumulator chamber 164 with the pumping chamber 132. The rear of the chamber 164 is maintained at atmospheric pressure to enable the portion of the chamber in front of piston 166 to expand upon pressurization by leakage fuel and serve as an accumulator. Many alternate forms of accumulators could also be utilized, including elastic lines, diaphragms, or compressed volume. The force of the spring 168 biasing piston 166 and the sub-atmospheric pressure in chamber 164 combine to force the leakage fuel accumulated during the previous engine cycle (i.e., since the last stroke of pump 24) into the pumping chamber 132.
Rotation of the cam 154 past BDC (FIG. 3F) strokes the plunger 134 upwardly, closing passage 170 and pressurizing the chamber 132 from sub-atmospheric to super-atmospheric pressures. As the pressure in the chamber 132 rises, any leakage past the plunger 134 will collect in an annular collector groove 172 and enter the leakage accumulator chamber 164 through the passage 170. As shown in FIG. 3G, after the leakage return port is closed, continued upward motion of the plunger 134 pressurizes the fuel until the outlet valve 146 opens. The outlet valve 146 remains open until the plunger 134 reaches TDC and begins a new cycle.
It is apparent that the quantity of fuel injected on each stroke of the plunger 134 depends on the duration of opening of inlet valve 136 which is controlled by the solenoid 82. Since operation of the solenoid 82 can be precisely controlled, the quantity of fuel pumped can likewise be precisely controlled.
As a safety feature, it is understood that any break in the electrical conductors connecting to the solenoids 82 and 84 will stop fuel delivery to the injectors served by the particular high-pressure pump.
The fuel injection nozzles 40-44, 52-56 for the common rail fuel injection system are electronically controlled solenoid valves having spray holes which convert the rail pressure head to velocity in the injection plume. As shown in FIG. 1, pressurized fuel is supplied by the high-pressure pumps 24, 26 and stored in the rails 28, 30, or distribution system, which serves as a fuel accumulator. FIGS. 4 and 5 show one of the nozzles 40 in the, closed (between injections) and open (during injection) positions, respectively.
Injector nozzle 40 injects precise amounts of fuel into an engine combustion chamber (not shown) through spray holes 180 as regulated by a pilot-controlled metering valve 182. Pressurized fuel is delivered from rail 28 through delivery line 46 through inlet port 184 to a chamber 186 housing valve 182, which is biased to its normally-closed FIG. 4 position by a compression spring 187.
Metering valve 182 has a stem 188 which terminates in a throttling stop 190. Chamber 186 connects through a passage 192 and an orifice 194 to a pilot chamber 196 atop valve stem 188. Chamber 196 connects through a passage 198 to a chamber 200 which connects through a passage 202 to fuel return line 66. Another passage 204 connects passage 202 with an annular chamber 206.
A solenoid-controlled pilot valve 208 has a nose 210, which valves passage 198, and an annular shoulder 212 which confines a spring 214 between it and a housing land 216, biasing valve 208 downwardly to close passage 198. Valve 208 includes a stem 218 that mounts a discoid solenoid armature 220 adjacent a solenoid stator 222. Operation of injector 40 will now be described.
With the injection valve 182 closed (FIG. 4), pressurized fuel from the rail 28 flows via line 46 to the nozzle inlet passage 184. Chamber 186 is at rail pressure. In this condition, the solenoid stator 222 is deenergized and the pilot valve 208 is closed by spring 214. With valve 208 closed, there is no flow through passage 198, permitting the fuel in chamber 196 to reach a pressure equal to the pressure in chamber 186, which is rail pressure. With the pressures in the two chambers equal, valve 182 is pressure balanced. The force of the spring 187 acting on valve 182 aids in closing the valve, but is used primarily to keep the valve seated against combustion chamber pressure. Passages 184, 192 and 198 and chambers 186 and 196 are all at rail pressure, and there is no flow through the system.
To begin injection, solenoid stator 222 is energized, attracting armature 220 toward stator 222 and lifting nose 210 of valve 208 from its seat to open passage 198. FIG. 5 shows the nozzle in the valve open condition during injection. With valve nose 210 unseated, flow starts through passage 198, reducing the pressure in chamber 196. Orifice 194, through which fuel from chamber 186 replaces the fuel leaving chamber 196, restricts the flow to create a pressure drop between chambers 186 and 196. With the pressure in chamber 196 less than that in chamber 186, valve 182 becomes pressure unbalanced. The pressure imbalance overcomes the force of spring 187 and lifts valve 182 from its seat, enabling pressurized fuel to be ejected through the spray holes 180 and starting fuel injection to the combustion chamber. The throttling stop 190 at the end of valve 182 throttles flow into passage 198, while permitting adequate fuel flow through orifice 194 and passage 198 to maintain the pressure imbalance and keep valve 182 open. Passages 202 and 204 are provided to drain leakage past valve 208 to the fuel leakage return system via line 66.
When solenoid stator 222 is deenergized to end fuel injection into the combustion chamber, spring 214 seats valve 182, stopping flow through passage 198. Pressure in chamber 196 increases until the combined force of rail pressure and spring 187 overcome the opposing force caused by combustion pressure and valve 182 closes. Fuel can now no longer flow to the spray holes and injection ends.
FIG. 6 is a graph showing the pressure at the spray hole entrance of the nozzles 40, 42 and 44 according to degrees of fuel pump cam rotation. It also shows the rail pressure being maintained relatively constant, varying only by fluctuations due to the output pulses of the pump. These fluctuations are small since they are attenuated by the elasticity of the rail structure and volume of high-pressure fuel. Rail pressure is independent of engine speed.
While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A common rail fuel system is described which consists primarily of a high-pressure fuel pump, nozzles and a rail or rails having a substantially constant rail pressure situated between the fuel pump and the nozzles, the necessary connecting fuel lines and electronic control system. The pump is constructed to add leakage fuel to each stroke output without the necessity for routing this leakage fuel through the primary supply. This reduces the total amount of fuel pumped and improves metering accuracy. | 5 |
FIELD OF THE INVENTION
Embodiments related in general to turbochargers and, more particularly, to vane packs for variable turbine geometry turbochargers.
BACKGROUND OF THE INVENTION
Turbochargers are a type of forced induction system. They deliver air, at greater density than would be possible in the normally aspirated configuration, to the engine intake, allowing more fuel to be combusted, thus boosting the engine's horsepower without significantly increasing engine weight. A smaller turbocharged engine, replacing a normally aspirated engine of a larger physical size, will reduce the mass and can reduce the aerodynamic frontal area of the vehicle.
Referring to FIG. 1 , a turbocharger ( 10 ) uses the exhaust flow from the engine exhaust manifold to drive a turbine wheel ( 12 ), which is located in a turbine housing ( 14 ) to form a turbine stage ( 16 ). The energy extracted by turbine wheel ( 12 ) is translated into a rotating motion which then drives a compressor wheel ( 18 ), which is located in a compressor cover ( 20 ), to form a compressor stage ( 22 ). The compressor wheel ( 18 ) draws air into the turbocharger ( 10 ), compresses this air, and delivers it to the intake side of the engine.
Variable Geometry turbochargers typically use a plurality of rotatable vanes ( 24 ) to control the flow of exhaust gas, which impinges on the turbine wheel ( 12 ) and controls the power of the turbine stage ( 16 ). These vanes ( 24 ) also therefore control the pressure ratio generated by the compressor stage ( 22 ). In engines, which control the production of NOx by the use of High Pressure Exhaust Gas Recirculation (HP EGR) techniques, the function of the vanes ( 24 ) in a VTG also provides a means for controlling and generating exhaust back pressure.
An array of pivotable vanes ( 24 ) is located between a generally annular upper vane ring (UVR) ( 26 ) and a generally annular lower vane ring (LVR) ( 28 ). Each vane rotates on a pair of opposing axles ( 30 ) ( FIG. 2 ), protruding from said vane ( 24 ) with the axles on a common axis. Each axle ( 30 ) is located in a respective aperture in the LVR ( 28 ) and a respective aperture in the UVR ( 30 ). The angular orientation of the UVR ( 26 ), relative to the LVR ( 28 ), is set such that the complementary apertures in the vane rings ( 26 , 28 ) are concentric with the axis of the axles ( 30 ) of the vane ( 24 ), and the vane ( 24 ) is free to rotate about the axis ( 32 ) of the two axles ( 30 ), which is concentric with the now established centerline of the two apertures. Each axle ( 30 ) on the UVR side of the vane ( 24 ) protrudes through the UVR ( 26 ) and is affixed to a vane arm ( 34 ), which controls the rotational position of the vane ( 24 ) with respect to the vane rings ( 26 , 28 ). Typically, there is a separate ring which controls all of the vane arms ( 34 ) in unison via small sliding blocks ( 48 ). This unison ring ( 50 ) is controlled by an actuator which is operatively connected to rotate the unison ring ( 50 ). The actuator is typically commanded by the engine electronic control unit (ECU). The assembly consisting of the plurality of vanes ( 24 ) and the two vane rings ( 26 , 28 ) is typically known as the vane pack.
In a vane pack, the clearance between the rotatable vanes ( 24 ), more specifically between the cheeks ( 36 ) of the vanes ( 24 ) and the inner surfaces ( 38 , 40 ) of the upper and lower vane rings ( 26 , 28 ), is a major contributor to a loss of efficiency in both the control of exhaust gas allowed to impinge on the turbine wheel ( 12 ) and in the generation of backpressure upstream of the turbine wheel ( 12 ). The clearances between the vane side cheeks ( 36 ) and the complementary inner surfaces ( 38 , 40 ) of the vane rings ( 26 , 28 ) should be kept to a minimum to increase the efficiency of the vane pack.
However, minimizing such clearances can be difficult. Because the turbine housing ( 14 ) is not symmetrically round in a radial plane, and because the heat flux within the turbine housing ( 14 ) is also not symmetrical, the turbine housing ( 14 ) is subject to asymmetric stresses and asymmetric thermal deformation. Thermal deformation in the turbine housing ( 14 ) is transferred to the vane pack, which can cause the vane pack to wear, stick, or completely jam. Thus, the vane pack must be accurately placed and constrained within the turbine housing ( 14 ) in a manner which minimizes the transference of thermally induced distortion.
Thus, there is a need for a vane pack configuration that can minimize such concerns.
SUMMARY OF THE INVENTION
Embodiments are directed to systems for minimizing the clearance between vane cheeks and the inner surfaces of the vane rings in a vane pack for a variable geometry turbocharger. According to embodiments herein, an abradable coating is applied to an inner surface of an upper vane ring, an inner surface of a lower vane ring and/or cheek surface(s) of a vane. In this way, a very small clearance can be established without interfering with the proper function of the vanes during turbocharger operation. As a result, there can be gains in efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the accompanying drawings in which like reference numbers indicate similar parts and in which:
FIG. 1 is a cross-sectional view of a typical variable geometry turbocharger;
FIG. 2 shows a cross-sectional view of a typical vane pack; and
FIG. 3 shows a view of an assembled vane pack.
DETAILED DESCRIPTION OF THE INVENTION
Arrangements described herein relate to a system and method for a vane ring assembly. Detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are intended only as exemplary. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the aspects herein in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of possible implementations. Arrangements are shown in FIG. 3 , but the embodiments are not limited to the illustrated structure or application.
According to embodiments herein, an abradable coating is applied to one or more of the surfaces that define the clearance between the vanes and the vane rings. Referring to FIG. 3 , a portion of a vane pack ( 50 ) is shown. Only one vane ( 24 ) is shown for purposes of clarity. An abradable coating ( 52 ) can be applied to at least a portion of the inner surface ( 40 ) of the LVR ( 28 ), at least a portion of the inner surface ( 38 ) of the UVR ( 26 ) and/or at least a portion of one or both of the cheek surfaces ( 36 ) of the vanes ( 24 ). In one embodiment, the abradable coating ( 52 ) can be applied to the inner surfaces ( 38 , 40 ) of the vane rings ( 26 , 28 ), but not on the cheek surfaces ( 36 ) of the vanes ( 24 ).
The abradable coating ( 52 ) can be provided in any suitable thickness on the treated surface. The thickness of the abradable coating ( 52 ) can be substantially uniform across the surface. Alternatively, the thickness of the coating ( 52 ) can vary in one or more locations. When the coating ( 52 ) is applied to a plurality of coating defining surfaces, the thickness of the coating ( 52 ) on one of the coating defining surfaces can be substantially equal to the thickness of the coating ( 52 ) on another one of the coating defining surfaces. Alternatively, the thickness of the coating ( 52 ) on one of the coating defining surfaces can be different from the thickness of the coating ( 52 ) on another one of the coating defining surfaces.
The abradable coating ( 52 ) can be any suitable material that can allow abrasive contact between the vane cheeks ( 36 ) and the inner surfaces ( 38 , 40 ) of the vane rings ( 26 , 28 ). In one embodiment, the abradable coating ( 52 ) can be Metco 480NS, which is available from Sulzer Metco (US) Inc., Westbury, N.Y. Such a coating can be a spheroidal, gas atomized alloy comprising 95% Nickel and 5% Aluminum. The particle size can range from about 45 μm to about 90 μm and/or approximately −170+325 mesh (e.g., about 90% or more of the material can pass through a 170 mesh sieve and can be retained by a 350 mesh sieve). The abradable coating can be dense and resistant to oxidation. The coating can withstand temperatures of at least about 800° C. (1470° F.). The coating can be self-bonding and can undergo an exothermic reaction during spraying, resulting in excellent bonding to the substrate. Materials similar to Metco 480NS can be used.
Additional examples of suitable abradable coatings include aluminium silicon alloy/polymer composites, aluminium silicon alloy/graphite composites, nickel/graphite composites, aluminium bronze/polymer composites, nickel chromium aluminium/boron nitride composites, nickel chromium aluminium/bentonite composites, nickel/aluminium composite sprayed porous, nickel chromium aluminium composite sprayed porous, MCrAIY/BN/Polyester composites and Yttria-stabilized zirconia (YSZ) ceramic/Polyester composites. Such coatings can be applied by thermal spraying.
In one embodiment, the abradable coating ( 52 ) can be a zirconia-polymer ceramic abradable powder. Such a powder can be applied by thermal spraying. Examples of such coatings include DURABLADE 2192, Sulzer Metco 2395 and/or Sulzer Metco 2460NS, which are available from Sulzer Metco (US) Inc., Westbury, N.Y.
DURABLADE 2192 can comprise about 9.5% Dy 2 O 3 , about 4.5% polymer, 0.7 hBN and the balance can substantially comprise ZrO 2 (with a maximum of 2.5 wt % hafnia). The nominal particle size distribution can be from about −176+11 μm with an average of about 65 μm. The service temperature can be less than or equal to about 1150° C. (2100° F.). DURABLADE 2191 can have a porosity of about 25-35%. It can have a hardness of about 70-90 HR15Y. It can have a coating strength of greater than 3 MPa (435 psi).
Sulzer Metco 2395 can comprise about 7.5% Y 2 O 3 , about 4.5% polymer, 0.7 hBN and the balance can substantially comprise ZrO 2 (with a maximum of 2.5 wt % hathia). The nominal particle size distribution can be from about −176+11 μm with an average of about 57 μm. The service temperature can be less than or equal to about 1150° C. (2100° F.). Sulzer Metco 2395 can have a porosity of about 25-40%. It can have a hardness of about 70-90 HR15Y. It can have a coating strength of greater than 3 MPa (435 psi).
Sulzer Metco 2460NS can comprise about 7.5% Y 2 O 3 , about 4.5% polymer, about 4% binder and the balance can substantially comprise ZrO 2 (with a maximum of 2.5 wt % hafnia). The nominal particle size distribution can be from about −176+11 μm with an average of about 74 μm. The service temperature can be less than or equal to about 1150° C (2100° F.). Sulzer Metco 2460NS can have a porosity of about 15-30%. It can have a hardness of about 80-95 HR15Y. It can have a coating strength of greater than 4 MPa (580 psi).
Further suitable abradable coatings include TECH 17, TECH 28 and/or TECH 40, which are available from Bodycote K-Tech Ltd., Cheshire, England. A coating comprising TECH 17 can have a thickness of less than about 5 μm. The maximum hardness can be about 2600 Hv. A TECH 28 coating can have a thickness of about 50 to about 100 μm with a hardness of about 1850 Hv. TECH 40 can have a coating thickness of of about 50 to about 100 μm with a hardness of about 2850 Hv.
Materials similar to those listed above may also be suitable. However, embodiments are not limited to any particular material. When the abradable coating ( 52 ) is applied to a plurality of coating defining surfaces, the material of the coating ( 52 ) on one of the coating defining surfaces can be the same as the material of the coating ( 52 ) on another one of the coating defining surfaces. Alternatively, the material of the coating ( 52 ) applied on one of the coating defining surfaces can be different than the material of the coating ( 52 ) applied on another one of the coating defining surfaces.
The abradable coating ( 52 ) can be applied on one or more of the clearance defining surfaces in any suitable manner. Once the abradable coating ( 52 ) is applied it can be machined, if necessary. The vane pack ( 50 ) can be assembled with an interference fit between the clearance defining surfaces. As an example, there can be an interference fit between the uncoated vane cheeks ( 36 ) and the coated upper vane ring ( 26 ) and/or the coated lower vane ring ( 28 ). Before the vane pack ( 50 ) is installed in the turbine housing ( 14 ), the vane pack ( 50 ) can be installed in a fixture and subjected to vibration or oscillations. In this way, the vanes ( 24 ) can engrave the abradable coating ( 52 ) and can establish an essentially zero or very small clearance therebetween while still allowing the vanes ( 24 ) to properly function during turbocharger operation.
During turbocharger operation, the small clearance will minimize the leakage of exhaust gas flow through the space between the vane cheeks ( 36 ) and the inner surfaces ( 38 , 40 ), thereby improving efficiency and performance. Further, it will be appreciated that if the clearance between the vane cheeks ( 36 ) and the inner surfaces ( 38 , 40 ) reduces during turbocharger operation, the vanes ( 24 ) may come into contact with the abradable coating ( 52 ). In such case, the vanes ( 24 ) can further wear away the abradable coating ( 52 ) without substantially impeding the function of the vanes ( 24 ).
The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language).
Aspects described herein can be embodied in other forms and combinations without departing from the spirit or essential attributes thereof. Thus, it will of course be understood that embodiments are not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the following claims. | A vane pack for a VTG turbocharger is provided. The vane pack includes a plurality of vanes pivotably positioned between an inner surface of an upper vane ring and an inner surface of a lower vane ring. Clearances are defined between opposing cheek surfaces of the vanes and the inner surfaces of the vane rings. The vane pack is configured to minimize these clearances by applying an abradable coating is to the inner surface of the upper vane ring, the inner surface of the lower vane ring and/or cheek surface(s) of one or more of the vanes. In this way, an essentially zero clearance can be established without interfering with the proper function of the vanes. As a result, there can be gains in efficiency. Further wearing of the abradable coating may occur during turbocharger operation. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The patent application is a continuation-in-part of U.S. Patent applications 652,179, filed on Feb. 7, 1991 abandoned, and 074,104 filed on Jun. 8, 1993 now U.S. Pat. No. 5,656,635.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to 5-trans-prostaglandins of the F series, homologues and esters and alcohols derived therefrom. More particularly, the present invention concerns 5-trans prostaglandin F (PGF), homologues and amino, amido, ether, alcohol and ester derivatives thereof, that are potent ocular hypotensives, and are particularly suitable for the management of glaucoma.
2. Description of Related Art
Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure glaucoma, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical b-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
Certain eicosanoids and their derivatives have been reported to possess ocular hypotensive activity, and have been recommended for use in glaucoma management. Eicosanoids and derivatives include numerous biologically important compounds such as prostaglandins and their derivatives. Prostaglandins can be described as derivatives of prostanoic acid which have the following structural formula: ##STR2##
Various types of prostaglandins are known, depending on the structure and substituents carried on the alicyclic ring of the prostanoic acid skeleton. Further classification is based on the number of unsaturated bonds in the side chain indicated by numerical subscripts after the generic type of prostaglandin and on the configuration of the substituents on the alicyclic ring indicated by a or b
Prostaglandins were earlier regarded as potent ocular hypertensives, however, evidence accumulated in the last decade shows that some prostaglandins are highly effective ocular hypotensive agents, and are ideally suited for the long-term medical management of glaucoma (see, for example, Bito, L.Z. Biological Protection with Prostaglandins, Cohen, M.M., ed., Boca Raton, Fla, CRC Press Inc., 1985, pp. 231-252; and Bito, L.Z., Applied Pharmacology in the Medical Treatment of Glaucomas Drance, S.M. and Neufeld, A.H. eds., New York, Grune & Stratton, 1984, pp. 477-505). Such prostaglandins include PGF 2a , PGF 1a , PGE 2 , and certain lipid-soluble esters, such as C 1 to C 2 alkyl esters, e.g. 1-isopropyl ester, of such compounds.
Although the precise mechanism is not yet known experimental results indicate that the prostaglandin-induced reduction in intraocular pressure results from increased uveoscleral outflow.
The isopropyl ester of PGF 2a has been shown to have significantly greater hypotensive potency than the parent compound, presumably as a result of its more effective penetration through the cornea. In 1987, this compound was described as "the most potent ocular hypotensive agent ever reported"
Whereas prostaglandins appear to be devoid of significant intraocular side effects, ocular surface (conjunctival) hyperemia and foreign-body sensation have been consistently associated with the topical ocular use of such compounds, in particular PGF 2a and its prodrugs, e.g., its 1-isopropyl ester, in humans. The clinical potentials of prostaglandins in the management of conditions associated with increased ocular pressure, e.g. glaucoma are greatly limited by these side effects.
In a series of co-pending United States patent applications assigned to Allergan, Inc. prostaglandin esters with increased ocular hypotensive activity accompanied with no or substantially reduced side-effects are disclosed. The co-pending U.S. Ser. No. 386,835 (filed 27 Jul. 1989), relates to certain 11-acyl-prostaglandins, such as 11-pivaloyl, 11-acetyl, 11-isobutyryl, 11-valeryl, and 11-isovaleryl PGF 2a . Intraocular pressure reducing 15-acyl prostaglandins are disclosed in the co-pending application U.S. Ser. No. 357,394 (filed 25 May 1989). Similarly, 11,15-9,15 and 9,11-diesters of prostaglandins, for example 11,15-dipivaloyl PGF 2a are known to have ocular hypotensive activity. See the co-pending patent applications U.S. Ser. Nos. 385,645, 386,312 and 385,834 (all filed 27 Jul. 1989). The disclosures of all of these patent applications are hereby expressly incorporated by reference.
SUMMARY OF THE INVENTION
The present invention concerns a method of treating ocular hypertension which comprises administering to a mammal having ocular hypertension a therapeutically effective amount of a compound of formula I: ##STR3## wherein wavy line attachments indicate either the alpha (a) or beta (b) configuration; hatched lines indicate a configuration, solid triangles are used to indicate b configuration, dashed bonds represent a double bond or a single bond, n is 0 or an integer of from 1 to 3; X is NH 2 or OR; R is hydrogen, R 4 or a --(CO)R 4 group; R 1 , R 2 , and R 3 independently are hydroxyl, or --O(CO)R 5 groups, wherein R 4 and R 5 independently stand for saturated or unsaturated acyclic hydrocarbons having from 1 to 20 carbon atoms, or --(CH 2 ) m R 6 where m is 0-10 and R 6 is an aliphatic, aromatic or heteroaromatic ring, R 7 and R 8 together represent ═O or independently are hydrogen or alkyl of 1 to 6 carbon atoms, or a pharmaceutically acceptable salt thereof.
In a further aspect, the present invention relates to an ophthalmic solution comprising a therapeutically effective amount of a compound of formula (I), wherein the symbols have the above meanings, or a pharmaceutically acceptable salt thereof, in admixture with a non-toxic, ophthalmically acceptable liquid vehicle, packaged in a container suitable for metered application.
In a still further aspect, the present invention relates to a pharmaceutical product, comprising
a container adapted to dispense its contents in a metered form; and
an ophthalmic solution therein, as hereinabove defined.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the use of trans derivatives of F-type prostaglandins, homologues and esters and alcohols derived therefrom as ocular hypotensives. The compounds used in accordance with the present invention are encompassed by the following structural formula I: ##STR4## wherein the substituents and symbols are as hereinabove defined. The dotted lines on bonds between carbons 13 and 14 (C-13) and carbons 17 and 18 (C-17) indicate a single or double bond. If two solid lines are used at C-13, or C-17, it indicates a specific configuration for that double bond. Hatched lines used at position C-9, C-11 and C-15 indicate the a configuration. If one were to draw the b configuration, a solid triangular line would be used at either of these three positions.
A preferred group of the compounds of the present invention includes PGF 2a derivatives that have the following structural formula II: ##STR5##
Another preferred group includes PGF 3a derivatives having the formula III: ##STR6## In the above formulae, the substituents and symbols are as hereinabove defined.
The PGF derivatives, including homologues and esters of said derivatives of the present invention may be prepared by methods that are known in the art. The primary alcohols can be conveniently prepared by reduction of the 1-carboxyl group of the corresponding PGF derivatives. For example, in an analogous process the reduction of PGF 2a methyl ester with diisobutylaluminium hydride in ether at 25° C. is disclosed by Maddox et.al., Nature 273,549 (1978).
In general, the reduction may be performed by chemical reducing agents conventionally used for the conversion of carboxylic acids to alcohols. Chemical reducing agents include, but are not restricted to hydrides, such as lithiumaluminium hydride or diisobutylaluminium hydride. As an alternative to direct reduction, the PGF acid may be converted into a corresponding 1-ester before reduction, and the obtained 1-ester may be reduced by chemical reduction. Methods of esterification and reduction of PGF compounds are disclosed in the Example below.
The hydroxyl group(s) present in any of the positions 9, 11 and 15 are protected from reduction by protecting groups known in the art.
The secondary and tertiary alcohols are usually prepared from the corresponding primary alcohols via oxidation to aldehydes or ketones and subsequent reaction with a suitable Grignard reagent. These reactions are well known in organic chemistry.
Esterification of the PGF 1-alcohols of this invention may further increase the ocular hypotensive activity, therefore, the compounds of formula (I) in which R is other than hydrogen are within the scope of the present invention.
In a preferred group of the PGF derivatives of formula (I) the hydroxyl groups in the 9, 11 and/or 15 positions are esterified. Particularly preferred are the 11-esters, 15-esters, 11,15-, 9,15- and 9,11-diesters. Esterification in these positions may be performed after the reduction of the 1-carboxyl group with appropriate protection.
The prostaglandin esters according to the present invention can comprise a variety of acyl substituents. In formula (I) R 4 and R 5 may include acyclic hydrocarbons having from one to twenty carbon atoms, inclusive, and preferably are straight or branched-chain alkyl, alkenyl or alkynyl groups of one to ten carbon atoms, such as methyl, ethyl, propyl, butyl, pentyl, etc., or an isomeric form thereof; vinyl, propenyl, etc. Most preferably, R 4 and/or R 5 are --CH 3 , --(CH 2 ) 3 CH 3 , --CH(CH 3 ) 2 or --C(CH 3 ) 3 .
Alternatively, R 4 and R 5 can comprise a cyclic component (R 6 ), which preferably is a saturated or unsaturated ring having from three to seven carbon atoms; or an aromatic or heteroaromatic ring, preferably having 5 to 10 carbon atoms and containing oxygen, nitrogen or sulfur as a heteroatom, if present. That is, R 6 may be phenyl, thienyl, pyridyl, or furyl, or the mono or disubstituted halo, e.g., fluoro or chloro, or C 1 to C 3 alkyl derivatives, thereof. Preferably, m is an integer between 0 and 4.
In another preferred group of the compounds of Formula (I) R 7 and R 8 are both hydrogen, or R 7 is hydrogen and R 8 is alkyl of one to six, preferably one to four carbon atoms.
A pharmaceutically acceptable salt is any salt which retains the activity of the parent compound and does not impart any deleterious or undesirable effect on the subject to whom it is administered and in the context in which it is administered. Of particular interest are salts formed with inorganic ions, such as sodium, potassium, calcium, magnesium and zinc.
Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable acid addition salt thereof, as an active ingredient, with conventional ophthalmically acceptable pharmaceutical excipients, and by preparation of unit dosage forms suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 1.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 6.5 and 7.2 with an appropriate buffer system. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place or in conjunction with it.
The ingredients are usually used in the following amounts:
______________________________________Ingredient Amount (% w/v)______________________________________active ingredient about 0.001-5preservative 0-0.10vehicle 0-40tonicity adjustor 1-10buffer 0.01-10pH adjustor q.s. pH 4.5-7.5antioxidant as neededsurfactant as neededpurified water as needed to make 100%______________________________________
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate the application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution.
The invention is further illustrated by the following non-limiting Examples.
EXAMPLE 1
Preparation of 1-Decarboxyl-1-hydroxymethyl-5-trans prostaglandin F 2a
A solution of diazomethane in ether was added dropwise to a solution of 5-trans PGF 2a (obtained from Cayman Chemical Company, 10 mg) in 1.5 ml methanol at 0° C. until a yellow color persisted. The solution was stirred at 0° C. for a further 10 minutes and the solvents were evaporated under reduced pressure to obtain 10.7 mg of 5-trans PGF 2a methyl ester as a colorless semi-solid.
1 H NMR (CDCL 3 , 300 MHz): d5.56 (1H, 1/2 ABX, JAB=15.2, JAX=6.7 Hz), 5.4-5.5 (3H, m), 4.20 (1H, t, J=4 Hz), 4.06 (1H, q, J=6.6 Hz), 3.96 (1H, m), 3.67 (3H, s, methyl ester), 2.30 (2H, t J=7.5 Hz), 2.0-2.6 (9H, m), 1.2-1.8 (12H, m) and 0.89 ppm (3H, t J=6.7 Hz).
The crude ester above was dissolved in dry tetrahydrofuran (THF, 1 ml) and cooled to -78° C. in a dry ice-acetone bath. A solution of diisobutylaluminium hydride in methylene chloride (1.0 M, 0.23 ml) was added. The dry ice-acetone bath was replaced with an ice bath after 15 minutes and stirring was continued for 2.5 hours at 0° C. Methanol (0.25 ml) was added to destroy excess diisobutylaluminium hydride. The crude reaction mixture was diluted with 10% citric acid solution and extracted with 4×8 ml ethyl acetate. The combined organic extracts were washed with saturated sodium carbonate and brine, dried over magnesium sulfate and concentrated to give 8 mg. crude product.
Purification was achieved by column chromatography over silica gel using gradient elution (ethyl acetate to 5% methanol in ethyl acetate) giving 6.0 mg. pure 1-decarboxyl-1-hydroxy-methyl-5-trans prostaglandin F 2a (62% yield overall).
1 H NMR (300 MHz, CDCL 3 ): d5.55 (1H, 1/2 ABX, JAB=15.3, JAX=6.9 Hz, H-14), 5.4-5.5 (3H, m), 4.19 (1H, distorted t, J=4 Hz), 4.05 (1H, q, J=6.6 Hz), 3.85-3.95 (1H, m), 3.63 (2H, t, J=6.5 Hz, CH 2 OH), 3.2 (1H, br s), 2.5 (2H, br s), 1.8-2.4 (7H, m) 1.73 (1H, 1/2 ABX, JAB=15, JAX=2.8 Hz), 1.2-1.6 (13H, m) and 0.89 ppm (3H, distorted t, J=7 Hz);
13 C NMR (75 MHz, CDCL 3 ): d13.78 (CH 3 ), 22.41 (CH 2 ), 25.02 (CH 2 ), 25.31 (CH 2 ), 30.95 (CH 2 ), 31.54 (CH 2 ), 31.91 (CH 2 ), 32.02 (CH 2 ), 37.12 (CH 2 ), 42.50 (CH 2 ), 49.85 (CH), 55.55 (CH), 62.67 (CH 2 ), 73.01 (CH), 77.20 (CH), 78.04 (CH), 129.17 (CH), 131.70 (CH), 132.75 (CH) and 135.37 (CH) ppm;
IR (CHCl 3 ): 3200-3600, 1225, 1130, 1100, 970 and 928 cm -1 .
MS (El, TMS derivative): m/z 628 (M + , 0.2%), 217 (26%), 191 (100%), 173 (73%), 129 (46%), 73 (60%).
HRMS (El, TMS derivative): calculated for C 32 H 68 O 4 Si 4: 628.4163, found: 628.4179.
EXAMPLE 2
Intraocular Pressure Reducing Activity of
1-Decarboxyl-1-hydroxymethyl-5-trans prostaglandin F 2a
Experimental quantities of the compound of Example 1 are prepared in an ophthalmic formulation containing 0.1% polysorbate (Tween 80)--10 mM TRIS. One eye of each experimental animal is treated by applying one 25 ul drop of the drug formulation to the ocular surface, the contralateral eye received 25 ul of vehicle as a control. Intraocular pressure is measured by applanation pneumatonometry immediately before drug administration and at subsequent, predetermined times thereafter. New Zealand albino cross rabbits and cynomolgus monkeys are employed as experimental animals. The data shows that the compound of Example 1 has ocular hypotensive activity.
TABLE 1__________________________________________________________________________CHANGES IN INTRAOCULAR PRESSURE(RABBIT) AT PREDETERMINED TIMES (HR) 1 2 3 4 6__________________________________________________________________________ **5-TRANS PGF.sub.2a -1-OH (0.01%) -1.28 ± 0.68 -3.81 ± 1.16 -2.02 ± 1.44 -1.01 ± 1.16 +0.07 ± 0.92 ** ** **5-TRANS PGF.sub.2a -1-OH (0.1%) +0.41 ± 1.08 -0.95 ± 1.02 -4.27 ± 1.02 -2.97 ± 0.87 -2.82 ± 0.77__________________________________________________________________________CHANGES IN INTRAOCULAR PRESSURE(MONKEY) AT PREDETERMINED TIMES (HR) 1 2 4 6__________________________________________________________________________ ** **5-TRANS PGF.sub.2a -1-OH (0.01%) 0 ± 0.36 -23 ± 0.61 -4.8 ± 0.91 -3.2 ± 0.80__________________________________________________________________________ **P < 0.01 (Student's paired Ttest)
EXAMPLE 3
Comparison of Prostaglandin F 2a and 5-trans Prostaglandin F 2a For
Lowering Intraocular Pressure
Experimental quantities of 5-trans Prostaglandin F 2a and Prostaglandin F 2a were prepared by dissolution in 2% (w/v) Na 2 CO 3 with the pH adjusted to 7.0 by 0.1N HCl. Experimental rabbits were treated by giving one drop to the ocular surface of either a 0.01%, 0.1% or 1% solution so that three treatment groups, each comprising 6-8 animals, were obtained for both 5-trans Prostaglandin F 2a and Prostaglanding F 2a . Intraocular pressure was measured by applanation pneumatonometry at the time of administration and at 0.5, 1, 2, 3, 4, and 6 hours thereafter. Ocular surface hyperemia was visually assessed and described as either absent or present in some degree. The following data were obtained.
TABLE 2__________________________________________________________________________INTROCULAR PRESSURE (mmHg) CHANGES AT PREDETERMINEDTIMES (HR) AFTER PROSTAGLANDIN ADMINISTRATIONPROSTAGLANDIN (DOSE %) 0.5 1.0 2.0 3.0 4.0 6.0__________________________________________________________________________ CHANGES IN INTRAOCULAR PRESSURE (mmHg) AT PREDETERMINED TIMES (HR)5-trans Prostaglandin 0.01% -1.7 -2.1* -3.1** -3.7 -1.2 0F.sub.2α5-trans Prostaglandin 0.1% -- -6.3* -3.0 -3.0 -1.5 0F.sub.2α5-trans Prostaglandin 1.0% -- +3.8* +0.7 -1.5 -3.5 -5.5**F.sub.2αProstaglandin F.sub.2α 0.01% -1.4** -1.2 -2.6* -1.3 -1.2 -0.3Prostaglandin F.sub.2α 0.1% +3.6** -2.7* -4.3* -2.9* +3.9** -1.7Prostaglandin F.sub.2α 1.0% +0.2 +4.8* +5.9** +2.8 -2.2** -4.1** PERCENT ANIMALS EXHIBITING OCULAR SURFACE HYPEREMIA % HYPEREMIA AT PREDETERMINED TIMES (HR)5-trans Prostaglandin 0.01% 33 66 50 50 33 17F.sub.2α5-trans Prostaglandin 0.1% 0 0 0 0 0 0F.sub.2α5-trans Prostaglandin 1.0% 100 100 100 100 100 100F.sub.2αProstaglandin F.sub.2α 0.01% 100 100 66 25 50 12Prostaglandin F.sub.2α 0.1% 100 100 100 87 100 75Prostaglandin F.sub.2α 1.0% 100 100 100 100 100 100__________________________________________________________________________ *p < 0.05, **p < 0.01 according to Students paired t test
Comparison of the data obtained with 5-trans Prostaglandin F 2a and Protaglandin F 2a indicates that they are essentially equipotent as an ocular hypotensive agent. However, Protaglandin F 2a induced ocular hypotension is achieved with a very high incidence of ocular surface hyperemia, whereas for the low (0.01%) and intermediate (0.1%) doses of 5-trans Prostaglandin F 2a similar ocular hypotension is achieved with minimal or, in the case of the 0.1% dose, no ocular surface hyperemia. Moreover, on a dose-effect basis, 5-trans Prostaglandin F 2a is less potent in causing ocular hypertension, an effect which is considered undesirable in glaucoma therapy.
EXAMPLE 4
Preparation of 1-Decarboxyl-1-Carboamino-5-trans Prostaglandin F 2a
and 5trans Prostaglandin F 2a , 1-methyl ester
The named compound may be prepared from 5-trans prostaglandin F 2a , by converting the 1-carboxylic acid group to an amide or a methyl ester by means known in the art.
EXAMPLE 5
Comparison of Compounds of 5-trans Prostaglandin F 2a and the 1-Decarboxyl-1-Carboamino,
Hydroxymethyl, or Methyl Ester
Derivatives Thereof
The above-named compounds are tested for lowering intraocular pressure in monkeys, dogs and rabbits. (See Tables 3, 4 and 5, respectively) The ophthalmic compositions comprising these compounds are prepared and administered as described above for Example 2. As shown below, the methyl ester and the 1-decarboxyl-1-hydroxymethyl derivatives of trans-Prostaglandin F 2a are effective for lowering intraocular pressure in monkeys. Also, the 1-decarboxyl-1-hydroxymethyl derivative of trans-Prostaglandin F 2a is effective for lowering intraocular pressure in dogs, while showing less hyperemia than cis prostaglandin F 2a or the isopropyl derivative thereof. Finally, the 1-decarboxyl-l-carboamino-5-trans prostaglandin F and trans prostaglandin F, 1-methyl ester are effective for lowering the intraocular pressure in rabbits.
TABLE 3______________________________________EFFECTS OF C.sub.1 MODIFIED 5-TRANS PGF.sub.2a ANALOGS ONMONKEY INTRAOCULAR PRESSUREChanges in intraocular Pressure (mm Hg)At Predetermined Times (HR)Compound Dose (%) 1 2 4 6______________________________________5-trans PGF.sub.2a -1- 0.1% -- -1.2* -2.2** -0.5methyl ester5-trans PGF.sub.2a -1-OH 0.1% 0 -2.3** -4.8** -3.2**5-trans PGF.sub.2a -1- 0.1% 0.7 -0.2 0 0CONH.sub.2______________________________________ (*p < 0.05; **p < 0.01; according to Students' paired t test)
TABLE 4______________________________________OCULAR EFFECTS OF C.sub.1 MODIFIED 5-TRANS PGF.sub.2aANALOGS IN DOGSChanges in Intraocular Pressure (mm Hg)At Predetermined Times (HR)Compound Dose (%) 1 2 3 4 6______________________________________5-trans PGF.sub.2a 0.1% -0.5- -1.1 -- -0.7 3.05-trans PGF.sub.2a -1-OH 0.1% 0.8 1.1 -- -0.2 -2.25-trans PGF.sub.2a -1- 0.1% 0.7 -0.2 -- 0 0CONH.sub.2______________________________________ Hyperemia observed for 5trans PGF.sub.2a1-OH was less than would be typically associated with PGF.sub.2a1-OH or PGF.sub.2a1-isopropyl ester a this dose.
TABLE 5__________________________________________________________________________OCULAR EFFECTS OF C.sub.1 MODIFIED 5-TRANS PGF.sub.2a ANALOGS IN RABBITSCompound Dose (%) 1 2 3 4 6 8__________________________________________________________________________Changes in Intraocular Pressure (mm Hg)At Predetermined Times (HR)5-trans PGF.sub.2a -1- 0.01% -0.8 -1.6 0.4 0.3 -0.6 -0.5CONH.sub.2 0.1% 0.1 -2.9 -3.4* -4.0** -3.6** -3.7**5-trans PGF.sub.2a -1- 0.01% 1.0 -0.7 -2.0 -3.4** 0.4methyl ester 0.1% +12.0 +2.6 -0.3 -5.2** -7.5% Animals Exhibiting Ocular SurfaceHyperemia at Predetermined Times5-trans PGF.sub.2a -1- 0.01% 100 100 100 100 87 0methyl ester 0.1% 100 100 100 100 100 100__________________________________________________________________________ (*p < 0.005; **p < 0.01; according to Students' paired t test)
The foregoing description details specific methods and compositions that can be employed to practice the present invention, and represents the best mode contemplated. However, it is apparent for one of ordinary skill in the art that further compounds with the desired pharmacological properties can be prepared in an analogous manner, and that the disclosed compounds can also be obtained from different starting compounds via different chemical reactions. Similarly, different pharmaceutical compositions may be prepared and used with substantially the same result. Thus, however detailed the foregoing may appear in text, it should not be construed as limiting the overall scope hereof; rather, the ambit of the present invention is to be governed only by the lawful construction of the appended claims. | The invention relates to the use of derivatives of F-type prostaglandins as ocular hypotensives. The PGF derivatives used in accordance with the invention are encompassed by the following structure formula I: ##STR1## wherein wavy line attachments indicate either the alpha (a) or beta (b) configuration; hatched lines indicate a configuration, solid triangles are used to indicate b configuration, dashed bonds represent a double bond, or a single bond; n is 0, or an integer of from 1 to 3; X is NH 2 or OR; R is hydrogen, R 4 or a --(CO)R 4 group; R 1 , R 2 , and R 3 independently are hydroxyl, or --O(CO)R 5 groups, wherein R 4 and R 5 independently stand for saturated or unsaturated acyclic hydrocarbon having from 1 to 20 carbon atoms, or --(CH 2 ) m R 6 where m is 0-10 and R 6 is an aliphatic, aromatic or heteroaromatic ring, R 7 and R 8 together are ═O, or independently are hydrogen or alkyl of one to 6 carbon atoms or pharmaceutically acceptable salts thereof. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 10/891,622, filed Jul. 15, 2004 which is a divisional of 10/276,203, filed Nov. 12, 2002, and claims a right of priority based upon PCT Application No. PCT/EP01/05157, filed 07 May 2001 and German Application No. 200 08 413.5 filed 07 May 2000, all of which are hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a detection system for sensing an object in motion relative to a container, especially tubular in design, whereby at least one magnetic unit is associated with the container and/or object, generating as well as measuring magnetic fields, and at least one evaluation device is connected to the magnetic units and serves to receive sensing signals from the magnetic units.
[0004] A detection system of this type is described in U.S. Pat. No. 3,103,976. That particular detection system is used in locating pipes, and especially pipe ends to be joined, in underwater drilling and similar operations. A guide tube, serving as a container extending between a topside derrick and a frame section anchored on the sea bottom, is equipped on its outside with a coil as the magnetic unit generating a magnetic field and with each two search coils respectively mounted above and below the first coil and serving as the magnetic-field measuring magnets. Electric cables connect these various coils with a topside evaluation unit within the derrick. The magnetic-held-generating coil produces a magnetic field inside the guide tube essentially along the longitudinal axis of the tube. That magnetic field also permeates the two magnetic-field-measuring coils. If and when within the guide tube a drill rod, tool, pipe or the like is shifted, the magnetic field in these measuring coils will change as a function of the position of the moving object, leading to a corresponding induction in these coils. It is thus possible to determine when the object concerned has reached one of these magnetic-field-measuring coils or for instance the blowout valve located on the sea bottom.
[0005] That earlier detection system, however, is essentially limited to sensing the position only of the forward end of the moving object, with the positional detection accuracy being determined by its distance from the coils which are mounted along the longitudinal axis of the guide tube, by the coil width in the longitudinal direction, and similar factors.
BRIEF SUMMARY OF THE PREFERRED EMBODIMENTS
[0006] It is the objective of this invention to provide an improved detection system of the type first above mentioned, the improvement consisting in the ability, in simple fashion and with a relatively high degree of accuracy, to determine not only the position of the object relative to the container in the longitudinal direction but also its position in the transverse direction relative to the container.
[0007] In conjunction with the characteristic features specified within the main concept of the claims, this is accomplished in that the magnetic units produce a maximum magnetic flux essentially perpendicular to the direction of relative movement between the object and the container. This causes a change in the magnetic field and in the magnetic flux when the object is close enough to the container that both are located within the magnetic field of the magnetic-field-generating magnetic unit. At the same time, given this position of the object and the container relative to each other, there will be a change in the magnetic field in the direction perpendicular to the relative movement, thus yielding for the evaluation device additional information on the position of the object and the container perpendicular to the direction of relative movement.
[0008] According to this invention, the functionality of the detection system does not depend on whether the container, for instance tubular in design, is stationary while the object moves relative to it, or vice versa, for as long as at least the moving part contains a magnetic element which triggers a corresponding change in the magnetic field between the magnetic units.
[0009] In oil-drilling or similar operations, it may be advantageous in this context if in particular the tubular container constitutes the aforementioned guide tube and the object is the part that moves relative to that tube. The latter should consist of, or contain, a magnetic material at least at the point which is to serve for the detection of the position and orientation of the object relative to the container. That point could for instance be the forward end of the object.
[0010] An object of this type typically moves within the container so that the corresponding magnetic units can be advantageously mounted in an inside area of the container. On the other hand, if the moving object consists of a non-magnetic material while the container is provided with a magnetic element in an appropriate location, the corresponding magnetic units may equally well be mounted on an outside surface of the object. It is also possible, for facilitated access, to position the magnetic units on an outside surface of the container with the generated magnetic field extending through the wall and into the interior of the container.
[0011] In one possible, simple configuration for the precise capture of the moving object the magnetic units are arranged along at least one orientational plane perpendicular to the direction of relative movement. For example, multiple magnetic units may be arranged in a circular array or in some other way depending on the cross-sectional shape of the container, with the possibility of mounting the magnetic units, with equidistant spacing from one another, in the circumferential direction of the container.
[0012] So as not to limit the detection of the object to essentially one such plane, magnetic units may be mounted perpendicular to the direction of relative movement in evenly spaced planar increments. This permits capture in each of these staggered planes as well as detection between these planes by means of suitably interconnected magnetic units.
[0013] Depending on the design of the magnetic unit, it is possible for such a magnetic unit to be switchable between magnetic-field generation and magnetic-field sensing. This can take place even during the course of a measurement. Evidently, such switchability of the magnetic units involves variable polarity of the magnetic units, variable magnetic-field intensity or the like.
[0014] A simple design example of a magnetic-field-generating magnetic unit can be implemented in the form of a permanent magnet.
[0015] For an expanded range of possibilities in object detection per the above, a magnetic unit may be constituted of an electrically powered coil which provides a simple way to permit operation both for magnetic-field generation and magnetic-field measurement. A coil also allows for easy variation of the magnetic-field intensity or polarity and the generation of alternating fields.
[0016] A magnetic-field-measuring unit that is at once precise, simple and inexpensive may be in the form of a magnetic-field sensor and in particular a Hall element. Magnetic-field sensors of that type can be installed, in simple fashion and at low cost, in arrays of the desired density and configuration for instance on the inside of the container.
[0017] Of course, a suitably designed magnetic unit can also detect magnetic attenuation instead of measuring the magnetic field or magnetic flux.
[0018] For an amplification of the magnetic field and thus of the magnetic flux perpendicular to the direction of relative movement, the magnetic unit may incorporate a magnetizable material, for instance a ferromagnetic or paramagnetic material.
[0019] To avoid having to separately provide each magnetic unit with a magnetizable material, the magnetic units may be interconnected by a magnetizable or magnetically conductive material.
[0020] For a secure installation of the magnetic unit, the unit may be placed for instance in a radial bore in the container wall. The radial bore should be at least deep enough in the radial direction for the magnetic unit to be fully insertable without protruding into the interior of the container.
[0021] To avoid having to drill a corresponding number of radial bores or similar recesses in the container wall while at the same time being able to simultaneously manipulate a larger number of magnetic units, it is possible to mount multiple magnetic units in a magnetic-detector insert which may be mounted for instance in a circumferential recess on the inside of the container. This recess can again be deep enough to prevent the magnetic-detector insert with the magnetic units from protruding into the interior of the container.
[0022] Suitably designed magnetic units allow for the deployment in objects with a variety of cross sections. Of course, for oil exploration and similar applications it will be advantageous, and at the same time the data capture for the detection of the object within the container will be simplified, if the container and/or object are essentially tubular in design. In applications related to oil and gas exploration, it is an essentially tubular object that is guided within an equally more or less tubular container. The object can be so guided that it is either in contact with or moves at a distance from the inside wall of the container.
[0023] In another possible, simple and space-saving design, a magnetic unit may be provided with a ramified and/or continuous helical, electrically conductive ribbon. Such a ribbon essentially corresponds to a coil and generates a comparable magnetic field.
[0024] For the convenient manipulation of ribbon-shaped magnetic units of this type, the ribbon may be mounted on a preferably annular insert. The insert, of course, is shaped to correspond to the cross section of the container, permitting easy installation on an inside surface of the container.
[0025] The insert can allow for further simplification in that the necessary electrical power-supply and/or signal-collecting leads are attached to the ribbon-shaped magnetic units mounted in the insert.
[0026] In analogous fashion it is possible in the case of the aforementioned magnetic-detector insert employing electrical coils to provide the electric coils with winding stems as magnetic units. The coils are wound on these winding stems which, like the entire magnetic-detector insert, may consist of a magnetizable material.
[0027] The evaluation especially of the signals received by the magnetic-field-sensing magnetic units is possible not only for determining the position of the object. A suitably equipped evaluation device may include a memory module and/or a display unit or may be connectable to the latter or for instance to a computer. Stored in the memory module may be the necessary mathematical evaluation algorithms and/or address tags permitting the analysis of the measured signals. The display unit may be used, for example, for a graphic illustration of the object or for detecting the object.
[0028] The evaluation device may also be so configured that in addition to merely detecting the presence of the object it also permits the determination of the position, shape, size or direction of movement of the object.
[0029] The analysis of the signals emanating from the magnetic units and the very positioning of the magnetic units can be simplified for instance by aligning the magnetic axes of the magnetic units with a longitudinal axis of symmetry of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The following describes desirable design examples of this invention in more detail with the aid of the figures in the attached drawings in which:
[0031] FIG. 1 is a perspective side view of a first design example of a detection system according to this invention, employing a tubular container;
[0032] FIG. 2 is a top view of a horizontal section through FIG. 1 ;
[0033] FIG. 3 is a perspective side view of a second design example of a detection system according to this invention;
[0034] FIG. 4 shows a partial vertical section through FIG. 3 ;
[0035] FIG. 5 is a perspective side view of a third design example of a detection system according to this invention;
[0036] FIG. 6 is an enlarged illustration of detail “A” in FIG. 5 ;
[0037] FIG. 7 is an enlarged illustration of detail “B” in FIG. 5 ;
[0038] FIG. 8 is a conceptual illustration of a horizontal cross section through a detection system according to this invention;
[0039] FIG. 9 is an illustration as in FIG. 8 with an object in central position;
[0040] FIG. 10 is an illustration as in FIG. 8 with an object in an off-center position;
[0041] FIG. 11 is an illustration as in FIG. 8 with an object in another off-center position;
[0042] FIG. 12 is an illustration as in FIG. 8 with an object in another central position;
[0043] FIG. 13 is a conceptual illustration explaining the magnetic flux; and
[0044] FIG. 14 shows in detail an area-array element per FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] FIG. 1 depicts a first design example of a detection system 1 according to this invention, with a tubular container 2 and a similarly tubular object 3 . The container extends for instance from an ocean-surface platform, not shown, to a frame section anchored on the sea floor. Inside the container 2 the object 3 is guided in the longitudinal direction 33 i.e. in the direction of relative movement 14 . The object may for instance be a section of a drill rod, a tool or similar implement employed in submarine oil exploration.
[0046] In an orientational plane 16 which extends perpendicular to the direction of relative movement 14 , the container 2 accommodates a number of magnetic units 4 to 9 . These are housed in corresponding radial bores of the container 2 and support at least one electric coil 17 each. The central axes of the coils 17 are positioned in the orientational plane 16 and point toward the center of the longitudinal bore 36 . All magnetic units 4 to 9 are mounted in an equidistant relation to one another on the inside 15 along the internal circumference of the container 2 . The coils 17 are positioned within the radial bore 19 so that the magnetic units 5 to 9 will not protrude past the inner surface 15 into the longitudinal bore 36 .
[0047] Each coil 17 connects to the appropriate electrical leads 35 which extend outward away from the container 2 from where they are bundled in omnibus cables, not shown, and run for instance to a topside point.
[0048] At least magnetic unit 4 is a magnetic-field-generating magnetic unit. Its magnetic field is modified by the object 3 which at least in part consists of a magnetizable or magnetically conductive material 18 , and the magnetic field, modified by the movement and changed position of the object 3 relative to the longitudinal bore 36 , can be captured by the magnetic-field-sensing magnetic units 5 to 9 . By way of their electrical leads 35 , the magnetic units 5 to 9 thus generate a corresponding induced voltage as a function of the magnetic flux permeating them and changing with time.
[0049] Instead of arranging the magnetic-field-generating magnetic unit 4 and the corresponding magnetic-field-sensing magnetic units 5 to 9 in one single plane 16 per FIG. 1 , it is also possible to position the magnetic-field-sensing magnetic units for instance partly or entirely in different orientational planes which are spaced at a distance from and offset upward and/or downward relative to the orientational plane 16 per FIG. 1 .
[0050] FIG. 2 shows a horizontal section through FIG. 1 in the area of the orientational plane 16 and more specifically in the area where magnetic unit 7 is located. The radial bore 19 in a wall 37 of the container 2 opens toward the inside surface 15 while at its opposite end a wire duct 38 allows the electrical leads 35 to run from the coil 17 to the outside and away from the longitudinal bore 36 . The wire duct 38 can be closed off with a cap 39 through which the leads 35 are passed via a water-tight seal.
[0051] The magnetic-field-generating magnetic unit 4 per FIG. 1 is configured in analogous fashion. It should be mentioned at this point that all magnetic units per FIG. 1 are capable of serving as magnetic-field-generating or magnetic-field-sensing magnetic units. For example, magnetic units 6 , 7 and 8 may be used as the magnetic-field-sensing units and the magnetic units 4 , 5 and 9 as the magnetic-field-generating units. Obviously, any arbitrary assignment of these magnetic units is possible both before and during a given detection process.
[0052] FIG. 3 is a perspective view, corresponding to FIG. 1 , of a second design example of the detection system 1 according to this invention. In this figure and in the figures that follow as well as in FIGS. 1 and 2 , identical components bear identical reference numbers which will be mentioned only occasionally.
[0053] FIG. 3 differs from FIG. 1 by the consolidation of the magnetic units 4 to 10 in one magnetic detection insert 20 consisting of a magnetizable or magnetically conductive material 18 . The magnetic detection insert 20 is suitably mounted in a circumferential recess 21 on the inside 15 of the wall 37 of the container 2 . The magnetic detection insert 20 has an essentially U-shaped cross section. The open end of the U-profile faces inward in the direction of the longitudinal bore 36 . Located at given points in the annular gap 40 between the legs of the U-profile is a winding stem 28 consisting of a magnetizable material and radially extending parallel with the U-legs toward the inside in the direction of the longitudinal bore 36 . Wound onto each such winding stem 28 is a coil 17 of the respective magnetic unit 4 to 10 . These magnetic units, i.e. coils, are arranged in one orientational plane 16 analogous to FIG. 1 . It should be pointed out again that similar magnetic detection inserts can be mounted in more than one orientational plane.
[0054] FIG. 4 shows a partial vertical section through the design example per FIG. 3 . It clearly illustrates that the coil 17 is wound on the winding stem 28 and that the associated electrical leads 35 of the coil 17 run through a hole in the wall 37 to the outside in a radial direction relative to the container 2 . As has been explained in connection with FIG. 1 , the various magnetic units 4 to 10 may be optionally set to operate as magnetic-field-generating or magnetic-field-sensing units.
[0055] FIG. 5 is a perspective view, analogous to FIGS. 1 and 3 , of a third design example of the detection system according to this invention.
[0056] In this design example, the magnetic units 4 to 11 are in the form of ribbons 22 applied on an insert 23 by a thin-film or similar technology process. The ribbons extend in a ramified and/or helical configuration. Each ribbon is provided at one end with an electrical connector 41 and at the other end with a corresponding electrical connector 42 for supplying power or collecting sensing signals. On the outside of the insert 23 opposite the longitudinal bore 36 the contacts 41 , 42 are connected, for instance as shown in FIG. 6 , to electrical power supply lines 24 , 25 or electrical signal-processing lines 26 , 27 . These electrical lines 24 , 25 and 26 , 27 , for instance as shown in FIG. 7 , can be switched to serve either as power-supply or signal-processing lines, thus affording the option of using the magnetic units.
[0057] The insert 23 consists of a thin ring of a magnetizable material which allows easy mounting on the inside wall 15 of the container 2 in essentially any desired location. Similar inserts 23 can be mounted in different orientational planes as described in connection with FIGS. 1 and 3 .
[0058] At one point the insert 23 , by way of its leads 24 to 27 , is connected to an evaluation device 12 which in the case of submarine oil exploration is typically located in a suitable place on a surface platform. For other applications of the detection system according to this invention, such as land-based oil exploration, the evaluation device 12 will be set up in a conveniently accessible location.
[0059] In the design example per FIG. 5 , the evaluation device 12 incorporates for instance a memory module 29 for saving the incoming sensing signals or for storing appropriate programs for the analysis of these sensing signals. The sensing signals, processed as necessary, can be viewed on a display monitor 30 connected to the evaluation device 12 . The evaluation device 12 may be computerized or connected to a remote computer 31 which may also allow the evaluation device to be programmed for instance to switch the magnetic units into the magnetic-field-generating or, respectively, magnetic-field-sensing mode.
[0060] At this juncture it should be mentioned that the magnetic-field-generating magnetic units may also be in the form of permanent magnets, for one example. The magnetic-field-sensing magnetic units on their part may be in the form of magnetic sensors such as Hall elements.
[0061] The evaluation device 12 also offers the possibility to change the polarity or field intensity of the magnetic field generated. Alternating magnetic fields can also be produced.
[0062] FIGS. 8 to 12 are conceptual illustrations of the detection system 1 according to this invention, showing different magnetic units 4 to 11 without an object 3 ( FIG. 8 ) and, respectively, with different objects in different positions within the container 2 .
[0063] FIG. 8 shows the magnetic field generated by the magnetic unit 4 , unaffected, as in FIG. 1 , by any object 3 . The corresponding magnetic-field flux lines 43 extend perpendicular to the longitudinal bore 36 and flow to the respective magnetic-field-sensing magnetic units 5 to 11 . The distance of the magnetic-field-sensing magnetic units 5 to 11 from the magnetic-field-generating magnetic unit 4 determines the extent to which the flux lines permeate the magnetic units. The magnetic flux itself varies accordingly.
[0064] The magnetic units 4 to 11 are arranged in a way that they, and in particular their respective magnetic axes 32 as shown for instance in FIG. 9 , are oriented toward a central point 34 in the longitudinal bore 36 , i.e. toward an axis of symmetry 34 which extends in the longitudinal direction 33 per FIG. 1 .
[0065] When an object 3 moves relative to the container 2 , the result will be a change in the path of the magnetic flux lines, as shown in FIGS. 9 to 11 . In FIG. 9 the object 3 is positioned at dead center 34 , causing a correspondingly symmetrical flux-line distribution pattern. In FIG. 10 , the object is situated off-center and close to the magnetic-field-generating magnetic unit 4 .
[0066] In FIG. 11 , the object 3 is again in an off-center position, in this case close to the magnetic-field-sensing magnetic unit 9 .
[0067] From the respective changes in the magnetic fields and the magnetic flux, detectable by the magnetic-field or magnetic-flux-sensing units 5 to 11 , conclusions can be drawn as to the presence of the object 3 in the vicinity of the magnetic unit as well as the distance between the object 3 and the individual magnetic units, the orientation and dimensions of the object 3 and its direction of movement. By means of appropriate imaging processes in the evaluation device 12 , for instance as shown in FIG. 5 , it is possible to view on the display monitor 30 the object 3 , its position, orientation, size and movement.
[0068] FIG. 12 shows an object 3 larger in overall dimensions and wall thickness, with corresponding changes in the magnetic field and magnetic flux pattern. FIG. 12 thus shows what other conclusions are possible in terms of the dimensions of the object 3 .
[0069] FIG. 13 is a simplified representation of a magnetic-field-generating magnetic unit 4 , the magnetic field and flux line 43 generated by it, and the respective magnetic flux 13 through different area-array elements 44 . Traditionally, the magnetic flux is determined by the following equation:
ϕ = ∫ Δ Bx ⅆ A
where
φ is the magnetic flux, B is the magnetic induction and dA is an infinitesimal vectorial area-array element. According to the invention, the magnetic units 4 to 11 are so arranged that the respective magnetic flux displays its maximum value perpendicular to the relative movement between the object and the container, meaning that the scalar product derived from magnetic induction and the vectorial area-array element takes on its maximum value for the respective area-array elements per FIG. 13 .
[0070] FIG. 14 is a conceptual illustration showing that for each area-array element 44 the magnetic flux derives from the scalar product of magnetic induction B und ΔA as the vectorial area-array element. The applicable equation is a follows:
φ=|β| x|ΔA|x cos α
where
α is the corresponding angle 46 between the vectors B and ΔA.
[0071] The following will briefly explain the operating mode of the detection system according to this invention with reference to the attached drawings.
[0072] By way of the magnetic flux and/or the magnetic attenuation, the detection system according to this invention measures any given object of any given shape, orientation, position and geometry within a magnetic field generated inside a container 2 . One or several magnetic units serve to generate the magnetic field and the corresponding magnetic flux. One or several additional magnetic units capture the magnetic flux that has been modified by the object and its movement or location and on the basis of the sensing signals received it is possible to determine the distance between the object and these magnetic units as well as the position, size and direction of movement of the object. The magnetic-flux-based measurement can take place in static and/or dynamic fashion through alternating fields, variable field intensity and variable polarity.
[0073] The magnetic-field-generating magnetic units may be in the-form for instance of a permanent magnet or electrically powered and controlled coil. The magnetic-field-sensing magnetic units can measure the magnetic flux produced in static fashion employing Hall elements and/or in dynamic fashion by way of electromagnetic induction. The configuration and the number of the magnetic-field-sensing and magnetic-field-sensing magnetic units are variable, and especially when coils are used as the magnetic units a switchover between the magnetic-field-generating and the magnetic-field-sensing mode of the magnetic units is easily accomplished.
[0074] The sensing signals are evaluated using mathematical operations and/or address tags and it is possible to display them in graphic form on a display monitor per FIG. 5 , showing the shape and position of the object under analysis.
[0075] The magnetic units can be arranged in a circular or other configuration in one or several planes and they are typically interconnected via a magnetically conductive or magnetizable material. The multiplicity of the different magnetic units and their utilization for generating or sensing and measuring magnetic fields produce magnetic flux patterns between all associated magnetic units which patterns, and any changes thereof, are used for the imaging and positional determination of the object to be measured. The varying magnetic flux is analyzed by appropriate metrics for a determination of the size, shape and position of drill pipes including their tool joints and any associated tools. It is also possible to detect the direction when the pipes or tools constituting the objects within the tubular container are moved. The magnetic units can further recognize drill pipes which are in contact with one of the inside walls of the container, causing the dreaded friction-induced wash-out of the equipment. | The invention relates to a measuring device for detecting a body moving in relation to an, in particular, tubular container. Said device comprises at least one magnet unit which generates a magnetic field, measures this magnetic field and which is assigned to the container and/or to the magnetic body. The device also comprises at least one evaluation device connected to the magnet units and provided for receiving measurement signals of the magnet units. The aim of the invention is to improve a measuring device of this type in order to be able to easily determine, in addition to the position of the body in relation to the container in a longitudinal direction, the position of the body in relation to the container in the transverse direction with a relatively high level of accuracy. To this end, the magnet units comprise a maximum magnetic flux that is essentially perpendicular to the direction of the relative motion of the body and container. | 6 |
FIELD
[0001] This relates to a method and apparatus for capturing LPGs using a separator vessel.
BACKGROUND
[0002] Hydrocarbon producing wells are often stimulated in order to enhance production. A fracing operation is a common method of stimulating a well. Propane is among the many types of frac fluids that may be used in the fracing operation. Propane has the advantage of being pumped into the well in liquid or gel form, and exiting the well as a gas. GasFrac Energy Services Inc. of Calgary, Alberta uses a proprietary liquefied petroleum gas in fracing operations. Other frac fluids may include propane, butane, or mixtures thereof.
SUMMARY
[0003] There is provided a method of recovering liquid petroleum gases (LPGs) from a wellbore, the wellbore having a wellbore pressure, the method comprising the steps of: performing a well treatment operation by injecting the LPGs into the wellbore to increase the wellbore pressure; flowing a fluid stream from the wellhead into a separation vessel, the fluid stream comprising the LPGs; reducing the pressure of the fluid stream from the wellbore pressure to a separation vessel pressure, the fluid stream in the separation vessel comprising the LPGs in liquid form and in vapour form; separating the vapour form from the liquid form; transferring the liquid form of the LPGs to a pressure vessel; and passing the vapour form through a condenser to condense the vapour form, and depositing the condensed vapour form into the pressure vessel.
[0004] According to another aspect, the liquid petroleum gases may comprise at least 80% propane by weight, or at least 90% propane by weight, or at least 80% butane by weight, or at least 90% butane by weight.
[0005] According to another aspect, the separation vessel pressure may be less than 500 psi, or less than 200 psi, or less than 100 psi, or less than 75 psi.
[0006] According to another aspect, the well treatment operation may be a fracturing operation.
[0007] According to another aspect, passing the vapour form through a condenser may comprise filtering the condensed liquid petroleum gases to remove entrained water and solid particles prior to condensing the vapour form.
[0008] According to another aspect, the method may further comprise the step of analyzing the composition of the fluid stream, and activating a heater to heat the fluid stream between the wellbore and the separation vessel in order to vapourize the LPGs once the LPG component of the fluid stream drops below a predetermined threshold.
[0009] According to another aspect, the method of claim 10 , wherein analysing the composition of the fluid stream comprises analysing the vapour phase, the liquid phase, or both exiting the separation vessel.
[0010] According to another aspect, the method may further comprise the step of, once the heater is activated, transferring hydrocarbon liquids from the separation vessel to a production fluid facility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to be in any way limiting, wherein:
[0012] FIG. 1 is a block diagram of an arrangement for recapturing LPGs (liquid petroleum gases) pumped into a wellbore
[0013] FIG. 2 is a block diagram of an arrangement for recapturing LPGs with heaters
[0014] FIG. 3 is a detailed block diagram of an arrangement for recapturing LPGs.
[0015] FIG. 4 is a side elevation view of a separation tank.
DETAILED DESCRIPTION
[0016] Referring to FIG. 1 , there is shown equipment that may be used in a method to capture LPGs used in a well treatment operation. During a wellbore treatment procedure, treatment fluid is pumped through a wellhead 12 into a wellbore 14 . In the examples discussed below, the treatment fluid is one or more type of LPGs (liquid petroleum gases). The LPGs are pumped into the wellbore 14 to cause the wellbore pressure to reach the desired treatment pressure. Once the well treatment operation has been concluded, it is desireable to recapture as much of the LPGs as possible such that they may be reused.
[0017] LPGs are a useful treatment fluid as they tend to avoid damage to the formation, and tend to mix well with the formation fluids. In this document, LPGs are hydrocarbons or hydrocarbon mixtures whose characteristics are selected that, at standard ambient temperature and pressure, they exist as a gas, and they exist as a liquid under conditions used for the well treatment operation. For example, a hydrocarbon or hydrocarbon mixture will be considered an LPG for the purposes of this patent document if it is a gas at standard ambient temperature and pressure (SATP) but is a liquid under when used in downhole operations. Examples of LPGs include propane, propane mixtures that include 80% propane or more, or 90% propane or more by weight, mixtures of propane and butane, butane, butane mixtures that include 80% butane or more, or 90% butane or more by weight, etc. Other LPGs may include ethane, isobutene, pentaines, etc., depending on the circumstances. The most common type of well treatment operation is a hydraulic fracturing operation, where fluid is pumped under pressure to apply a pressure that is greater than the formation fracture pressure in order to stimulate the well. The formation fracture pressure is the point at which a formation will crack. The actual pressure that needs to be applied will depend on many factors, such as the depth of the zone, the water depth the air gap, the formation pore pressure, etc. Proppant, such as sand, is pumped down with the treatment fluid in order to keep the fractures open once the pressure is released.
[0018] Once the treatment operation is complete, the pressure must be relieved by flowing back the treatment fluid. It is important that the fluid not be flowed back too quickly, otherwise the formation fractures may become clogged due to sand that flows out with the treatment fluid. Referring to FIG. 1 , when flowing back a well, a fluid stream is allowed to exit wellhead 12 through line 16 . As shown, the fluid stream exits wellhead 12 and passes through a pressure control device, such as a choke 18 and an emergency shut down valve (ESD) 20 . Choke 18 controls the pressure and flow rate of the fluid stream. For example, choke 18 may limit the pressure to between 50 psi and 200 psi. The actual pressure may be outside this range, and will depending on the characteristics of the well (i.e. to prevent the fractures from being filled with sand) and will also depend on the pressure ratings of equipment downstream of wellhead 12 . A preferred flowback pressure is between 65 psi and 100 psi, although it may be as high as allowed by the pressure vessels and the preferences of the user. ESD 20 is a safety device that will stop the fluid stream if there is a problem. As the LPGs are volatile fluids and are at high pressures, ESD 20 is an important safety feature. The system also includes a number of check valves 21 for safety reasons.
[0019] It has been found that the fluid stream is made up primarily of the LPGs used to treat the wellbore when the well is first flowed back. This allows the user to capture LPGs as they flow from wellhead 12 in liquid form as shown in FIGS. 1 and 3 , and will be described below. As more fluids are flowed out of wellhead 12 , more contaminants will rise with the LPGs, making it necessary to separate the LPGs from these contaminants. While water and sand will not dissolve in the LPGs, crude oil and other hydrocarbons will dissolve in the LPGs, making it necessary to flash off the LPG's once the amount of undesireable hydrocarbons exceeds a certain threshold.
[0020] Referring to FIG. 3 , line 16 is connected to a separation vessel 22 . Referring to FIG. 4 , separation vessel 22 is a pressure vessel capable of withstanding up to the desired flowback pressure, i.e. the flowback pressure and the separation vessel pressure will be equivalent. In many circumstances, a pressure rating of up to 285 psi would be sufficient, although the pressure rating may be up to 500 psi, 200 psi, 100 psi or 65 psi. As can be seen, separation vessel 22 includes a first zone 24 with a first outlet 25 , a second zone 26 with a second outlet 27 , a third zone 28 with a third outlet 34 , and a fourth zone 30 (for vapour) with a fourth outlet 36 . Separation vessel also has an inlet 32 that depicts the fluid stream into first zone 24 .
[0021] Referring to FIG. 1 , as mentioned above, choke 18 controls the pressure to less than 200 psi, and preferably around 100 psi or less. This represents a significant pressure drop from the pressure in wellbore 14 , where the pressure will be at the wellbore treatment pressure to begin with. The pressure drop across choke 18 will cause a drop in temperature for any vapours exiting wellhead 12 , such that the primary component of the fluid stream will be liquids. Referring to FIG. 3 , these liquids enter separation vessel 22 via inlet 32 . As depicted, separation vessel 22 is in a configuration to capture LPGs in liquid form in the fluid stream. As the fluid stream is primarily LPGs with little contaminants at the beginning, this may be done by drawing liquids out of first zone 24 through first outlet 25 and into a holding tank 37 via line 35 . As there will be some LPGs in vapour state, these vapours are captured in fourth zone 30 and removed through line 33 via fourth outlet 36 . These vapours pass through a condenser stage 38 , through a flash tank 40 and into holding tank 37 . Condenser stage 38 may include a chiller 42 , a coolant holding tank 44 , and coolant pumps 46 that pump coolant through a heat exchanger 48 that is used to condense the LPG vapour. There may also be some sample catchers 50 that are used to analyse the components of the gas. Referring to FIG. 1 , there may also be some filters, such as aerolecent and coalescent filters 52 and 54 that remove water and dust, sand or other solid particles from the LPG vapour stream. In addition, each of these tanks is preferably connected to a flare stack 56 as a safety measure and also to flare of any vapours that are not condensed at the end of the process. It will be noted that, in FIG. 1 , the liquid LPGs are placed in a different holding tank, labelled 58 , than holding tank 37 as shown in FIG. 3 . It will be understood that the ultimate destination of the recaptured LPGs is at the user's discretion, and may also include a pipeline or other capture/processing facility.
[0022] As noted above with reference to FIG. 3 , there may be one or more sample collectors 50 that are used to analyze the composition of the LPG vapour stream through line 33 . This is used to determine whether the LPG stream is sufficiently pure to continue capturing liquid LPG directly from separation vessel 22 . Other analyzers may also be used, and may also be positioned in different locations, such as on line 16 , line 35 , or any other convenient location that will permit meaningful results. Once a certain threshold of hydrocarbon contaminants in the fluid stream is reached, the configuration of the equipment shown in FIGS. 1 and 3 is changed to heat the fluid stream in order to flash off the LPGs. The threshold will depend on the desired quality of LPGs. For example, the threshold may be at 98% LPGs by weight, 95% LPGs by weight, 90% LPGs by weight, 85% LPGs by weight, or 80% LPGs by weight, or any percentage therebetween. The desired purity will depend on how the LPGs will be processed afterward and what they are intended to be used for. A higher purity may be achieved by activating the heaters earlier.
[0023] An example of a heating strategy is shown in FIG. 2 , where line heaters 60 are included. As shown, line heaters 60 are used to heat the fluid stream as it flows out of wellhead 12 in order to cause the LPGs to flash off. The heated fluid stream enters separation vessel 22 . As shown in FIG. 2 , line heaters 60 may be powered by LPGs that are collected from the fluid stream, and may also heat a coolant fulid that is pumped via pump 62 through a loop 64 in separation vessel 22 and also a loop 66 in flash tank 40 . The capacity of line heaters 60 will depend on the heating requirements. There should be sufficient heat to cause the LPGs to flash off from the fluid stream and to prevent freezing of any components. The amount of heating may be calculated by a person of ordinary skill based on the phase change characteristics of the particular LPG being recovered, the temperature of the fluid stream before heaters 60 , the pressure of the fluid stream, etc.
[0024] Once heaters 60 are in use, the operation of separation vessel 22 may change. For example, referring to FIG. 4 , while liquid LPGs were previously withdrawn from first zone 24 , crude oil or other liquid hydrocarbons that have not flashed may be collected in this zone 24 . Alternatively, if there is a significant sand component and water component, zone 24 may be used to collect the sand, zone 26 may be used to collect the water, and zone 28 may be used to collect the crude oil, such that outlet 25 withdraws sand and other solids, second outlet 27 withdraws water and third outlet 34 withdraws oil. If there is no sand component, or no water component, zone 26 may also be used to collect the crude oil. The crude oil that is collected may be transferred to production tanks 68 as shown in FIG. 2 . Throughout the process, vapour zone 30 is used to collect the LPG vapours, which are condensed using similar techniques to those discussed previously with respect to the vapour present when the liquid LPGs were recovered directly.
[0025] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
[0026] The following claims are to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, and what can be obviously substituted. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. | A method of recovering liquid petroleum gases (LPGs) from a wellbore includes: performing a well treatment operation by injecting the LPGs into the wellbore to increase the wellbore pressure; flowing a fluid stream from the wellhead into a separation vessel, the fluid stream comprising the LPGs; reducing the pressure of the fluid stream from the wellbore pressure to a separation vessel pressure, the fluid stream in the separation vessel comprising the LPGs in liquid form and in vapour form; separating the vapour form from the liquid form; transferring the liquid form of the LPGs to a pressure vessel; and passing the vapour form through a condenser to condense the vapour form, and depositing the condensed vapour form into the pressure vessel. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to lid openers for use in motor vehicles for remotely controlling or unlatching a lid, such as a filler cap, a trunk lid or the like. More specifically, the present invention relates to the lid openers of a double lever type having two control levers for remotely controlling or unlatching two lid members respectively.
2. Description of the Prior Art
In order to clarify the task of the present invention, one conventional lid opener will be briefly described with reference to FIGS. 10 and 11 of the accompanying drawings.
As is seen from FIG. 10, the lid opener 100 shown is of a double lever type. The lid opener 100 is arranged on a vehicle floor “F”, more specifically, on a base member 102 tightly held by a cross member 104 of the vehicle body.
The lid opener 100 comprises two, viz., longer and shorter control levers 106 and 108 which are pivotally disposed about a common shaft 110 held by the base member 102 . The two control levers 106 and 108 have rear ends 106 a and 108 a from which respective wires 112 ( 114 ) extend to respective latch mechanisms of a trunk lid and a filler cap. The two control levers 106 and 108 are biased to assume horizontal rest positions by respective biasing springs 116 and 118 . When the longer control lever 106 is pulled up against the biasing force of the spring 116 , the wire 112 is driven in a direction to cancel a latched condition of the latch mechanism of the trunk lid. Upon this, the trunk lid becomes unlatched and thus can be opened. While, when the shorter control lever 108 is pulled up against the force of the spring 118 , the wire 114 is pulled to unlatch the filler cap.
For ease with which the two control levers 106 and 108 are manipulated by a driver, such lid opener 100 is arranged just beside the driver's seat, that is, in a limited space defined between the driver's seat and the driver's door.
However, due to inherency originating from the position where the lid opener 100 is located, it often happens that the lid opener 100 is strongly stepped on by the driver at his or her ingress and egress into and from the vehicle cabin, which tends to cause damages of the control levers 106 and 108 .
For eliminating such drawbacks, various measures have been hitherto proposed, which are, for example, covering the lid opener 100 with a cover member, using a much thicker metal plate as the material of the control levers 106 and 108 , locating the lid opener 100 away from such limited space, etc.,. However, even these measures have failed to provide users with satisfaction. In fact, such measures tend to induce a bulky, costly and/or ill-handy lid opener.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a lid opener which is free of the above-mentioned drawbacks.
According to the present invention, there is provided a lid opener which is so constructed that when a marked stress is applied to a control lever of the lid opener due to accidental stepping by a passenger, the control lever becomes supported by at least three supporting points thereby minimizing the force actually applied to each point. Thus, undesired deformation and damage of the control lever is suppressed.
According to a first aspect of the present invention, there is provided a lid opener for use in a vehicle having a body and a floor. The lid opener comprises a base member adapted to be secured to the body; a control lever pivotally connected to the base member, the control lever including front and rear portions which are defined with respect to the pivoted portion, the rear portion being connected through a power transmitting member to a latch mechanism of a lid member, the control lever being capable of canceling a latched condition of the latch mechanism when pivoted in a normal direction from a rest position to a work position; biasing means for biasing the control lever to assume the rest position; a first stopper structure including the rear portion of the control lever and a part of the base member, the rear portion being kept in contact with the part of the base member when the control lever assumes the rest position; and a second stopper structure including a part of the control lever and a stopper member which is defined by either one of the vehicle floor and the base member, the part of the control lever being brought into abutment with the stopper member when, upon receiving a marked stress, the control lever is pivoted from the rest position in a direction opposite to the normal direction.
According to a second aspect of the present invention, there is provided a lid opener unit for use in a vehicle. The vehicle has a hollow cross member mounted on a vehicle floor, and the hollow cross member has in a wall thereof an opening. The lid opener unit includes a base member installed in and secured to the hollow cross member near the opening; a control lever pivotally connected to the base member, the control lever including front and rear portions which are defined with respect to the pivoted portion, the front portion being exposed to the outside through the opening, the rear portion being connected through a power transmitting member to a latch mechanism of a lid member, the control lever being capable of canceling a latched condition of the latch mechanism when pivoted in a normal direction from a rest position to a work position; biasing means for biasing the control lever in a direction to assume the rest position; a first stopper structure including the rear portion of the control lever and a part of the base member, the rear portion being kept in contact with the part of the base member when the control lever assumes the rest position; and a second stopper structure including a part of the control lever and a stopper member which is defined by either one of the vehicle floor and the base member, the part of the control lever being brought into abutment with the stopper member when, upon receiving a marked stress, the control lever is pivoted from the rest position in a direction opposite to the normal direction.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a view of the interior of a vehicle cabin, showing a double lever type lid opener of a first embodiment of the present invention;
FIG. 2 is a front view of the double lever type lid opener of the first embodiment;
FIG. 3 is a plan view of the double lever type lid opener of the first embodiment;
FIG. 4 is view similar to FIG. 2, but showing a condition wherein control levers are pulled up;
FIG. 5 is a view similar to FIG. 2, but showing a condition wherein the control levers are trampled;
FIG. 6 is a front view of a double lever type lid opener which is a second embodiment of the present invention;
FIG. 7 is art enlarged view of the portion indicated by an arrow “VII” in FIG. 6;
FIG. 8 is a plan view of the double lever type lid opener of the second embodiment;
FIG. 9 is a partial and enlarged perspective view of a base member employed in the lid opener of the second embodiment;
FIG. 10 is a front view of a conventional double lever type lid opener; and
FIG. 11 is a plan view of the conventional double lever type lid opener.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring to FIGS. 1 to 5 , there is shown a double lever type lid opener 100 A which is a first embodiment of the present invention.
As is seen from FIG. 1, a major section of the lid opener 100 A is installed in a hollow cross member 10 of a vehicle body at a position between a side sill 12 and a driver's seat 14 .
In the following, directional terms, such as “right”, “left”, “front”, “rear”, “rightward”, “leftward”, “forward”, “rearward” and the like are to be understood with respect to the driver sitting on the seat 14 .
Although not shown in the drawing, a front right door (viz., driver's door) is arranged on the side sill 12 , which closes and opens a door opening defined above the side sill 12 . In the illustrated embodiment, a front portion of the driver's seat 14 is disposed on the cross member 10 through a pair of seat sliders 16 . Denoted by reference “F” is a floor of the vehicle.
The hollow cross member 10 is formed at its front wall with a rectangular opening 18 through which front portions of the control levers 20 and 22 are projected forwardly. Thus, a driver sitting on the seat 14 can easily handle the control levers 20 and 22 only by extending down his or her right hand toward the levers 20 and 22 . Denoted by numeral 24 is a base member of the lid opener 10 A, which is secured via a bolt 26 to the cross member 10 for supporting essential parts of the double lever type lid opener 100 A.
As is seen from FIGS. 2 and 3, the lid opener 100 A comprises two, viz., longer and shorter control levers 20 and 22 which are pivotally disposed about a common pivot shaft 28 which is held by the base member 24 . The levers 20 and 22 and the base member 24 are constructed of reinforced plastics, such as reinforced polyacetal resin or the like. However, if desired, these members 20 , 22 and 24 may be constructed of metals. For increased strength, each lever 20 or 22 is shaped to have a generally L-shaped cross section. Furthermore, each lever 20 or 22 has at the front exposed part a convexly curved upper edge (no numeral).
The base member 24 comprises a front flat part 24 a bolted to the front wall of the cross member 10 , a middle flat part 24 b extending rearward from the front flat part 24 a, an upper cover part 24 c extending laterally from an upper end of the middle flat part 24 b and an inclined rear part 24 d. The common shaft 28 is held by the middle flat part 24 b. The middle flat part 24 b is formed at its lower portion with a stopper projection 24 e which extends rightward in FIG. 1, that is, toward the shorter control lever 22 . The shape of the stopper projection 24 e may be imaged from the drawing of FIG. 8 .
As is seen from FIG. 3, the longer control lever 20 has a recess 20 x in which the shorter control lever 22 is snugly received.
As is seen from FIG. 2, the longer control lever 20 has at a front end a thinner grip portion 20 a which is shaped to be easily gripped by an operator (viz., driver). A rear end 20 b of the longer control lever 20 is connected to the inclined rear part 24 d of the base member 24 through a biasing spring 30 . Due the force of this spring 30 , the longer control lever 20 is biased to assume its horizontal rest position as illustrated by a solid line in FIG. 2. A wire connector 20 c is provided on the rear end 20 b of the control lever 20 , which holds one end of a wire 32 extending from a latch mechanism of a trunk lid. A guide member 34 is pivotally held by the inclined rear part 24 d of the base member 24 , through which the wire 32 passes. When thus the longer control lever 20 is pulled up against the force of the biasing spring 30 , the wire 32 is driven in a direction to cancel a latched condition of the latch mechanism of the trunk lid. Upon this, the trunk lid becomes unlatched and thus can be opened. As will be described in detail hereinafter, when the longer control lever 20 is pulled up to its uppermost position as illustrated by a phantom line in FIG. 2, the wire connector 20 c of the lever 20 abuts against the stopper projection 24 e of the base member 24 . That is, the stopper projection 24 e functions to suppress excessive upward pivoting of the longer control lever 20 .
It is now to be noted that the shorter control lever 22 has substantially the same construction as the above-mentioned longer control lever 20 except that in the shorter control lever 22 , a wire connected to the rear end of the lever 22 extends to a latch mechanism of a filler cap. That is, when the shorter control lever 22 is pulled up against the force of a corresponding biasing spring, the latch mechanism of the filler cap becomes unlatched ant thus the filler cap can be opened. Also in this case, the stopper projection 24 e functions to suppress excessive upward pivoting of the shorter control lever 22 .
In the first embodiment 100 A, the following measures are further employed.
That is, as is seen from FIG. 2, front and rear stopper portions 20 A and 20 B are defined at front and rear portions of the control lever 20 . The front stopper portion 20 A is constituted by a downwardly protruded part of the front portion of the lever 20 , and the rear stopper portion 20 B is constituted by an upwardly protruded part of the rear portion of the lever 20 . That is, when the longer control lever 20 assumes the horizontal rest position as shown in FIG. 2, the rear stopper portion 20 B abuts against the upper cover part 24 c of the base member 24 leaving a predetermined space “Sa” between the front stopper portion 20 A and the vehicle floor “F”.
It is to be noted that the thickness of the space “Sa” is determined smaller than a moved distance which is exhibited by the front stopper portion 20 A when the latter is subjected to a maximum resilient deformation, that is, when the lever 20 is strongly stepped by a passenger (viz., driver). Preferably, the thickness of the space “Sa” is smaller than about 5 mm.
It is to be noted that the above-mentioned measures of the longer control lever 20 are not needed by the shorter control lever 22 . However, if desired, such measures may be applied to the shorter one.
In the following, operation will be described with the aid of the drawings.
For ease of understanding, the description will be commenced with respect to a rest condition of the lid opener 100 A wherein both the longer and shorter control levers 20 and 22 assume their horizontal rest positions, as is seen from FIG. 2 .
When the longer control lever 20 is pulled up against the force of the spring 30 , the wire 32 is driven in a direction to cancel the latched condition of the latch mechanism of the trunk lid. Thus, the trunk lid becomes unlatched and thus can be opened. As is mentioned hereinabove, due to provision of the stopper projection 24 e against which the wire connector 20 c of the lever 20 can abut, the upper work position of the longer control lever 20 is assured. When then the longer control lever 20 is released, the lever 20 is returned to the horizontal rest position of FIG. 2 due to the force of the spring 30 .
When the shorter control lever 22 is pulled up, the latched condition of the filler cap becomes canceled and thus the filler cap can be opened, like in the case of the above-mentioned trunk lid.
When, with the lid opener 100 A assuming the rest condition, a remarkable force “P” is suddenly applied to the exposed front portions of the longer and shorter control levers 20 and 22 due to accidental stepping by a driver's shoe as is seen from FIG. 5, the longer control lever 20 is pressed down bringing the front stopper portion 20 A thereof into abutment with the vehicle floor “F” while keeping the abutment of the rear stopper portion 20 B with the upper cover part 24 c of the base member 24 . During this, the longer control lever 20 is subjected to a resilient deformation by a degree of the thickness of the space “Sa”, and upon abutment of the front stopper portion 20 A with the vehicle floor “F”, the force “P” applied to the longer control lever 20 becomes supported by three supporting points, which are a first supporting point “P 1 ” where the front stopper portion 20 A contacts the vehicle floor “F”, a second supporting point “P 2 ” where the rear stopper portion 20 B contacts the upper cover part 24 c of the base member 24 and a third supporting point “P 3 ” where the longer control lever 20 is disposed about the pivot shaft 28 . That is, the shock “P” applied to the longer control lever 20 is supported by the three points minimizing the force actually applied to each supporting point “P 1 ”, “P 2 ” or “P 3 ”. Thus, undesired deformation and damage of the longer control lever 20 are suppressed.
It is to be noted that when both the longer and shorter control levers 20 and 22 are stepped by the driver's shoe, the longer control lever 20 protects the shorter control lever 22 by carrying out the above-mentioned self-supporting function.
Referring to FIGS. 6 to 9 , there is shown a double lever type lid opener 100 B which is a second embodiment of the present invention.
The lid opener 100 B of this embodiment is similar to that of the above-mentioned first embodiment 100 A. Thus, detailed explanation will be directed to only parts or portions which are different from those of the first embodiment 100 A.
As is seen from FIGS. 6 and 8, like in the first embodiment 10 A, the lid opener 100 B of this second embodiment comprises longer and shorter control levers 20 ′ and 22 ′ which are pivotally disposed about a common pivot shaft 28 . Each control lever 20 ′ or 22 ′ has at the front exposed part a convexly curved upper edge. The pivot shaft 28 is held by a base member 24 ′ which is constructed of a metal. The base member 24 ′ comprises a front flat part 24 ′ a secured to the cross member 10 , a middle flat part 24 ′ b extending rearward from the front flat part 24 ′ a, an upper cover part 24 ′ c extending laterally from an upper end of the middle flat part 24 ′ b and an inclined rear part 24 ' d. The middle flat part 24 ′ b is formed at its lower portion with a stopper projection 24 ′ e which extends toward the shorter control lever 22 ′. The shape of the stopper projection 24 ′ e may be seen from FIG. 9 .
As is seen from FIG. 6, the longer control lever 20 ′ has near the wire connector 20 ′ c a forward projection 36 which abuts against the stopper projection 24 ′ e when the lever 20 ′ is pivoted up to the upper work position. A biasing spring 30 extends between a rear end 20 ′ b of the longer control lever 20 ′ and the middle flat part 24 ′ b. From a wire connector 20 ′ c provided by the rear end 20 ′ b, there extends a wire 32 to a latch mechanism of a trunk lid. A guide member 34 is pivotally held by the inclined rear part 24 ′ d of the base member 24 ′, through which the wire 32 extends. Due to the force of the biasing spring 30 , the longer control lever 20 ′ is biased to assume the horizontal rest position. The shorter control lever 22 ′ has substantially the same construction as the longer control lever 20 ′ except that in the shorter control lever 22 ′, a wire connected to the rear end of the lever 22 ′ extends to a latch mechanism of a filler cap.
In the second embodiment 100 B, the following measures are further employed.
That is, as is seen from FIG. 6, the longer control lever 20 ′ is formed at a rear portion thereof with a rear stopper portion 20 ′B which is contactable with the upper cover part 24 ′ c of the base member 24 ′.
Furthermore, as is seen from FIGS. 6 and 7, the longer control lever 20 ′ is formed near the pivot shaft 28 with a middle stopper portion 20 ′A which projects downward. When the longer control lever 20 ′ assumes the horizontal rest position as shown in FIGS. 6 and 7, the rear stopper portion 20 B abuts against the upper cover part 24 ′ c of the base member 24 ′ leaving a predetermined space “Sb” between the middle stopper portion 20 ′A and the stopper projection 24 ′ e. The thickness of the space “Sb” is determined smaller than a moved distance which is exhibited by the middle stopper portion 20 ′A when the latter is subjected to a maximum resilient deformation, that is, when the lever 20 ′ is strongly stepped by a passenger (viz., driver). Preferably, the thickness of the space “Sb” is smaller about 1 mm.
It is to be noted that the above-mentioned measures of the longer control lever 20 ′ are not needed by the shorter control lever 22 ′. However, if desired, such measures may be applied to the shorter one.
When, with the lid opener 100 B assuming a rest condition as shown in FIG. 6, the longer control lever 20 is pulled up against the force of the spring 30 , the wire 32 is driven in a direction to cancel the latched condition of the trunk lid. Due to provision of the stopper projection 24 ′ e against which the forward projection 36 of the lever 20 ′ can abut, the upper position of the longer control lever 20 ′ is assured. When the longer control lever 20 ′ is released, the lever 20 ′ is returned to the horizontal rest position of FIG. 6 due to the force of the spring 30 . When the shorter control lever 22 ′ is pulled up, the latched condition of the filler cap becomes canceled and thus the filler cap can be opened, like in the case of the above-mentioned trunk lid.
When, with the lid opener 100 B assuming the rest condition, a remarkable force is suddenly applied to the exposed front portions of the longer and shorter control levers 20 ′ and 22 ′ due to accidental stepping by a driver's shoe, the longer control lever 20 ′ is pressed down bringing the middle stopper portion 20 ′A thereof into abutment with the stopper projection 24 ′ e of the base member 24 ′ while keeping the abutment of the rear stopper portion 20 ′B with the upper cover part 24 ′ c of base member 24 ′. During this, the longer control lever 20 ′ is subjected to a resilient deformation by a degree of the thickness of the space “Sb”, and upon abutment of the middle stopper portion 20 ′A with the stopper projection 24 ′ e, the force applied to the longer control lever 20 ′ becomes supported by three supporting points, which are a first supporting point “P′ 1 ” where the middle stopper portion 20 ′A″ contacts the stopper projection 24 ′ e of the base member 24 ′, a second supporting point “P′ 2 ” where the rear stopper portion 20 ′B contacts the upper cover part 24 ′ c of the base member 24 ′ and a third supporting point “P′ 3 ” where the longer control lever 20 ′ is disposed about the pivot shaft 28 . That is, like in the case of the above-mentioned first embodiment 100 A, the shock applied to the longer control lever 20 ′ is supported by the three points minimizing the force actually applied to each supporting point “P′ 1 ”, “P′ 2 ” or “P′ 3 ”. Thus, undesired deformation and damage of the longer control lever 20 ′ are suppressed.
It is to be noted that even when both the longer and shorter control levers 20 ′ and 22 ′ are stepped by the driver's shoe, the longer control lever 20 ′ protects the shorter control lever 22 ′ by carrying out the above-mentioned self-supporting function.
The entire contents of Japanese Patent Application P10-87235 (filed Mar. 31, 1998) are incorporated herein by reference.
Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. | A lid opener for use in a vehicle comprises a base member secured to a vehicle body. A control lever is pivotally connected to the base member. A rear portion of the control lever is connected through a wire to a latch mechanism of a lid member. The control lever is capable of canceling a latched condition of the latch mechanism when pivoted in a normal direction from a rest position to a work position. A spring is used for biasing the control lever to assume the rest position. A first stopper structure includes the rear portion of the control lever and a part of the base member. The rear portion is kept in contact with the part of the base member when the control lever assumes the rest position. A second stopper structure includes a part of the control lever and a stopper member which is defined by either one of the vehicle floor and the base member. The part of the control lever is brought into abutment with the stopper member when, upon receiving a marked stress, the control lever is pivoted from the rest position in a direction opposite to the normal direction. | 8 |
CLAIM OF PRIORITY
[0001] This application is a non-provisional application and claims no priority to any patent or patent application.
FIELD OF THE EMBODIMENTS
[0002] The field of the embodiments of the present invention relate to a portable storage unit that keeps food items cool as well as provides entertainment and fun. In particular, the present invention relates to a portable cooler that includes gaming platforms useful for a variety of games, as well as a bottle opening, additional storage, and the like.
BACKGROUND OF THE EMBODIMENTS
[0003] Typically, partygoers and tailgaters have been required to transport numerous items to varied locations for use in recreational activities. Often times, one must park their car in one location or otherwise travel to a disparate location by foot to a second particular location for a gathering. In many of these instances, a person is required to bring numerous separate and bulky items, such as tables, games, food, and the like, placing a considerable burden upon the traveling individual.
[0004] Popular party and tailgating activities often include dining, drinking, and games associated with said drinking such as the wildly popular beer pong and cornhole/bag toss. In order to play such games, typically, more than one person is required to transport a separate game table(s), coolers, and gaming supplies. This requires that an individual have a large amount of cargo space or requires the coordination of multiple people in attempt to ensure the required materials are all accounted for.
[0005] As mentioned, beer pong is a table top game that involves throwing or bouncing ping pong balls across a table in an attempt to land the balls in drink cups across the table. In cornhole, bean bags are attempted to be tossed and either landed on the gaming surface or thrown through a hole in the gaming surface. Each of the aforementioned games requires different materials, gaming setups, and gaming boards. The high difficultly in accommodating all these materials becomes apparent when you factor in the food and drinks and other party necessities that need to be provided at a particular location.
[0006] Thus, there is a need for a set up that enables quick and efficient transportation of such items, including game boards, gaming materials/components, coolers, and food, to virtually any location. Further, there should be game boards that are readily convertible for one game or another to allow a singular gaming set to be utilized in multiple fashions. Even still, all of said materials should be capable of being transported in a single unit, while still permitting food and drinks to be transported in the same fashion. The present invention and its embodiments meet and exceeds these objectives.
Review of Related Technology:
[0007] U.S. Pat. No. 8,905,406 pertains to a portable point/beer pong game for individual or team use. The point/game is portable where it can be broken down, carried or stored in a bag, or other suitable container. The invention can be used as a ‘Beer Pong’ game as is common or it can be used as a game where points are scored. The invention top can also be used as a floating game in a swimming pool.
[0008] U.S. Pat. No. 7,451,709 pertains to a portable cooler and table assembly that may be easily transported in a single, self-contained unit. The assembly may be converted for use as a table for a variety of recreational activities, e.g., dining, drinking, games such as ping pong, beer pong, table hockey, card games, board games, preparation for sporting events and meals. The table and cooler may be permanently attached to each other, or alternatively, the cooler may be detachable from the table. The table may fold or collapse to assist in converting the assembly from a compact, lightweight transportable unit into a fully extended and operable table and cooler. The table surface may contain surface features such as grooves, indentations, nets, game pieces, etc. The cooler may comprise any container that is capable of containing ice or some other refrigeration or heating system, e.g., a conventional 54 quart beverage cooler. Alternatively, the cooler may be replaced with a storage container or other storage device. The assembly may also contain various wheels, legs and handles to assist in mobility and conversion.
[0009] U.S. Patent Application 2014/0252718 pertains to a modular beer pong table comprising a plurality of planar members. Each planar member having the ability to connect to any other planar member indiscriminately by a unique mechanism that employs an alternating pattern of protrusions which can mate with any other similar set of alternating protrusions. The mating protrusions providing for a strong joint and easy assembly. The planar members along with cap-like members combine to form a briefcase-like assembly for easy transportability and storability. The briefcase-like assembly further being able to retain two specialized stands which can be used to elevate the modular beer pong table during use. The modular beer pong table having the ability to float on water. Additional planar members of a modular nature that facilitate multiple concurrent beer pong game sessions. One embodiment employing the unique method of connecting modules for use in a toy construction set.
[0010] Various devices are known in the art. However, their structure and means of operation are substantially different from the present disclosure. The other inventions fail to solve all the problems taught by the present disclosure. The present invention provides for a portable cooler having a variety of functionality. In particular, the portable cooler has storage for gaming platforms that can be used to provide entertainment during indoor and outdoor events. At least one embodiment of this invention is presented in the drawings below and will be described in more detail herein.
SUMMARY OF THE EMBODIMENTS
[0011] Generally the present invention and its embodiments provide for a portable cooler that is designed to provide storage and transportation for a variety of party related items. The present invention is generally embodied as a portable cooler plus gaming system. The portable cooler has rugged wheels which enable the cooler to traverse a number of terrain obstacles. Further, handles are provided which enable the cooler to be carried as needed.
[0012] The cooler has multiple storage areas for differing items such as cups, balls, and the like disposed thereon. Further, there may be a bottle opener. Internally, the cooler is preferably divided into at least two spaces or compartments. One space is intended for foods, beverages, and the like and the other space holds the gaming platforms. The gaming platforms are compact and can be unfolded into multiple configurations to be used in multiple game types. Further, in some embodiments, the gaming platforms can be used as a table to hold food and beverages and the like.
[0013] The gaming platforms contain the necessary legs, gaming components, and the like to enable a variety of games to be played such as beer pong and corn hole. The flexibility for these gaming platforms to have multiple uses reduces the amount of gaming devices that need be transported for a party or tailgate. By storing the gaming platforms (with the gaming components stored on parts of the gaming platforms) in the cooler, further burden is reduced in the transportation and storage of the system as a whole.
[0014] Other features included in varying embodiments may include light sources to illuminate an interior of the cooler, locking mechanisms to prevent unauthorized theft of components, temporary dividers for subdividing the internal area of the cooler, telescoping handles, drains, and tie down hooks. These features may or may not be present and may be present in varying combinations with one another.
[0015] In one embodiment there is an apparatus having a plurality of sidewalls having an outer surface and an inner surface, the plurality of sidewalls defining an opening and an interior, wherein the interior is compartmentalized to define at least two interior spaces; a lid member capable of covering or uncovering the opening; at least one light source configured to illuminate at least one of the at least two interior spaces; and two game platforms configured to be positioned in at least one of the at least two interior spaces, wherein in each of the two game platforms has a first section and a second section and an aperture extending through at least one of the first section or second section.
[0016] In another embodiment there is an apparatus having a plurality of sidewalls having an outer surface and an inner surface, the plurality of sidewalls defining an opening and an interior, wherein the interior is compartmentalized to define at least two interior spaces, wherein a first interior space is capable of receiving a divider that slidably engages the first interior space, and wherein a second interior space has a dividing mechanism coupled to at least one wall of the second interior space; a bottle opener disposed on the outer surface of one of the plurality of sidewalls; a lid member capable of covering or uncovering the opening; a telescoping handle; at least one light source configured to illuminate at least one of the at least two interior spaces; and two game platforms configured to be positioned in at least one of the at least two interior spaces, wherein in each of the two game platforms has a first section and a second section and an aperture extending through at least one of the first section or second section, wherein a disk is capable of being retained by the aperture.
[0017] In yet another embodiment there is an apparatus having a plurality of sidewalls having an outer surface and an inner surface and a base having an outer and an inner surface, the plurality of sidewalls being coupled to the base and defining an opening and an interior, wherein the interior is compartmentalized to define at least two interior spaces, wherein a first interior space is capable of receiving a divider that slidably engages the first interior space, and wherein a second interior space has a dividing mechanism coupled to at least two walls of the second interior space; a bottle opener disposed on the outer surface of one of the plurality of sidewalls; at least two storage units accessible from an outer surface of the plurality of sidewalls; a first lid member and a second lid member capable of covering or uncovering the opening; a telescoping handle; at least one light source configured to illuminate at least one of the at least two interior spaces; and two game platforms configured to be positioned in at least one of the at least two interior spaces, with each of the two game platforms having a first section and a second section, a hinged member coupling the first section to the second section, a first set of legs and a second set of legs, at least one storage unit coupled to an underside of the first section or second section, and a handle, wherein an aperture extends through at least one of the first section or second section, wherein a disk is capable of being retained by the aperture thereby forming a contiguous game surface.
[0018] In yet another embodiment there is an apparatus comprising a plurality of sidewalls having an outer surface and an inner surface, the plurality of sidewalls defining an opening and an interior;
[0019] a liner capable of being retained in the interior; at least one lid member capable of covering or uncovering the opening; two game platforms configured coupled to the apparatus, wherein in each of the two game platforms has a first section and a second section and an aperture extending through at least one of the first section or second section, and wherein the two game platforms each have two pair of collapsible legs.
[0020] In general, the present invention succeeds in conferring the following, and others not mentioned, benefits and objectives.
[0021] It is an object of the present invention to provide an apparatus that can store items and keep certain items hot or cold.
[0022] It is an object of the present invention to provide an apparatus that has multiple storage areas.
[0023] It is an object of the present invention to provide an apparatus that can be used in a number of environments and conditions.
[0024] It is an object of the present invention to provide an apparatus that can be easily cleaned and stored when not in use.
[0025] It is an object of the present invention to provide an apparatus that has multiple storage configurations.
[0026] It is an object of the present invention to provide an apparatus that provides at least two game platforms to be used for entertainment and competition purposes.
[0027] It is an object of the present invention to provide an apparatus that is lightweight enough to be readily portable.
[0028] It is an object of the present invention to provide an apparatus that employs a locking mechanism to securely store items.
[0029] It is an object of the present invention to provide an apparatus that contains the necessary components for providing entertainment for a group of people.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of an embodiment of the cooler in a closed configuration.
[0031] FIG. 2 is a side view of an embodiment of the cooler in a closed configuration.
[0032] FIG. 3 is a back view of an embodiment of the cooler in a closed configuration.
[0033] FIG. 4 is a perspective view of an embodiment of the cooler in an open configuration demonstrating at least some of the internal components.
[0034] FIG. 5 is a top perspective view of an embodiment of the cooler in an open configuration.
[0035] FIG. 6 is a perspective view of a table of the present invention in a folded configuration.
[0036] FIG. 7 is a top view of the table in an unfolded configuration.
[0037] FIG. 8 is a bottom view of the table in an unfolded configuration.
[0038] FIG. 9 is perspective view of the table in one game configuration.
[0039] FIG. 10 is a perspective view of the table in another game configuration.
[0040] FIG. 11 is an exploded perspective view of an alternative embodiment of the cooler.
[0041] FIG. 12 is a perspective view of a cooler body.
[0042] FIG. 13 is a top view of a cooler cover.
[0043] FIG. 14 is a perspective view of a cooler tray.
[0044] FIG. 15 is a top view of a tray lid.
[0045] FIG. 16 is a top view of an alternate tray lid.
[0046] FIG. 17 is an alternate game table in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0048] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
[0049] Referring now to FIG. 1 , there is an embodiment of an apparatus 100 shown from a perspective view. The apparatus 100 generally has sidewalls 101 and lid members 102 . There may be one lid member or multiple lid members as shown. The lid member(s) 102 may be manipulated using recesses 110 formed from part of the lid member 102 . A front tie down hook 104 may allow articles to be held down on the lid member 102 when the lid member is closed. A rear tie hook 112 (see FIG. 2 ) is preferably used in conjunction with the front tie hook 104 . The tie hooks are configured to receive a fastening mechanism, not shown, that can be used to secure the position of an article to be secured thereto.
[0050] Further, handles 108 formed from the sidewalls 101 may be present to provide a surface by which the apparatus 100 may be further manipulated. Wheels 106 provide for ease of transportation of the apparatus 100 over a variety of terrain.
[0051] In FIG. 2 , the apparatus 100 is viewed from a side. Features include the lid members 102 , front tie hook 104 , rear tie hook 112 , wheels 106 , handle 108 , and a leveling foot 114 . The leveling foot 114 may extend or retract via a variety of mechanisms to allow the apparatus 100 to remain level and upright, or to otherwise be positioned at an angle.
[0052] Referring now to FIG. 3 , the apparatus is shown from a back view. Shown are the lid members 102 , bottle opener 116 , cup storage 118 , storage 122 , locking mechanism 124 , drain 120 , wheels 106 , telescoping handle 126 , and handles 108 .
[0053] The telescoping handle 126 is a handle that slidably expands or retracts as needed by the user. The handle may have between about two to about ten concentric segments that allow for proper height requirements to be attained. In some embodiments, the handle may be padded.
[0054] The cup storage 118 is designed and configured to hold a plurality of cups or other receptacles such as bowls, basins, and the like. The cup storage 118 may permit for the articles contained therein to be stacked upon one another thereby increasing the amount of items that may be stored. A locking mechanism such as a latch, clip, or the like may be used to access the cup storage and otherwise keep the cup storage 118 closed as needed.
[0055] The storage 122 enables a plurality of items to be stored therein. The storage 122 may take various forms including hollow spaces, slidable drawers, and the like. As with the cup storage 118 , a comparable or different locking mechanism may be used thereon to prevent the contents from spilling. The bottle opener 116 is adhered to an outer surface of the cooler and can be used to open a variety of beverages.
[0056] The locking mechanism 124 may be the same or different as the other locking mechanisms described herein. Preferably, this locking mechanism 124 is a number code or keyed entry that requires a specific combination or apparatus to access the lock. The contents protected by this locking mechanism 124 may include the contents of the cooler, the mechanism of wheels, or control locking mechanisms that are used on multiple components (i.e. both the cooler and the cup storage.)
[0057] In FIG. 4 , there is an illustration showing how the first game platform 134 and the second game platform 136 reside in the apparatus. A dividing mechanism 128 divides the first interior space 140 roughly in half thereby providing space for both platforms. In other embodiments, the dividing mechanism 128 is offset to one side or the other of the first interior space 140 .
[0058] In a second interior space 142 there is a removable divider 130 . This divider 130 may slidably engage a groove (not shown) within the second interior space 142 . A power switch 132 is also shown to control the operative state of the LEDs as shown in FIG. 5 .
[0059] Referring now to FIG. 5 , there is a top view demonstrating the interior space of the apparatus. In addition to the dividing mechanism 128 , there are also drainage slots 144 in the bottom of the first interior space to allow for drainage of fluids and other material from the drain 120 (see FIG. 3 ). In the second interior space 142 are the grooves 146 by which the divider 128 interacts, as well as the LEDs 138 for illuminating the interior of the apparatus.
[0060] FIGS. 6-7 demonstrate a view of one of the gaming platforms. Generally, the gaming platforms have a first section 148 , a second section 156 , a veneer 154 , a handle 150 , and a disk 152 . The first and second section are hingably coupled via a hinge 162 (see FIG. 8 ).
[0061] In FIG. 8 , there is a view of an underside of the gaming platform. The underside contains a first set of legs 158 , a second set of legs 160 a disk storage 164 , a leg retainment mechanism 166 , and a mesh storage 168 with a gaming component 170 contained therein. The gaming component 170 may be virtually any game components including beanbags, balls, cones, flags, and the like or any combination thereof.
[0062] The first set of legs 158 may be shorter in length than the second set of legs 160 . It is intended that matching sets from each section of the gaming platform are to be used in conjunction with one another, although in some embodiments, one may intermix the set of legs to provide a unique gaming experience. At least one of the sets of legs may be height adjustable. The disk storage 164 allows for the disk 153 to be removed from the veneer 154 and be securely stowed. The removal of the disk leaves an aperture which may be used for various entertainment games. The disk 152 may be rotatably lockable or otherwise capable of being secured in place. The disk storage 164 may provide the similar or same features that enable the disk to be secured in place on with the veneer 154 .
[0063] FIGS. 9 and 10 show the gaming platform(s) set up in two different gaming configurations. In FIG. 9 , the gaming platform is set up using the first set of legs. Note that in this embodiment, two of the four legs are larger than the other two. In other embodiments, all legs may be the same or different heights. Additionally, the first section 148 and the second section 156 have been rotated about the hinge 162 to provide for a “flat” veneer 152 . The disk has been removed thereby leaving an aperture 172 through which a gaming components may be tossed, thrown, or slid. One game that may be played with such a configuration is typically called “bag toss” or “cornhole.” The table design is your standard beer pong table design with adjustable legs attached by a hinge to the bottom of the table. These legs can be folded in order to be stored away and fit in the cooler. The “cornhole” legs are shorter than the beer pong table legs and are placed directly next to the “beer pong table” legs. There are only 2 cornhole legs compared to the 4 beer pong legs due to the needed slope of a cornhole set. These 2 shorter “cornhole” legs allow the beer pong table to turn into a cornhole set with ease.
[0064] In FIG. 10 , both gaming platforms have been set up using the second set of legs 160 . Note how, in this embodiment, the legs closest to each of the gaming platforms have been offset to allow the gaming platforms to be brought together. The disks 152 have been left to remain forming a continuous playing surface or veneer 154 . The legs have a first section 174 and a second section 176 , via which the height may be independently adjusted. One game that may be played in this configuration is typically called “beer pong” or “Beirut.” In the event that liquids are spilled on the veneer 154 or the veneer 154 otherwise becomes compromised, the veneers 154 may be removable for cleaning or otherwise replaceable.
[0065] Referring now to FIGS. 11- 17 , there is an alternate form of the multi-componential cooler. The cooler has side walls 101 defining an interior into which a liner 182 may be positioned. Further, the cooler has wheels 106 , a handle 108 , and speakers 178 . The speakers 178 may be Bluetooth® speakers or may be hard wired into the cooler. The speakers 178 reside and are retained in an aperture 186 . The handle 108 may be telescoping or slidable in relation to the cooler and when not in use can be positioned within a recess 188 as shown in FIG. 12 .
[0066] The liner 182 has a lid member 102 having cup holders 180 , as well as two dry storage lids 184 coupled to the liner 182 . As shown in FIG. 14 , there are magnetic locks 190 positioned on the liner 182 to help retain the dry storage lids 184 in a closed position. The cup holders 180 may be rubber lined or lined with another resilient material to adequately grip the beverage placed therein. As shown in FIG. 13 , the cup holders 180 may be positioned in each of the four corners of the lid member 102 . In other embodiments, other arrangement of the cup holders 180 may be utilized.
[0067] FIGS. 15 and 16 demonstrate two different form factors of the dry storage lids 184 . Each of the lids 184 generally has a hinge 192 and a latch catch 194 . The hinge 192 is meshed with the liner 182 (see FIG. 14 ) to be coupled to the liner. The latch catch 194 preferably has a magnet either located on an outer surface or internally that allows the dry storage lid 184 to interact with the magnetic lock 190 of FIG. 14 . As shown, the lids 184 may have varying shapes and dimensions to fit the corresponding shape on the liner. Virtually any shape or dimension capable of being positioned within the cooler may be utilized.
[0068] Referring now to FIG. 17 , there is an alternate game board to be used in accordance with the present invention. Here, the game board has a disk 152 and a triangle 196 area. The disk 152 is removable allowing the aforementioned “cornhole” to be played. The collapsible legs 198 can also be configured to suit this particular game's needs. The triangle 196 comprises markings that define an area for cups to be set upon to play “Beirut” or “beer pong” or any variation thereof. The collapsible legs 198 can be used to change the height of the table independently in the event that the table is desired to be at varying heights or have differing heights between ends of the table. Additionally, the collapsible legs 198 can be removed and used for other games such as “ladder ball.” For such a game, the legs are fully extended and the cross bars forming the legs are utilized as functional components for which the ladder balls can be thrown and retained thereon.
[0069] In some embodiments, the cooler may have an alternative embodiment, where the bottle opener, cup storage, and storage compartments are not present. In a preferred embodiment, the measurements of the apparatus may be: height from wheel to top of the gaming platform is 25.50 inches; the width from handle to handle is 31.22 inches and the depth from tie down to tie down is 23.14 inches. In a preferred embodiment, the wheel dimensions are 3 inches in diameter and the height from the ground to the wheel is 4.5 inches. However, the gaming platform may be of varying heights, lengths and widths to accommodate a variety of intended and foreseeable uses. For instance, the gaming platform, storage and table games can be larger, smaller, and miniature and or oversized for display reasons.
[0070] In another embodiment of the invention, the gaming platform may be equipped with charging stations for a variety of wireless and mobile devices. Charging stations may include USB and HDMI ports. The gaming platform may be adapted and configured to act as a “hotspot” for an Internet connection and/or be equipped to engage a Bluetooth® device such as Bluetooth® speakers that can connect to any smart phone device. In another embodiment of the invention, the speakers would be high quality and water proof. In another embodiment of the invention, a battery pack would be included. The battery pack would be used to charge a plurality of devices such as tablets, computers and smart phones.
[0071] In another embodiment, the components of the gaming platform may be manufactured with recycled plastic or be made out of bamboo/polynomial wood. Such woods are very strong, flexible and possesses green properties. In another embodiment, the gaming platform may be composed of metals, composite metals such as aluminum and water proof and resistant materials.
[0072] In another embodiment of the invention, the gaming tables may be attached or stored in a cubby or compartment which is located on the outside of the gaming platform. This exterior compartment or storage space would be attached to the back side of the gaming platform. In this alternative embodiment, the exterior compartment would be in addition to or instead of the interior storage compartment. In another embodiment of the invention, the gaming platform may accommodate other gaming options such as “ladders” or “horseshoes.”
[0073] In another embodiment of the invention, the gaming platform may be equipped with additional compartments for storing multiple accessories such as portable/foldable chair, a foldable bench, a disposable BBQ Grill, a tent, and other outdoor and gaming activities and accessories. The portable/foldable tables that the gaming platform may accommodate could be used for hunting, fishing, and emergency uses.
[0074] In another embodiment, the gaming platform may be used for indoor games and uses. In another embodiment, the gaming platform may be equipped with a plurality of advertising means such as interactive displays and sides with insets and inlays for banners, graphics and other promotional marketing materials. For example, the NFL, NHL, and the MLB (all National sports leagues and associations) may use the gaming platform to display their logo. In yet another embodiment of the present invention, the gaming platform itself would be condensable and foldable into a compact and portable unit. In another embodiment of the invention, all sides and walls of the gaming platform may be interconnected by hinges such to enable the sides or walls to collapse. In another embodiment, the gaming platform may be equipped with an electric or solar powered light sources such as a lantern, back, front and side lights and a flashlight. In yet another embodiment, the gaming platform may be composed of material that may float on water. In yet another embodiment, the gaming platform may be equipped with electric and remote controlled wheels to allow the gaming platform to be controlled remotely and tugged around easier.
[0075] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | An apparatus may be a cooler capable of transporting and retaining various implements for entertainment purposes. The cooler has an interior that is preferably compartmentalized to define at least two interior spaces. A lid may be employed to cover or uncover the interior spaces. One of the interior spaces is configured to hold two game platforms. These game platforms may be used for different party games, such as corn hole and/or beer pong. The cooler further has various features and implements stored therein to ensure the proper equipment needed for such games and other forms of entertainment are contained within one unit. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of 35 U.S.C. 111(b) provisional application Ser. No. 60/530,314 filed Dec. 17, 2003, and entitled Rotating Drilling Head Drive.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
FIELD OF THE INVENTION
The present invention relates generally to methods and apparatus for driving the rotating components of a rotating drilling head. More specifically the present invention relates to methods and apparatus for rotating the sealing element of a rotating drilling head in coordination with a rotating drilling string passing through the sealing element.
BACKGROUND
Rotating drilling heads employ elastomeric sealing elements to effectuate a seal between a rotating drillstring and the stationary head. The elastomeric sealing element is mounted on bearings that allow the sealing element to rotate with the drillstring. In most conventional drilling operations, the drilling head is positioned below the drill floor and above the blowout preventer. The drilling head operates to divert pressurized drilling fluids, and other materials flowing up through the wellbore, away from the drill floor.
In rotary drilling operations, the drillstring is rotated by a kelly drive or a top drive. A kelly drive engages a faceted member of the drill string, or kelly, that is connected to the drillstring. The kelly drive is often powered by a rotary table on the drill floor. Many rotating drilling heads are configured to be rotated by interfacing with the kelly either directly, or through a mechanical interface.
Top drive drilling systems rotate the drillstring using an electric or hydraulic motor mounted directly to the top of the drillstring. In top drive drilling systems no kelly is used and the rotating drilling head has to rely on the friction contact between the sealing element and the drillstring to rotate the sealing element. This friction contact is often insufficient to cause sufficient rotation of the sealing element, resulting in relative rotary motion between the drill pipe and the sealing element. A relative rotary motion between the sealing element and the drill pipe can lead to excessive wear in the sealing element, thus reducing the effective life of the seal.
Accordingly, there remains a need to develop methods and apparatus for rotating the sealing element of a rotating drilling head that overcome certain of the foregoing difficulties while providing more advantageous overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention are directed to methods and apparatus for rotating a stripper assembly in use with a rotating drilling head. The preferred drive systems seek to synchronize the rotation of the rotating head sealing element with the rotation of the drillstring passing through the sealing element in order to reduce wear on the sealing element. A drive system is disposed external to the rotating drilling head and generates rotational motion to match the rotation of a drillstring running through the rotating drilling head. A connection transfers rotational motion from the drive system to the stripper assembly. In one embodiment, the drive system comprises a housing disposed about the drillstring and a one or more contact members connected to said housing and operable to contact the drillstring. One or more biasing members urge the contact members into contact with the drillstring so as to transfer rotational motion from the drillstring to the housing.
In one embodiment, a drive system comprises a housing containing roller assemblies that contact the drillstring. The housing is coupled to the sealing element of a rotating drilling head such that the sealing element rotates with the housing. The roller assemblies are urged into contact with the drillstring by a biasing member that maintains a contact force on the drillstring but allows tool joints and other increased diameter objects to pass through the roller assemblies. The contact force on the drillstring creates a friction force that causes the roller assemblies and housing to rotate with the drillstring, thus driving the sealing element of the drilling head.
In another embodiment, a drive system comprises a casing surrounding the drillstring and linking the sealing element of a rotating drilling head to the rotary table on the drill floor. The rotary table is rotated in unison with the drillstring such that the casing rotates the sealing element in unison with the drillstring. In certain embodiments, the casing has an upper and lower section that are rotationally coupled but are allowed to translate axially relative to each other, thus allowing for variation in the distance between the rotary table and the drilling head.
In another embodiment, a drive system comprises a rotating motor adapted to directly rotate the sealing element of a rotating drilling head. In one embodiment, a gear is coupled to the sealing element and engaged with a pinion powered by a hydraulic or electric motor. A control system operates the motor so as to rotate the sealing element in unison with the drillstring.
Thus, the present invention comprises a combination of features and advantages that enable it to overcome various shortcomings of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
FIG. 1 illustrates an exemplary drilling rig arrangement;
FIG. 2 illustrates an exemplary rotating drilling head;
FIG. 3 illustrates a partial sectional elevation view of one embodiment of a rotating drilling head drive system;
FIG. 4 illustrates a partial sectional plan view of the drive system of FIG. 3 ;
FIG. 5 illustrates a partial sectional elevation view of an alternate embodiment of a rotating drilling head drive system;
FIG. 6 illustrates a partial schematic view of an alternate embodiment of a rotating drilling head drive system;
FIG. 7 illustrates a partial sectional elevation view of one embodiment of a rotating drilling head drive system;
FIG. 8 illustrates a partial sectional plan view of the system of FIG. 7 ; and
FIG. 9 illustrates a partial sectional elevation view of the drive system of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results.
In particular, various embodiments described herein thus comprise a combination of features and advantages that overcome some of the deficiencies or shortcomings of prior art rotating drilling head systems. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of preferred embodiments, and by referring to the accompanying drawings.
Referring now to FIG. 1 , there is shown a conventional rig 10 for rotating a drill bit 12 on the end of a drillstring 14 for drilling a well bore 16 . The drillstring 14 extends through a blowout preventer (“BOP”) stack 18 located beneath the rig floor 20 and includes a plurality of drill pipes 14 extending to the drill bit 12 . The drillstring 14 transmits rotational and axial movements to the drill bit 12 for drilling the well bore 16 . The drilling rig 10 includes a rotary table 22 connected to the floor 20 of rig 10 . Torque is transmitted to drillstring 14 by rotary table 22 or a top drive system suspended in the rig 10 .
Drilling fluids, often referred to as drilling mud, are pumped downward through drillstring 14 under high pressure, through drill bit 12 and then return upwardly via the annulus 44 formed between well bore 16 and drillstring 14 . The returning drilling fluid is diverted beneath the rig floor 20 to a mud reservoir 24 by means of a device commonly referred to in the industry as a rotating drilling head assembly 26 . Pump 28 draws drilling fluid from reservoir 24 and pumps it back into drillstring 14 .
A rotating drilling head assembly 26 is typically mounted below the floor 20 of the drilling rig 10 on the top of the BOP stack 18 to redirect the drilling fluid returning from the well bore 16 and to allow rotation and deployment of the drillstring 14 through the rotary table 22 . Rotating drilling head 26 includes a sealing element 30 that seals the annulus between drillstring 14 and the drilling head. Thus, drilling fluid is forced out through outlet 32 into reservoir 24 . During normal drilling operations, the blowout preventers are maintained in the “open” position, leaving only rotating drilling head 26 to contain any pressure within wellbore 16 and divert the returning pressurized drilling fluids away from the rig 10 .
FIG. 2 illustrates a typical prior art rotating drilling head assembly 26 having an outer stationary housing or bowl 48 and an inner drive ring 50 with a bearing assembly 52 disposed in between allowing drive ring 50 to rotate within bowl 48 . Outer bowl 48 includes a flange 54 for mounting the assembly 26 to the BOP stack and a flow diverter port or outlet 32 having a flange 58 for the attachment of a pipe extending to the mud reservoir. Assembly 26 further includes stripper assembly 60 , which is slidably received within drive ring 50 and connected to the upper end of drive ring 50 by a retaining clamp 62 allowing stripper assembly 60 to rotate with inner drive ring 50 .
Stripper assembly 60 includes sealing element, or stripper rubber, 30 bonded to inner drive bushing 34 . Inner drive bushing 34 has a faceted profile 44 that can be engaged to impart torque onto stripper assembly 60 . Non-rotary seals 70 and 72 , respectively, serve to isolate bearing assembly 52 from drilling fluids and to keep lubricating fluid from escaping the bearing assembly. Sealing engagement between sealing element 30 and drillstring 14 is effectuated by the sealing element being stretched to fit around the drillstring.
Referring now to FIGS. 3 and 4 a rotating drilling head drive system 100 is shown engaged with drillstring 14 and rotating drilling head assembly 26 . Drive system 100 comprises housing 110 and roller assemblies 120 . Housing 110 includes an upper portion 112 containing roller assemblies 120 and a lower portion 114 having a faceted outer surface adapted to engage faceted surface 44 of stripper assembly 60 . Each roller assembly 120 includes roller 122 , shaft 124 , biasing members 126 , and base 128 .
Roller 122 engages drillstring 14 and is rotatably mounted to shaft 124 . Shaft 124 is supported by biasing members 126 , which push roller 122 against drillstring 14 . Biasing members 126 are affixed to housing 110 by base 128 . Rollers 122 are preferably constructed from a material having a surface that will provide sufficient contact with drillstring 14 without damaging the drillstring. For example, roller 122 may be constructed from a steel core covered with a resilient coating.
Rollers 122 are urged against drillstring 14 by biasing members 126 . Biasing members 126 act to apply sufficient force to maintain the contact of rollers 122 on drillstring 14 but also allow increased diameter portions of the drillstring, such as tool joint 50 , to pass through the rollers. Biasing members 126 are supported by base 128 , which is attached to housing 110 . Biasing members 126 may be coil springs, leaf springs, hydraulic springs, or any other type of biasing system that support rollers 122 .
Drillstring 14 is moved axially while being rotated about its longitudinal axis. Rollers 122 allow for axial translation of drillstring 14 . Rollers 122 grip drillstring 14 so that the rotation of the drillstring imparts a torque on housing 110 that is transferred through faceted members 114 and 44 into stripper assembly 60 . Thus, stripper assembly 60 will rotate with substantially the same rate of rotation as drillstring 14 , reducing wear on the stripper assembly.
Drive system 100 is shown having three rollers 122 but any number of rollers may be used to achieve sufficient transfer of torque to the drive system from drillstring 14 . In the preferred embodiments, the surface area of the engagement between drive system 100 and drillstring 14 is maximized in order to minimize the contact stress, or pressure, on the drillstring. Non-rolling contact members could also be used as an alternative to rollers 122 , as long as wear to drillstring 14 is minimized.
Drive system 100 is shown as an additional component that interfaces with stripper assembly 26 but it could also be integrated into the stripper assembly. In certain embodiments, drive system 100 may be locked, or otherwise releasably latched, to stripper assembly 26 to maintain the position of the drive system during back-reaming or to provide positive engagement during installation and removal of the drive system. As an alternative to engaging stripper assembly 26 , drive system 100 may also be constructed to directly engage the rotating section of bearing assembly 52 .
Referring now to FIG. 5 , an alternative drive system 130 is shown connecting drilling head 26 to rotary table 22 . Drive system 130 includes an upper casing 132 and a lower casing 134 joined at connection 140 . Upper casing 132 has upper end 138 coupled to rotary table 22 so that the rotary table can be used to rotate the upper casing. Connection 140 transfers torque from upper casing 132 to lower casing 134 . Connection 140 preferably allows axial translation between casings 132 and 134 so as to allow for height variations between drill floor 20 and drilling head 26 . Lower casing 134 has a faceted lower end 136 adapted to interface with faceted profile 44 of stripper assembly 60 .
Therefore, the rotation generated by rotary table 22 is transferred through upper casing 132 and lower casing 134 into stripper assembly 60 . Because the relative rotary slippage between stripper assembly 60 and drillstring 14 is reduced, the service life of the stripper assembly is increased. In the preferred embodiments, rotary table 22 is synchronized with the rotation of drillstring 14 so as to closely match the rotation of the drillstring and stripper assembly 60 . In top drive drilling systems, this synchronization is likely carried out by a control system regulating the rotational speed of the top drive and the rotary table.
Referring now to FIG. 6 a second alternative drive system 150 is shown. Drive system 150 includes a drive pinion 152 that engages corresponding gear 63 attached to flange 62 . Flange 62 is connected to the rotating portion of head 26 such that stripper assembly 60 rotates with the flange. Drive pinion 152 is rotated by hydraulic motor 154 , which is powered by pump 156 and controlled by controller 158 . In alternate embodiments, an electric, pneumatic, or other motor may replace hydraulic motor 154 .
The speed of motor 154 is controlled so as to rotate stripper assembly 60 at the same rotational speed of a drillstring passing through the stripper assembly, which reduces wear on the stripper assembly. Thus, in the preferred embodiments controller 158 is linked to the drilling control system so as to match the rotational speed of stripper assembly 60 to the rotational speed of a top drive or kelly drive.
Referring now to FIGS. 7-9 , a rotating drilling head drive system 200 is shown engaged with drillstring 14 and rotating drilling head assembly 26 . Drive system 200 comprises housing 210 , roller assemblies 220 , and adapter plate 230 . Housing 210 comprises an upper portion 212 containing roller assemblies 220 and drive lugs 215 that connect housing 210 to adapter plate 230 . Adapter plate 230 is connected to stripper assembly 60 via bolts 232 or some other rigid connection. Roller assemblies 220 engage drillstring 14 and transfer torque from the drillstring through adapter plate 230 to stripper assembly 60 .
As can be seen in FIG. 9 , each roller assembly 220 includes roller 221 , upper link 222 , and lower link 223 . Lower links 223 are pivotally connected to housing base plate 214 by individual lower anchor blocks 224 . Upper links 222 are pivotally connected to follower plate 216 by individual upper anchor blocks 225 . Biasing member 218 is disposed between follower plate 216 and housing base plate 214 so as to urge the follower plate upward. Biasing member 218 may be one or more coil springs, a hydraulic spring system, or any other system for urging follower plate 216 upward.
The upward movement of follower plate 216 and upper anchor blocks 225 moves rollers 221 inward toward the center of housing 210 and drillstring 14 . Rollers 221 allow drillstring 14 to move axially while being rotated about its longitudinal axis. Biasing member 218 applies sufficient force to maintain the contact of rollers 221 on drillstring 14 but also allow increased diameter portions of the drillstring, such as tool joint 50 , to pass through the rollers.
Rollers 221 are preferably constructed from a material having a surface that will provide sufficient contact with drillstring 14 without damaging the drillstring. For example, rollers 221 may be constructed from steel cores having a concave outer surface covered with a resilient coating. Drive system 200 is shown having three rollers 221 but any number of rollers may be used to achieve sufficient transfer of torque to the drive system from drillstring 14 . In the preferred embodiments, the surface area of the engagement between drive system 200 and drillstring 14 is maximized in order to minimize the contact stress, or pressure, on the drillstring.
To install drive system 200 , follower plate 216 is pushed downward, compressing biasing member 218 and moving rollers 221 outward. Follower plate 216 may be maintained in the lowered position by a retainer pin (not shown) or other member that fixes the position of the follower plate relative to housing 210 . Once drillstring 14 is disposed within drive system 200 , the retainer pin is released and biasing member 218 urges follower plate 216 upward, moving rollers 221 inward until they contact the drillstring.
Drive lugs 215 are L-shaped members that engage slots 234 on adapter plate 230 . As housing 210 is rotated clockwise by the rotation of drillstring 14 , the horizontal portion of drive lugs 215 prevent vertical disengagement of the lugs and adapter plate 230 . Therefore, system 200 will rotate stripper assembly 60 whether drillstring 14 is being moved downward, such as in normal drilling, or upward, such as during backreaming. Lugs 215 can be disengaged from slots 234 by rotating drillstring 14 , and therefore housing 210 , counterclockwise and upward.
While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | Methods and apparatus for rotating a stripper assembly in use with a rotating drilling head. A drive system is disposed external to the rotating drilling head and generates rotational motion to match the rotation of a drillstring running through the rotating drilling head. A connection transfers rotational motion from the drive system to the stripper assembly. In one embodiment, the drive system comprises a housing disposed about the drillstring and a one or more contact members connected to said housing and operable to contact the drillstring. One or more biasing members urge the contact members into contact with the drillstring so as to transfer rotational motion from the drillstring to the housing. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to an improved catalytic process for producing hydrogen peroxide directly by reaction of hydrogen and oxygen. The process involves sequentially staged or serial feeding of portions of the hydrogen feedstream to the continuous catalytic reactor downstream from the initial locus of the feedstream entrance to the reactor. The staged addition of hydrogen allows preferred oxygen to hydrogen stoichiometry to be maintained throughout the reactor. This significantly reduces the amount of unconverted oxygen, thereby reducing or eliminating the need for recompression and recycling of effluent gases while improving the selectivity of the catalytic reaction.
BACKGROUND OF THE INVENTION
[0002] While the direct production of hydrogen peroxide (H 2 O 2 ) from hydrogen (H 2 ) and oxygen (O 2 ) is known in the art, commercial processes are typically indirect processes using a hydrogen donor organic compound as the source of hydrogen needed to react with oxygen in order to circumvent the explosive hazard of direct mixtures of hydrogen and oxygen. Usually, anthraquinone or a derivative thereof is employed as a hydrogen donor molecule by first reducing the molecule to the dihydro moiety and then oxidizing the reduced dihydro moiety with oxygen to yield hydrogen peroxide and the starting anthraquinone. While a relatively safe process, the indirect process has many drawbacks, not the least of which is the fact that it is a multistep process which consumes anthraquinone and solvent by oxidation.
[0003] The direct catalytic production of hydrogen peroxide from hydrogen and oxygen, although well-studied, has not achieved commercial acceptance as yet. When the direct process is carried out at hydrogen levels below 5% by volume to avoid the explosive hydrogen gas mixture range, the yields of hydrogen peroxide are low. Further, the process selectivity is low as a consequence of the conversion of hydrogen peroxide to water in the catalytic environment. The cost of hydrogen and oxygen is an important economic factor in the direct synthesis process. Inefficiencies in their use caused by low selectivity constitute a significant problem.
[0004] Another significant economic problem in direct hydrogen peroxide production arises from the use of large gas excesses. It is common practice in direct synthesis processes to employ large excesses of one of the gaseous components, especially oxygen. Consequently, large gas flows must be handled in the process. Since direct synthesis processes typically operate at pressures of at least 500 psig, and often greater than 1000 psig, the copious amount of excess oxygen in the reaction mixture which must be recompressed for recycle imposes a significant cost burden on the process. Large and expensive compressors are required to accommodate the recycle stream from direct synthesis processes that employ excessively large oxygen flows.
[0005] It is also well known in the prior art that the ratio of oxygen and hydrogen gases in the direct catalytic synthesis process has a critical effect on the yield of hydrogen peroxide produced as well as the selectivity of the process for hydrogen peroxide production. U.S. Pat. No. 4,336,239 teaches a direct synthesis hydrogen peroxide production process using noble metal catalysts where the molar ratio of oxygen to hydrogen is greater than about 3.4, preferably above 5 and most preferably a molar ratio of 12-15, at catalyst loadings of more than 30 mg per 100 ml of medium. According to the '239 patent, higher oxygen to hydrogen ratios above 3.4 results in an increase in the amount of hydrogen peroxide obtained.
[0006] U.S. Pat. No. 6,375,920 teaches a reactor system for hydrogen peroxide production wherein hydrogen is fed to the reactor in staged points of entry above an oxygen and hydrogen inlet. The process is distinguished by employing a woven catalyst having a long on-stream life in a fixed bed reactor which produces a selectivity of above 65%. The patent does not teach or claim the adjustment of the oxygen to hydrogen gas ratio at each stage to provide a preferred ratio that yields a minimum volume of a recycle stream
[0007] U.S. Pat. No. 6,447,743 teaches a method for preparing hydrogen peroxide directly using staged oxygen addition into the reactor at a relatively high ratio of oxygen to hydrogen.
[0008] U.S. Pat. No. 5,641,467 to Huckins teaches and claims a method for safe hydrogen peroxide production in a catalytic reactor by injecting oxygen or oxygen and hydrogen into a flowing medium at multiple points downstream in a catalytic reactor. The volumetric ratios of flowing medium to injected hydrogen and/or oxygen are selected to preferable maintain a safe combination of hydrogen to oxygen or where the volume ratio of oxygen to hydrogen is from 1:1 to 20:1. However, the patent does not teach or claim the staged injection of hydrogen at varying hydrogen to oxygen ratios preselected to maximize the conversion and selectivity of hydrogen peroxide production while producing low oxygen recycle ratios.
[0009] U.S. Pat. No. 6,042,804 is related to the foregoing '467 patent and teaches and claims separation of hydrogen peroxide plus process operating conditions within the explosive limits of hydrogen gas and oxygen mixtures.
[0010] It is an objective of the present invention to provide a process for the direct continuous synthesis of hydrogen peroxide from hydrogen gas and oxygen in a catalytic reactor that avoids the necessity of feeding a large excess of oxygen that results in a substantial recycle stream of unconverted oxygen. It is a further objective of the invention to provide such a process that avoids the production of and need for recycling a large excess of oxygen but, nevertheless, achieves improved process conversion of hydrogen and oxygen to hydrogen peroxide with high selectivity.
SUMMARY OF THE INVENTION
[0011] The invention describes an improved process for the production of hydrogen peroxide by the direct reaction of oxygen and hydrogen. The governing principle of the invention is the fact that performance of the direct synthesis process is significantly improved in terms of process selectivity and conversion when the oxygen concentration in the direct synthesis feedstream is higher than at least 50 weight percent or preferably at least 70 weight percent. Additionally, performance is improved when the oxygen to hydrogen molar ratio is preferably greater than a value of about 1.5 or, preferably, greater than 3. However, these preferred values of oxygen concentration and oxygen to hydrogen molar ratio typically require the use of excesses of oxygen feed, and therefore lead to effluent gas flows containing large amounts of oxygen which must be recompressed and recycled to the process at a significant economic penalty.
[0012] The hydrogen peroxide process of the present invention allows the overall hydrogen and oxygen feeds to the direct synthesis reactor to be maintained at or near the desired stoichiometric molar ratio of approximately 1:1 which eliminates the need for large excesses of oxygen. This is achieved while distributing the oxygen and hydrogen feedstreams to the reactor in a manner that maintains the desired minimum concentration of oxygen in the reactor for hydrogen peroxide production while maintaining the desired molar ratio of oxygen to hydrogen in most or the entire continuous reactor. As a result, high values of selectivity and yield of hydrogen peroxide are realized in the process of the invention without experiencing the production of large excesses of unconverted oxygen that require recompression with large compressors and recycling of large quantities of oxygen to the direct synthesis reactor. The objects of the invention are realized by a staged addition of hydrogen to a multi-zoned reactor where portions of the hydrogen fed to the reactor are injected at points downstream of the reactor first inlet.
[0013] More particularly, the invention comprises a multizoned or multistaged direct catalytic process for the production of hydrogen peroxide from hydrogen and oxygen feedstreams wherein catalyst in decreasing amounts is loaded into serially connected catalyst conversion zones in a catalytic reactor. The zones comprise a first zone and at least one receivably connected intermediate or terminal zone maintained under conditions sufficient to convert hydrogen and oxygen to hydrogen peroxide. All of an oxygen feedstream and a major portion of a hydrogen feedstream are passed into the first conversion zone at an inlet molar ratio of oxygen to hydrogen between 1.5 and 10. Sequentially decreasing portions of the remaining fresh hydrogen feedstream are passed to the inlet of each of the receivably connected serial intermediate or terminal conversion zones at a zone inlet molar ratio of oxygen to hydrogen the same as that employed in the first zone inlet. Hydrogen peroxide and unconverted hydrogen and oxygen are recovered from the terminal zone effluent. Optionally, the unconverted oxygen and hydrogen from the terminal zone effluent are recycled or sufficient quantities of hydrogen and oxygen are utilized in a single pass process that obviates the necessity of recycling the reactor's gaseous effluent. Notably, the molar ratio of oxygen to hydrogen in the combined total of oxygen and hydrogen feedstreams is less than the inlet molar ratio of oxygen to hydrogen introduced into each of the conversion zones.
[0014] Preferably, most of the oxygen plus a portion of the hydrogen feedstream and a liquid media feedstream in a molar ratio of oxygen to hydrogen between 1.5 and 10 are introduced into the first catalyst-containing stage of the staged catalytic reactor. Hydrogen is fed into the downstream feedstream containing hydrogen peroxide, unconverted oxygen and hydrogen in all subsequent catalyst-containing stages in an amount sufficient to reestablish the molar ratio of oxygen to hydrogen at the inlet of each stage to correspond to the molar ratio established at the first stage inlet. More particularly, additional amounts of hydrogen are fed into the second and subsequent catalyst-containing stages along with the entire effluent from the previous stage
[0015] The multizoned or multistaged direct catalytic process of the invention includes at least one reactor with serially connected conversion zones of successively decreasing size. In one embodiment of the invention, the reactor is of the fixed bed or ebullated bed type, and the serially connected zones of the reactor each contain successively decreasing amounts of catalyst, either immobilized as a fixed bed or agitated as an ebullated bed. In another embodiment, the reactor is of the slurry or fluidized bed type, where the liquid/solid slurry of reaction liquid and catalyst passes through a series of reactor zones of successively decreasing volume. For the fixed bed reactor, the size of each zone is defined by the amount of catalyst loaded into that zone. For the slurry/fluidized bed reactor, the catalyst is dispersed and travels along with the liquid phase. The size of each zone is determined by the reactor volume which, in turn, determines how long the liquid/solid mixture stays in each zone.
DESCRIPTION OF THE DRAWINGS
[0016] The FIGURE is a drawing depicting one example of the staged catalytic reactor vessel of the invention for the direct production of hydrogen peroxide.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention is a process for the production of hydrogen peroxide by direct synthesis from oxygen and hydrogen that avoids the use of a large excess of one gas reactant and provides a means to achieve high selectivity, It has been found that high selectivity of hydrogen peroxide production can be achieved if the direct synthesis is carried out using an overall gas composition where the oxygen concentration is at least 50% by volume of the total gas feed, and preferably at least 70%. It has also been determined that high selectivity for hydrogen peroxide production can be achieved by maintaining an oxygen-to-hydrogen ratio, molar or volume, of at least 2 to 1, and preferably at least 3 to 1 in the reactor.
[0018] While excess oxygen is preferred in the process in order to achieve high selectivity for hydrogen peroxide production, in either or both of the above cases the significant amount of excess oxygen used must be recovered and recycled in the process to maintain an economically feasible process. But the cost of oxygen recycle is itself a serious economic liability for the process because the amount of oxygen to be recycled dictates the use of large and expensive compressors.
[0019] The present invention provides a means to operate a continuous direct hydrogen peroxide synthesis process under the foregoing preferred process conditions of overall oxygen concentration in the reactor and the preferred ratios of oxygen to hydrogen while avoiding the need for a significant excess of oxygen in the overall rector feed. The process of the invention provides a substantially diminished requirement in terms of the volume of the oxygen recycle stream and, consequently, the size of the required recycle compressors. In one preferred embodiment, the process of the invention can completely eliminate the need for recycling of unconverted gases. These advantages are realized by carrying out the continuous direct synthesis of hydrogen peroxide in a catalytic reactor where the hydrogen gas that is fed to the reactor overall is injected serially in diminishing discrete stages along the reactor length. The amount of catalyst in each stage decreases from the first to the last stage of hydrogen gas injection corresponding to the decrease in the amount of hydrogen gas injected or fed at each stage. The amount of hydrogen injected at each stage is held to an amount sufficient to establish essentially the same ratio of oxygen to hydrogen at the locus of inject for all stages. Preferably, the ratio of oxygen to hydrogen for all stages taken at their inlet hydrogen feed position is a constant selected from 1.5 to 10, but more preferably from 2 to 4.
[0020] Referring to the FIGURE, one schematic example of the reactor vessel useful in the process of the invention is presented. The reactor shell 2 contains multiple ports of feed entry including inlet 3 for feeding all of the oxygen and inlet ports 4 , 5 and n for introducing hydrogen. An essentially inert media feed may be introduced into the bottom of the reactor at 6 and product collected as an overhead stream 7 .
[0021] One key characteristic of the reactor is that there is little or no back-mixing of the gas flow throughout the reactor vessel. The reactor has an essentially plug flow configuration with respect to the gas flow whereas the liquid flow may be plug flow or back mixed. Another characteristic of the process of the invention is that the oxygen containing feed, which may be oxygen, air, enriched air, or any other oxygen containing gas is fed entirely to the first stage of the reactor, i.e., the first inlet to the reactor. Yet another distinguishing characteristic of the process of the invention is that the hydrogen feed is divided into multiple fractions, only one of which is fed at the reactor entrance along with all of the oxygen-containing gas. The remainder of the hydrogen feed is injected in decreasing amounts at the subsequent downstream stages of the reactor. The number of stages in the reactor may be arbitrarily selected, but it is preferable to provide at least two hydrogen feed injection plus the first injection point where all of the oxygen feed plus a major portion of the hydrogen gas feed is injected. Although larger numbers of injection points can be used to provide very uniform gas compositions, excessive numbers will make the reactor design needlessly complicated. In practice, it is preferred to use no more than 6 injection points.
[0022] Each stage of the reactor vessel contains catalyst, preferably supported noble metal catalyst particles, preferably in decreasing amounts progressing from the first stage to the terminal or last stage wherein the amount of catalyst in any one stage corresponds approximately to the total quantity of oxygen and hydrogen present at the inlet of the specific stage. The ratio of oxygen to hydrogen at the inlet of each stage is predetermined to be constant or the same for each stage, although it is recognized that the ratio of oxygen to hydrogen within each stage will rise sequentially as the reactants linearly traverse each stage of the reactor. However, the hydrogen addition that is carried out at each stage is in an amount sufficient to adjust or lower the oxygen to hydrogen ratio to the preferred consistent ratio. The hydrogen feed may be divided into equal fractions or unequal fractions and the injection points may be equally spaced or unequally spaced without departing from the requirement of the invention for maintaining the oxygen to hydrogen ratio at the same preferred ratio at the inlet of each successive stage.
[0023] A particular useful aspect of the present invention is the fact that the process of the invention avoids the requirement of many hydrogen peroxide processes of the prior art to execute the process a staged hydrogen additions simply to assure that the process operates below the flammability or explosive limits of hydrogen. The process of the present invention is not limited to any such requirement. The process may run within the explosive limits of hydrogen or outside those limits.
[0024] The preferred gas composition ranges of the invention are selected according to a completely different set of criteria than those imposed by the prior art relating to hydrogen peroxide production. It has been found that the process of the present invention can continuously produce extremely high selectivity for hydrogen peroxide production exceeding 80% and even exceeding 90% selectivity when the process is carried under the conditions described herein. This benefit is not anticipated in the prior art.
[0025] A preferred embodiment of the subject invention is one where the overall hydrogen and oxygen feed rates to the reactor are close to the stoichiometric ratio required for the reaction to produce hydrogen peroxide. In cases of high hydrogen peroxide selectivity, the desired ratio of oxygen to hydrogen is approximately 1:1. However, in cases where the overall selectivity is less than 100%, the actual stoichiometry of the reaction corresponds to lower oxygen to hydrogen ratios. This is because the non-selective side reaction of hydrogen and oxygen to form water consumes less oxygen than the desired reaction to form hydrogen peroxide.
[0026] Another preferred embodiment of the process of the invention is one where the process is operated at a high per pass conversion of the gaseous reactants. The preferred conversion of hydrogen should be at least 70%, and more preferably, at least 80%. In the case where the overall oxygen to hydrogen ratio is close to the actual stoichiometry, the per pass oxygen conversion is similarly high. The advantage of this embodiment is that most of the gas feeds are utilized in a once-through gas flow mode. This reduces or even eliminates the need for recompression and recycling of the effluent gas and achieves significant capital and operating cost savings.
[0027] A particularly advantageous embodiment of the invention is that where the direct synthesis reaction is conducted using the Pd/C catalysts as described in either applicant's U.S. Pat. No. 6,168,775B1 or in pending U.S. patent application Ser. No. 10/205,881, filed Jul. 26, 2002. Both the '775 U.S. patent and the pending 10/205,881 patent application are incorporated herein by reference for all that they teach and claim of catalysts useful in the process of the instant invention. Very high selectivity levels can be achieved using the '775 catalyst in the process of this invention. However, the present invention may be conducted using any direct synthesis catalyst.
[0028] An especially preferred mode for the subject invention is one where the reactor operation and multiple hydrogen feeds are arranged to provide for a relatively uniform oxygen-to-hydrogen ratio throughout the reactor. It is well-known in the literature that O2:H2 ratio exerts an important role in the selectivity and productivity of catalysts for the direct synthesis of hydrogen peroxide from hydrogen and oxygen. In particular, it is known that ratios of greater than 1.5:1 are preferred, and ratios of more than 3:1 are more preferred. However, no prior art provides a reactor that create a uniform distribution of oxygen-hydrogen ratios, while also avoiding the need for substantial and costly excesses of oxygen to maintain the preferred ratio.
[0029] In the preferred mode of the subject invention, a relatively uniform profile of O2:H2 ratios are maintained across the reactor by subdividing the reactor into a series of zones s described herein. While the zones may be of equal size, they are preferably designed to be of unequal size. In the case where the reactor is of the fixed bed type, each zone will be a section of packed catalyst wherein the “size” of the different sections is defined by the amount of catalyst packed in each section.
[0030] To the first reactor zone, essentially all of the oxygen is fed, as well as all of the liquid feed to the reactor, but only part of the hydrogen. Additional parts of the hydrogen feed are then fed at points intermediate between the ensuing reactor zones, until the last portion of hydrogen is fed just upstream of the final reactor zone.
[0031] Where the sizes of the reactor zones differ, the amount of hydrogen fed to each bed will also differ, although not necessarily in exact proportion to the sizes of the reaction zones. The key aspect is that the scheme for subdividing the hydrogen feed is predicated on achieving the desired uniform profile of oxygen/hydrogen ratio throughout the reactor.
[0032] While other arrangements are also possible, a further aspect of the preferred mode of the invention is that the differing sized reactor zones will preferably be arranged in order of decreasing size, with the largest reactor zone placed at the inlet part of the reactor, and the smallest located at the exit. Correspondingly, the part of hydrogen feed to the first reactor section will be largest, and that to the last bed will be the smallest.
[0033] The following examples are provided to illustrate the process of the invention as well as the utility of the invention.
EXAMPLE 1
[0034] A catalyst containing 0.75% Pd on a carbon support is packed into a fixed bed reactor where the reactor is subdivided into 4 zones or beds constituting stages in the process of the invention. The reactor is arranged for cocurrent upflow of liquid and gas streams. The first bed is located at the bottom of the reactor and the last bed is located at the top of the reactor. A total of 1667 kg of catalyst is charged to this reactor across the four zones. The total amount of catalyst and the hydrogen feed are subdivided between the stages according to:
Hydrogen Feed Catalyst Section Catalyst Amount (kg) (kgmol/hr) 1 (Inlet) 764 250 2 474 114 3 271 59 4 (Outlet) 158 32 Total 1667 454
[0035] To the inlet of the first bed is fed 111,794 kg/hr of a liquid feed mixture comprised of methanol with 1% H 2 SO 4 and 5 ppm NaBr. Also fed to the first reactor section is 531 kgmol/hr of oxygen, which corresponds to an overall O 2 :H 2 feed ratio of 1.17, or only 17% excess oxygen. The reactor is operated at a total pressure of 27.5 bar (≠400 psia). Cooling is adjusted to maintain an average temperature of 45° C.
[0036] The following results were achieved:
Hydrogen Section Inlet Section Outlet H 2 O 2 Reactor Conversion O 2 :H 2 ratio O 2 :H 2 ratio Produced Section (%) molar) (molar) (kg/hr) 1 75 2.13 5.66 5730 2 66 2.01 4.06 3553 3 56 2.04 3.44 2036 4 46 2.14 3.15 1183 Overall 90 12503
[0037] Based on hydrogen converted, the overall hydrogen peroxide selectivity is 90%. Based on hydrogen fed, the overall hydrogen peroxide yield is 81%. Based on total oxygen fed, the overall hydrogen peroxide yield is 69%. The product solution contains 10% hydrogen peroxide by weight. This example shows that with the present invention, a minimum O 2 :H 2 ratio of 2 can be maintained while only feeding a 17% excess of oxygen on an overall basis.
EXAMPLE 2
[0038] A catalyst containing 0.75% Pd on a carbon support is packed into a fixed bed reactor where the reactor is subdivided into 4 zones or beds defining stages. The reactor is arranged for cocurrent upflow of liquid and gas streams, so the first bed is located at the bottom of the reactor and the last bed located at the top. A cooling medium is circulated through the shell of the reactor. A total of 1664 kg of catalyst is charged overall to this reactor with the catalyst amount subdivided between the sections according to:
Hydrogen Feed Catalyst Section Catalyst Amount (kg) (kgmol/hr) 1 (Inlet) 689 211 2 458 116 3 306 77 4 (Outlet) 212 50 Total 1664 454
[0039] To the inlet of the first bed is fed 111,624 kg/hr of a liquid feed mixture comprised of methanol with 1% H 2 SO 4 and 5 ppm NaBr. Also fed to the first reactor section is 636 kgmol/hr of oxygen, which corresponds to an overall O 2 :H 2 feed ratio of 1.4, or only 40% excess oxygen. The reactor is operated at a total pressure of 27.5 bar (≠400 psia). Cooling is adjusted to maintain an average temperature of 45° C.
[0040] This leads to the following performance results:
Hydrogen Section Inlet Section Outlet H 2 O 2 Reactor Conversion O 2 :H 2 Ratio O 2 :H 2 Ratio Produced Section (%) (molar) (molar) (kg/hr) 1 80 3.01 11.2 5168 2 71 3.01 8.04 3432 3 61 3.00 6.20 2296 4 53 3.04 5.39 1588 Overall 90 12484
[0041] Based on hydrogen converted, the overall hydrogen peroxide selectivity is 90%. Based on hydrogen fed, the overall hydrogen peroxide yield is 81%. Based on total oxygen fed, the overall hydrogen peroxide yield is 58%. The product solution contains 10% hydrogen peroxide by weight. This example shows that with the present invention, a minimum O 2 :H 2 ratio of 3 can be maintained while only feeding a 40% excess of oxygen on an overall basis.
EXAMPLE 3
[0042] A catalyst containing 0.75% Pd on a carbon support is packed into a fixed bed reactor, where the reactor is subdivided into 4 zones or beds. The reactor is arranged for cocurrent upflow of liquid and gas streams, so the first bed is located at the bottom of the reactor, and the last bed located at the top. A total of 1655 kg of catalyst is charged to this reactor with the catalyst amount subdivided between the sections according to:
Hydrogen Feed Catalyst Section Catalyst Amount (kg) (kgmol/hr) 1 (Inlet) 635 190 2 455 118 3 324 85 4 (Outlet) 241 61 Total 1655 454
[0043] To the inlet of the first bed is fed 110,979 kg/hr of a liquid feed mixture comprised of methanol with 1% H 2 SO 4 and 5 ppm NaBr. Also fed to the first reactor section is 758 kgmol/hr of oxygen, which corresponds to an overall O2:H2 feed ratio of 1.67, or only 67% excess oxygen. The reactor is operated at a total pressure of 27.5 bar (≠400 psia). Cooling is adjusted to maintain an average temperature of 45° C.
[0044] This leads to the following performance results:
Hydrogen Section Inlet Section Outlet H 2 O 2 Reactor Conversion O 2 :H 2 Ratio O 2 :H 2 Ratio Produced Section (%) (molar) (molar) (kg/hr) 1 82 4.00 17.9 4762 2 73 4.00 12.2 3410 3 63 4.00 9.19 2431 4 55 4.00 7.71 1809 Overall 90 12412
[0045] Based on hydrogen converted, the overall hydrogen peroxide selectivity is 90%. Based on hydrogen fed, the overall hydrogen peroxide yield is 81%. Based on total oxygen fed, the overall hydrogen peroxide yield is 48%. The product solution contains 10% hydrogen peroxide by weight. This example shows that with the present invention, a minimum O 2 :H 2 ratio of 4 can be maintained while only feeding a 67% excess of oxygen on an overall basis.
[0046] The process of the invention lends itself well to the use of a variety of reactor types and configurations known to those skilled in the art. As noted herein before, staged reactors are known in the art and can be applied to fixed catalyst bed reactors, fluid bed reactors, ebullated catalyst bed reactors, catalyst slurry bed reactors and the like. These reactors are applicable as well to the process of the invention. They may be configured in a variety of ways known in the art such as a single, vertical reactor shell containing multiple zones or stages containing individual beds of catalyst particles and individual inlet ports to admit hydrogen feed. Optionally, each zone may comprise a separate reactor shell connected to receive the feedstream from a preceding stage and designed to discharge an effluent to the next stage. The choice as to whether the reactor(s) are installed as a single or multiple vertical reactor installation or a train of horizontal vessels is the artisan's option.
[0047] Any catalyst known to those skilled in the art of hydrogen peroxide production may be used in the process of the invention. However, it is well known that supported noble metal catalyst particles, particularly palladium on carbon support, are preferred as the catalyst for direct hydrogen peroxide production from oxygen and hydrogen gases. An especially useful catalyst is the supported palladium catalyst prepared by the process described in the previously mentioned U.S. Pat. No. 6,168,775. The catalyst described in that patent is the most preferred catalyst for the process of this invention.
[0048] The amount of catalyst used in each zone of the process of the invention is determined by consideration of a variety of variables including reactor type and size, catalyst activity and life, and the feedstream rate to each zone. Since all of the oxygen feed and a major portion of the hydrogen feed are introduced into the reactor in the first stage that stage will typically hold the preponderant share of catalyst particles.
[0049] A carrier liquid is preferably included as part of the total feedstream to the first zone of the reactor of the process of the invention to assist in partly dissolving the reactants and propelling the feedstream and products through the reactor. Preferred carrier liquids are water, organic solvents, and mixtures thereof. In cases where the preferred carrier includes, at least in part, an organic solvent, the preferred solvents are alcohols such as methanol.
[0050] Reaction conditions that are useful for the process of the invention include temperature of 0° to 150° C. and pressure from 1 bar to 100 bar (15 psia to 1500 psia). The more preferred reactions conditions include a temperature of about 30° C. to 45° C. at a pressure of 1 bar to 70 bar (4001015 psia). The amount of catalyst used in each zone of the multistaged reactor vessel of the process of the invention may be the same quantity for each stage or the quantity may vary for each stage. Most preferably, the hydrogen feed to each stage of the process declines from the first to the last stage as the oxygen feed that is fed only to the first stage declines in concentration in subsequent stages as it is converted to hydrogen peroxide. Accordingly, the amount of catalyst in each successive stage may be reduced in approximate proportion to the feedrate of hydrogen gas into the particular stage. The amount of catalyst will also depend on the type of catalytic vessel being employed, i.e., fixed bed, ebullated bed, etc. and the activity of the catalyst. These variables are well understood by artisans in the field who can select the amount of catalyst in each stage sufficient to optimally satisfy the variables. In the most preferred case, the catalyst will comprise palladium on carbon support for all stages with the catalyst optionally containing a minor amount of platinum in addition to the palladium. | An improved catalytic process for producing hydrogen peroxide directly by reaction of hydrogen and oxygen is disclosed. The process employs staged or sequential feeding of portions of the hydrogen feedstream into zones in the catalytic reactor in amounts sufficient to maintain an essentially constant and preferred ratio of oxygen to hydrogen at the inlet to each of the vessel's zones whereby high selectivity for hydrogen peroxide production is achieved and excess oxygen recycle requirements are minimized. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an anchor for small boats which is particularly adapted to be useful for anchoring in a variety of conditions, including rocky bottoms and reefs, and a method of making such an anchor which provides enhanced durability, strength and a longer usable life.
[0003] 2. Description of Related Art
[0004] Known boat anchors generally rely primarily on their weight to serve their intended function. Heavyweight anchors have disadvantages including that they are difficult to retrieve because, among other things, their significant weight requires considerable effort to haul up by hand. Additionally, heavyweight anchors function best in sandy bottoms, but are poorly adapted to rigid bottoms, such as rocky bottoms. A heavyweight anchor is designed to displace sand from the bottom of the body of water in which the boat is to be anchored, as the heavyweight anchor sinks into the sand, displaced sand settles back into place above the anchor until the anchor becomes lodged sufficiently that the boat cannot drift away. Such anchors don't work well in other conditions, such as where there are large rocks on the bottom of the body of water in which the boat is to be anchored, a heavyweight anchor will not displace the rocks and will not be able to sink in and secure the boat as intended. Further, if a heavyweight anchor becomes entangled with a rocky bottom, tree roots or other debris, it can become difficult or even impossible to retrieve the anchor.
[0005] There are some lightweight boat anchors known in the art, such as that of U.S. Pat. No. 2,791,982, by L. S. Parry (hereafter “Parry”). Parry solves some of the problems with heavyweight anchors discussed hereinabove. Parry discloses flexible tines 7 that permit the anchor to grab on to a rocky bottom and then to release that grip when sufficient force is applied to bend the tines 7 . The tines 7 of Parry are constrained and limited in their range of motion by a lug 6 . The lug 6 not only impedes the flexibility of the tines 7 , but also forces the tines 7 to always bend at a certain point, this fulcrum point continually places the maximum bending stress on the same part of the tines 7 every time the anchor is used (see, e.g., FIG. 3 and col. 3, lines 8-20 of Parry). Accordingly, it is readily appreciated by one skilled in the art that the tines 7 of Parry will fatigue most rapidly at the single fulcrum point and that failure will occur at the fulcrum point.
[0006] The prior art also includes anchors with some form of protective coating, such as those taught by U.S. Pat. No. 5,819,681, Barnes et al. (hereafter, “Barnes”) and U.S. Pat. No. 3,754,524, Locks (hereafter “Locks”). Such prior art anchors are coated by dipping the anchors into the coating material to be applied. This method of applying a protective coating can result in incomplete or insufficient bonding between the anchor and the coating. Further, this method can be time-consuming because it requires multiple repetitions to achieve the desired coating thickness (e.g., as described by Barnes at col. 2, lines 47-50).
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a lightweight anchor that operates by gripping engagement with the bottom surface such that it can be used with many commonly encountered surface conditions. The anchor disclosed herein may be quickly and easily deployed, because it is lightweight the user can lift and throw it with minimal effort. The disclosed anchor is also easily retrieved, even under conditions that would present substantial difficulty with a conventional anchor. The anchor disclosed herein further includes a protective coating which provides greater strength and durability for the anchor, and in particular for the flexible tines.
[0008] In contrast with heavyweight anchors most commonly used today, the anchor of the present invention works by hooking into or otherwise engaging the bottom surface of the body of water in which the boat is to be anchored. The anchor of the present invention may therefore be easily retrieved, firstly because it is light in weight, and secondly because its tines will flex under sufficient force to unhook or disengage from the bottom surface. Once the anchor is retrieved, the flexible tines can easily be bent back to their operative configuration to engage with the bottom surface again when the anchor is next deployed. Additionally, the flexible tines are unrestrained in their movement and bending. This allows the tines to freely flex as needed to engage any type of bottom surface. Moreover, the unconstrained bending of the flexible tines allows the bending stress incurred when the tines flex during disengagement from the bottom to be distributed along the length of each tine as it bends, avoiding any fulcrum points so that the bending stress ideally has no concentration point, or at least does not concentrate at the same point repeatedly, which would cause that point to quickly fail under extended use. The protective coating reinforces the flexible tines throughout repeated cycles of bending and re-shaping, which increases the durability and usable life of the anchor.
[0009] The ease of retrieval of the disclosed anchor can be enhanced with an additional quick-release feature. In one embodiment, the present invention includes a second attachment point on the bottom end of the main body. The quick-release feature is implemented by rigging the anchor using the second, bottom attachment point as the primary rode attachment point, e.g., by tying a rope or by securely connecting a chain to the bottom attachment point, and the top attachment point is used as a temporary attachment point, e.g., by attaching the rope or chain thereto with a cable tie, also known as a zip tie. When the anchor is deployed, the temporary rode attachment at the top attachment point will be operative. When sufficient force is applied to break the temporary connection at the top attachment point, the anchor will be inverted and disengage from the surface, allowing for quick and easy retrieval of the anchor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front perspective view of an embodiment of the disclosed anchor, illustrating an example of possible lettering which can be included, and with a portion of the protective coating removed for illustration purposes.
[0011] FIG. 2 is a rear view of an embodiment of the disclosed anchor including a variety of possible positions within the free range of movement of an illustrated flexible tine.
[0012] FIG. 3 is a top-down view of an embodiment of the disclosed anchor.
[0013] FIG. 4 is a bottom-up view of an embodiment of the disclosed anchor.
[0014] FIG. 5 is a section view of an embodiment of the disclosed anchor taken along line 5 - 5 in FIG. 3 .
DETAILED DESCRIPTION
[0015] As seen in FIGS. 1-4 , The disclosed anchor includes a main body 1 which is formed of a cylindrical surface enclosed by circular faces on each end. A rode attachment point 2 A, 2 B is provided on one or both ends of the main body 1 , on or near one or both endpoints of the longitudinal axis of the main body 1 (i.e., on or near the centerpoint of one or both of the circular end faces). The attachment points 2 A, 2 B may be provided, e.g., as eye bolts threadedly received by each circular face of the main body, or, as shown in the attached drawings, in the form of a semi-circular arch. The disclosed anchor further includes a plurality of flexible tines 3 attached to one end of the cylindrical surface of the main body 1 , the end of the main body 1 where the tines 3 are attached is referred to as the bottom end.
[0016] A rode attachment point 2 A is provided on or near the top endpoint of the longitudinal axis of the main body 1 . A second rode attachment point 2 B may optionally be provided on or near the bottom endpoint of the longitudinal axis of the main body. When the top attachment point 2 A is the only attachment point provided, it is intended to be used to provide a secure and relatively permanent connection of the rode to the anchor. When a second, bottom attachment point 2 B is also provided, it is intended to be used as the primary rode attachment point, e.g., by tying a rope or by securely connecting a chain to the bottom attachment point. Further, when a second, bottom attachment point 2 B is provided, the top attachment point 2 A is used as a temporary attachment point, e.g., by attaching the rope or chain thereto with a cable tie, also known as a zip tie. When the anchor is deployed, the temporary rode attachment at the top attachment point 2 A will be operative. When sufficient force is applied to break the temporary connection at the top attachment point 2 A, the anchor will be inverted and disengage from the surface, allowing for quick and easy retrieval of the anchor.
[0017] As seen in FIG. 5 , the main body 1 is comprised of a tube 1 A, enclosed by a top end plug 1 B and a bottom end plug 1 C. The interior of tube 1 A is filled with a heavy material 5 , such as concrete as shown in FIG. 5 . Tines 3 are preferably attached to main body 1 at the bottom end plug 1 C as shown in FIG. 5 . However, alternate configurations are contemplated within the scope of the invention. For example, tines 3 can be attached to the tube 1 A, in which case the outer edge of bottom end plug 1 C may be aligned with the bottom end of tube 1 A, in a similar fashion to that illustrated in FIG. 5 for top end plug 1 B.
[0018] It is preferred that the main body 1 , rode attachment point(s) 2 A, 2 B, and flexible tines 3 be formed of a metallic material. In particular, an aluminum alloy provides desirable characteristics of flexibility and corrosion resistance which are advantageous in this application. The flexible tines 3 are preferably equally spaced around the circumference of the cylindrical surface of the main body 1 . In a preferred embodiment, six such tines are provided. In cross-section, the tines 3 are generally shaped like wires, that is, the tines 3 are solid elongated cylinders with a constant diameter. This embodiment provides advantages in ease of manufacture and reduced expense, however, additional configurations of the tines 3 may be considered within the scope of this disclosure, as further discussed hereinbelow. A first portion of each tine 3 is attached to the main body 1 (i.e., is proximal to the main body, and therefore the termination of this portion is described as the proximal end). When in their operative configuration, a second portion of the tine 3 (the terminus of which is referred to as the distal end) is bent back on itself, forming an angle of approximately 45 degrees with respect to the main body 1 . When the tines 3 are so arranged, they are in their operative configuration and are capable of gripping engagement with a variety of bottom surfaces.
[0019] While a simple wire-like shape for the tines 3 is a preferred embodiment, other shapes may have different advantages and are contemplated within the scope of this invention. Some anchoring conditions may require enhanced grappling engagement. It is contemplated within the scope of this invention to provide tines 3 with barbs on their distal ends for use in such conditions.
[0020] The disclosed anchor further includes a protective coating 4 . In a preferred embodiment, the protective coating 4 is an elastomeric coating. It is further preferred that the elastomeric coating 4 be a sprayed-on material, for example, one of the LINE-X® type spray-on coatings. Such coatings can be rapidly and effectively applied by spraying with little wasted coating material, in contrast to dipped coatings which require a reservoir of coating material containing far more material than will actually be used to coat the anchor. In particular, a two-part polyurea which is applied by spraying with sufficiently high temperature and high pressure such that it will bond with the substrate to which it is applied has been found advantageous. The elastomeric coating 4 prevents the anchor from scratching the vessel with which the anchor is used. The elastomeric coating 4 further enhances the durability and usable life of the anchor. When the flexible tines 3 bend and are re-shaped, their material undergoes stress and strain, the long-term cumulative effects of these forces will ultimately cause the tines to break. Because the tines 3 of the disclosed anchor are reinforced by the protective coating 4 , their resistance to the stress and strain of bending and re-shaping is increased and their working life is extended.
[0021] Also as shown in FIG. 1 , the disclosed anchor can be customized with text 6 . Text can be included by placing raised letters 6 on the main body 1 prior to application of the protective coating 4 . The letters 6 may be formed of a polymeric material. When the protective coating 4 is applied, it is applied over the polymeric letters 6 and the metallic main body 1 to effectively bond the letters 6 to the main body 1 . Thus, the finished product anchor can include custom text such as the user's name or the name of their boat, among other possibilities.
[0022] The protective coating 4 can also provide custom color. The preferred spray-on coating 4 described hereinabove can be provided in black, charcoal, blue, white, red, and green. Custom color and custom text are desirable in that users prefer the unique appearance one or both of these features provide. Further, custom colors are useful in that they can make the anchor easier to locate should it become accidentally detached from the rode while underwater.
[0023] While preferred embodiments and example configurations have been shown and described, it is to be understood that various further modifications and additional configurations will be apparent to those skilled in the art. All such modifications and configurations are contemplated as being within the scope of the present invention. The specific embodiments and configurations disclosed are illustrative of the preferred and best modes for practicing the invention as defined by the appended claims, and should not be interpreted as limitations on the scope of the invention as defined by the appended claims. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | A lightweight anchor for small boats and a method of making the same. The anchor includes a protective coating. The anchor also includes a release mechanism. The primary release mechanism is provided by flexible tines. The flexible tines make the anchor adaptable to work in various conditions, such as rocky bottoms, reefs, or other similar conditions. The flexible tines also make the anchor easily retrievable. If the tines are bent during retrieval, the tines may be readily returned to their operative configuration. | 1 |
TECHNICAL FIELD
The present invention relates generally to a console for use with a vehicle. More specifically, the present invention relates to a dual opening console with a slidable armrest assembly.
BACKGROUND OF THE INVENTION
It is well known to provide a console between the driver and front passenger seats in an automotive vehicle. The console has many functions. It may operate as an armrest, a storage unit, a writing table or a cup holder. Three types of center consoles exist, those that open on one side, those that open on two sides, and those that open from the front. Each type of console has disadvantages.
Consoles that open on one side only, typically open in a manner that limits access only to the driver of the vehicle. Further, those that open on one side only are not suitable in today's global marketplace; i.e., a console suitable for a right-hand drive vehicle would not be suitable for a left-hand drive vehicle. While they provide access to both the driver and passenger in the front seat, they do not allow access to passengers sitting in the rear seats. Finally, consoles that open on two sides typically utilize a complex dual-hinge system, such systems result in increased manufacturing costs.
Additionally, current console assemblies lack user friendliness in a variety of areas. For example, as stated above, drivers and passengers in the front seats often use the console top as an armrest. However, because people are built differently, sit in vehicle seats differently than others, and sit closer to the steering wheel than others, current consoles are unable to provide user armrests that are uniformly comfortable and adjustable in all positions for all people. Therefore, there is a need in the art for an inexpensive console that provides all drivers and passengers of the vehicle with a comfortable weight bearing surface to act as an armrest at little, if any, additional cost.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a console for use with a vehicle that has an adjustable armrest assembly. It is a further object of the present invention to provide a slidable armrest assembly for a dual opening console.
It is yet another object of the present invention to provide a slidable console assembly that is user friendly and relatively inexpensive.
In accordance with the objects of the present invention, a console for use with an automobile vehicle is provided. The console includes a compartment having a bottom surface, a first side wall, a second side wall, a front end well, and a rear end well. The compartment has a lid connected thereto with the lid being operative to open from any of the first side or the second side. The lid has a padded weight bearing arm support positioned thereon with the lid and the padded weight bearing arm support being operative to move toward and away from the front end wall and the rear end wall. The lid has a slider assembly which affixes the lid to the compartment to allow such movement of the lid away from any of the front end or the rear end walls.
In accordance with a further object of the present invention, a lock assembly hingeably connects the lid with the compartment such that the lid can be opened from more than one side, but only on one side at a time. The lock assembly includes at least one lock bar located on the lid. The at least one lock bar extends between the opposite side walls or end walls of the compartment. The at least one lock arm rides on two parallel pivot pins. The at least one lock arm snaps onto the pivot pins by a respective flange that allows the lid to open in one direction only at a time.
Other features and advantages of the present invention will be readily appreciated as the same becomes better understood after reading the subsequent description when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vehicle console in accordance with a preferred embodiment of the present invention;
FIG. 2 is a cross-sectional view of vehicle console along line 2 — 2 ;
FIG. 3 is an enlarged sectional view of a pivot mechanism for a slidable vehicle console in accordance with a preferred embodiment of the present invention;
FIG. 4 is a sectional view of the pivot mechanism of FIG. 3 along the lines 4 — 4 ;
FIG. 5 illustrates an alternative embodiment of a pivot mechanism for a slidable vehicle console in accordance with a preferred embodiment of the present invention;
FIG. 6 illustrates a side cross-sectional view of a rear portion of a vehicle console in accordance with a preferred embodiment of the present invention;
FIG. 7 is a perspective view of an alternative slidable vehicle console in accordance with another preferred embodiment of the present invention;
FIG. 8 is a cross-sectional view of the vehicle console of FIG. 7 along the line along the line 8 — 8 ;
FIG. 9 is a side view of a vehicle console with the lid in a closed position in accordance with a preferred embodiment of the present invention;
FIG. 10 illustrates a lid of a dual opening vehicle console in two open positions in accordance with a preferred embodiment of the present invention; and
FIG. 11 illustrates a parallel pivot pin arrangement for a slidable vehicle console in accordance with a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, one embodiment of a vehicle console 20 according to the present invention is shown. The console 20 is preferably positioned between a driver's seat and a passenger's seat of a vehicle. A console 20 as shown is generally elongated and rectangular in shape to fit the space between the seats. It should be understood however that the console may take on a variety of different shapes. Further, while the disclosed console is preferably a dual opening console, i.e., opens from both sides, the disclosed invention may alternatively be utilized with a single opening console.
The console 20 includes a rectangular elongated member or lower console housing 22 defining a compartment 24 therewithin. As shown, the compartment 24 includes a bottom 26 , a first side wall 28 , a second side wall 30 , a front end wall 32 , and a rear end wall 34 . A lid 36 is connected to the compartment 24 . As will be explained later, the lid 36 may be hinged to any one of the walls; i.e., the first side wall 22 and the second side wall 24 . Attaching the lid 36 in this manner, enables the lid 36 to be opened in any one of two directions, i.e., front to back or side to side to allow access from any point adjacent to console 20 .
The lid 36 includes an outer lid 38 that is preferably filled with a foam cushion 40 and an inner lid 42 that is disposed beneath the foam cushion 40 . The foam cushion 40 forms an arm rest or comfortable weight bearing surface for a user's arm. The lid 36 is disposed above a dual opening lock bar 44 . Preferably, the inner lid 42 is secured to the dual opening lock bar 44 by known securing means 46 , such as screws or the like. Alternatively, the dual opening lock bar 44 may be integrally molded with the inner lid 42 to form an integral single part. The lock bar 44 preferably rides on a pair of parallel pivot pins 48 , 50 that are positioned within the compartment 24 . The compartment 24 is preferably in communication with a lower slide housing 52 within which the first and second pivot pins 48 , 50 are housed.
The lower slide housing 52 has an upper portion 53 and a base portion 54 . The base portion 54 has a pair of horizontal flanges 56 , 58 that fit into a respective horizontal slot 60 , 62 formed in the opposing side surfaces 28 , 30 of the compartment 24 . The interaction of the pair of horizontal flanges 56 , 58 and the horizontal slots 60 , 62 allow the outer lid 38 to slide back and forth on the lower console housing 22 . Additionally, the area where the horizontal flanges 56 , 58 bear on the slots 60 , 62 offers support to the upper console lid 38 when it is in its forward extended position. Because the dual opening lock bar 44 rides on the lower slide housing 52 as the lid 36 is slid, the dual opening bar 44 and thus the lid 36 can open in all positions. The lid 36 has a rear portion 64 that has a sliding shade 76 or a tambour door attached thereto (FIG. 6 ). The sliding shade 76 acts to keep dust and other undesirables out of the console 20 when the lid 36 is pulled forward. The shade or tambour door 76 also adds to the look or appearance of the console 20 .
FIGS. 3 and 4 illustrate an enlarged sectional view through the pivot pin 48 . While the structure and operation of the pivot pin 48 is discussed specifically, it should be understood that the description of the pivot pin 48 applies equally to the pivot pin 50 . As shown, the dual open lock bar 44 has a pivot arm 67 which engages the pivot pin 48 . The pivot arm 67 employs a dove tail 68 that interlocks with a mating cut 70 formed in the slide housing. In the normally closed position, shown in FIG. 3, the pivot arm 67 is supported on the upper portion of the pivot pin 48 . In an open position, shown in phantom in FIG. 3, the pivot arm 67 rotates around the pivot pin 48 allowing the lid 36 to be rotated to an open position. When the lid 36 is opened, the dove tail 68 and the dove tail mating cut 70 interlock and prevent the removal of the lid 38 until it is closed.
FIG. 5 illustrates an alternative embodiment for preventing the removal of the upper lid 38 when the lid 36 is in an open position. In this design, an extended snap-on flange 72 is employed which snaps onto the respective first and second pivot pins 48 , 50 . The snap-on flange 72 extends further around the pins 48 , 50 in a tangential direction then the prior dove tail 68 (FIG. 3) in order to prevent the removal of the lid 36 when opened and allow it to open with the same friction resistance as other designs. The console 20 in this embodiment, includes a lower clearance shelf 74 to allow the snap-on flange 72 to rotate around the respective pins 48 , 50 without interference with the slide housing 52 . When the lid 36 is opened, as shown in phantom lines, the snap-on flange 72 is configured to prevent the lid 36 from being pulled off. Similarly, when the lid 36 is in a closed position, it can be pivoted in the opposite direction without the flange 72 preventing its opening.
FIG. 6 illustrates the rear portion 64 of the console 20 in accordance with the present invention. The rear portion 64 of the lid 36 includes a tambour door 76 attached thereto. When the lid 36 is slid forward, its rear portion 64 also moves forward which pulls forward the tambour door or shade 76 connected thereto. This ensures that the rear opening to the compartment 24 is covered by the tambour door 76 when the lid 36 is slid toward the front end wall 32 . When the lid 36 is in its rearward position, as shown in phantom, the tambour door 76 slides into a storage compartment 80 and is not visible. A pair of grooves (not shown) are preferably located in the opposing side surfaces 28 , 30 of the compartment 24 to guide the tambour door 76 as it slides. The tambour door 76 also offers a pleasant looking design for the console 20 from the perspective of a rear passenger both when it is employed and when the console lid is in the rear position, i.e., the tambour door 76 is not visible.
FIGS. 7 and 8 illustrate another embodiment of a sliding console 20 in accordance with the present invention. The features of this embodiment that are the same as the prior embodiment are referred to by the same reference numbers. In this embodiment, the console 20 , includes a second lock bar 82 that is also attached to the inner lid 42 . The lock bar 82 rides on a second pair of parallel pivot pins 84 , 86 . The second pair of parallel pivot pins 84 , 86 are preferably positioned near the rear portion 64 of the console 20 . The length of the pivot pins 48 , 50 , 84 , 86 are preferably each one half the length of the pivot pins in the prior embodiment.
The lock bars 44 , 82 preferably each slide under a pair of locking flanges 88 , 90 that hold the bars 44 , 82 , in position when the lid 36 is extended forward, as is shown in phantom lines in FIG. 7 . With this configuration, the dual opening lid 36 cannot be opened in any direction when it is extended forward. This design has fewer parts than the prior embodiment.
FIG. 9 is a side view of the console 20 with the lid 36 in a closed and fully rearward position. The lid 36 is shown in phantom lines in both a partially extended position 92 and a fully extended position 94 . FIG. 10 illustrates the lid 36 in a closed position. The lid 36 is shown in phantom lines in an open position 96 , pivoted around pivot pin 48 . Similarly, the lid 36 is shown in phantom lines in an open position 98 , pivoted around pivot pin 50 .
FIG. 11 illustrates the snap-on guides 100 of the dual lock bar 44 as positioned on the parallel pivot pin 48 . obviously, an identical snap-on guide 100 is positioned on the parallel pivot pin 50 . The lock bar 44 is shown in phantom lines in an open position with the snap-on guide being partially rotated around the pivot pin 48 .
The dual opening sliding console assembly of both FIGS. 1 and 7 are advantageous in that they have very few moving parts and are easily serviceable if necessary. It should be understood that the design can be adapted into existing consoles adding the features of dual opening as well as a sliding armrest assembly with a minimal amount of change and cost to the existing console. The sliding armrest offers sturdy, flange supports for the resting of the arm on the extended area of the lid, at the same time, the lid can be easily opened. Two methods of anti-removal flanging on the sliding bar have been utilized to prevent its removal while it is opened. Further, an alternate for the sliding console would allow the armrest to be slid forward with it remaining latched closed until it is returned to its home position.
Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically prescribed. | A sliding console ( 20 ) for use with a vehicle. The console ( 20 ) includes a padded upper portion ( 40 ) to serve as an arm rest. The console ( 20 ) includes a slider assembly ( 52 ) that moves toward and way form the front end ( 32 ) and rear end walls ( 34 ) to allow the padded upper portion ( 40 ) to be adjusted. | 4 |
FIELD OF THE INVENTION
The present invention relates to a method for the improvement of yield of fine fibers and the filler and also the improvement of freeness in the paper-making process and a sulfonated phenol-formaldehyde resin (referred to as SPFR hereinafter) used as the promotor in combination with polyethylene oxide (referred to as PEO hereinafter) in the above method.
BACKGROUND OF THE INVENTION
In the paper-making process for newspaper and telephone directory paper and so, various yield-improving systems have been adopted for the purpose of improvement in the yield of fine fibers and fillers and improvement of freeness. Among them, the technology using polyethylene oxide as a yield-improving agent has an advantage in that it is not affected by a large amount of water-soluble anionic substance and suspended colloid substance contained in the paper stuff. In the yield-improving system by PEO, it is not substantially used alone but various agents are used in combination (yield-improvement promotor). Various water-soluble phenol resins have been developed as effective promotors.
However, when a well-known water-soluble phenol resin is added, the pH of paper stuff becomes high. When the amount of the phenol resin is increased, the paper product is discolored, the life of the product is reduced and it is hardened by thickening and self-crosslinking.
Further, in the case of a combination of a phenol resin and PEO according to the conventional technology, it has been pointed out that the yield becomes unstable by admixture of a deinking agent originated from deinked pulp (referred to as DIP hereinafter) thereby effecting the yield of fillers and making the removal of sticky materials are insufficient.
The subject of the present invention is to solve the conventional problems described above and to provide a method for the improvement of yield and freeness in the paper-making and waste water treating process which gives no discoloration of paper product and extends the product life and can exert stable yield improving effect on the paper product containing a large amount of DIP and filler.
Further, the subject of the present invention is to provide an excellent yield improvement promotor for paper-making which is a phenol resin used in combination with PEO in the method and gives no discolorarion of paper product and extends the product life and can exert stable yield improving effect on the paper product containing a large amount of DIP and filler.
We, inventors, have investigated eagerly to solve the above problems and have found that a reaction product able to provide an aqueous solution of neutral to acidic, to give no discoloration of paper product and to extend the product life and to exert stable yield improving effect on the paper product containing a large amount of DIP and filler can be obtained by sulfonating a phenol and then condensing it with formaldehyde, and have found that the improvement of yield and freeness in the paper-making and waste water treating process can be attained when the reaction product is used in combination with PEO to complete the present invention.
SUMMARY OF THE INVENTION
The method for the improvement of yield and freeness in the paper-making process and the waste water treating process according to the present invention wherein a combination of a yield and freeness improver and a polyethylene oxide is added to a paper stuff and said yield and freeness improver is a sulfonated phenol-formaldehyde resin for paper-making, said resin being synthesized by sulfonating a phenol and then condensing it with formaldehyde. The preferred phenols to be sulfonated are bis(4-hydroxyphenyl)sulfone marketed as Bisphenol S and 4,4'-dihydroxydiphenyl-2,2-propane marketed as Bisphenol A. Those provided by various manufacturers can be also used.
The sulfonated phenol-formaldehyde resin (SPFR) for paper-making used in the method is a phenol resin used in combination with a polyethylene oxide as the yield and freeness improver in the paper-making and waste water treating process said phenol resin is synthesized by sulfonating a phenol and then condensing with formaldehyde. Preferred phenols to be sulfonated are bis (4-hydroxyphenyl)sulfone, 4,4'-dihydroxydiphenyl-2,2-propane, 1-naphthol and 2-naphthol. The phenol to be sulfonated can have at least one substituent, which may be positioned at any of 2-, 3-, 4-, 5- and 6-positions of the benzene ring.
The SPFR for paper-making in the present invention may be a product synthesized by sulfonating a mixture containing a combination of at least two selected from the group consisting of bis(4-hydroxy-phenyl)sulfone, 4,4'-dihydroxydiphenyl-2,2-propane, 1-naphthol and 2-naphthol and then condensing it with formaldehyde. Further, the SPFR for paper-making of the present invention may be the corresponding sodium salt or ammonium salt formed by neutralization.
DETAILED DESCRIPTION OF THE INVENTION
Now, the method for the preparation of the SPFR for paper-making of the present invention will be described.
When the SPFR of the present invention is prepared, the phenol mentioned above is first sulfonated. The method for sulfonating the phenol is not particularly restricted and it can be sulfonated according to a usual method by using sulfuric acid, anhydrous sulfuric acid or chlorosulfonic acid. However, the degree of sulfonation (molar ratio) of the phenol mentioned above is required to be 0.4 or higher to keep water solubility of the final reaction product. Furthermore, a degree of sulfonation of 0.4 to 0.8 is preferable to prevent the decrease and fluctuation of the yield effect when various deinked regenerated old papers (DIP) are admixed. The sulfonation degree of the phenol of less than 0.4 lowers a storage quality of the final reaction product and that of more than 0.8 lowers the yield improving effect.
The method for the condensation reaction of the sulfonated phenol thus prepared and formaldehyde is also not particularly restricted and can be carried out by a usual method. However, when the condensation reaction of the sulfonated phenol and formaldehyde proceeds excessively, the viscosity of the final product becomes undesirably higher. Likewise, when the amount of formaldehyde is too small, the yield effect in paper-making is lowered disadvantageously. Thus, the molar ratio of the sulfonated phenol to formaldehyde is preferably 1:0.3 to 1.5, more preferably 1:0.5 to 0.8.
The average molecular weight of the SPFR is preferably 300 to 3000, more preferably 400 to 1500 from the viewpoint of water solubility, effect and handling.
An aqueous solution of the SPFR thus prepared is neutral or acidic by sulfonation of the phenol and therefore gives no discoloration of the paper product and exerts stable yield improving effect and freeness improving effect.
In the method of the present invention, said SPFR is used in combination with PEO as the yield and freeness improving agent and the weight ratio of SPFR to PEO is preferably 0.1 to 5:1, more preferably 0.5 to 2:1. The concentrations of SPFR and PEO added are preferably 0.005 to 0.05% and 0.001 to 0.03% respectively based on the paper stuff solid. In such concentrations, the yield and the freeness can be improved in the paper-making and waste water treating process.
PREFERRED EMBODIMENTS OF THE INVENTION
Examples wherein the SPFRs of the invention are used as the yield improving agent in paper-making are shown as follows to illustrate the present invention. However, the present invention is not resticted to these Examples.
1. Test Method for Yield Improvement
Equipment: Dynamic Drainage Jar (abbreviated to DDJ) made by Paper Chemisty Laboratory Inc.
Method: 500 ml of paper stuff was fed in the Jar and stirred at a rate of 600 rpm for 10 seconds and then the cock was opened to collect the drain for 30 seconds. The yield was measured from the paper stuff concentration or ash contained in the drain.
2. Paper Stuff
Paper stuff-1: Thermomechanical pulp (TMP), refiner grand pulp (RGP) and medium quality paper broke were mixed at a ratio of 35, 35 and 30% and disintegrated in a standard pulp disintegrator made by Kumagaya Riki Kogyo Co., Ltd. and the paper stuff concentration was adjusted to 1.0% to prepare a test paper stuff sample. Its fine fiber content was 35%.
Paper stuff-2: White water from the paper-making machine for domestic paper using waste paper was used. The white water concentration was 0.12% and the pH was 7.1.
3. Polyethylene Oxide (abbreviated to PEO hereinafter)
PEO: Alcox E-300 (Trade name. manufactured by Meisei Kagaku Kogyo Co., Ltd.) having an average molecular weight of about 8 million was used. An aqueous solution of 0.01% concentration was used for the addition of PEO. The amount added was expressed by g/ton on solid basis for the paper stuff-i and by ppm based on white water for the paper stuff-2.
4. Sulfonated Phenol-Formaldehyde Resin (SPFR)
SPFR-1: Bisphenol-S was used as the phenol. A reaction product having a sulfonating molar ratio of 0.7 and a formaldehyde ratio of 0.7. It had properties of a solid content of 43%, a pH of 3.5 and a viscosity of 100 cp.
SPFR-2: Bisphenol-A was used as the phenol. A reaction product having a sulfonating molar ratio of 0.5 and a formaldehyde ratio of 0.7. It had properties of a solid content of 25%, a pH of 3.0 and a viscosity of 85 cp.
EXAMPLE 1
SPFR-1 was used as the promotor. Paper stuff-1 was used as the paper stuff.The yields (%) when the amount of the promotor added and the amount of PEO added are changed are shown in the following Table 1.
TABLE 1______________________________________Amount ofSPFR-1 added Amount of PEO added and yield (%)(g/ton ) 0 50 100 150 200______________________________________0 44.4 45.6 43.6 52.4 46.7200 43.7 62.9 74.6 72.3 80.7300 44.9 65.6 75.9 80.3 82.3500 44.3 68.8 79.4 78.4 88.5800 44.9 60.9 72.7 81.6 84.1______________________________________
EXAMPLE 2
SPFR-2 was used as the promotor. Paper stuff-1 was used as the paper stuff.The yields (%) when the amount of the promotor added and the amount of PEO added are changed are shown in the following Table 2.
TABLE 2______________________________________Amount ofSPFR-2 added Amount of PEO added and yield (%)(g/ton ) 50 100 150 200______________________________________0 43.0 43.3 43.6 44.475 55.4 63.1 64.3 65.1150 56.7 61.2 72.7 71.3300 54.8 72.8 80.2 78.4450 55.7 65.8 78.4 83.6______________________________________
EXAMPLE 3
Experiment for the comparison of yield of the ash content
TABLE 3______________________________________ Amount of polymer added and yield (%)Promotor 50 100 200 300______________________________________SPFR-1 *1 37.5 48.3 60.5 72.5Phenol resin *2 25.7 31.0 43.5 58.5PAAM-1 system *3 21.5 29.5 33.8 45.5PAAM-2 system *4 30.0 39.8 42.2 45.2______________________________________RemarksPaper stuff composition: TMP 50% Mechanical pulp 15% Bleached pulp 10% Deinked pulp 5% Filler 20%pH of paper stuff: 5.5The yield when no yield improver was used: 13 to 15%Phenol resin: Commercial product. pH: 11.5______________________________________*1, *2: Three times amount was used to the amount of PEO added.*3: A system of combination of anionic/cationic polyacrylamide.*4: A cationic modified inorganic filler, 2 kg/ton added.An anionic polyacrylamide was used as the polymer.
EXAMPLE 4
Experiment for the comparison of yield of fine fiber in white water. Paper stuff-2 was used.
TABLE 4______________________________________Combination ofpromotor and Amount of promotor added (ppm) and yield (%)polymer 5 10 20 40 70 100______________________________________ ##STR1## 67.4 90.6 95.0 81.0 63.0 59.8 ##STR2## 53.1 42.1 40.2 47.0 48.3 89.4 ##STR3## 51.7 42.4 42.6 63.3 80.6 85.5______________________________________Remarks*1,*3: Amount of polymer added is 3 ppm based on white water.*2: Commercial cationic polyacrylamide (coagulant).*3: Commercial anionic polyacrylamide (coagulant).*4: Commercial modified polyethylene imine (coagulant).
EXAMPLE 5
Experiment for the comparison of yield when a paper stuff containing 41% ofdeinked pulp (DIP) is used
TABLE 5______________________________________ Amount of promotor added (g/ton) and yield (%)Promotor name 0 75 150 250 450______________________________________SPFR-1 46.2 57.2 60.0 65.8 69.9Phenol resin *1 45.8 53.5 53.5 54.7 55.0______________________________________ Remarks The amount of PEO added is 150 g/ton. Phenol resin: Same as *2 in Example 3. Composition of the paper stuff: TMP 44% Bleached pulp 15% DIP 41%______________________________________
EXAMPLE 6
Experiment for the comparison of yield when a paper stuff containing 95% ofdeinked pulp (DIP) is used
TABLE 6______________________________________Combination of chemicalsand amount added (g/ton) Yield (%) Yield of ash (%)______________________________________Blank (no addition) 53.6 17.8SPFR-1 PEO100 50 71.7 53.0200 100 87.5 80.2300 150 93.9 93.2400 200 95.6 94.0Inorganic filler *1 A. PAAM *11000 100 66.8 46.51000 300 79.9 69.81000 500 81.9 69.21000 800 93.5 90.6C. PAAM *2 A. PAAM *3580 295 67.5 49.9Alum A. PAAM *30 295 61.9 42.85000 295 65.9 49.210000 295 67.0 50.3Alum PEO5000 150 87.3 78.010000 150 86.9 81.0______________________________________RemarksComposition of the paper stuff: DIP 95% BCMP 5% (Bleached mechanical pulp)Concentration of the paper stuff: 0.6% Head box paper stuffHead box ash content: 23.7%______________________________________*1: Same as *4 in Example 3.*2: Cationic polyacrylamide*3: Anionic polyacrylamide
EXAMPLE 7
Experiment for the comparison of freeness
TABLE 7______________________________________Combination of chemicals Freeness time of 200 mland amount added (g/ton) (sec.)______________________________________Blank (no addition) 143SPFR-1 PEO80 100 61160 100 32240 100 25320 100 18Inorganic filler *1 A. PAAM *11000 100 1241000 300 1031000 500 851000 800 82______________________________________RemarksTest method:The freeness time of 200 ml was measuredaccording to the device and the methoddescribed in Example.Composition of the paper stuff: Bleached pulp 15.2% DIP 8.5% GP 18.0% TMP 58.3%Concentration of the paper stuff: 0.8%______________________________________*1: Sample as *4 in Example 3.
Comparative Example 1
Experiment for the comparison of yield when the phenol resin of Example 3 was used as the phenol resin. Paper stuff-1 was used.
TABLE 8______________________________________Amount of phenolresin added Amount of PEO added and yield (%)(g/ton) 0 50 100 200______________________________________0 48.3 49.8 50.6 54.3200 49.6 55.8 57.1 59.7400 49.5 59.5 84.1 68.8600 50.9 56.8 67.4 72.01200 49.8 56.5 63.9 78.6______________________________________
As apparent from the experimental results shown in Tables 1 to 8, it can befound that the sulfonated phenol-formaldehyde resin of the present invention is highly excellent as a yield improver. Further, the method of the present invention using this resin in combination with PEO is superiorto other yield improving systems in not only the yield of fine fiber but also the yield of filler from the experimental result of Example 3. As shown in the experimental result of Example 4, the method of the present invention can provide an excellent yield of white water for paper-making, highly decreases contamination load in waste water treatment and saves waste water treating cost. Furthermore, in the experimental result of Example 5, the sulfonated phenol-formaldehyde resin of the present invention shows an excellent yield improving effect compared to the conventional phenol resin even for a paper stuff containing a large amountof DIP. The method of the present invention using such a resin together with PEO is also advantageous in a paper-making factory where the amount of DIP used is increasing.
The above-mentioned sulfonated phenol-formaldehyde resin of the present invention can improve the yields of fine fiber and filler in the paper-making process by a combined use of PEO. By using the method of the present invention using such a specific resin in combination with PEO, effects including an improvement in productivity, saving of paper-making materials and decrease in waste water treating load in the paper-making process or the waste water treating process. | A method for the improvement of yield and freeness which does not discolor the paper product and gives a long life to the product and exerts stable yield improving effect even for the paper stuff containing much deinked pulp and filler as well as a yield improving promotor used in this method are provided.
In the method for the improvement of yield and freeness in the paper-making process and the waste water treating process according to the present invention, a special phenol resin is used in combination with polyethylene oxide (PEO). The phenol resin of the present invention is a sulfonated phenol-formaldehyde resin synthesized by sulfonating a phenol and then condensing it with formaldehyde. Preferred as the phenol to be sulfonated are Bisphenol A and Bisphenol S.
By using the method of the present invention, the yields of fine fiber and filler can be improved and the paper stuffs can be saved and the waste water treating load can be decreased. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a feed spacer for filtration membrane modules used in cross-flow filtration. More particularly, it concerns the novel cross-sectional shape of the spacer strands, which are arranged in a plurality of rows to constitute a feed spacer mesh.
BACKGROUND OF THE INVENTION
[0002] Net-type spacers are an essential feature in commercially available filtration membrane modules. For example, they are an essential feature of the spirally wound module cartridges used in cross-flow ultrafiltration or in reverse-osmosis separation equipment. Such spacers play a dual role, first, keeping adjacent membrane leaves apart so as to form a feed channel therebetween and, second, promoting the mixing between the bulk of the fluid and the fluid element adjacent to the membrane surface so as to keep the membrane surface relatively clean. Efficient membrane module performance depends on the efficacy of the spacers to increase mass transport away from the membrane surface so as to reduce concentration polarization by enhancing mixing at the membrane surface.
[0003] The spacer has a plurality of rows of elongated strands, for example two rows. The strands of a same row are substantially parallel to each other, The rows are disposed in layers where the strands of one row are attached to, typically by fusion, and generally crossing the strands of adjacent rows at an angle.
[0004] Several propositions have been made regarding the shape and dimensions of the strands (referred as filaments in some documents) and to the crossing angles of the strands in the mesh (referred as net in some documents),
[0005] For example, the use of spacers in the prior art has been mainly as part of the development of membrane modules. For example U.S. Pat. No. 4,861,487, describes that elongated strands of spacers are placed parallel to flow of fluid before making the spirals. In U.S. Pat. No. 5,429,744 a module is made with a spacer material glued to the membrane. In U.S. Pat. No. 4,834,881 a corrugated type of spacer has been described. This type of spacer is claimed to distribute the flow of raw water efficiently. In U.S. Pat. No. 4,902,417 a detailed description of making a spiral wound membrane module is given for application to various types of feeds. The shape of the strands of the spacers is vaguely discussed in this patent document. Also, the description does not mention clearly any specific shapes, and fails to provide any dimensional ratios.
[0006] Da Costa et al. (Journal of Membrane Science, 87 (1994) 79-98) have studied effects on pressure drop and flux in a flat sheet membrane system in rectangular cells where a channel between a membrane layer and a top cover is spacer filled. These authors concluded that (FIG. 6 on page 88 of this document): “fluid flows in zig-zag path, changing direction at each mesh”.
[0007] Karode and Kumar (Journal of Membrane Science, 193 (2001) 69-84) have estimated pressure drop by solving Navier-Stokes equations in 3D flow domains in similar spacer filled channels and found that observations made by Da Costa et al. were not accurate. Pressure drops and shear rates for various commercially available spacers were also determined with simulations. It was also reported that the dimensions of the strands and angles of intersection of strands in spacers are important parameters. For example, the commercially available spacers included several symmetric and asymmetric spacer designs, the former including two fused together rows of strands crossing each other at an angle, and being of the same plastics material, inter-strand spacing, circular cross-sectional shape and diameter, and the latter differing in its diameter and inter-strand spacing. A further variation in that the two rows of strands cross each other at different angles to each other and to the longitudinal axis of the channel, was also disclosed.
SUMMARY OF THE INVENTION
[0008] According to the invention, we have found that the unique cross-sectional shape of strands of spacers provide significant advantages over the commercially available spacers.
[0009] More specifically, a feed spacer according to the invention has been found to improve the fluid flow characteristics, resulting in higher efficiency of the associated membrane module, as a result of a lower pressure drop across the membrane.
[0010] Thus, according to one embodiment of the invention, a filtration membrane spacer is provided, comprising a plurality of rows of elongated strands, the strands in each row being arranged substantially in parallel to one another, with adjacent rows being attached and disposed at an angle to one another, the strands of at least one row when viewed in cross-section having a central portion of a width smaller than the width of its extremities.
[0011] A typical embodiment of a spacer according to the invention comprises two rows of strands fused together.
[0012] The central portion may be in the form of a concave surface, a grooved surface or any kind of recessed surface. More specifically, such cross-sections may be in the form of an hourglass (double-concave) or a hexagonal (double-concave groove), as will be apparent hereinafter.
[0013] According to another embodiment of the invention, a cross-flow filtration membrane module is provided, the membrane module including at least one layer of a membrane material, a feed flow channel having a longitudinal axis, and a membrane spacer filling the channel comprising a plurality of rows of elongated strands, the strands in each row being arranged substantially in parallel to one another, with adjacent rows being attached and disposed at an angle to one another and to the longitudinal axis, the strands of at least one row when viewed in cross-section having a central portion of a width smaller than the width of its extremities, such that in operation, fluid is flowed into the channel substantially parallel to the longitudinal axis, and the central portion of the strands is presented to the fluid flow.
[0014] For example, a flat sheet membrane typically has one membrane layer and includes a fluid flow channel between the membrane layer and the casing of the membrane module. A spiral wound membrane module includes two membrane layers, forming the feed flow channel therebetween,
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be explained in more detail by way of the following disclosure to be taken in conjunction with the drawings, in which:
[0016] [0016]FIG. 1 a illustrates a cross-section of a commercially available spacer strand (prior art).
[0017] [0017]FIG. 1 b to 1 e illustrate cross-sections of spacer strands according to different embodiments of the invention.
[0018] [0018]FIG. 2 illustrates a cross-section of two adjacent strands showing dimension variables.
[0019] [0019]FIG. 3 illustrates prior art net-type spacers having strands of a circular cross-section.
[0020] [0020]FIG. 4 illustrates a first embodiment of net-type spacers according to the present invention having strands of a double concave cross-section.
[0021] [0021]FIG. 5 illustrates a second embodiment of net-type spacers according to the present invention having strands of a double concave hexagonal cross-section.
[0022] [0022]FIG. 6 illustrates the location of the cut in prior art net-type spacers for the two-dimensional fluid flow model of FIG. 8 and FIG. 10.
[0023] [0023]FIG. 7 illustrates the location of the cut for one of the embodiments of the net-type spacers according to the present invention for the two-dimensional fluid flow model of FIG. 9.
[0024] [0024]FIG. 8 illustrates velocity profile for prior art net-type spacers.
[0025] [0025]FIG. 9 illustrates velocity profile for one of the embodiments of the net-type spacers according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring to FIG. 1 a to 1 e , cross-sections of various spacer strands are shown. FIG. 1 a shows the circular cross-section of commercially available spacers. The side of the enclosed square (dotted line) is equal to the strand diameter, such as the figure known in geometry as a square inscribed circle. In reality, due to the fabrication process, the section varies from circular to slightly ellipsoidal, the minor axis being perpendicular to the length of the spacer web, such as shown on FIG. 3.
[0027] In a first embodiment of the invention, the spacer strand corresponds to the square shown in dotted line on FIG. 1 a , but having two opposite corresponding concave surfaces resulting in the shape, referred as “concave-square”, shown on FIG. 1 b.
[0028] It will be appreciated that the square can be of smaller or larger dimensions, but in the current example the width and height of the enclosing square is kept the same as that in the commercially available spacer for the sake of performance comparison.
[0029] In a second embodiment of the invention, the spacer strand corresponds again to the previous square, but having two opposite V-grooves, resulting in the shape, referred to as “concave-hexagonal”, shown on FIG. 1 c.
[0030] NOW referring to FIG. 2 the different concave embodiments can be expressed as a matter of relation of their different dimensions. W is the width of the strand at its extremities, H is the overall height of the strand, T is the thickness of the strand at its reduced width center portion, and D is inter-strand distance between the center of a strand and the center of the next strand.
[0031] In order to study the effects of varying width to height ratios of the new modified strand, the shapes in a rectangle with cross-sections are shown in FIG. 1 d and FIG. 1 e ie. where W≠H, In FIG. Ed, the width of the strand is increased by ⅓ rd , keeping the height unchanged (ratio W/H={fraction (4/3)}). This embodiment is referred as “concave-rectangular {fraction (4/3)}”. While in FIG. 1 e , the height is increased by ⅓ rd keeping the width unchanged (ratio W/H is {fraction (4/3)}). This last embodiment is referred as “concave-rectangular W/H=¾”.
[0032] For a better understanding of the overall arrangement of the strands,
[0033] [0033]FIG. 3 shows in a 3-D model, the prior art spacer having strands such as shown on FIG. 1 a . Similarly FIG. 4 shows in a 3-D model the “concave-square” spacer of FIG. 1 b , and FIG. 5 shows in a 3-D model the “concave-vertical” spacer of FIG. 1 c . All the spacers shown in the 3-CD mode have two layers of strands, the strands in each layer being arranged substantially in parallel, with the layers being fused together at a selected angle. The strands can be of the same (symmetric) or different (asymmetric) thickness. It is also understood that the spacer can have more than two layers of strands, when needed, Also, these spacers can be made or cut to various shapes (e.g. spiral wound) to adapt to different type of membrane modules.
[0034] The angles of orientation of each the two rows spacer strands to the longitudinal axis of the channel is fixed as are the other parameters to facilitate comparison between the conventional spacers, and the novel spacers of different cross-sectional strand diameter, such that the only difference is in the cross-sectional shape of the strands. The legend of Table 1 shows these fixed angles. The specific comparisons are shown in comparing the data in Table 1 with that in Table 2.
[0035] In operation, the bulk fluid e.g. water, is flowed into the channels in the direction of the longitudinal axis of the channel, the strands being arranged at an angle to the longitudinal axis, such that the reduced width central portion of the strands is presented to the fluid flow, to induce an additional upward velocity to the fluid as it flows past the spacer, which results in higher shear rates on the membrane surface along with a lower pressure drop.
EXAMPLES
[0036] Description of The Results And Procedure Used
[0037] Membrane modules made with each of the above described novel cross-sectional shapes of strands were modeled using Computational Fluid Dynamics (CFD) to estimate the pressure drop across the membrane module and the velocity profiles by rigorously solving the laminar/turbulent Navier-Stokes equations.
[0038] Table 1 shows the geometric characteristics of several commercially available spacers. As described in Karode and Kumar (Journal of Membrane Science, 193 (2001) 69-84), the disclosure of which is incorporated herein by reference, the flow test cell used in simulations included a spacer filled rectangular flow feed channel, used various spacer configurations, and had dimensions of 25 mm wide and 35 mm long. The term “spacer filled” as used herein means that the spacer fills the channel, such that no short-circuiting of the fluid flow between the spacer and the adjacent membrane or membrane module casing occurs.
[0039] For simulation purposes, as used herein the context of a flat membrane module, the channel is created between a flat sheet membrane and the membrane module casing. In the case of a spiral wound membrane module, the channel is created between two layers of the membrane. The conventional spacer configurations included symmetric spacers with equal strand diameters and asymmetric spacers with unequal strand diameters.
[0040] Bird et al. (Transport Phenomena, Wiley, New York, 1982) reported governing equations for steady-state fluid flow with no-slip boundary conditions at all fluid-solid interfaces were used.
[0041] The details of simulation procedure can also be be found in Karode and Kumar, Each of the new cross-sections was simulated maintaining the inter-strand spacing and angles of commercially available spacers as shown in Table 1 so as to facilitate meaningful comparisons. Specifically, in Table 1, h sp is height of spacer; d t is diameter of spacer; I f , is distance between parallel strands, measured perpendicular to the strand; ε is spacer porosity; θ is hydrodynamic angle, which describes the change in direction of the fluid as it enters the channel, and d h is hydraulic diameter.
TABLE 1 Geometric characteristics of spacers* Spacer h sp d f l f ε θ d h k name (×10 3 m) (×10 3 m) (×10 3 m) (−) (deg) (×10 3 m) Conwed- 2.01 1.03 2.17 0.618 90 0.997 1 a (S) UF2 b (AS) 1.68 0.76 4.06 0.763 0 1.375 (1.07)** (5.3)** NALTEX- 1.11 0.55 4.3 0.880 56 1.316 56 c (S) # Conwed-1 types this angle is 45°, for UF2 types the angle is 0° ie. since the bottom row is parallel to the channel axis, and for Naltex-types, the angle is 28°.
[0042] For ease in comparison, Table 2 shows the use of the same conventional spacers, with the only difference being in the cross-sectional shape of the strands. It will be appreciated that for comparison purposes, d f is equivalent to the width of the strands at their extremities. Illustrated is the reduction in pressure drop for each of the new cross-sections as a function of inlet velocity for a flow test cell described earlier in Karode and Kumar (Journal of Membrane Science, 193 (2001) 69-84). Notably, reduction in pressure drop is highest for the Conwed-1 spacer. This is primarily as a result of increased fluid mixing at the plane of intersection of the spacer strands in the new cross-section.
TABLE 2 Variation in pressure drops with change in cross-sectional shapes of various spacers. % change in Pressure Drop a for New Spacer Cross Section Pressure Drop Concave- Concave- Velocity for unmodified Concave- V-Shaped- Rect. Rect. Spacer Name (m/s) spacer (Pa) square square W/H = 4/3) W/H = 3/4) Conwed-1 0.25 1058 −24 −12 NSC −33 Conwed-1 0.5 3762 −31 −20 NSC −39 Conwed-1 0.75 7368 −27 −15 NSC NSC Conwed-1 1.0 13348 −33 −21 −39 −6 UF2 0.25 394 −5 NSC NSC −68 UF2 0.5 1147 −5 −19 −29 −34 UF2 0.75 2255 −12 −29 −18 −33 UF2 1.0 3758 −17 −34 −27 −42 NALTEX-56 0.25 562 −10 −28 −19 −36 NALTEX-56 0.5 1527 −14 −11 −7 −16 NALTEX-56 0.75 3595 −28 −15 −19 −26 NALTEX-56 1.0 5177 −11 −11 −5 −13 a : % change = Pressure Drop - Pressure Drop unmodified Pressure Drop unmodified × 100 NSC: No Significant Change
[0043] It was shown in Karode and Kumar (Journal of Membrane Science, 193 (2001) 69-84) that majority of the pressure drop in Conwed-1 spacer was controlled by the change in the direction of the velocity vector across a thin transition region corresponding to the plane of intersection of the spacer strands. FIGS. 6 and 7 show the location of the two dimensions model cut in the 3-D model of respectively the prior art and of the first embodiment spacer.
[0044] [0044]FIG. 8 shows the velocity contours along a constant y section for the Conwed-1 spacer. The dotted section is the location of strands in the cut and the hatched section corresponds to the reference velocity for comparison between the prior art and new spacer. All the values are velocity in m/s. As can be seen, there is very little mixing between the fluid flowing along the axis of the bottom row of strands and the top row. Across the plane of intersection, the velocity vectors undergo an abrupt rotation leading to an increased pressure drop.
[0045] [0045]FIG. 9 shows a similar cross section for the spacer with a cross section corresponding to FIG. 1( b ). As can be seen, there is enhanced mixing between the fluid flowing along the bottom row of strands and the top row. This mixing is primarily caused by an upward movement of the fluid elements induced by the concave shape of the strand cross-section. Further simulations were performed with four different modifications for all of the spacers listed in Table 1. As can be seen from Table 2, all of these modifications in tested spacers produced significant pressure reductions of up to 42% over their unmodified counterpart.
[0046] It is understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | The invention disclosed relates to feed spacers used in various filtration membrane modules, such as in spiral wound membranes, used in cross-flow filtration. Such spacers have an influence in promoting the mixing between the bulk of the fluid and the fluid element adjacent to the membrane surface so as to keep the membrane surface relatively clean. To optimize these properties, novel spacer designs are disclosed having a plurality of rows of elongated strands, the strands in each row being arranged substantially in parallel to one another, with adjacent rows being attached and disposed at an angle to one another, the strands of at least one row when viewed in cross-section having a central portion of a width smaller than the width of its extremities. Novel membrane modules incorporating such feed spacers are also disclosed. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a filter component cutting system for producing individual filter components for use in filter constructions for cigarettes.
In many instances wrapped tobacco rods are connected to filter constructions of one type or another in the manufacture of cigarettes. Filter constructions often include individual filter components comprising one or more plugs of cellulose acetate through which tobacco smoke passes during the smoking process. In some instances cellulose acetate is used alone in the filter construction, and in other instances cellulose acetate plugs are used in combination with other material such as particulates of activated carbon and silica gels, for example. Compound filters such as plug-space-plug filter constructions may include spaced apart cellulose acetate plugs that define a space or cavity filled with particulate material.
Cellulose acetate filter components are often cut to size from longer stock material, and the present invention is directed to machines and processes that perform the cutting operation.
SUMMARY OF THE INVENTION
Accordingly, one of the objects of the present invention is a filter component cutting system that functions to cut filter components from longer stock material and delivery them single file to a filter combining operation.
Another object of the present invention is a filter component cutting system that includes a cutting drum that cut filters from longer stock material into accurate length components.
Still another object of the present invention is a cutting drum that allows quick and easy adjustment of filter component length.
In accordance with the present invention, a filter component cutting system comprises a supply hopper of elongate filter rods, and a rotating cutting drum with spaced flutes on an exterior surface of the drum arranged to receive the filter rods. A transfer mechanism receives filter rods from the supply hopper and delivers the rods to the flutes on the cutting drum. At least one cutter blade is positioned adjacent the cutting drum for cutting the elongate filter rods into individual filter components as the cutting drum rotates.
Preferably the filter component cutting system includes a stop at one end of each of the flutes on the cutting drum against which the elongate filter rods are positioned prior to being cut into individual filter components. Each stop may be adjustable within its respective flute depending upon the desired length of the individual filter components.
A vacuum assist on the cutting drum functions to position the elongate filter rods adjacent the stops prior to being cut into individual filter components.
The transfer mechanism may comprise a pair of cooperating fluted vacuum drum, and in one embodiment of the present invention the pair of cooperating fluted vacuum drums and the cutting drum each have a horizontal axis of rotation. In another embodiment of the invention the transfer mechanism comprises a single fluted vacuum drum, and the single fluted vacuum drum and the cutting drum each have a horizontal axis of rotation.
In still another embodiment of the invention the transfer mechanism comprises a single fluted vacuum drum having a horizontal axis of rotation and a bevel transfer drum, and in this embodiment the cutting drum has a vertical axis of rotation.
The cutter blade may comprise a single bade or a plurality of blades for simultaneously cutting each elongate filter rod into individual filter components.
In the process of cutting filter components according to the present invention, the various steps include delivering elongate filter rods from a supply hopper to a cutting drum having flutes on an outside surface of the drum arranged to receive the rods. Next, the filter rods are moved on the drum to positions against stops in the drum flutes. The filter rods are then cutting into individual filter components.
Prior to the cutting procedure, the position of the stops on the cutting drum may be adjusted depending upon the desired length of each of the individual filter components.
BRIEF DESCRIPTION OF THE DRAWINGS
Novel features and advantages of the present invention in addition to those noted above will be become apparent to persons of ordinary skill in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which:
FIG. 1 is a diagrammatic front elevational view of a filter component cutting system, in accordance with the present invention, with portions broken away to illustrate interior details;
FIG. 2 is a side elevational of the filter component cutting system shown in FIG. 1 ;
FIG. 3 is a diagrammatic front elevational view of an alternative filter component cutting system, according to the present invention;
FIG. 4 is a diagrammatic side elevational view of a modified filter component cutting system similar to FIG. 3 , but including a vertically oriented cutting down, according to the present invention;
FIG. 5 is a diagrammatic front elevational view of another filter component cutting system; according to the present invention;
FIG. 6 is a side elevational view of the filter component cutting system shown in FIG. 5 ;
FIG. 7 is a top plan view of the filter component cutting system shown in FIGS. 5 and 6 ;
FIG. 8 is diagrammatic front elevational view of still another filter component cutting system that includes a shifting drum for handling the cut components;
FIG. 9 is a rear elevational view of the system shown in FIG. 8 ; and
FIG. 10 is a diagrammatic sectional top plan view taken along line 10 - 10 of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
Referring in more particularity to the drawings, FIGS. 1 and 2 illustrate a filter component cutting system 10 where elongate filter rods 12 of cellulose acetate, for example, are supplied from a hopper 14 to a pair of cooperating fluted vacuum transfer drums 16 , 18 . The transfer drums 16 , 18 run continuously and deposit the elongate filter rods 12 onto the flutes 20 of a vacuum cutting drum 22 . The ratio of the number of flutes on the transfer drums and the number of flutes on the cutting drum allow the transfer drums to run several revolutions before a pattern of depositing filter rods on the cutting drum repeats.
As the filter rods 12 rotate on the cutting drum 22 the rods pass under a cowl 24 and vacuum in the rear of the cowl draws air in from the front of the flutes which shifts the filter rods back against an adjustable stop 26 mounted in each flute 20 of the cutting drum. As an option, air jets can be used on the front of the cowl to blow against the front of the filter rods to assist the shifting of the filter rods against the adjustable stops. The position of the adjustable stops determines the length of each of the individual filter components 28 cut from the filter rods, as explained below.
As the filter rods leave the cowl 24 , vacuum in the cutting drum 22 holds the filter rods in the flutes 20 . The filter rods then travel through a rotating knife blade 30 which severs an individual filter component 28 from the original elongate filter rod. The cut component 28 and remaining portion of the original filter rod are still held in the flutes 20 by vacuum. As the cutting drum 22 continues to rotate, vacuum is released on the cut component 28 , and the component is removed by a vacuum take-off drum 32 . The take-off drum transfers the cut component to a feed vane 34 , or drum (not shown) which then transfers the filter components to a filter combining operation.
The remaining portions of the original filter rods continue to rotate on the cutting drum. As they again pass under the cowl, vacuum holding them in the flutes, is released and they are once again shifted back against the adjustable stops 26 by vacuum from the rear of the cowl and possibly air jets on the front of the cowl. As they again pass the knife another group of individual components 28 is cut and later removed by the take-off drum 32 . This process continues until the original filter rod has been completely cut into individual filter components 28 . If the original filter rod length is not a multiple of the cut length of the filter components 28 the rod portion remaining after the last cut is rejected by an air jet.
By way of example, the cutting drum 22 and the blade 30 may be designed to cut each elongate filter rod 12 six times. The transfer drums 16 , 18 deposit a filter rod in every sixth flute 20 of the cutting drum 22 and the cutting drum has thirty five flutes. The adjustable stops 26 are positioned to cut 20 mm long filter components, and the original filter rod is 122 mm long. After six revolutions of the cutting drum, six 20 mm long filter components have been cut from the original filter rod and the remaining 2 mm of each original filter rod is rejected. This leaves each flute 20 empty and ready to receive the next full length filter rod to be deposited when the flute meshes with the transfer drum 18 .
FIG. 3 illustrates another filter component cutting system 40 similar in many respect to system 10 shown in FIGS. 1 and 2 , and similar reference characters have been used to identify similar parts. In system 40 one transfer drum 42 is used, and the drum does not run continuously. The transfer drum has a diameter larger than cutting drum 22 and one revolution of the transfer drum completely fills the cutting drum with filter rods. The transfer drum 42 has flutes 44 around approximately 270 degrees of its periphery. The remaining 90 degrees is undercut. The transfer drum 42 rotates 270 degrees and completely fills the flutes 20 on the cutting drum 22 . The transfer drum 42 continues to rotate slightly and then stops to place the undercut portion inline with the cutting drum 22 .
The cutting drum 22 rotates multiple times to completely cut the original filter rods 12 into individual components 28 . With each rotation, vacuum in the cowl 24 shifts the filter rods against the adjustable stops 26 , and the blade 30 cuts the components to length. The take-off drum 32 removes the cut components in the same manner as discussed above with respect to system 10 of FIGS. 1 and 2 . As the last components are removed, the transfer drum 42 rotates once again the refills the cutting drum with filter rods 12 .
As another option FIG. 4 illustrates still another filter component cutting system 50 similar in many respects to the systems 10 and 40 shown in FIGS. 1-3 , and similar reference numerals are used to identify similar parts. In system 50 two transfer drums 42 , 52 are used, and drum 52 is a conical/bevel drum as shown. The conical/bevel drum 52 turns the filter rods 123 vertically which allows the cutting drum 22 to be positioned in a vertical orientation. The vertical orientation of the cutting drum 22 allows gravity to assist in the shifting of the filter rods against the adjustable stops 26 . The transfer drum 42 receives filter rods 12 from hopper 14 in the same manner as described above with respect to the system 40 of FIG. 3 . Filter rods 12 on drum 42 are then transferred to the conical/bevel drum 52 .
The adjustable stops 26 of all embodiments are intended to be manually set to a desired component cut length. As an option, these stops may be attached to a plate (not shown) which rotates with the cutting drum 22 . The mechanism could then be used to change the cut length by adjusting the plate position. This allows fine tuning of the component cut length as the machine runs.
FIGS. 5-7 illustrate another filter component cutting system 60 similar in many respects to system 50 of FIG. 4 and similar reference characters have been used to identify similar parts. System 60 includes a longer cutting drum 62 with flutes 64 . Filter rods 12 are fed to the upper portion of the cutting drum 62 by transfer drum 42 and conical/bevel drum 52 . As the filters travel under the cowl 24 they are positioned by end guides 66 located between the cowl and the drum. The elongate filter rods 12 then pass through rotating cutter blades 68 which cut the filter rods into multiple filter components 28 . As the cut components 28 leave the cutter blades, vacuum in the lower end of the cowl and air jets in the upper end shift the entire stack of cut components in each flute 64 down against a stop 69 in the lower portion of the drum. As the drum rotates, the lowest component in each flute 64 is removed by the take-off drum 32 . The cutting drum rotates multiple times until all of the components are removed. As the last components are removed, the transfer drums 42 , 52 deliver another full load of filter rods 12 to the upper portion of the cutting drum 62 .
The foregoing description illustrates and describes the present invention. Additionally, the disclosure shows and describes only the preferred embodiments of the invention, but as mentioned above, it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings and/or skill or knowledge of the relevant art. The embodiments described hereinabove are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with the various modifications required by the particular applications or uses of the invention. Accordingly, the description is not intended to limit the invention to the form or application disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments.
By way of example, cutting system 60 shown in FIG. 5-7 may be modified to include continuously running transfer feed drums similar to those of system 10 , but with the lower transfer drum being a conical/bevel drum. In this embodiment (not shown), filter rods from a hopper are supplied to the continuously running transfer drums which then deposit the filter rods on the upper fluted portion of a cutting drum such as drum 62 .
The ratio of the number of flutes on the transfer drums and the number of flutes on the cutting drum allow the drums to run several revolutions before the pattern of depositing filter rods on the cutting drum repeats. As the filter rods rotate on the cutting drum, they pass under a cowl, and as the filter rods travel under the cowl they are positioned by end guides located between the cowl and the drum. The filter rods then pass through rotating knives which cut the filters into multiple components. As the cut components leave the knives, vacuum in the lower end of the cowl and air jets in the upper end shift the entire stack of cut filter rods in each flute down against a stop in the lower portion of the cutting drum. As the cutting drum rotates, the lower filter component in each flute is removed by a take-off drum. On the next revolution, the stack is again shifted down and the lowest components are removed. As explained in system 10 , the ratio of the number of flutes on the vacuum transfer drums to the number of flutes on the cutting drum allows the process to run continuously.
In still another embodiment (not shown), the long cutting drum just described may be replaced with separate cutting and shifting drums. Filter rods are supplied from a hopper to the fluted vacuum transfer drums just described, and the drums run continuously to deposit filter rods on a fluted vacuum cutting drum. As the filter rods rotate on the cutting drum, they pass under a cowl, and as the filter rods travel under the cowl they are positioned by end guides located between the cowl and the drum. The filter rods then pass through rotating knives which cut the filter rods into multiple components. As the cut components leave the knives, they are transferred to a fluted shifting drum. The ratio of the number of flutes on the cutting drum and the number of flutes on the shifting drum allows the drums to run several revolutions before the pattern of depositing filter rods on the shifting drum repeats. As the cut components rotate on the shifting drum they pass under a cowl where vacuum in the lower end of the cowl and air jets in the upper end shift the entire stack of cut segments in each flute down against a stop in the lower portion of the shifting drum. As the shifting drum rotates, the lower component in each stack is removed by a take-off drum. On the next revolution the stack is again shifted down and the lowest components are removed. The ratio of the number of flutes on the cutting drum to the number of flutes on the shifting drum allows the feed process to run continuously.
FIGS. 8-10 illustrate an embodiment 70 which is a variation of the embodiment just described in that it uses a mechanical method of shifting a stack of cut plugs 72 on a shifting drum 74 having flutes 76 on the outside thereof. The upper portion of the shifting drum 74 incorporates a gravity pin drum which comprises a separate drum 78 with vertical holes 80 that line up with the flutes 76 on the shifting drum. Headed pins 82 are positioned in each of the vertical holes 80 , and these pins function as individual air cylinders. A vacuum valve 84 is located at the top of the pin drum 78 , and when activated each of the headed pins 82 is individually raised by the vacuum. The vacuum is removed in the area on the shifting drum where the cut plugs 72 are to be pushed down along the flutes 76 which allows the pins 82 to push the stack of plugs 72 to the lowermost point on the flutes. An air assist may be employed, if desired. Once the stack of plugs is pushed down on the shifting drum, the vacuum is engaged to retract the push pins into the pin drum 78 thereby allowing room for another stack of plugs to be introduced onto the shifting drum. A mild vacuum is applied to the flutes 76 to retain the cut plugs 72 .
At the lower end of the shifting drum 74 , the individual plugs are removed one-at-a time from the shifting drum and transferred onto a dual component drum 86 having flutes 88 . This transfer is accomplished by a pair of stripper belts 90 that wrap around on the bottom of the shifting drum. The belts are taken up on a grooved roller 92 . The plugs 72 are sandwiched between the stripper belts 90 and the dual component drum 86 forcing each plug to be stripped from the shifting drum 74 and transferred onto the flutes 88 of the dual component drum 86 . | A filter component cutting system comprises a supply hopper of elongate filter rods and a cutting drum with spaced apart flutes on an exterior surface of the drum for receiving the elongate filler rods. A transfer mechanism receives the elongate filter rods from the supply hopper and delivers the rods to the flutes on the cutting drum. At least one cutter adjacent the cutting drum functions to cut the filter rods in to individual filter components as the cutting drum rotates. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to immunomodulatory polyhydroxylated pyrrolizidine compounds and to their use in medicine. In particular, the invention relates to the use of casuarine and certain casuarine analogues as immunomodulatory (immunostimulatory or immunosuppressive) drugs.
BACKGROUND TO THE INVENTION
[0000] Immunity
[0002] When the immune system is challenged by a foreign antigen it responds by launching a protective response. This response is characterized by the coordinated interaction of both the innate and acquired immune systems. These systems, once thought to be separate and independent, are now recognized as two interdependent parts that when integrated fulfill two mutually exclusive requirements: speed (contributed by the innate system) and specificity (contributed by the adaptive system).
[0003] The innate immune system serves as the first line of defence against invading pathogens, holding the pathogen in check while the adaptive responses are matured. It is triggered within minutes of infection in an antigen-independent fashion, responding to broadly conserved patterns in the pathogens (though it is not non-specific, and can distinguish between self and pathogens). Crucially, it also generates the inflammatory and co-stimulatory milieu (sometimes referred to as the danger signal) that potentiates the adaptive immune system and steers (or polarizes it) towards the cellular or humoral responses most appropriate for combating the infectious agent (discussed in more detail below).
[0004] The adaptive response becomes effective over days or weeks, but ultimately provides the fine antigenic specificity required for complete elimination of the pathogen and the generation of immunologic memory. It is mediated principally by T and B cells that have undergone germline gene rearrangement and are characterized by an exquisite specificity and long-lasting memory. However, it also involves the recruitment of elements of the innate immune system, including professional phagocytes (macrophages, neutrophils etc.) and granulocytes (basophils, eosinophils etc.) that engulf bacteria and even relatively large protozoal parasites. Once an adaptive immune response has matured, subsequent exposure to the pathogen results in its rapid elimination (usually before symptoms of infection become manifest) because highly specific memory cells have been generated that are rapidly activated upon subsequent exposure to their cognate antigen.
[0000] Interdependence of Innate and Adaptive Responses
[0005] It is now thought that the earliest events following pathogen invasion are effected by cellular components of the innate immune system. The response is initiated when resident tissue macrophages and dendritic cells (DCs) encounter pathogen and become activated by signals generated by interaction between pattern-recognition receptors (PRRs) and the pathogen-associated molecular patterns (PAMPs) shared by large groups of microorganisms. The activated macrophages and DCs are stimulated to release various cytokines (including the chemokines IL-8, MIP-1α and MIP-1β), which constitute the danger signal and triggers an influx of Natural Killer (NK) cells, macrophages, immature dendritic cells into the tissues.
[0006] Loaded with antigen, the activated DCs then migrate to lymph nodes. Once there, they activate immune cells of the adaptive response (principally naïve B- and T-cells) by acting as antigen-presenting cells (APCs). The activated cells then migrate to the sites of infection (guided by the “danger signal”) and once there further amplify the response by recruiting cells of the innate immune system (including eosinophils, basophils, monocytes, NK cells and granulocytes). This cellular trafficking is orchestrated by a large array of cytokines (particularly those of the chemokine subgroup) and involves immune cells of many different types and tissue sources (for a review, see Luster (2002), Current Opinion in Immunology 14: 129-135).
[0000] Polarization of the Adaptive Immune Response
[0007] The adaptive immune response is principally effected via two independent limbs: cell-mediated (type 1) immunity and antibody-mediated or humoral (type 2) immunity.
[0008] Type 1 immunity involves the activation of T-lymphocytes that either act upon infected cells bearing foreign antigens or stimulate other cells to act upon infected cells. This branch of the immune system therefore effectively contains and kills cells that are cancerous or infected with pathogens (particularly viruses). Type 2 immunity involves the generation of antibodies to foreign antigens by B-lymphocytes. This antibody-mediated branch of the immune system attacks and effectively neutralizes extracellular foreign antigens.
[0009] Both limbs of the immune system are important in fighting disease and there is an increasing realization that the type of immune response is just as important as its intensity or its duration. Moreover, since the type 1 and type 2 responses are not necessarily mutually exclusive (in many circumstances an effective immune response requires that both occur in parallel), the balance of the type 1/type 2 response (also referred to as the Th1:Th2 response ratio/balance by reference to the distinct cytokine and effector cell subsets involved in the regulation of each response—see below) may also play a role in determining the effectiveness (and repercussions) of the immune defence.
[0010] In many circumstances the immune response is skewed heavily towards a type 1 or type 2 response soon after exposure to antigen. The mechanism of this type 1/type 2 skewing or polarization is not yet fully understood, but is known to involve a complex system of cell-mediated chemical messengers (cytokines, and particularly chemokines) in which the type 1/type 2 polarization (or balance) is determined, at least in part, by the nature of the initial PRR-PAMP interaction when the DCs and macrophages of the innate immune system are first stimulated and subsequently by the cytokine milieu in which antigen priming of naïve helper T cells occurs.
[0011] Two cytokines in particular appear to have early roles in determining the path of the immune response. Interleukin-12 (IL-12), secreted by macrophages, drives the type 1 response by stimulating the differentiation of Th1 cells, the helper cells that oversee the type 1 response. Another macrophage cytokine, interleukin-10 (IL-10) inhibits this response, instead driving a type 2 response.
[0012] The type 1 and type 2 responses can be distinguished inter alia on the basis of certain phenotypic changes attendant on priming and subsequent polarization of naïve helper T cells. These phenotypic changes are characterized, at least in part, by the nature of the cytokines secreted by the polarized helper T cells.
[0013] Th1 cells produce so-called Th1 cytokines, which include one or more of TNF, IL-1, IL-7, IFN-gamma, IL-12 and/or IL-18. The Th1 cytokines are involved in macrophage activation and Th1 cells orchestrate Type 1 responses. In contrast, Th2 cells produce so-called Th2 cytokines, which include one or more of IL-4, IL-5, IL-10 and IL-13. The Th2 cytokines promote the production of various antibodies and can suppress the type 1 response.
[0014] The involvement of Th1 and Th2 cells and cytokines in type 1:type 2 immune response polarization has given rise to the terms Th1 response and Th2 response being used to define the type 1 and type 2 immune responses, respectively. Thus, these terms are used interchangeably herein.
[0015] There is an increasing realization that the type of immune response is just as important in therapy and prophylaxis as its intensity or its duration. For example, an excess Th1 response can result in autoimmune disease, inappropriate inflammatory responses and transplant rejection. An excess Th2 response can lead to allergies and asthma. Moreover, a perturbation in the Th1:Th2 ratio is symptomatic of many immunological diseases and disorders, and the development of methods for altering the Th1:Th2 ratio is now a priority.
[0000] Alkaloids
[0016] The term alkaloid is used herein sensu stricto to define any basic, organic, nitrogenous compound which occurs naturally in an organism. The term alkaloid is also used herein sensu lato to define a broader grouping of compounds which include not only the naturally occurring alkaloids, but also their synthetic and semi-synthetic analogues and derivatives.
[0017] Most known alkaloids are phytochemicals, present as secondary metabolites in plant tissues (where they may play a role in defence), but some occur as secondary metabolites in the tissues of animals, microorganisms and fungi. There is growing evidence that the standard techniques for screening microbial cultures are inappropriate for detecting many classes of alkaloids (particularly highly polar alkaloids, see below) and that microbes (including bacteria and fungi, particularly the filamentous representatives) will prove to be an important source of alkaloids as screening techniques become more sophisticated.
[0018] Structurally, alkaloids exhibit great diversity. Many alkaloids are small molecules, with molecular weights below 250 Daltons. The skeletons may be derived from amino acids, though some are derived from other groups (such as steroids). Others can be considered as sugar analogues. It is becoming apparent (see Watson et al. (2001) Phytochemistry 56: 265-295) that the water soluble fractions of medicinal plants and microbial cultures contain many interesting novel polar alkaloids, including many carbohydrate analogues. Such analogues include a rapidly growing number of polyhydroxylated alkaloids.
[0019] Most alkaloids are classified structurally on the basis of the configuration of the N-heterocycle. Examples of some important alkaloids and their structures are set out in Kutchan (1995) The Plant Cell 7:1059-1070.
[0020] Watson et al. (2001) Phytochemistry 56: 265-295 have classified a comprehensive range of polyhydroxylated alkaloids inter alia as piperidine, pyrroline, pyrrolidine, pyrrolizidine, indolizidine and nortropanes alkaloids (see FIGS. 1-7 of Watson et al. (2001), the disclosure of which is incorporated herein by reference).
[0021] Watson et al. (2001), ibidem also show that a functional classification of at least some alkaloids is possible on the basis of their glycosidase inhibitory profile: many polyhydroxylated alkaloids are potent and highly selective glycosidase inhibitors. These alkaloids can mimic the number, position and configuration of hydroxyl groups present in pyranosyl or furanosyl moieties and so bind to the active site of a cognate glycosidase, thereby inhibiting it. This area is reviewed in Legler (1990) Adv. Carbohydr. Chem. Biochem. 48: 319-384 and in Asano et al., (1995) J. Med. Chem. 38: 2349-2356.
[0022] It has long been recognized that many alkaloids are pharmacologically active, and humans have been using alkaloids (typically in the form of plant extracts) as poisons, narcotics, stimulants and medicines for thousands of years. The therapeutic applications of polyhydroxylated alkaloids have been comprehensively reviewed in Watson et al. (2001), ibidem: applications include cancer therapy, immune stimulation, the treatment of diabetes, the treatment of infections (especially viral infections), therapy of glycosphingolipid lysosomal storage diseases and the treatment of autoimmune disorders (such as arthritis and sclerosis).
[0023] Both natural and synthetic mono- and bi-cyclic nitrogen analogues of carbohydrates are known to have potential as chemotherapeutic agents. Alexine (1) and australine (2) were the first pyrrolizidine alkaloids to be isolated with a carbon substituent at C-3, rather than the more common C-1 substituents characteristic of the necine family of pyrrolizidines.
[0024] The alexines occur in all species of the genus Alexa and also in the related species Castanospermum australe . Stereoisomers of alexine, including 1,7a-diepialexine (3), have also been isolated (Nash et al. (1990) Phytochemistry (29) 111) and synthesised (Choi et al. (1991) Tetrahedron Letters (32) 5517 and Denmark and Cottell (2001) J. Org. Chem. (66) 4276-4284).
[0025] Because of the reported weak in vitro antiviral properties of one 7,7a-diepialexine (subsequently defined as 1,7a-diepialexine), there has been some interest in the isolation of the natural products and the synthesis of analogues.
[0026] As an indolizidine alkaloid (and so structurally distinct from the pyrrolizidine alexines), swainsonine (4) is a potent and specific inhibitor of α-mannosidase and is reported to have potential as an antimetastic, tumour anti-proliferative and immunoregulatory agent (see e.g. U.S. Pat. No. 5,650,413, WO00/37465, WO93/09117).
[0027] The effect of variation in the size of the six-membered ring of swainsonine on its glycosidase inhibitory activity has been studied: pyrrolizidine derivatives (so-called “ring contracted swainsonines”) have been synthesised. However, these synthetic derivatives (1S,2R,7R,7aR)1,2,7-trihydroxypyrrolizidine (5) and the 7S-epimer (6)) were shown to have much weaker inhibitory activity relative to swainsonine itself (see U.S. Pat. No. 5,075,457).
[0028] Another compound, 1α,2α,6α,7α,7αβ-1,2,6,7-tetrahydroxypyrrolizidine (7) is an analogue of 1,8-diepiswainsonine and described as a “useful” inhibitor of glycosidase enzymes in EP0417059.
[0029] Casuarine, (1R,2R,3R,6S,7S,7aR)-3-(hydroxymethyl)-1,2,6,7-tetrahydroxypyrrolizidine (8) is a highly oxygenated bicyclic pyrrolizidine alkaloid that can be regarded as a more highly oxygenated analogue of the 1,7a-diepialexine (shown in 3) or as a C(3) hydroxymethyl-substituted analogue of the 1α,2α,6α,7α,7αβ-1,2,6,7-tetrahydroxypyrrolizidine (shown in 7).
[0030] Casuarine can be isolated from several botanical sources, including the bark of Casuarina equisetifolia (Casuarinaceae), the leaves and bark of Eugenia janibolana (Myrtaceae) and Syzygium guineense (Myrtaceae) (see e.g. Nash et al. (1994) Tetrahedron Letters (35) 7849-7852). Epimers of casuarine, and probably casuarine itself, can be synthesised by sodium hydrogen telluride-induced cyclisation of azidodimesylates (Bell et al. (1997) Tetrahedron Letters (38) 5869-5872).
[0031] Casuarina equisetifolia wood, bark and leaves have been claimed to be useful against diarrhoea, dysentery and colic (Chopra et al. (1956) Glossary of Indian Medicinal Plants, Council of Scientific and Industrial Research (India), New Delhi, p. 55) and a sample of bark has recently been prescribed in Western Samoa for the treatment of breast cancer. An African plant containing casuarine (identified as Syzygium guineense ) has been reported to be beneficial in the treatment of AIDS patients (see Wormald et al. (1996) Carbohydrate Letters (2) 169-174).
[0032] The casuarine-6-α-glucoside (casuarine-6-α-D-glucopyranose, 9) has also been isolated from the bark and leaves of Eugenia jambolana (Wormald et al. (1996) Carbohydrate Letters (2) 169-174).
[0033] Eugenia jambolana is a well known tree in India for the therapeutic value of its seeds, leaves and fruit against diabetes and bacterial infections. Its fruit have been shown to reduce blood sugar levels in humans and aqueous extracts of the bark are claimed to affect glycogenolysis and glycogen storage in animals (Wormald et al. (1996) Carbohydrate Letters (2) 169-174).
[0000] Dendritic Cells and their Immunotherapeutic Uses
[0000] (a) Introduction
[0034] Dendritic cells (DCs) are a heterogeneous cell population with distinctive morphology and a widespread tissue distribution (see Steinman (1991) Ann. Rev. Immunol. 9: 271-296). They play an important role in antigen presentation, capturing and processing antigens into peptides and then presenting them (together with components of the MHC) to T cells. T cell activation may then be mediated by the expression of important cell surface molecules, such as high levels of MHC class I and II molecules, adhesion molecules, and costimulatory molecules.
[0035] Dendritic cells therefore act as highly specialized antigen-presenting cells (APCs): serving as “nature's adjuvants”, they potentiate adaptive T-cell dependent immunity as well as triggering the natural killer (NK and NKT) cells of the innate immune system. Dendritic cells therefore play a fundamental and important regulatory role in the magnitude, quality, and memory of the immune response. As a result, there is now a growing interest in the use of dendritic cells in various immunomodulatory interventions, which are described in more detail below.
[0036] Dendritic cells can be classified into different subsets inter alia on the basis of their state of maturation (mature or immature) and their cellular developmental origin (ontogeny). Each of these subsets appear to play distinct roles in vivo, as described below.
[0000] (b) Dendritic Cell Maturation
[0037] Immature (or resting) DCs are located in non-lymphoid tissue, such as the skin and mucosae, are highly phagocytic and readily internalize soluble and particulate antigens. It is only when such antigen-loaded immature DCs are also subject to inflammatory stimuli (referred to as maturation stimuli) that they undergo a maturation process that transforms them from phagocytic and migratory cells into non-phagocytic, highly efficient stimulators of naïve T cells.
[0038] Immature DCs are characterized by high intracellular MHC II in the form of MIICs, the expression of CD1a, active endocytosis for certain particulates and proteins, presence of FcgR and active phagocytosis, deficient T cell sensitization in vitro, low/absent adhesive and costimulatory molecules (CD40/54/58/80/86), low/absent CD25, CD83, p55, DEC-205, 2A1antigen, responsiveness to GM-CSF, but not M-CSF and G-CSF and a sensitivity to IL-10, which inhibits maturation.
[0039] Upon maturation, mature DCs, loaded with antigen and capable of priming T cells, migrate from the non-lymphoid tissues to the lymph nodes or spleen, where they process the antigen load and present it to the resident naïve CD4 + T cells and CD8 + cytotoxic T cells. This latter interaction generates CTLs, the cellular arm of the adaptive immune response, and these cells eliminate virally infected cells and tumour cells. The naïve CD4 + T cells differentiate into memory helper T cells, which support the differentiation and expansion of CD8 + CTLs and B cells. Thus, helper T cells exert anti-tumour activity indirectly through the activation of important effector cells such as macrophages and CTLs.
[0040] Having activated the T cells in this way, the mature DCs undergo apoptosis within 9-10 days.
[0041] Mature DC cells are characterized morphologically by motility and the presence of numerous processes (veils or dendrites). They are competent for antigen capture and presentation (exhibiting high MHC class I and II expression) and express a wide range of molecules involved in T cell binding and costimulation, (e.g. CD40, CD54/ICAM-1, CD58/LFA-3, CD80/B7-1 and CD86/B7-2) as well as various cytokines (including IL-12). They are phenotypically stable: there is no reversion/conversion to macrophages or lymphocytes.
[0042] Thus, mature DCs play an important role in T cell activation and cell-mediated immunity. In contrast, immature DCs are involved in regulating and maintaining immunological tolerance (inducing antigen-specific T cell energy).
[0000] (c) Dendritic Cell Ontogenic Subsets
[0043] Dendritic cells are not represented by a single cell type, but rather comprise a heterogeneous collection of different classes of cells, each with a distinct ontogeny. At least three different developmental pathways have been described, each emerging from unique progenitors and driven by particular cytokine combinations to DC subsets with distinct and specialized functions.
[0044] At present it is thought that the earliest DC progenitors/precursors common to all DCs originate in the bone marrow. These primitive progenitors are CD34 + , and they are released from the bone marrow to circulate through both the blood and lymphoid organs.
[0045] Once released from the bone marrow, the primitive CD34 + DC progenitors are subject to various stimulatory signals. These signals can direct the progenitors along one of at least three different pathways, each differing with respect to intermediate stages, cytokine requirements, surface marker expression and biological function.
Lymphoid DCs are a distinct subset of DCs that are closely linked to the lymphocyte lineage. This lineage is characterized by the lack of the surface antigens CD11b, CD13, CD14 and CD33. Lymphoid DCs share ancestry with T and natural killer (NK) cells, the progenitors for all being located in the thymus and in the T cell areas of secondary lymphoid tissues. The differentiation of lymphoid DCs is driven by Interleukins 2, 3 and 15 (IL-3, IL-2 and IL-1), but not by granulocyte macrophage colony-stimulating factor (GM-CSF). Functionally, lymphoid promote negative selection in the thymus (possibly by inducing fas-mediated apoptosis) and are costimulatory for CD4 + and CD8 + T cells. More recently, lymphoid-like DCs derived from human progenitors have also been shown to preferentially activate the Th2 response. Because of their capacity to induce apoptosis and their role in eliminating potentially self-reactive T cells, it has been suggested that lymphoid DCs primarily mediate regulatory rather than stimulatory immune effector functions. Myeloid DCs are distinguished by a development stage in which there is expression of certain features associated with phagocytes. There appear to be at least two structurally and functionally distinct subsets. The first is defined antigenically as CD14 − , CD34 + , CD68 − and CD1a + and sometimes referred to as DCs of the Langerhans cell type. This subset appears to prime T cells to preferentially activate Th1 responses and IL-12 appears implicated in this process. The subset may also activate naïve B cells to secrete IgM and may therefore be predominantly associated with an inflammatory Th1 response. A second myeloid DC subset, sometimes referred to as interstitial DCs, is defined antigenically as CD14 + , CD68 + and CD1a − and related to monocytes (as a result they are also referred to as monocyte-derived DCs or Mo-DCs).
(d) Dendritic Cell Vaccines
[0048] In one dendritic cell-based treatment paradigm (reviewed in Schuler et al. (2003) Current Opinion in Immunol 15: 138-147), DC cells are taken from a patient (for example by apheresis) and then pulsed (primed or spiked) with a particular antigen or antigens (for example, tumour antigen(s)). They are then re-administered as an autologous cellular vaccine to potentiate an appropriate immune response.
[0049] In this treatment paradigm, the responding T cells include helper cells, especially Th1 CD4 + cells (which produce IFN-γ) and killer cells (especially CD8 + cytolytic T lymphocytes). The DCs may also mediate responses by other classes of lymphocytes (B, NK, and NKT cells). They may also elicit T cell memory, a critical goal of vaccination.
[0050] At present, little is known about the identity of the DC subset(s) required for optimum effectiveness of DC vaccines, beyond the recognition that maturation is required and immature DCs are to be avoided (Dhodapkar and Steinman (2002) Blood 100: 174-177).
[0051] Hsu et al. (1996) Nat Med 2: 52-58 used rare DCs isolated ex vivo from blood. These DCs were highly heterogeneous with respect to their ontogenic subsets but matured spontaneously during the isolation procedure. However, the yields were very low.
[0052] The yield problem has been addressed by the development of techniques for expanding the DCs ex vivo, for example with Flt3 ligand (Fong et al. (2001) PNAS 98: 8809-8814), but this is of limited effectiveness.
[0053] However, most studies have used Mo-DCs. These cells are obtained by exposing monocytes to GM-CSF and IL-4 (or IL-13) to produce immature Mo-DCs, which are then matured by incubation in a maturation medium. Such media comprise one or more maturation stimulation factor(s), and typically comprise Toll-like receptor (TLR) ligands (e.g. microbial products such as lipopolysaccharide and/or monophosphoryl lipid), inflammatory cytokines (such as TNF-α), CD40L, monocyte conditioned medium (MCM) or MCM mimic (which contains IL-1β, TNF-α, IL-6 and PGE 2 ).
[0054] Although little is known at present about the influence of maturation medium on DC vaccine performance, MCM or MCM mimic currently represent a standard: Mo-DCs matured using these media are homogenous, have a high viability, migrate well to chemotactic stimuli and induce CTLs both in vitro and in vivo.
[0055] Techniques have been developed for generating large numbers of Mo-DCs (300 to 500 million mature DCs per apheresis) from adherent monocytes within semi-closed, multilayered communicating culture vessels offering a surface area large enough to cultivate one leuk-apheresis product. These so-called cell factories can be used to produce cryopreserved aliquots of antigen preloaded DCs which are highly viable on thawing, and optimised maturation and freezing procedures have been described (Berger et al. (2002) J. Immunol. Methods 268: 131-140; Tuyaerts et al. (2002) J. Immunol. Methods 264: 135-151).
[0056] Dendritic cells for vaccination have also been prepared from CD34 + -derived DCs comprising a mixture of interstitial and DCs of the Langerhans cell type. Some workers believe that the latter DC subset are more potent than Mo-DCs when used as DC vaccines.
[0057] With regard to antigen selection, various approaches have been used. Both defined and undefined antigens can be employed. The antigens can be xenoantigens or autoantigens. One or more defined neoantigen(s) may be selected: in the case of cancer treatment, the neoantigen(s) may comprise a tumour-associated antigen. However, most popular are 9-11 amino acid peptides containing defined antigens (either natural sequences or analogues designed for enhanced MHC binding): such antigens can be manufactured to good manufacturing practice (GMP) standard and are easily standardized.
[0058] Other approaches have employed antigens as immune complexes, which are delivered to Fc-receptor-bearing DCs and which results in the formation of both MHC class I and MHC class II peptide sequences. This offers the potential for inducing both CTLs and Th cells (Berlyn et al. (2001) Clin Immunol 101: 276-283).
[0059] Methods have also been developed for exploring the whole antigenic repertoire of any given tumour (or other target cell, such as a virally-infected cell). For example, DC-tumour cell hybrids have been successfully used to treat renal cell carcinoma (Kugler et al. (2000) 6: 332-336), but the hybrids are difficult to standardize and short-lived. Necrotic or apoptotic tumour cells have been used, as have various cellular lysates.
[0060] It appears that the selection of patient-specific antigens may be important in the treatment of at least some cancers, and antigens derived from fresh tumour cells rather than tumour cell lines or defined antigens may prove important (Dhodapkar et al. (2002) PNAS 99: 13009-13013).
[0061] As regards delivery of the selected antigen(s) to the DCs, various techniques are available. Since the number and quality of MHC-peptide complexes directly influences the immunogenicity of the DC, the antigen loading technique may prove critical to DC vaccine performance (van der Burg et al. (1996) J Immunol 156: 3308-3314). It seems that prolonged presentation of MHC-peptide complexes by the DCs enhances immunogenicity and so loading techniques which promote prolonged presentation may be important. This has been achieved by loading the DCs internally through the use of peptides linked to cell-penetrating moieties (Wang and Wang (2002) Nat Biotechnol 20: 149-154).
[0062] Antigens can also be loaded by transfecting the DCs with encoding nucleic acid (e.g. by electroporation) such that the antigens are expressed by the DC, processed and presented at the cell surface. This approach avoids the need for expensive GMP proteins and antibodies. RNA is preferred for this purpose, since it produces only transient expression (albeit sufficient for antigen processing) and avoids the potential problems associated with the integration of DNA and attendant long-term expression/mutagenesis. Such transfection techniques also permit exploration of the whole antigenic repertoire of a target cell by use of total or PCR-amplified tumour RNA.
[0063] There is some evidence that helper proteins (for example, keyhole limpet hemocyanin (KLH) and tetanus toxoid (TT)) can provide unspecific help for CTL induction (Lanzavecchia (1998) Nature 393: 413-414) and it may prove advantageous to pulse DC with such helper proteins prior to vaccination.
[0064] With regard to posology, the dose, frequency and route of DC vaccine administration have not yet been optimised in clinical trials. Clearly, the absolute number of cells administered will depend on the route of administration and effectiveness of migration after infusion. In this respect there are indications that intradermal or subcutaneous administration may be preferred for the development of Th1 responses, although direct intranodal delivery has been employed to circumvent the need for migration from the skin to the nodes (Nestle et al. (1998) Nat Med 4: 328-332).
[0065] Quite distinct from the antigen-pulsed DC vaccine paradigm described above is an approach in which dendritic cells secreting various chemokines are injected directly into tumours where they have been shown to prime T cells extranodally (Kirk et al. (2001) Cancer Res 61: 8794-8802). Thus, in another treatment paradigm, DCs are targeted to a tumour and activated to elicit immune responses in situ without the need for ex vivo antigen loading.
[0066] In situ DC vaccination constitutes yet another distinct (but related) approach (Hawiger et al. (2001) J Exp Med 194: 769-779. In this therapeutic paradigm, antigen is targeted to DCs in vivo which are expanded and induced to mature in situ. This approach depends on efficient targeting of antigen to endogenous DCs (for example, using exosomes—see Thery et al. (2002) Nat Rev Immunol 2: 569-579) and the development of maturation stimulants that can effectively trigger maturation (preferably of defined DC subset(s)) in vivo.
[0000] (e) Use of Dendritic Cells in Adoptive CTL Immunotherapy
[0067] Cytotoxic T lymphocytes (CTLs) can be administered to a patient in order to confer or supplement an immune response to a particular disease or infection (typically cancer). For example, tumour specific T cells can be extracted from a patient (e.g. by leukapheresis), selectively expanded (for example by tetramer-guided cloning—see Dunbar et al. (1999) J Immunol 162: 6959-6962) and then re-administered as an autologous cellular vaccine.
[0068] The clinical effectiveness, applicability and tractability of this type of passive immunotherapy can be greatly increased by using dendritic cells to prime the T cells in vitro prior to administration.
[0000] (f) Dendritic Cell-Based Approaches to the Treatment of Autoimmune Disorders
[0069] Dendritic cells are also involved in regulating and maintaining immunological tolerance: in the absence of maturation, the cells induce antigen-specific silencing or tolerance.
[0070] Thus, in another dendritic cell-based treatment paradigm, immature DCs are administered as part of an immunomodulatory intervention designed to combat autoimmune disorders. In such applications, the suppressive potential of the DCs has been enhanced by in vitro transfection with genes encoding cytokines.
[0000] (g) The Role of IL-2 in Dendritic Cell Function
[0071] Granucci et al. (2002) Trends in Immunol. 23: 169-171 have reported transient upregulation of mRNA transcripts for IL-2 in dendritic cells following microbial stimulus. In WO03012078 Granucci describes the important role played by DC-derived IL-2 in mediating not only T cell activation but also that of NK cells and goes on to suggest that DC-derived IL-2 is a key factor regulating and linking innate and adaptive immunity.
[0072] Moreover, systemic administration of IL-2 has recently been shown to enhance the therapeutic efficacy of a DC vaccine (Shimizu et al. (1999) PNAS 96: 2268-2273), while the presence of IL-2 was shown to be essential for specific peptide-mediated immunity mediated by dendritic cells in at least some DC vaccination regimes (Eggert et al. (2002) Eur J Immunol 32: 122-127). In their recent review, Schuler et al. (ibidem) conclude that “ . . . it might be worthwhile to explore the combination of DC vaccination with IL-2 administration, as the T-cell responses induced by DC vaccination appear enhanced and therapeutically more effective.”.
[0073] It will be clear from the foregoing discussion that dendritic cells are now proven as valuable tools in immunotherapy (particularly in the treatment of cancer), but that DC vaccination is still at a relatively early stage. Methods for preparing DCs are improving continuously and an increasing number of Phase I, II and III clinical trials are driving intense research and development in this area. However, there is still a need to improve efficacy at the level of DC biology.
[0074] The present inventors have now surprisingly discovered that casuarine and certain casuarine analogues have unexpected immunomodulatory activity, and that this activity may not be dependent on glycosidase inhibition.
SUMMARY OF THE INVENTION
[0075] According to the invention there is provided an isolated immunomodulatory (e.g. immunostimulatory) polyhydroxylated pyrrolizidine compound for use in therapy or prophylaxis having the formula:
wherein R is selected from the group comprising hydrogen, straight or branched, unsubstituted or substituted, saturated or unsaturated acyl, alkyl (e.g. cycloalkyl), alkenyl, alkynyl and aryl groups, or a pharmaceutically acceptable salt or derivative thereof.
[0076] Preferably, the compounds of the invention are alkaloids (as hereinbefore defined).
[0077] The compound of the invention preferably has the formula:
wherein R is selected from the group comprising hydrogen, straight or branched, unsubstituted or substituted, saturated or unsaturated acyl, alkyl (e.g. cycloalkyl), alkenyl, alkynyl and aryl groups, or a pharmaceutically acceptable salt or derivative thereof.
[0078] Particularly preferred is 1R,2R,3R,6S,7S,7aR)-3-(hydroxymethyl)-1,2,6,7-tetrahydroxypyrrolizidine (casuarine), wherein R is hydrogen and which has the formula:
or a pharmaceutically acceptable derivative or salt thereof.
[0079] Particularly preferred is a casuarine glucoside, or a pharmaceutically acceptable salt or derivative thereof.
[0080] Other preferred compounds include 6-O-butanoylcasuarine of the formula:
or a pharmaceutically acceptable salt or derivative thereof.
[0081] A particularly preferred casuarine glucoside is casuarine-6-α-D-glucoside of the formula:
or a pharmaceutically acceptable salt or derivative thereof.
[0082] As mentioned infra, the invention contemplates diastereomers of the compounds of the invention. Particularly preferred are diastereomers selected from 3,7-diepisuarine (10), 7-epi-casuarine (11), 3,6,7-triepi-casuarine (12), 6,7-diepi-casuarine (13) and 3-epi-casuarine (14), as well as pharmaceutically acceptable salts and derivatives thereof.
[0083] Other preferred diastereomers are selected from 3,7-diepi-casuarine-6-α-D-glucoside (15), 7-epi-casuarine-6-α-D-glucoside (16), 3,6,7-triepi-casuarine-6-α-D-glucoside (17), 6,7-diepi-casuarine-6-α-D-glucoside (18) and 3-epi-casuarine-6-α-D-glucoside (19), as well as pharmaceutically acceptable salts and derivatives thereof.
[0084] Other preferred diastereomers include 7a epimers selected from 3,7,7a-triepi-casuarine, 7,7a-diepi-casuarine, 3,6,7,7a-tetraepi-casuarine, 6,7,7a-triepi-casuarine and 3,7a-diepi-casuarine, as well as pharmaceutically acceptable salts and derivatives thereof.
[0085] In another aspect the invention provides a method for immunomodulation (e.g. immunostimulation) comprising administering to a patient a composition comprising a polyhydroxylated pyrrolizidine compound having the formula:
wherein R is selected from the group comprising hydrogen, straight or branched, unsubstituted or substituted, saturated or unsaturated acyl, alkyl (e.g. cycloalkyl), alkenyl, alkynyl and aryl groups, or a pharmaceutically acceptable salt or derivative thereof.
[0086] The immunostimulatory methods of the invention are described in more detail infra.
[0087] In another aspect, the invention provides a method for chemoprotection comprising administering the compound of the invention to a patient undergoing chemotherapy.
[0088] The invention also contemplates the use of the polyhydroxylated pyrrolizidine compound of the invention for the manufacture of a medicament for use in immunostimulation and/or chemoprotection, as well as a process for the manufacture of a medicament for use in immunostimulation and/or chemoprotection, characterized in the use of the polyhydroxylated pyrrolizidine compound of the invention.
[0089] In another aspect, the invention contemplates a composition comprising the polyhydroxylated pyrrolizidine compound of the invention in combination with an immunostimulant and/or cytotoxic agent (e.g. AZT) and/or an antimicrobial (e.g. antibacterial) agent and/or an antiviral agent and/or a dendritic cell (e.g. a primed dendritic cell). Such compositions preferably further comprise a pharmaceutically acceptable excipient.
[0090] In another aspect the invention contemplates a vaccine comprising the polyhydroxylated pyrrolizidine compound of the invention in combination with an antigen, the compound being present in an amount sufficient to produce an adjuvant effect on vaccination.
[0091] In another aspect the invention contemplates a pharmaceutical kit of parts comprising the polyhydroxylated pyrrolizidine compound of the invention in combination with an immunostimulant and/or cytotoxic agent (e.g. 5′ fluoro-uracil and ricin) and/or an antimicrobial (e.g. antibacterial) agent and/or an antiviral agent (e.g. AZT). Such kits preferably further comprise instructions for use in immunotherapy.
[0092] The compounds of the invention have broad utility in therapy and prophylaxis, including treatments for increasing the Th1:Th2 response ratio, for example in the treatment of Th1-related diseases or disorders (e.g. proliferative disorders or microbial infection) and/or Th2-related diseases or disorders (for example allergies, e.g. asthma), as well as in haemorestoration, the alleviation of immunosuppression, in cytokine stimulation, in the treatment of proliferative disorders, vaccination (wherein the compound acts as an adjuvant), vaccination with dendritic cell vaccines (e.g. with primed dendritic cell vaccines, wherein the dendritic cells are contacted with the compound), in the administration of dendritc cells in the treatment or prophylaxis of autoimmune disorders (wherein the dendritic cells are contacted with the compound) and in wound healing. These medical uses are described in more detail below.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0093] Where used herein and unless specifically indicated otherwise, the following terms are intended to have the following meanings in addition to any broader (or narrower) meanings the terms might enjoy in the art:
[0094] The term adjunctive (as applied to the use of the drugs of the invention in therapy) defines uses in which the pyrrolizidine compound is administered together with one or more other drugs, interventions, regimens or treatments (such as surgery and/or irradiation). Such adjunctive therapies may comprise the concurrent, separate or sequential administration/application of the pyrrolizidine compound of the invention and the other treatment(s). Thus, in some embodiments, adjunctive use of the pyrrolizidine compound of the invention is reflected in the formulation of the pharmaceutical compositions of the invention. For example, adjunctive use may be reflected in a specific unit dosage, or in formulations in which the pyrrolizidine compound of the invention is present in admixture with the other drug(s) with which it is to be used adjunctively (or else physically associated with the other drug(s) within a single unit dose). In other embodiments, adjunctive use of the pyrrolizidine compound of the invention may be reflected in the composition of the pharmaceutical kits of the invention, wherein the pyrrolizidine compound of the invention is co-packaged (e.g. as part of an array or unit doses) with the other drug(s) with which it is to be used adjunctively. In yet other embodiments, adjunctive use of the pyrrolizidine compound of the invention may be reflected in the content of the information and/or instructions co-packaged with the pyrrolizidine compound relating to formulation and/or posology.
[0095] The term neoantigen is used herein to define any newly expressed antigenic determinant. Neoantigens may arise upon conformational change in a protein, as newly expressed determinants (especially on the surfaces of transformed or infected cells), as the result of complex formation of one or more molecules or as the result of cleavage of a molecule with a resultant display of new antigenic determinants. Thus, as used herein, the term neoantigen covers antigens expressed upon infection (e.g. viral infection, protozoal infection or bacterial infection), in prion-mediated diseases (e.g. BSE and CJD), an on cell transformation (cancer), in which latter case the neoantigen may be termed a tumour-associated antigen.
[0096] The term tumour-associated antigen is used herein to define an antigen present in transformed (malignant or tumourous) cells which is absent (or present in lower amounts or in a different cellular compartment) in normal cells of the type from which the tumour originated. Oncogenic viruses can also induce expression of tumour antigens, which are often host proteins induced by the virus.
[0097] The term herbal medicine is used herein to define a pharmaceutical composition in which at least one active principle is not chemically synthesized and is a phytochemical constituent of a plant. In most cases, this non-synthetic active principle is not isolated (as defined herein), but present together with other phytochemicals with which it is associated in the source plant. In some cases, however, the plant-derived bioactive principle(s) may be in a concentrated fraction or isolated (sometimes involving high degrees of purification). In many cases, however, the herbal medicine comprises a more or less crude extract, infusion or fraction of a plant or even an unprocessed whole plant (or part thereof, though in such cases the plant (or plant part) is usually at least dried and/or milled.
[0098] The term bioactive principle is used herein to define a phytochemical which is necessary or sufficient for the pharmaceutical efficacy of the herbal medicament in which it is comprised. In the case of the present invention, the bioactive principle comprises the immunomodulatory compound of the invention (e.g. casuarine, casuarine glucoside or mixtures thereof.
[0099] The term standard specification is used herein to define a characteristic, or a phytochemical profile, which is correlated with an acceptable quality of the herbal medicine. In this context, the term quality is used to define the overall fitness of the herbal medicament for its intended use, and includes the presence of one or more of the bioactive principles (at an appropriate concentration) described above or else the presence of one or more bioactive markers or a phytochemical profile which correlates with the presence of one or more of the bioactive principles (at an appropriate concentration).
[0100] The term phytochemical profile is used herein to define a set of characteristics relating to different phytochemical constituents.
[0101] The term isolated as applied to the pyrrolizidine compounds of the invention is used herein to indicate that the compound exists in a physical milieu distinct from that in which it occurs in nature. For example, the isolated material may be substantially isolated (for example purified) with respect to the complex cellular milieu in which it naturally occurs. When the isolated material is purified, the absolute level of purity is not critical and those skilled in the art can readily determine appropriate levels of purity according to the use to which the material is to be put. Preferred, however, are purity levels of 90% w/w, 99% w/w or higher. In some circumstances, the isolated compound forms part of a composition (for example a more or less crude extract containing many other substances) or buffer system, which may for example contain other components. In other circumstances, the isolated compound may be purified to essential homogeneity, for example as determined spectrophotometrically, by NMR or by chromatography (for example GC-MS).
[0102] The term pharmaceutically acceptable derivative as applied to the pyrrolizidine compounds of the invention define compounds which are obtained (or obtainable) by chemical derivatization of the parent pyrrolizidine compounds of the invention. The pharmaceutically acceptable derivatives are therefore suitable for administration to or use in contact with the tissues of humans without undue toxicity, irritation or allergic response (i.e. commensurate with a reasonable benefit/risk ratio). Preferred derivatives are those obtained (or obtainable) by alkylation, esterification or acylation of the parent pyrrolizidine compounds of the invention. The derivatives may be immunomodulatory per se, or may be inactive until processed in vivo. In the latter case, the derivatives of the invention act as pro-drugs. Particularly preferred pro-drugs are ester derivatives which are esterified at one or more of the free hydroxyls and which are activated by hydrolysis in vivo. The pharmaceutically acceptable derivatives of the invention retain some or all of the immunomodulatory activity of the parent compound. In some cases, the immunomodulatory activity is increased by derivatization. Derivatization may also augment other biological activities of the compound, for example bioavailability and/or glycosidase inhibitory activity and/or glycosidase inhibitory profile. For example, derivatization may increase glycosidase inhibitory potency and/or specificity.
[0103] The term pharmaceutically acceptable salt as applied to the pyrrolizidine compounds of the invention defines any non-toxic organic or inorganic acid addition salt of the free base compounds which are suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response and which are commensurate with a reasonable benefit/risk ratio. Suitable pharmaceutically acceptable salts are well known in the art. Examples are the salts with inorganic acids (for example hydrochloric, hydrobromic, sulphuric and phosphoric acids), organic carboxylic acids (for example acetic, propionic, glycolic, lactic, pyruvic, malonic, succinic, fumaric, malic, tartaric, citric, ascorbic, maleic, hydroxymaleic, dihydroxymaleic, benzoic, phenylacetic, 4-aminobenzoic, 4-hydroxybenzoic, anthranilic, cinnamic, salicylic, 2-phenoxybenzoic, 2-acetoxybenzoic and mandelic acid) and organic sulfonic acids (for example methanesulfonic acid and p-toluenesulfonic acid). The drugs of the invention may also be converted into salts by reaction with an alkali metal halide, for example sodium chloride, sodium iodide or lithium iodide. Preferably, the pyrrolizidine compounds of the invention are converted into their salts by reaction with a stoichiometric amount of sodium chloride in the presence of a solvent such as acetone.
[0104] These salts and the free base compounds can exist in either a hydrated or a substantially anhydrous form. Crystalline forms of the compounds of the invention are also contemplated and in general the acid addition salts of the pyrrolizidine compounds of the invention are crystalline materials which are soluble in water and various hydrophilic organic solvents and which in comparison to their free base forms, demonstrate higher melting points and an increased solubility.
[0105] In its broadest aspect, the present invention contemplates all optical isomers, racemic forms and diastereomers of the pyrrolizidine compounds of the invention. Those skilled in the art will appreciate that, owing to the asymmetrically substituted carbon atoms present in the compounds of the invention, the pyrrolizidine compounds of the invention may exist and be synthesised and/or isolated in optically active and racemic forms. Thus, references to the pyrrolizidine compounds of the present invention encompass the pyrrolizidine compounds as a mixture of diastereomers, as individual diastereomers, as a mixture of enantiomers as well as in the form of individual enantiomers.
[0106] Therefore, the present invention contemplates all optical isomers and racemic forms thereof of the compounds of the invention, and unless indicated otherwise (e.g. by use of dash-wedge structural formulae) the compounds shown herein are intended to encompass all possible optical isomers of the compounds so depicted. In cases where the stereochemical form of the compound is important for pharmaceutical utility, the invention contemplates use of an isolated eutomer.
Biological Activities of the Compounds of the Invention
[0107] Without wishing to be bound by any theory, it is thought that the immunomodulatory activity of the compounds of the invention may arise from the stimulation and/or suppression of cytokine secretion in vivo. In particular, it is thought that that the immunomodulatory activity of the compounds of the invention arises from the stimulation of secretion of one or more cytokines (e.g. one or more Th1 cytokines), including interleukins 2 and/or 12 (IL-2 and/or IL-12) and/or the suppression of secretion of one or more Th2 cytokines (e.g. IL-5).
[0108] In particular, it is thought that the immunostimulatory activity of the compounds of the invention may arise from the stimulation of IL-12 and IL-2 by dendritic cells. This leads to the stimulation of NK cells to produce IFN-γ and induces the development of CD4 + Th1 cells. The induced Th1 cells then produce IFN-γ and IL-2. The IL-2 then enhances further proliferation of Th1 cells and the differentiation of pathogen (e.g. tumour and virus)-specific CD8 + T cells. The IL-2 also stimulates the cytolytic activity of NK cells of the innate immune system.
[0109] IL-12 is the primary mediator of type-1 immunity (the Th1 response). It induces natural killer (NK) cells to produce IFN-γ as part of the innate immune response and promotes the expansion of CD4 + Th1 cells and cytotoxic CD8 + cells which produce IFN-γ. It therefore increases T-cell invasion of tumours as well as the susceptibility of tumour cells to T-cell invasion.
[0110] Thus, the compounds of the invention are preferably stimulators of cytokine secretion. Particularly preferred are compounds which induce, potentiate, activate or stimulate the release one or more cytokines (for example Th1 cytokines, e.g. IL-12 and/or II-2, optionally together with one or more other cytokines) in vitro.
[0111] This primary immunomodulatory activity of the compounds of the invention is particularly important in certain medical applications (discussed in detail infra). For example, increased production of IL-12 may overcome the suppression of innate and cellular immunities of HIV-1-infected individuals and AIDS patients.
[0112] The cytokine stimulation exhibited by the compounds of the invention may be dependent, in whole or in part, on the presence of co-stimulatory agents. Such co-stimulatory agents may include, for example, agents that stimulate the innate immune system, including Toll-like receptor (TLR) ligands. These ligands include microbial products such as lipopolysaccharide (LPS) and/or monophosphoryl lipid) as well as other molecules associated with microbial infection. In many applications, such co-stimulatory agents will be present in the patient to be treated at the time of administration of the compounds of the invention.
[0113] Without wishing to be bound by any theory, it is thought that at least some of the pharmacological activities of the compounds of the invention may be based on a secondary glycosidase inhibitory activity.
[0114] Such glycosidase inhibition may lead to any or all of the following in vivo:
Modification of tumour cell glycosylation (e.g. tumour antigen glycosylation); Modification of viral protein glycosylation (e.g. virion antigen glycosylation); Modification of cell-surface protein glycosylation in infected host cells; Modification of bacterial cell walls.
[0119] This ancillary biological activity may therefore augment the primary immunomodulatory activity in some preferred embodiments of the invention. It may be particularly desirable in certain medical applications, including the treatment of proliferative disorders (such as cancer) or in applications where infection is attendant on immune suppression. For example, selective modification of virion antigen glycosylation may render an infecting virus less (or non-) infective and/or more susceptible to endogenous immune responses. In particular, the compounds of the invention may alter the HIV viral envelope glycoprotein gp120 glycosylation patterns, hence inhibiting the entry of HIV into the host cell by interfering with the binding to cell surface receptors.
[0120] Thus, the compounds of the invention are preferably (but not necessarily) glycosidase inhibitors. Particularly preferred are compounds which exhibit specificity of glycosidase inhibition, for example Glucosidase I rather than mannosidases. Such preferred compounds can therefore be quite different in their glycosidase inhibitory profile to swainsonine and its analogues, since the latter are potent and specific inhibitors of mannosidase.
Medical Applications of the Compounds of the Invention
[0121] The invention finds broad application in medicine, for example in methods of therapy, prophylaxis and/or diagnosis.
[0122] These medical applications may be applied to any warm-blooded animal, including humans. The applications include veterinary applications, wherein the pyrrolizidine compounds of the invention are administered to non-human animals, including primates, dogs, cats, horses, cattle and sheep.
[0123] The pyrrolizidine compounds of the invention are immunomodulators. Thus, they find general application in the treatment or prophylaxis of conditions in which stimulation, augmentation or induction of the immune system is indicated and/or in which suppression or elimination of part or all of the immune response is indicated.
[0124] Particular medical uses of the pyrrolizidine compounds of the invention are described in detail below. References to therapy and/or prophylaxis in the description or claims are to be interpreted accordingly and are intended to encompass inter alia the particular applications described below.
1. Increasing the Th1:Th2 Response Ratio
[0000] General Considerations
[0125] As explained earlier, the immune response comprises two distinct types: the Th1 response (type-1, cellular or cell mediated immunity) and Th2 response (type-2, humoral or antibody mediated immunity).
[0126] These Th1 and Th2 responses are not mutually exclusive and in many circumstances occur in parallel. In such circumstances the balance of the Th1/Th2 response determines the nature (and repercussions) of the immunological defence (as explained herein).
[0127] The Th1/Th2 balance (which can be expressed as the Th1:Th2 response ratio) is determined, at least in part, by the nature of the environment (and in particular the cytokine milieu) in which antigen priming of naïve helper T cells occurs when the immune system is first stimulated.
[0128] The Th1 and Th2 responses are distinguished inter alia on the basis of certain phenotypic changes attendant on priming and subsequent polarization of naïve helper T cells. These phenotypic changes are characterized, at least in part, by the nature of the cytokines secreted by the polarized helper T cells.
[0129] Th1 cells produce so-called Th1 cytokines, which include one or more of IL-1, TNF, IL-2, IFN-gamma, IL-12 and/or IL-18. The Th1 cytokines are involved in macrophage activation and Th1 cells orchestrate cell-mediated defences (including cytotoxic T lymphocyte production) that form a key limb of the defence against bacterial and viral attack, as well as malignant cells.
[0130] Th2 cells produce so-called Th2 cytokines, which include one or more of IL-4, IL-5, IL-10 and IL-13. The Th2 cytokines promote the production of various antibodies and can suppress the Th1 response.
[0131] Accordingly, in the mouse, a cell that makes IFN-gamma and not IL4 is classified as Th1, whereas a CD4 + cell that expresses IL-4 and not IFN-gamma is classified as Th2. Although this distinction is less clear in humans (T cells that produce only Th1 or Th2 cytokines do not appear to exist in humans), the phenotype of the T cell response (Th1 or Th2) can still be distinguished in humans on the basis of the ratio of Th1 to Th2 cytokines expressed (usually, the ratio of IFN-gamma to IL-4 and/or IL-5).
[0132] There is an increasing realization that the type of immune response is just as important in therapy and prophylaxis as its intensity or its duration. For example, an excess Th1 response can result in autoimmune disease, inappropriate inflammatory responses and transplant rejection. An excess Th2 response can lead to allergies and asthma. Moreover, a perturbation in the Th1:Th2 ratio is symptomatic of many immunological diseases and disorders, and the development of methods for altering the Th1:Th2 ratio is now a priority.
[0133] It has now been discovered that the immunomodulatory pyrrolizidine compounds of the invention can increase the Th1:Th2 response ratio in vivo (for example, by preferentially promoting a Th1 response and/or preferentially suppressing a Th2 response).
[0134] Thus, the compounds of the invention find application in methods of therapy and/or prophylaxis which comprise increasing the Th1:Th2 response ratio (for example, by preferentially promoting a Th1 response and/or preferentially suppressing a Th2 response).
[0135] The medical applications contemplated herein therefore include any diseases, conditions or disorders in which an increase in the Th1:Th2 response ratio is indicated or desired. For example, the medical applications contemplated include diseases, conditions or disorders in which stimulation of a Th1 response and/or suppression of a Th2 response is indicated or desired.
[0136] The mechanism(s) by which the compounds of the invention increase the Th1:Th2 response ratio are not yet fully understood. It is likely that the activity is based, at least in part, on selective Th1 cytokine induction (since Th1 and Th2 cytokines exhibit mutual inhibition), for example in dendritic cells.
[0137] For example, the compounds of the invention may induce, potentiate, activate or stimulate (either directly or indirectly) the release and/or activity (in vitro and/or in vivo) of one or more Th1 cytokines (for example one or more cytokines selected from IFN-gamma, IL-12, IL-2 and IL-18). Particularly preferred are compounds which induce, potentiate, activate or stimulate the release and/or activity (in vitro and/or in vivo) of IFN-gamma and/or IL-12 and/or IL-2.
[0138] Particularly preferred are compounds that stimulate the release of IL-2 and IL-12 in dendritic cells.
[0139] The compounds of the invention may also suppress or inactivate (either directly or indirectly) the release and/or activity (in vitro and/or in vivo) of one or more Th2 cytokines (for example one or more cytokines selected from IL-4, IL-5, IL-10 and IL-13). Particularly preferred are compounds which suppress or inactivate the release and/or activity (in vitro and/or in vivo) of IL-5.
[0140] Thus, particularly preferred are compounds which exhibit a Th-1 cytokine stimulatory activity together with a complementary Th2 cytokine inhibitory activity.
[0141] Specific examples of applications falling within the general class of treatments based on increasing the Th1:Th2 response ratio are described in the following sections.
[0000] Th1-Related Diseases
[0142] Th1-related diseases are diseases, disorders, syndromes, conditions or infections in which Th1 cells are involved in preventing, curing or alleviating the effects of the disease, disorder, syndrome, condition or infection.
[0143] Th1-related diseases may also include diseases, disorders, syndromes, conditions or infections in which the Th1 component of the immune response is pathologically depressed or diseases, disorders, syndromes, conditions or infections in which stimulation of a Th1 response is indicated.
[0144] Such conditions may arise, for example, from certain proliferative disorders (typically cancers) in which the proliferating (e.g. tumour) cells exert a suppressive effect on one or more components of the Th1 response. For example, tumour cells may inhibit dendritic cells, cause the expression of inhibitory receptors on T cells, down regulate MHC class I expression and induce the secretion of anti-inflammatory factors and immunosuppressive cytokines which deactivate or suppress immune cell cytotoxicity.
[0145] Thus, the compounds of the invention find application in the treatment or prophylaxis of Th1-related diseases.
[0146] Examples of Th1-related diseases include infectious diseases (particularly viral infections) and proliferative disorders (e.g. cancer).
[0147] Thus, the Th1-related diseases include any malignant or pre-malignant condition, proliferative or hyper-proliferative condition or any disease arising or deriving from or associated with a functional or other disturbance or abnormality in the proliferative capacity or behaviour of any cells or tissues of the body.
[0148] Thus, the invention finds application in the treatment or prophylaxis of breast cancer, colon cancer, lung cancer and prostate cancer. It also finds application in the treatment or prophylaxis of cancers of the blood and lymphatic systems (including Hodgkin's Disease, leukemias, lymphomas, multiple myeloma, and Waldenstrom's disease), skin cancers (including malignant melanoma), cancers of the digestive tract (including head and neck cancers, cesophageal cancer, stomach cancer, cancer of the pancreas, liver cancer, colon and rectal cancer, anal cancer), cancers of the genital and urinary systems (including kidney cancer, bladder cancer, testis cancer, prostate cancer), cancers in women (including breast cancer, ovarian cancer, gynecological cancers and choriocarcinoma) as well as in brain, bone carcinoid, nasopharyngeal, retroperitoneal, thyroid and soft tissue tumours. It also finds application in the treatment or prophylaxis of cancers of unknown primary site.
[0149] The Th1-related infectious diseases include bacterial, prion (e.g. BSE and CJD), viral, fungal, protozoan and metazoan infections. For example, the Th1-related infectious diseases include infection with respiratory syncytial virus (RSV), hepatitis B virus (HBV), Epstein-Barr, hepatitis C virus (HCV), herpes simplex type 1 and 2, herpes genitalis, herpes keratitis, herpes encephalitis, herpes zoster, human immunodeficiency virus (HIV), influenza A virus, hantann virus (hemorrhagic fever), human papilloma virus (HPV), tuberculosis, leprosy and measles.
[0150] Particularly preferred Th1-related infectious diseases include those in which the pathogen occupies an intracellular compartment, including HIV/AIDS, leishmaniasis, trypanosomiasis, influenza, tuberculosis and malaria.
[0151] The compounds of the invention may also find application in the treatment of patients in which the Th1 immune response is defective. Such patients may include neonates, juveniles in which the Th1 response is immature and not fully developed, as well as older patients in which the Th1 response has become senescent or compromised over time. In such patient populations the compounds of the invention may be used prophylactically (as a generalized type 1 immune stimulant to reduce the risks of (e.g. viral) infections.
[0000] Th2-Related Diseases and Allergy
[0152] Th2-related diseases are diseases, disorders, syndromes, conditions or infections in which Th2 cells are implicated in (e.g. support, cause or mediate) the effects of the disease, disorder, syndrome, condition or infection.
[0153] Thus, the compounds of the invention find application in the treatment or prophylaxis of Th2-related diseases.
[0154] One important class of Th2-related diseases treatable with the compounds of the invention is allergic disease.
[0155] It is well known that genetically predisposed individuals can become sensitised (allergic) to antigens originating from a variety of environmental sources. The allergic reaction occurs when a previously sensitised individual is re-exposed to the same or to a structurally similar or homologous allergen. Thus, as used herein the term allergy is used to define a state of hypersensitivity induced by exposure to a particular antigen (allergen) resulting in harmful and/or uncomfortable immunologic reactions on subsequent exposures to the allergen.
[0156] The harmful, uncomfortable and/or undesirable immunologic reactions present in allergy include a wide range of symptoms. Many different organs and tissues may be affected, including the gastrointestinal tract, the skin, the lungs, the nose and the central nervous system. The symptoms may include abdominal pain, abdominal bloating, disturbance of bowel function, vomiting, rashes, skin irritation, wheezing and shortness of breath, nasal running and nasal blockage, headache and mood changes. In severe cases the cardiovascular and respiratory systems are compromised and anaphylactic shock leads in extreme cases to death.
[0157] It is known that the harmful, undesirable and/or uncomfortable immunologic reactions characteristic of allergy have a Th2 response component.
[0158] As explained above, the compounds of the invention may suppress or inactivate (either directly or indirectly) the release and/or activity (in vitro and/or in vivo) of one or more Th2 cytokines (for example one or more cytokines selected from IL-4, IL-5, IL-10 and IL-13). Thus, the compounds of the invention may be used to effect a remedial or palliative modulation of the harmful and/or uncomfortable immunologic reactions characteristic of allergic reactions by inhibiting, suppressing or eliminating the Th2 response to the allergen.
[0159] The compounds of the invention therefore find application in the treatment or prophylaxis of allergy.
[0160] Any allergy may be treated according to the invention, including atopic allergy, allergic rhinitis, allergic conjunctivitis, atopic dermatitis, hypereosinophilia, irritable bowel syndrome, allergen-induced migraine, bacterial allergy, bronchial allergy (asthma), contact allergy (dermatitis), delayed allergy, pollen allergy (hay fever), drug allergy, sting allergy, bite allergy, gastrointestinal or food allergy (including that associated with inflammatory bowel disease, including ulcerative colitis and Crohn's disease) and physical allergy. Physical allergies include cold allergy (cold urticaria or angioedema), heat allergy (cholinergic urticaria) and photosensitivity.
[0161] Particularly important is the treatment or prophylaxis of asthma.
2. Haemorestoration
[0162] The pyrrolizidine compounds of the invention increase splenic and bone marrow cell proliferation and can act as myeloproliferative agents. They therefore find application as haemorestoratives.
[0163] Haemorestoration may be indicated following immunosuppressant therapies (such as cyclosporine A, azathioprine or immunosuppressant radiotherapies), chemotherapy (including treatment with both cycle-specific and non-specific chemotherapeutic agents), steroid administration or other forms of surgical or medical intervention (including radiotherapy). Thus, the use of the pyrrolizidine compounds of the invention as haemorestoratives may be adjunctive to other treatments which tend to depress splenic and bone marrow cell populations. Particularly preferred adjunctive therapies according to the invention include the administration of an immunorestorative dose of the pyrrolizidine compound of the invention adjunctive to: (a) chemotherapy; and/or (b) radiotherapy; and/or (c) bone marrow transplantation; and/or (d) haemoablative immunotherapy.
3. Alleviation of Immunosuppression
[0164] The pyrrolizidine compounds of the invention may be used to alleviate, control or modify states in which the immune system is partially or completely suppressed or depressed. Such states may arise from congenital (inherited) conditions, be acquired (e.g. by infection or malignancy) or induced (e.g. deliberately as part of the management of transplants or cancers).
[0165] Thus, the pyrrolizidine compounds of the invention may find application as adjunctive immunomodulators (e.g. immunostimulants) in the treatment and/or management of various diseases (including certain cancers) or medical interventions (including radiotherapy, immunosuppressant therapy (such as the administration of cyclosporine A, azathioprine or immunosuppressant radiotherapies), chemotherapy and cytotoxic drug administration (for example the administration of ricin, cyclophosphamide, cortisone acetate, vinblastine, vincristine, adriamycin, mercaptopurine, 5-fluorouracil, mitomycin C, chloramphenicol and other steroid-based therapies). They may therefore be used as chemoprotectants in the management of various cancers and infections (including bacterial and viral infections, e.g. HIV infection) or to induce appropriate and complementary immunotherapeutic activity during conventional immunotherapy.
[0166] In particular, the pyrrolizidine compounds of the invention may find application as immunostimulants in the treatment or management of microbial infections which are associated with immune-suppressed states, including many viral infections (including HIV infection in AIDS) and in other situations where a patient has been immunocompromised (e.g. following infection with hepatitis C, or other viruses or infectious agents including bacteria, fungi, and parasites, in patients undergoing bone marrow transplants, and in patients with chemical or tumor-induced immune suppression).
[0167] Other diseases or disorders which may give rise to an immunosuppressed state treatable according to the invention include: ataxia-telangiectasia; DiGeorge syndrome; Chediak-Higashi syndrome; Job syndrome; leukocyte adhesion defects; panhypogammaglobulinemia (e.g. associated with Bruton disease or congenital agammaglobulinemia); selective deficiency of IgA; combined immunodeficiency disease; Wiscott-Aldrich syndrome and complement deficiencies. It may be associated with organ and/or tissue (e.g. bone marrow) transplantation or grafting, in which applications the pyrrolizidine compounds of the invention may be used adjunctively as part of an overall treatment regimen including surgery and post-operative management of immune status.
4. Cytokine Stimulation
[0168] The pyrrolizidine compounds of the invention may be used to induce, potentiate or activate various cytokines in vivo, including various interleukins (including IL-2 and/or IL-1).
[0169] Accordingly, the pyrrolizidine compounds of the invention find general application in the treatment or prophylaxis of conditions in which the in vivo induction, potentiation or activation of one or more cytokines (e.g. IL-12 and/or II-2) is indicated. Such applications may be employed to stimulate particular elements of the cellular immunity system, including dendritic cells, macrophages (e.g. tissue-specific macrophages), CTL, NK, NKT, B and LAK cells.
[0170] In such applications, the compounds of the invention may be employed as an adjunct to gene therapies designed to increase the production of endogenous cytokines (for example IL-2).
5. Treatment of Proliferative Disorders
[0171] The invention finds application in the treatment of proliferative disorders, including various cancers and cancer metastasis. For example, the pyrrolizidine compounds of the invention may find particular application in the treatment of leukemias, lymphomas, melanomas, adenomas, sarcomas, carcinomas of solid tissues, melanoma (including melanoma of the eye), pancreatic cancer, cervico-uterine cancer, cancers of the kidney, stomach, lung, ovary, rectum, breast, prostate, bowel, gastric, liver, thyroid, neck, cervix, salivary gland, leg, tongue, lip, bile duct, pelvis, mediastinum, urethra, lung, bladder, esophagus and colon, and Kaposi's Sarcoma (e.g. when associated with AIDS).
[0172] In such applications the compounds of the invention may exhibit a secondary glycosidase inhibitory activity.
[0173] The invention may therefore find application in methods of therapy or prophylaxis which comprise the modification of tumour cell glycosylation (e.g. tumour antigen glycosylation), the modification of viral protein glycosylation (e.g. virion antigen glycosylation), the modification of cell-surface protein glycosylation in infected host cells and/or the modification of bacterial cell walls, hence promoting an increased immune response or inhibiting growth/infectivity directly.
6. Use as Adjuvant
[0174] The pyrrolizidine compounds of the invention find utility as vaccine adjuvants, in which embodiments they may promote, induce or enhance an immune response to antigens, particularly antigens having low intrinsic immunogenicity. Without wishing to be bound by any theory, the pyrrolizidine compounds of the invention may augment vaccine immunogenicity by stimulating cytokine release, thereby promoting T-cell help for B cell and CTL responses. They may also change glycosylation of cancer or viral antigens and increase vaccine effectiveness.
[0175] When used as adjuvant, the compounds of the invention may be administered concurrently, separately or sequentially with administration of the vaccine. The invention finds application in any vaccine, but may be particularly as a subunit vaccine, a conjugate vaccine, a DNA vaccine, a recombinant vaccine or a mucosal vaccine. The vaccine may be therapeutic or prophylactic. It may be used immunoprophylactically or immunotherapeutically in both human and non-human subjects. Preferred non-human subjects include mammals and birds. Particularly preferred are veterinary applications. Such applications include the treatment or prophylaxis of infection in domesticated animals (for example dogs and cats) and livestock (e.g. sheep, cows, pigs, horses, chickens and turkeys).
[0176] Thus, in some embodiments, the pyrrolizidine compound of the invention may be present in admixture with other vaccine component(s), or else co-packaged (e.g. as part of an array of unit doses) with the other vaccine components with which it is to be used as adjuvant. In yet other embodiments, the use of the pyrrolizidine compounds of the invention as adjuvant is simply reflected in the content of the information and/or instructions co-packaged with the vaccine components and relating to the vaccination procedure, vaccine formulation and/or posology.
7. Dendritic Cell-Based Applications
[0177] As described above, it has now been found that the pyrrolizidine compounds of the invention may induce sustained and pronounced cytokine production (e.g. sustained and pronounced IL-12 and/or IL-2 production) in dendritc cells. Thus, the compounds of the invention find application in methods of therapy or prophylaxis comprising the induction of cytokine production in dendritic cells or in which the induction of cytokine production in dendritic cells is indicated or required.
[0000] Dendritic Cell Vaccines
[0178] In one dendritic cell-based treatment paradigm, the cells are pulsed (primed or spiked) with a particular antigen or antigens (for example, tumour antigen(s)) and then administered to promote a Th1 immune response. The responding T cells include helper cells, especially Th1 CD4 + cells (which produce IFN-γ) and killer cells (especially CD8 + cytolytic T lymphocytes). The dendritc cells may also mediate responses by other classes of lymphocytes (B, NK, and NKT cells). They may also elicit T cell memory, a critical goal of vaccination.
[0179] With regard to antigen selection for use in the dendritic cell vaccines of the invention, both defined and undefined antigens can be employed. The antigens can be xenoantigens or autoantigens. One or more defined neoantigen(s) may be selected: in the case of cancer treatment, the neoantigen(s) may comprise a tumour-associated antigen.
[0180] However, most preferred for use according to the invention are peptides (for example, synthetic 9-11 amino acid peptides) containing defined antigens. Such peptides may comprise natural sequences. Alternatively, they may be synthetic analogues designed for enhanced MHC binding.
[0181] In other embodiments, the antigens used according to the invention are provided in the form of immune complexes. These are preferably delivered to Fc-receptor-bearing DCs so that both MHC class I and MHC class II peptide sequences are formed. In this way, dendritic cell vaccines can be used according to the invention for inducing both CTLs and Th cells.
[0182] In another approach to antigen selection for use according to the invention, the whole antigenic repertoire of any given tumour (or other target cell, such as a virally-infected cell) is explored. Thus, in another embodiment of the invention there is provided DC-tumour cell hybrids in which the dendritic cells are treated with compound (thereby to induce the expression of IL2) before or after hybridisation.
[0183] In yet other embodiments, necrotic or apoptotic tumour cells or cell lysates (for example lysates of infected cells or tumour cells) are used.
[0184] Antigens derived from fresh tumour cells (rather than tumour cell lines or defined antigens) may also be employed.
[0185] It is also contemplated that the compounds of the invention be incorporated into cellular antigens by introducing them into the cellular membrane or into an intracellular compartment (as described for example in WO96017614, the contents of which are incorporated herein by reference).
[0186] Various techniques can be used to deliver the selected antigen(s) to the DCs (variously referred to in the art as antigen loading, pulsing, priming or spiking). Preferred are loading techniques which load the DCs internally: this can be achieved through the use of peptides linked to cell-penetrating moieties.
[0187] Antigens can also be loaded by transfecting the DCs with encoding nucleic acid (e.g. by electroporation) such that the antigens are expressed by the DC, processed and presented at the cell surface. This approach avoids the need for expensive GMP proteins and antibodies. RNA is preferred for this purpose, since it produces only transient expression (albeit sufficient for antigen processing) and avoids the potential problems associated with the integration of DNA and attendant long-term expression/mutagenesis. Such transfection techniques also permit exploration of the whole antigenic repertoire of a target cell by use of total or PCR-amplified tumour RNA.
[0188] Current strategies for using dendritic cells in this way focus on identifying specific tumour antigens and defining antigenic peptides that bind to the particular MHC alleles expressed by each patient. However, a more general approach would involve the stimulation of the dendritic cells in a manner appropriate for potentiating Th1 responses irrespective of the antigens present and either with or without antigen priming. Cytokine production by activated dendritic cells would then promote the appropriate Th1 response.
[0189] The dendritic cell based vaccines of the invention find particular application in the treatment or prophylaxis of various proliferative disorders (including various cancers, as described below). In such applications, the dendritic cells are preferably pulsed (primed or spiked) with one or more tumour antigens ex vivo and the compounds of the invention used to potentiate the dendritic cell component of the vaccine by contacting the dendritic cells with the compound either ex vivo (before or after pulsing of the cells) or in vivo (for example by co-administration, either concurrently, separately or sequentially, of the dendritic cells and the compound).
[0190] The dendritic cell based vaccines of the invention may be used in the treatment or prophylaxis of any malignant or pre-malignant condition, proliferative or hyper-proliferative condition or any disease arising or deriving from or associated with a functional or other disturbance or abnormality in the proliferative capacity or behaviour of any cells or tissues of the body.
[0191] Thus, the invention finds application in the treatment or prophylaxis of breast cancer, colon cancer, lung cancer and prostate cancer. It also finds application in the treatment or prophylaxis of cancers of the blood and lymphatic systems (including Hodgkin's Disease, leukemias, lymphomas, multiple myeloma, and Waldenstrom's disease), skin cancers (including malignant melanoma), cancers of the digestive tract (including head and neck cancers, cesophageal cancer, stomach cancer, cancer of the pancreas, liver cancer, colon and rectal cancer, anal cancer), cancers of the genital and urinary systems (including kidney cancer, bladder cancer, testis cancer, prostate cancer), cancers in women (including breast cancer, ovarian cancer, gynecological cancers and choriocarcinoma) as well as in brain, bone carcinoid, nasopharyngeal, retroperitoneal, thyroid and soft tissue tumours. It also finds application in the treatment or prophylaxis of cancers of unknown primary site.
[0192] The dendritic cell based vaccines of the invention also find application in the treatment or prophylaxis of various infections, including bacterial, viral, fungal, protozoan and metazoan infections. For example, the vaccines may be used in the treatment or prophylaxis of infection with respiratory syncytial virus (RSV), Epstein-Barr, hepatitis B virus (HBV), hepatitis C virus (HCV), herpes simplex type 1 and 2, herpes genitalis, herpes keratitis, herpes encephalitis, herpes zoster, human immunodeficiency virus (HIV), influenza A virus, hantann virus (hemorrhagic fever), human papilloma virus (HPV), tuberculosis, leprosy and measles.
[0193] Particularly preferred is the treatment or prophylaxis of infections in which the pathogen occupies an intracellular compartment or causes the expression of neoantigens by host cells, including HIV/AIDS, leishmania, trypanosomiasis, influenza, tuberculosis and malaria.
[0194] The present invention also contemplates a more general approach to DC cell-based therapy which involves the stimulation of the dendritc cells with the compound of the invention irrespective of the antigens present and either with or without antigen priming.
[0195] Thus, the invention finds application in therapies in which dendritic cells exposed to the compound of the invention are targeted to diseased or infected tissue (for example injected directly into a tumour), where the cells can prime endogenous T cells extranodally. In such embodiments, the invention contemplates targeting of DCs to a tumour and their activation in situ to elicit immune responses without the need for ex vivo antigen loading.
[0196] In yet another embodiment, the invention contemplates in situ DC vaccination where antigen is targeted to DCs in vivo which are then expanded and induced to mature in situ (by the co-administration of one or more DC maturation stimulants). In such embodiments, antigen is targeted to endogenous DCs by any convenient method, for example through the use of exosomes (as described in Thery et al. (2002) Nat Rev Immunol 2: 569-579).
[0197] Any class of dendritic cell may be used according to the invention. Thus, the dendritic cells may be myeloid or lymphoid, or mixtures thereof. The myeloid dendritic cells, if used, may be of the Langerhans cell type or interstitial DCs. Alternatively, mixtures of these myeloid subsets may be used. Especially preferred is the use of monocyte-derived DCs (Mo-DCs).
[0198] Helper proteins may be used to potentiate the activity of the dendritic cell vaccines of the invention.
[0000] Dendritic Cell-Based Approaches to Autoimmune Disorders
[0199] Dendritic cells are also involved in regulating and maintaining immunological tolerance: in the absence of maturation, the cells induce antigen-specific silencing or tolerance. Thus, in another dendritic cell-based treatment paradigm the cells are administered as part of an immunomodulatory intervention designed to combat autoimmune disorders.
[0200] In such applications, the suppressive potential of dendritic cells has been enhanced by in vitro transfection with genes encoding cytokines. However, such gene therapy approaches are inherently dangerous and a more efficient and attractive approach would be to pulse dendritic cells in vitro with biologically active compounds which stimulate an appropriate cytokine secretion pattern in the dendritic cells.
[0201] As described above, it has now been discovered that the pyrrolizidine compounds of the invention can induce sustained and pronounced cytokine production in dendritic cells. Thus, the compounds of the invention find application in the enhancement of the suppressive potential of dendritic cells.
[0202] Thus, the invention finds application in the treatment or prophylaxis of autoimmune disorders, including myasthenia gravis, rheumatoid arthritis, systemic lupus erythematosus, Sjogren syndrome, scleroderma, polymyositis and dermomyositis, ankylosing spondylitis, and rheumatic fever, insulin-dependent diabetes, thyroid diseases (including Grave's disease and Hashimoto thyroidits), Addison's disease, multiple sclerosis, psoriasis, inflammatory bowel disease, ulcerative colitis and autoimmune male and female infertility.
8. Wound Healing
[0203] The pyrrolizidine compounds of the invention can reverse a Th2 type splenocyte response ex vivo in a normally non-healing infectious disease model. Antigen specific splenocyte IFN-gamma can be significantly increased and IL-5 production significantly reduced in such models, indicative of a healing response.
[0204] Thus, the invention finds application in the treatment of wounds. In particular, the invention finds application in the treatment or prophylaxis of wounds and lesions, for example those associated with post-operative healing, burns, infection (e.g. necrotic lesions), malignancy or trauma (e.g. associated with cardiovascular disorders such as stroke or induced as part of a surgical intervention).
[0205] The wound treatments may involve the selective suppression or elimination of a Th2 response (for example to eliminate or suppress an inappropriate or harmful inflammatory response).
Posology
[0206] The pyrrolizidine compounds of the present invention can be administered by oral or parenteral routes, including intravenous, intramuscular, intraperitoneal, subcutaneous, transdermal, airway (aerosol), rectal, vaginal and topical (including buccal and sublingual) administration.
[0207] The amount of the pyrrolizidine compound administered can vary widely according to the particular dosage unit employed, the period of treatment, the age and sex of the patient treated, the nature and extent of the disorder treated, and the particular pyrrolizidine compound selected.
[0208] Moreover, the pyrrolizidine compounds of the invention can be used in conjunction with other agents known to be useful in the treatment of diseases, disorders or infections where immunostimulation is indicated (as described infra) and in such embodiments the dose may be adjusted accordingly.
[0209] In general, the effective amount of the pyrrolizidine compound administered will generally range from about 0.01 mg/kg to 500 mg/kg daily. A unit dosage may contain from 0.05 to 500 mg of the pyrrolizidine compound, and can be taken one or more times per day. The pyrrolizidine compound can be administered with a pharmaceutical carrier using conventional dosage unit forms either orally, parenterally, or topically, as described below.
[0210] The preferred route of administration is oral administration. In general a suitable dose will be in the range of 0.01 to 500 mg per kilogram body weight of the recipient per day, preferably in the range of 0.1 to 50 mg per kilogram body weight per day and most preferably in the range 1 to 5 mg per kilogram body weight per day.
[0211] The desired dose is preferably presented as a single dose for daily administration. However, two, three, four, five or six or more sub-doses administered at appropriate intervals throughout the day may also be employed.
[0212] These sub-doses may be administered in unit dosage forms, for example, containing 0.001 to 100 mg, preferably 0.01 to 10 mg, and most preferably 0.5 to 1.0 mg of active ingredient per unit dosage form.
Formulation
[0213] The compositions of the invention comprise the pyrrolizidine compound of the invention, optionally together with a pharmaceutically acceptable excipient.
[0214] The pyrrolizidine compound of the invention may take any form. It may be synthetic, purified or isolated from natural sources (for example from Casuarina equisetifolia or Eugenia jambolana ), using techniques described in the art (and referenced infra).
[0215] When isolated from a natural source, the pyrrolizidine compound of the invention may be purified. However, the compositions of the invention may take the form of herbal medicines, as hereinbefore defined. Such herbal medicines preferably are analysed to determine whether they meet a standard specification prior to use.
[0216] The herbal medicines for use according to the invention may be dried plant material. Alternatively, the herbal medicine may be processed plant material, the processing involving physical or chemical pre-processing, for example powdering, grinding, freezing, evaporation, filtration, pressing, spray drying, extrusion, supercritical solvent extraction and tincture production. In cases where the herbal medicine is administered or sold in the form of a whole plant (or part thereof), the plant material may be dried prior to use. Any convenient form of drying may be used, including freeze-drying, spray drying or air-drying.
[0217] In embodiments where the pyrrolizidine compound of the invention is formulated together with a pharmaceutically acceptable excipient, any suitable excipient may be used, including for example inert diluents, disintegrating agents, binding agents, lubricating agents, sweetening agents, flavouring agents, colouring agents and preservatives. Suitable inert diluents include sodium and calcium carbonate, sodium and calcium phosphate, and lactose, while corn starch and alginic acid are suitable disintegrating agents. Binding agents may include starch and gelatin, while the lubricating agent, if present, will generally be magnesium stearate, stearic acid or talc.
[0218] The pharmaceutical compositions may take any suitable form, and include for example tablets, elixirs, capsules, solutions, suspensions, powders, granules and aerosols.
[0219] The pharmaceutical composition may take the form of a kit of parts, which kit may comprise the composition of the invention together with instructions for use and/or a plurality of different components in unit dosage form.
[0220] Tablets for oral use may include the pyrrolizidine compound of the invention, either alone or together with other plant material associated with the botanical source(s) (in the case of herbal medicine embodiments). The tablets may contain the pyrrolizidine compound of the invention mixed with pharmaceutically acceptable excipients, such as inert diluents, disintegrating agents, binding agents, lubricating agents, sweetening agents, flavouring agents, colouring agents and preservatives. Suitable inert diluents include sodium and calcium carbonate, sodium and calcium phosphate, and lactose, while corn starch and alginic acid are suitable disintegrating agents. Binding agents may include starch and gelatin, while the lubricating agent, if present, will generally be magnesium stearate, stearic acid or talc. If desired, the tablets may be coated with a material such as glyceryl monostearate or glyceryl distearate, to delay absorption in the gastrointestinal tract
[0221] Capsules for oral use include hard gelatin capsules in which the pyrrolizidine compound of the invention is mixed with a solid diluent, and soft gelatin capsules wherein the active ingredient is mixed with water or an oil such as peanut oil, liquid paraffin or olive oil.
[0222] Formulations for rectal administration may be presented as a suppository with a suitable base comprising for example cocoa butter or a salicylate.
[0223] Formulations suitable for vaginal administration may be presented as pessaries, tampons, creams, gels, pastes, foams or spray formulations containing in addition to the active ingredient such carriers as are known in the art to be appropriate.
[0224] For intramuscular, intraperitoneal, subcutaneous and intravenous use, the compounds of the invention will generally be provided in sterile aqueous solutions or suspensions, buffered to an appropriate pH and isotonicity.
[0225] Suitable aqueous vehicles include Ringer's solution and isotonic sodium chloride. Aqueous suspensions according to the invention may include suspending agents such as cellulose derivatives, sodium alginate, polyvinylpyrrolidone and gum tragacanth, and a wetting agent such as lecithin. Suitable preservatives for aqueous suspensions include ethyl and n-propyl p-hydroxybenzoate.
[0226] The compounds of the invention may also be presented as liposome formulations.
[0227] For oral administration the pyrrolizidine compound of the invention can be formulated into solid or liquid preparations such as capsules, pills, tablets, troches, lozenges, melts, powders, granules, solutions, suspensions, dispersions or emulsions (which solutions, suspensions dispersions or emulsions may be aqueous or non-aqueous). The solid unit dosage forms can be a capsule which can be of the ordinary hard- or soft-shelled gelatin type containing, for example, surfactants, lubricants, and inert fillers such as lactose, sucrose, calcium phosphate, and cornstarch.
[0228] In another embodiment, the pyrrolizidine compounds of the invention are tableted with conventional tablet bases such as lactose, sucrose, and cornstarch in combination with binders such as acacia, cornstarch, or gelatin, disintegrating agents intended to assist the break-up and dissolution of the tablet following administration such as potato starch, alginic acid, corn starch, and guar gum, lubricants intended to improve the flow of tablet granulations and to prevent the adhesion of tablet material to the surfaces of the tablet dies and punches, for example, talc, stearic acid, or magnesium, calcium, or zinc stearate, dyes, coloring agents, and flavoring agents intended to enhance the aesthetic qualities of the tablets and make them more acceptable to the patient.
[0229] Suitable excipients for use in oral liquid dosage forms include diluents such as water and alcohols, for example, ethanol, benzyl alcohol, and the polyethylene alcohols, either with or without the addition of a pharmaceutically acceptably surfactant, suspending agent or emulsifying agent.
[0230] The pyrrolizidine compounds of the invention may also be administered parenterally, that is, subcutaneously, intravenously, intramuscularly, or interperitoneally.
[0231] In such embodiments, the pyrrolizidine compound is provided as injectable doses in a physiologically acceptable diluent together with a pharmaceutical carrier (which can be a sterile liquid or mixture of liquids). Suitable liquids include water, saline, aqueous dextrose and related sugar solutions, an alcohol (such as ethanol, isopropanol, or hexadecyl alcohol), glycols (such as propylene glycol or polyethylene glycol), glycerol ketals (such as 2,2-dimethyl-1,3-dioxolane-4-methanol), ethers (such as poly(ethylene-glycol) 400), an oil, a fatty acid, a fatty acid ester or glyceride, or an acetylated fatty acid glyceride with or without the addition of a pharmaceutically acceptable surfactant (such as a soap or a detergent), suspending agent (such as pectin, carnomers, methylcellulose, hydroxypropylmethylcellulose, or carboxymethylcellulose), or emulsifying agent and other pharmaceutically adjuvants. Suitable oils which can be used in the parenteral formulations of this invention are those of petroleum, animal, vegetable, or synthetic origin, for example, peanut oil, soybean oil, sesame oil, cottonseed oil, corn oil, olive oil, petrolatum, and mineral oil.
[0232] Suitable fatty acids include oleic acid, stearic acid, and isostearic acid. Suitable fatty acid esters are, for example, ethyl oleate and isopropyl myristate.
[0233] Suitable soaps include fatty alkali metal, ammonium, and triethanolamine salts and suitable detergents include cationic detergents, for example, dimethyl dialkyl ammonium halides, alkyl pyridinium halides, and alkylamines acetates; anionic detergents, for example, alkyl, aryl, and olefin sulphonates, alkyl, olefin, ether, and monoglyceride sulphates, and sulphosuccinates; nonionic detergents, for example, fatty amine oxides, fatty acid alkanolamides, and polyoxyethylenepolypropylene copolymers; and amphoteric detergents, for example, alkyl-beta-aminopropionates, and 2-alkylimidazoline quarternary ammonium salts, as well as mixtures.
[0234] The parenteral compositions of this invention will typically contain from about 0.5 to about 25% by weight of the pyrrolizidine compound of the invention in solution. Preservatives and buffers may also be used. In order to minimize or eliminate irritation at the site of injection, such compositions may contain a non-ionic surfactant having a hydrophile-lipophile balance (HLB) of from about 12 to about 17. The quantity of surfactant in such formulations ranges from about 5 to about 15% by weight. The surfactant can be a single component having the above HLB or can be a mixture of two or more components having the desired HLB. Illustrative of surfactants used in parenteral formulations are the class of polyethylene sorbitan fatty acid esters, for example, sorbitan monooleate and the high molecular weight adducts of ethylene oxide with a hydrophobic base, formed by the condensation of propylene oxide with propylene glycol.
[0235] The pyrrolizidine compounds of the invention may also be administered topically, and when done so the carrier may suitably comprise a solution, ointment or gel base. The base, for example, may comprise one or more of the following: petrolatum, lanolin, polyethylene glycols, bee wax, mineral oil, diluents such as water and alcohol, and emulsifiers and stabilizers. Topical formulations may contain a concentration of the compound from about 0.1 to about 10% w/v (weight per unit volume).
[0236] When used adjunctively, the pyrrolizidine compounds of the invention may be formulated for use with one or more other drug(s), in particular, the pyrrolizidine compounds of the invention may be used in combination with antitumor agents, antimicrobial agents, anti-inflammatories, antiproliferative agents and/or other immunomodulatory (e.g. immunostimulatory) agents. For example, the pyrrolizidine compounds of the invention may be used with anti-viral and/or anti-proliferative agents such as cytokines, including interleukins-2 and 12, interferons and inducers thereof, tumor necrosis factor (TNF) and/or transforming growth factor (TGF), as well as with myelosuppressive agents and/or chemotherapeutic agents (such as doxorubicin, 5-fluorouracil, cyclophosphamide and methotrexate), isoniazid (e.g. in the prevention or treatment of peripheral neuropathy) and with analgesics (e.g. NSAIDs) for the prevention and treatment of gastroduodenal ulcers.
[0237] Thus, adjunctive use may be reflected in a specific unit dosage designed to be compatible (or to synergize) with the other drug(s), or in formulations in which the pyrrolizidine compound is admixed with one or more antitumor agents, antimicrobial agents and/or antiinflammatories (or else physically associated with the other drug(s) within a single unit dose). Adjunctive uses may also be reflected in the composition of the pharmaceutical kits of the invention, in which the pyrrolizidine compound of the invention is co-packaged (e.g. as part of an array of unit doses) with the antitumor agents, antimicrobial agents and/or antiinflammatories. Adjunctive use may also be reflected in information and/or instructions relating to the co-administration of the pyrrolizidine compound with antitumor agents, antimicrobial agents and/or antiinflammatories.
EXEMPLIFICATION
[0238] The invention will now be described with reference to specific Examples. These are merely exemplary and for illustrative purposes only: they are not intended to be limiting in any way to the scope of the monopoly claimed or to the invention described. These examples constitute the best mode currently contemplated for practicing the invention.
Example 1
Induction of IL-12 Secretion in Dendritic Cells
[0000] Mice
[0239] BALB/c male and female mice bred and maintained at the University of Strathclyde under conventional conditions were used at 8 weeks old.
[0000] Isolation of Bone Marrow and Culture of Dendritic Cells
[0240] Bone marrow was obtained from the femurs of mice. The femurs were washed in 70% ethanol and placed in a 40 clean petri dish. Dendritic cell (DC) medium (2.5% granulocyte-macrophage colony-stimulating factor (GM-CSF), 10% heat and activated foetal calf serum, 1% L-glutamine, 1% Penicillin/Streptomycin in RPMI-1640 medium) was injected into the bone marrow of the femur by a pumping action and the cells and medium were collected. 1 ml of the cells in medium was added to a 75 cm 2 flask with 15 mls of DC medium. The flasks were then incubated at 37° C., 5% CO 2 to allow DC growth and development. After 5 days an additional 10 mls of DC medium was added.
[0000] Harvesting of Dendritic Cells
[0241] After 10 days of incubation of bone marrow with GM-CSF, the dendritic cells were harvested. This process was carried out in a tissue culture hood. The contents of the flasks were poured into centrifuge tubes to ensure collection of floating DCs. Approximately 10 mls of cooled phosphate buffered saline (PBS) was added to each empty flask, the flasks gently agitated and the contents collected. This ensured recovery of adhesive DCs. The collected contents of the flasks were centrifuged for 5 minutes at 200 g and the pellet resuspended in 2 mls of DC medium without GM-CSF. A cell count was then carried out.
[0000] Cell Count and Assay Conditions
[0242] Cells were counted using a haemocytometer. Approximately 20 μl of the resuspended cells was pipetted into the chamber of the haemocytometer, the cells were adjusted to the correct cell concentration (approx. 5×10 4 and not less than 1×10 4 , per well) and then plated out for assay.
[0243] The plates were incubated overnight at 37° C. with 5% CO 2 and allowed to settle (harvesting stimulates them). The next day the compounds (50 μg/ml and 20 μg/ml) and controls were added then again incubated at 37° C. with 5% CO 2 for 24 hrs (or 48 hrs). Harvesting and addition of the compounds was all done in a hood. The plates were then frozen to kill the cells and once defrosted the supernatant analysed as described below.
[0000] Measurement of IL-12
[0244] Using an enzyme linked immunosorbent assay (ELISA) IL-12 concentration in the supernatants was measured. All reagents used in this assay were from PharMingen. A 96-well flat-bottomed ELISA plate was coated with purified rat anti-mouse IL-12 (p40/p70) MAb (Cat no. 554478) at 2 μg/ml diluted in PBS pH 9.0 at 50 μl/well. The plate was then covered in cling film and incubated at 4° C. Following incubation the plate was washed 3 times in washing buffer and dried. 200 μl of blocking buffer (10% foetal calf serum in PBS pH 7.0) was added to each well then covered in cling film and incubated at 37° C. for 45 minutes. The plate was washed 3 times and dried. Recombinant mouse II-12 standard was added at 30 μl in duplicate wells, starting at 10 ng/ml then 5, 2.5, 1.25, 0.625, 0.31, 0.156, 0.078, 0.039, 0.020, 0.010, 0.005 ng/ml. Standards were diluted in blocking buffer. The supernatant samples were added in at 50 μl/well. The plate was then covered in cling film and incubated for 2 hours at 37° C. The plate was then washed 4 times, dried and the secondary antibody added.
[0245] Biotin labeled anti-mouse IL-12 (p40/p70) MAb (Cat no. 18482D) at 1 μg/ml (diluted in blocking buffer) was added to each well at a volume of 100 μl/well. The plate was covered in cling film and incubated at 37° C. for 1 hour. The plate was then washed 5 times, dried and the conjugate added. Streptavidin-AKP (Cat no. 13043E) at 100 μl/well was added at a dilution of 1/2000 in blocking buffer followed by incubation under cling film at 37° C. for 45 minutes.
[0246] The plate was finally washed 6 times, dried and the substrate added: pNPP (Sigma) in glycine buffer at 1 mg/ml was added at 100 μl/well. The plate was then covered in tinfoil, incubated at 37° C. and checked every 30 minutes for a colour change.
[0247] The plate was then read at 405 nm using a SPECTRAmax 190 spectrometer. The results are shown in FIGS. 1 and 2 , in which LPS is lipopolysaccharide, IFN-g is interferon gamma, 462a is casuarine (8), 462b is casuarine-6-α-D-glucopyranose (9), 23 is 7-epicasuarine (11) and 24 is 3,7-diepi-casuarine (10).
[0248] When tested at 50 μg/ml in the same assay, swainsonine (4) failed to induce IL-12 secretion. Similar studies with other compounds for comparative purposes are shown in Table 1.1, below.
COM- IL-12 POUND STRUCTURE RELEASE casuarine (8) Yes casuarine- 6-α- D- gluco- pyranose (9) Yes 3,7-diepi- casuarine (10) Yes 7-epi- casuarine (11) Yes 3-epi- casuarine (14) Yes Castano- spermine (20) No Swain- sonine (4) No 1-Deoxy- no- jirimycin (DNJ) (21) No 7- epialexine (22) No 3,7a- diepi- alexine (23) No Alexine (1) No
Example 2
Stimulation of IL-2 Production by Dendritic Cells
[0249] The protocols described in Example 1 above were carried out but the appropriate Mabs and standards for determination of II-2 were substituted. The results are shown in Table 2.1, below.
Treatment IL-2 (units/ml) LPS 0.00 LPS + IFN- Y 0.00 3,7-diepi-casuarine (10) 0.00 3,7-diepi-casuarine (10) + LPS 0.69
Example 3
Cytokine Modulation in Spleen Cells
[0000] Mice
[0250] BALB/c male and female mice bred and maintained at the University of Strathclyde under conventional conditions were used at varying age.
[0000] Isolation of Spleen Cells and Culture of Spleen Cells
[0251] The mouse spleen was removed aseptically and placed in a sterile petri dish containing 5 mls of complete medium (RPMI, 1% L-Glutamine, 1% Penicillin/Streptomycin and 10% foetal calf serum). Cells suspensions were prepared by using the end of a syringe and grinding the spleen through a wire mesh. The cell suspension was then centrifuged at 1000 rpm for 5 minutes. To remove the erythrocytes, the cell pellet was resuspended in Boyle's solution (Tris 0.17M Ammonium Chloride 0.16M) and centrifuged again for 5 minutes. The pellet was then washed in medium a further two times, then resuspended in 3 mls medium. A cell count was then carried out.
[0000] Experimental Protocol
[0252] All spleen cell experiments were carried out in 96-well tissue culture plates. 100 μl aliquots of 5×10 5 /well cells were added to all wells and each well had a final volume of 200 μl. Unstimulated wells contained 100 μl of cells and 100 μl of medium. The stimulated wells contained 100 μl of cells plus 50 μl of LPS at 1 μg/ml or 50 μl anti-CD3 at 0.5 μg/ml and 50 μl of medium. The remaining wells contained 100 μl cells, 50 μl of MNLP compound and either 50 μl of anti-CD3 or medium alone.
[0000] Measurement of IL-12, IL-2, IL-5 and IFN-γ
[0253] The appropriate Mabs and standards were used according to the protocol described for IL-12 (described in Example 1, above). The results are shown in Tables 3.1-3.3, below.
TABLE 3.1 Promotion of activated splenocyte (T-cell) IFN- Y production Treatment IFN- Y (ng/ml) None (control) 0.64 αCD3 3.21 3,7-diepi-casuarine (10) 0.22 3,7-diepi-casuarine (10) + αCD3 13.50
[0254]
TABLE 3.2
Effect of castanospermine on splenocyte IFN-y production
Treatment
IFN- Y (ng/ml)
None (control)
<1.0
αCD3
22.5
Castanospermine (20)
<1.0
Castanospermine (20) + aCD3
9.0
[0255] As can be seen from the results shown in Tables 3.1 and 3.2, compounds according to the invention stimulate IFN-γ secretion/production in splenocytes, whereas castanospermine inhibits the production of this cytokine in such assays. Similar tests carried out with 1-Deoxynojirimycin (DNJ) (21) showed that this imino sugar also inhibited IFN-γ secretion/production in splenocytes (data not shown).
Example 4
Inhibition of Glycosidase Activity
[0256] All enzymes were purchased from Sigma, as were the appropriate p-nitrophenyl substrates. Assays were carried out in microtitre plates. Enzymes were assayed in 0.1M citric acid/0.2M di-sodium hydrogen phosphate (McIlvaine) buffers at the optimum pH for the enzyme. All assays were carried out at −20° C. For screening assays the incubation assay consisted of 10 μl of enzyme solution, 10 μl of inhibitor solution (made up in water) and 50 μl of the appropriate 5 mM p-nitrophenyl substrate (3.57 mM final conc.) made up in McIlvaine buffer at the optimum pH for the enzyme.
[0257] The reactions were stopped with 0.4M glycine (pH 10.4) during the exponential phase of the reaction, which was determined at the beginning of the assay using blanks with water, which were incubated for a range of time periods to measure the reaction rate using 5 mM substrate solution. Endpoint absorbances were read at 405 nm with a Biorad microtitre plate reader (Benchmark). Water was substituted for the inhibitors in the blanks.
[0258] The enzymes tested are shown in Table 4.1, below.
Enzyme Source pH Conc. Substrate α-D Saccharomyces cerevisiae 6.0 0.1 unit/ml PNP-α-D-glucopyranoside glucosidase (Baker's yeast), rice ( Oryza sativa ), Bacillus stearothermophilus β-D-glucosidase Almonds ( Prunus sp.) 5.0 0.2 unit/ml PNP-β-D-glucopyranoside α-D- Green coffee beans ( Coffea sp.) 6.5 1 unit/ml PNP-α-D-galactopyranoside galactosidase β-D- Bovine liver 7.3 0.1 unit/ml PNP-β-D-galactopyranoside galactosidase α-D- Jack beans ( Canavalia ensiformis ) 4.5 0.1 unit/ml PNP-α-D-mannopyranoside mannosidase α-L-fucosidase Bovine kidney N-acetyl-β-D- Bovine kidney 4.2 0.1 unit/ml PNP-N-acetyl-β-D-glucosminide glucosaminidase 5 Naringinase Penecillium decumbens 4.0 1 unit/ml PNP-α-L-rhamnopyranoside
[0259] The compounds tested are shown in Table 4.2, below.
Compound name Structure Reference Castanospermine 20 Swainsonine 4 Casuarine 8 3,6,7-triepi-casuarine 12 3,6,7,7a-tetraepi- casuarine 21 3,7,7a-triepi-casuarine 22 3-epi-casuarine 14 3,7-diepi-casuarine 10 7-epi-casuarine 11
[0260] The results (% inhibition) for a number of different compounds (all at 1 mg/ml) are shown in Table 4.3, below:
Compound/ Enzyme 20 4 8 12 21 22 14 10 11 gluc (yeast) −8 nd 64 2 −1 29 0 −2 11 gluc (rice) 77 nd 76 0 46 0 13 7 73 gluc ( Bacillus ) 6 nd 86 9 −2 87 12 −7 5 glucosidase 88 nd 0 6 44 52 56 5 30 galactosidase −3 nd 4 2 −3 −2 4 −11 1 galactosidase 16 nd 0 6 3 52 6 24 35 mannosidase 9 74 5 8 1 −1 −4 8 10 fucosidase 3 nd −1 −11 nd nd −2 5 25 Naringinase 39 nd −2 0 5 10 21 6 −4 N-acetyl-β-gluc 16 nd 14 19 27 11 −1 −6 11
[0261] The results show that the profile of inhibition for the compounds of the invention is quite different from that of castanospermine. None inhibits mannosidase significantly (see also further data below). Some of the compounds tested (e.g. 3,7-diepi-casuarine) do not significantly inhibit any of the enzymes tested.
[0262] Further studies showed that the K i for casuarine (8) with yeast α-D-glucosidase was 217 μM (castanospermine not being inhibitory at a concentration of 800 μM). The K i for castanospermine (20) with almond β-D-glucosidase was 9 μM (casuarine not being inhibitory at 800 μM). Moreover, casuarine also inhibited rabbit gut mucosa α-D-glucosidase with an IC 50 value of 210 μM, as compared with an IC 50 value of 8 μM for castanospermine. Both casuarine and castanospermine inhibited rabbit small intestine sucrose at a concentration of 700 μM. Castanospermine also inhibited rabbit small intestine lactase and trehalase by over 50% at this concentration.
Example 5
Differential Inhibition of Mannosidase and Glucosidase
[0263] The glycosidase inhibitory profiles of swainsonine (45, casuarine (8) and casuarine glucoside (9) with respect to a mannosidase and a glucosidase were compared. The results (all at <0.1 mg/ml) are shown in Table 5.1, below.
Glucosidase I Compound Mannosidase inhibition inhibition Swainsonine (4) + − Casuarine (8) − + Casuarine glucoside (9) − +
Example 6
Treatment of Murine HSV-1 Infection
[0264] Mice were 3-4 weeks old female BALB/c. Mice were inoculated with 10 4 p.f.u. HSV-1 (SC16) using the neck skin method. This dose is sublethal but produces clinical symptoms, including inflammation (measured by increase in ear pinna thickness).
[0265] Mice were administered (100 ml i.p.) with one of two doses of casuarine (8) on day one and daily thereafter for 5 days. Group 1 received 15 mg/kg in PBS, group 2 received 150 mg/kg in PBS. A negative control group 3 were infected but received no casuarine. A positive control group 4 were administered with famciclovir (via drinking water spiked at 1 mg/ml for the same time period).
[0266] Mice were checked daily and samples were obtained from mice killed on selected days. The results are presented in Tables 6.1-6.3, below.
TABLE 6.1 Weight (% change) Group Day 1 2 3 4 −2 0 0 0 0 −1 0 3.1 3.2 1.3 9 1 5.6 5.8 4.6 13 2 5.6 5.2 6.5 14.5 3 8.6 7.1 9.3 18.8 4 7.4 5.8 9.8 18.1 5 8.6 8.4 10.5 21 6 9.2 9.7 12.4 23.9 7 7.4 7.7 11.1 21 8 9.3 8.4 13.7 23.9
[0267]
TABLE 6.2
Group mean weight (g)
Group
Day
1
2
3
4
−2
16.2
15.5
15.3
13.8
−1
0
16.7
16
15.5
15.1
1
17.1
16.4
16
15.6
2
17.1
16.3
16.3
15.8
3
17.6
16.6
16.7
16.4
4
17.4
16.4
16.8
16.3
5
17.6
16.8
16.9
16.7
6
17.7
17
17.2
17.1
7
17.4
16.7
17
16.7
8
17.7
16.8
17.4
17.1
9
17.3
17.1
10
17.4
17.2
11
17.3
17.1
12
17.3
17.2
[0268]
TABLE 6.3
Ear pinna thickness (mm 2 )
Group
Day
1
2
3
4
−2
0
0
0
0
−1
0
0.7
0.7
2.2
0
1
0
3.6
4.4
0
2
13.9
23.4
14.7
0
3
9
5.7
17.7
7
4
9
9.2
26.5
7
5
7.6
2.1
12.5
0
6
12.5
14.9
13.2
4
7
6.2
0
11
0
8
0
12.1
6.6
2.9
9
11.8
2.9
10
14
10.7
11
11
2.9
12
7.4
12.9
13
16.2
12.9
[0269] The results show the expected pattern of ear pinna thickness increase, peaking at day 4. Famvir almost completely negated the ear thickness response. Casuarine at both doses tested also produced a reduction in ear thickness.
Example 7
Control of Lung Metastasis in Mice
[0270] Mice (C57/bl6 under i/p ketamine anaesthesia) were challenged i/v (tail vein) with 5×10 4 B16-F10 tumour cells in a final volume of 100 μl per mouse on day 0. Test compounds (50 mg/kg in 200 μl sterile non-pyrogenic saline) were administered s/c (right flank) on days 2 and 4. On day 14 the mice were sacrifices and the lungs dissected and stained in Indian ink solution (150 ml bidistilled water, 30 ml India Ink, 4 drops NH 4 OH) for 10 minutes then fixed for at least 24 hr in Fakete's solution (90 ml 37% formaldehyde, 900 ml 70% EtOH and 45 ml glacial acetic acid). The metastases in the stained and fixed lungs could then be visualized, counted and photographed.
[0271] The results are shown below in Table 7.1, below.
Compound Metastatic morphology PBS (control) Metastasis over entire lung surface casuarine (8) Metastasis restricted to apical tip of lung 3-epi-casuarine (14) Metastasis restricted to apical tip of lung
Example 8
Effect on Glycosylation of Breast Cancer Cells
[0000] Cell Culture
[0272] MCF-7 cells (European Collection of Cell Cultures Ref. 86012803) were taken from liquid nitrogen stock, thawed at room temperature and transferred to 10 ml Dulbeccos Modified Eagle's Medium with Hams F12, 15 mM Hepes and L-glutamine (DMEM: Cambrex. Cat. No. BE12-719F) supplemented with 10% v/v foetal calf serum (FCS: BioWest Labs Cat. No. S02755, Lot. No. S1800). The FCS was pre-filtered through a 0.2 μm sterile filter.
[0273] The cells were then centrifuged at 1,500 rpm in a Centaur bench-top centrifuge and the supernatant removed. The cells were reconstituted in fresh media and seeded into two T75 cm 3 Nunclon tissue culture flasks and allowed to settle overnight at 37° C. in a 5% CO 2 incubator. The flasks were wrapped in cling film to prevent cross-contamination and the following day the media was changed to include the antibiotics penicillin and streptomycin as a precautionary measure against infection (at concentrations of 1 mg/cm 3 and 5 mg/cm 3 , respectively).
[0274] The cells were allowed to grow near confluence and then split at a 1 in 4 resuspension. The cells used for the experiments were of passage number 31. Two flasks of cells were prepared in media containing 20% v/v FCS with 10% dimethylsulphoxide and banked down into liquid nitrogen for later use if necessary.
[0275] A total of 16 T25 cm 3 flasks were used. Each flask was seeded with 8.5×10 5 cells/cm 3 and 4 cm 3 media added. The cells were allowed to adhere to the culture flask overnight. The following morning the flasks were observed under the light microscope and the cells appeared 50-60% confluent. The cells from two of the flasks were harvested (see below) for the t=0 time point.
[0276] The remaining 14 flasks were available for testing with casuarine (8). Seven of these (untreated group) had their media changed to 7 cm 3 of fresh media containing 10% FCS, penicillin and streptomycin (as before), whilst the remaining seven were incubated with fresh media supplemented with 0.75 mM casuarine (treated group).
[0277] Cells were harvested at t=1.5 hours, t=28 hours, t=62 hours and t=86 hours.
[0000] Harvesting of Cells and Cell Counting
[0278] The cells were harvested using a non-enzymatic method. At each of the time points the cells were viewed under the inverted light microscope and the morphology evaluated. Before harvesting, the cells were washed with sterile PBS, three times, 7 cm 3 per wash. The cells were then scraped from the flasks using a sterile cell scraper and transferred to Grenier tubes. The cells were quickly passed through a 21G2 gauge needle to disaggregate the cells. Cells were then pelleted by centrifugation at 1500 g/5 min and resuspended in a known volume of PBS. The number of cells was then counted in a haemocytometer and cell viability evaluated by mixing 0.1 cm 3 of each cell suspension with a drop of trypan blue solution. Each of the cell pellets was frozen at −80° C. until glycan release and analysis.
[0000] Homogenisation
[0279] The cell pellets were placed in an iced water bath and allowed to thaw. The pellets were then homogenized in a total of 4 cm 3 (made up to volume with deionized water). An Ultraturrax T25 homogeniser was used for this purpose, with the blade speed set to 22,500 rpm. The samples were maintained on ice and 3 bursts, each of 10 sec, were applied with a period of approximately 1 min between each homogenisation step to allow the froth the settle. The blade was washed carefully between each of the samples to prevent sample cross-contamination. The homogenates were stored in 1 cm 3 aliquots at −80° C. prior to the protein assay and glycan release.
[0000] Protein Assay
[0280] Evaluated using the BioRad protein assay according to the manufacturer's instructions. BSA was used as standard. Each of the homogenate samples was tested in duplicate using 100 μl aliquots from each time point
[0000] Glycan Release
[0281] For the time points of 62 hours and 86 hours the equivalent of 25 μg of protein was taken and dried for 3 hours on a centrifugal evaporator (without heating). For the earlier time points, whose protein concentration could not be assessed with the protein assay, 200 μl was taken and dried down ready for glycan release. Release was confirmed using 25 μg of fetuin from foetal calf serum.
[0282] Glycans were incubated at 37° C. overnight with N-glycosidase F (Roche Biosciences Cat. No. 1365185, Lot. No. 9280212/31) at a final concentration of 5U enzyme in 25 μl of sample all in 20 mM sodium phosphate buffer pH 7.2. After the incubation step, the samples were loaded onto prewashed and primed Ludger Clean E cartridges (Cat. No. LC-E10-A6). The glycans were eluted according to the manufacturer's instructions and dried by centrifugal evaporation overnight.
[0000] Glycan Labeling
[0283] The glycans were labeled by reductive amination, for 2 hours at 65° C., according to the method described by Bigge et al. (1995) Anal. Biochem. 230(2): 229-238. The incubation mixture was then “cleaned up” to remove any unconjugated fluorophore by spotting the samples onto Whatman 3MM paper and running in a descending chromatography tank with a mobile phase of 4:1:1 butanol:ethanol:water overnight. Glycans were then eluted with 0.5 cm 3 methanol and 2×1 cm 3 HPLC grade water then filtered through a 0.2 μm syringe top filter.
[0000] Analysis Using Normal Phase HPLC
[0284] The glycans were separated on a normal phase (hydrophilic interaction) HPLC column (LudgerSep N1 amide) 4.6×25 cm in size.
[0285] The basis of the separation is described in Guile et al. (1996) Anal. Biochem. 240(2): 210-226. The column was fitted to a Dionex BioLC system with autosampler and switching pump heads and in-line mixer. The column was maintained at 30° C. and the glycans detected using a Perkin Elmer LS30 fluorimeter with excitation λ=330 nm and emission λ=420 nm, the gain was set to 2. The buffer system used was the high salt system, with acetonitrile as buffer A and 0.25M ammonium formate pH4.4 as buffer B. Flow rate was maintained at 0.3 cm 3 /min throughout.
[0286] The protocol used is summarized below in Table 8.1, below.
Time (min) % A % B Comment 0 80 20 Elution of N-linked glycans 132 47 53 135 0 100 Elution of large charged glycans 142 0 100 145 80 20 Re-equilibration 180 80 20 End of run
[0287] An 80 μl aliquot of each of the glycan mixtures was loaded onto the column and the elution position compared, with reference to a hydrolysate of dextran.
[0000] Summary of Results and Conclusions
[0288] At the initial harvest point and the 28 hour time point, there was no obvious difference between the glycans released from the treated and untreated cells (data not shown). However, at the 62 and 86 hour time points, the untreated cells showed a marked preponderance of larger N-linked glycans than their treated counterparts (data not shown). In addition, the overall signal (amount of fluorescently labeled glycan) was greater in the untreated group.
[0289] The results show that casuarine can inhibit glycan synthesis and/or N-linked glycosylation in breast cancer cells.
Example 9
Effect on Glucose Transport
[0290] The effect of casuarine (8) and castanospermine (20) on the initial rate of Na + -dependent D-glucose uptake into ovine intestinal brush border membrane vesicles was examined in a competition assay with labeled D-glucose. The results are shown in Table 9.1, below:
Compound Reference Glucose uptake (pmol s −1 mg −1 ) None (control) 240 Casuarine 8 265 Castanospermine 20 225
[0291] It can be seen that glucose transport was slightly inhibited by castanospermine but slightly stimulated by casuarine.
Example 10
Increasing the Th1:Th2 Response Ratio in a Non-Healing Leishmaniasis Model
[0292] Leishmaniasis is a classic model of a Th1 disease: non-healing cutaneous lesions arise from an undesirable polarization of the immune response which becomes heavily Th2-skewed.
[0293] In order to study the ability of the compounds of the invention to increase the Th1:Th2 response ratio in this disease model (and so promote a healing Th1 response), spleen cells from Leishmania major infected BALB/c mice having a non-healing cutaneous infection were stimulated with parasite antigen (Table 10.1) or polyclonally with anti-CD3 (Table 10.2) in the presence of 3,7-diepi-casuarine (10).
TABLE 10.1 Reversal of the inability of T-cells to produce IFN-y in a non-healing mouse model Treatment IFN-y (ng/ml) None (control) ˜0.5 L. major Ag ˜0.5 3,7-diepi-casuarine (10) ˜0.5 3,7-diepi-casuarine (10) + L. major Ag 5.5
[0294]
TABLE 10.2
Downregulation of Th2 cytokine response in a non-healing mouse model
Treatment
IL-5 (pg/ml)
None (control)
50
aCD3
240
3,7-diepi-casuarine (10) + aCD3
150
[0295] It can be seen that the presence of 3,7-diepi-casuarine (10) enhances IFN-γ (associated with a healing Th1 response) whilst suppressing the Th2 response (via downregulation of the Th2 cytokine IL-5). The Th2-skewed immune response profile associated with a non-healing disease was clearly reversed ex vivo by 3,7-diepi-casuarine (10).
Example 11
Synthesis of 3,7-diepi-casuarine (10)
[0000] General Experimental
[0296] All reactions were carried out under an atmosphere of argon at room temperature using anhydrous solvents unless otherwise stated. Anhydrous solvents were purchased from Fluka Chemicals and were used as supplied. Reagents were supplied from Aldrich, Fluka and Fisher and were used as supplied. Thin layer chromatography (Tlc) was performed on aluminium sheets pre-coated with Merck 60 F 254 silica gel and were visualised under ultra-violet light and staining using 6% phosphomolybdic acid in ethanol. Silica gel chromatography was carried out using Sorbsil C60 40/60 silica gel under a positive atmosphere. Amberlite IR-120, strongly acidic ion-exchange resin was prepared by soaking the resin in 2M hydrochloric acid for at least two hours followed by elution with distilled water until the eluant reached pH 5. Dowex: 50WX8-100 was prepared by soaking the resin with 2M hydrochloric acid for at least two hours followed by elution with distilled water until neutral. Infrared spectra were recorded on a Perkin-Elmer 1750 IR Fourier Transform spectrophotometer using thin films on sodium chloride plates. Only characteristic peaks are recorded. Optical rotations were measured on a Perkin-Elmer 241 polarimeter with a path length of 1 dm. Concentrations are quoted in g/100 mL. Nuclear magnetic resonance spectra were recorded on a Bruker DQX 400 spectrometer in the stated deuterated solvent. All spectra were recorded at ambient temperature. Chemical shifts (δ) are quoted in ppm and are relative to residual solvent as standard. Proton spectra (δ H ) were recorded at 400 MHz and carbon spectra (δ C ) at 100 MHz.
[0000] 2,3:5,6:7,8-Tri-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone (Qc)
[0000] 5,6:7,8-Di-O-isopropylidene-D-erythro-L-galacto-octono-1,4-lactone (Qb)
[0297] Sodium cyanide (7.02 g, 142 mmol) was added to a stirred solution of D-glycero-D-gulo-heptose (Qa, 21 g, 100 mmol) in water (300 ml). The reaction mixture was stirred at room temperature for 48 h, heated at reflux for 48 h and passed through a column containing Amberlite IR-120 (strongly acidic ion-exchange resin, 300 ml). The eluent was concentrated under reduced pressure and the residue dried in vacuo for 24 hours. The resulting foam was treated with acetone (500 ml) and sulphuric acid (5.4 ml) in the presence of anhydrous copper sulphate (10 g, 62 mmol) at room temperature for 48 h. T.l.c analysis indicated the presence of two major products (ethyl acetate:cyclohexane, 1:1; R f 0.72, 0.18). The reaction mixture was filtered and the filtrate was treated with sodium bicarbonate (50 g) for 24 h at room temperature. Solid residues were removed by filtration and the filtrate was concentrated under reduced pressure. The resulting crude yellow syrup was purified by silica gel chromatography providing 2,3:5,6:7,8-tri-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qc as a colourless syrup (R f 0.72; 7.672 g; 21%;) and 5,6:7,8-di-O-isopropylidene-D-erythro-L-galacto-octono-1,4-lactone Qb as a clear oil (R f 0.18; 8.105 g; 25%) 2,3:5,6:7,8-tri-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qc : δ H (CDCl 3 ) 1.29, 1.33, 1.35, 1.38, 1.42, 1.48 (6×s, 18H, 3×C(CH 3 ) 2 ), 3.93-3.99 (m, 2H, H-8 a , H-7), 4.03-4.07 (m, 2H, H-5, H-6), 4.15 (dd, 1H, J 8a,8b 8.7 J 8b,7 6.1, H-8 b ), 4.75-4.78 (m, 3H, H-2, H-3, H-4); δ C (CDCl 3 ) 25.23, 25.51, 26.00, 26.71, 26.73, 27.16 (3×C(CH 3 ) 2 ), 67.93, 74.93, 76.33, 76.69, 78.65, 79.40, 80.06, 109.95, 110.72, 113.19, 174.27; ν max (film) 1793. 5,6:7,8-di-O-isopropylidene-D-erythro-L-galacto-octono-1,4-lactone Qb : δ H (d 6 -acetone) 1.28, 1.32, 1.34, 1.35 (4s, 12H, 2×C(CH 3 ) 2 ), 3.92 (1H, m, H-8 a ), 3.98 (m, 1H, H-7), 4.14 (m, 2H, H-5, H-8 b ), 4.23-4.25 (m, 2H, H-4, H-6), 4.35-4.40 (m, 2H, H-2, H-3); δ C (d 6 -acetone) 25.31, 25.87, 26.72, 27.31, 68.06, 75.15, 75.23, 77.51, 78.05, 78.41, 79.01, 110.06, 110.31, 174.25; ν max (film) 1793, 3541.
[0000] 2,3:5,6-Di-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qd
[0298] A solution of 2,3:5,6:7,8-tri-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone (Qc, 3.8 g, 10.6 mmol) was treated with acetic acid:water (2:3, 100 ml) at 50° C. for 2 h. T.l.c analysis (ethyl acetate:cyclohexane, 1:1) indicated the disappearance of the starting material (R f 0.72) and the presence of a more polar compound (R f 0.15). The solvent was removed under reduced pressure and the residue was purified by silica gel chromatography (ethyl acetate:cyclohexane, 1:1 to 3:1) yielding 2,3:5,6-di-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qd as a clear oil (3.23 g, 94%): δ H (CD 3 OD) 1.28, 1.38, 1.43 (3×s, 12H, 2×C(CH 3 ) 2 ), 3.59 (dd, 1H, J 8a,7 5.40 J 8a,8b 11.41, H-8 a ), 3.66-3.69 (m, 1H, H-7), 3.74 (dd, 1H, J 8ab,7 2.90 Hz, H-8 b ), 4.01 (app t, 1H, J 6,7 7.62 Hz, H-6); 4.24 (dd, 1H, J 5,6 8.17 Hz J 5,4 0.89 Hz, H-5), 4.79-4.81 (m, 2H, H-3, H-4), 4.89-4.91 (m, 1H, H-2); δ C (CD 3 OD) 24.62, 25.42, 26.05, 26.49, 63.86, 73.81, 75.40, 75.91, 79.18, 70.90, 80.78, 110.53, 113.09, 175.76; ν max (film) 1791, 3478; [α] D −35.7 (c 1, CHCl 3 ).
[0000] 8-O-tert-Butyldimethylsilyl-2,3:5,6-di-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qe
[0299] To a solution of 2,3:5,6-di-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone (Qd, 3.18 g, 10 mmol) in N,N-dimethylformamide (40 ml) was added tert-butyldimethylsilyl chloride (1.808 g, 12 mmol) and imidazole (1.361 g, 20 mmol). The reaction mixture was stirred at room temperature for 16 h after which t.l.c. analysis (ethyl acetate:cyclohexane, 1:1) showed no starting material (R f 0.15) and the formation of one major product (R f 0.63 ). The solvent was removed under reduced pressure and the residue was partitioned between ethyl acetate and brine. The aqueous layer was extracted with ethyl acetate and the combined organic layers were dried (MgSO 4 ), filtered and the solvent removed. The resulting pale oil was purified by silica gel chromatography (ethyl acetate:cyclohexane, 0:1 to 1:2) to give 8-O-tert-butyldimethylsilyl-2,3:5,6-di-O-isopropylidene-D-erythro-L-talo-octono-1,4-lactone Qe as a clear oil (3.612 g, 85%): δ H ((CDCl 3 ) 0.04 (br s, 6H, 2×CH 3 ), 0.86 (s, 9H, C(CH 3 ) 3 ), 1.23, 1.30, 1.32, 1.41 (4×s, 12H, 2×C(CH 3 ) 2 ), 3.63-3.67 (m, 2H, H-8 a , H-7), 3.76 (br d, 1H, H-8 b ), 3.96 (app t, J 6,7 8.21 J 6,5 7.98, H-6), 4.08 (br d, 1H, H-5), 4.72 (br s, 2H, H-2, H-3), 4.78 (br s, 1H, H-4); δ C (CDCl 3 ) −5.52, −5.45, 18.25, 25.51, 25.80, 25.93, 26.68, 27.18, 63.95, 72.97, 74.88, 74.93, 78.71, 79.63, 79.87, 110.34, 113.00, 174.42; ν max (film) 1794, 3570; [α] D −20.1 (c 1, CHCl 3 ).
[0000] 7-Azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octono-1,4-lactone Qf
[0300] A solution of 8-O-tert-butyldimethylsilyl-2,3:5,6-di-o-isopropylidene-D-erythro-L-talo-octono-1,4-lactone (Qe, 3.5 g, 8.2 mmol) in a pyridine:dichloromethane mixture (1:4, 25 ml) was cooled to −30° C. Trifluoromethanesulfonic anhydride (3.5 g, 2.09 ml, 12.4 mmol) was added portion-wise and the mixture was stirred for 2 h. T.l.c analysis (ethyl acetate:cyclohexane, 1:3) indicated the disappearance of starting material (R f 0.38) and the presence of a less polar product (R f 0.48). The reaction mixture was concentrated under reduced pressure and the residue was partitioned between ethyl acetate and 0.5 M hydrochloric acid. The organic layer was washed with brine, dried (MgSO 4 ), filtered and concentrated under reduced pressure. The resulting crude pale orange residue was treated with sodium azide (807 mg, 12.4 mmol) in N,N-dimethylformamide (25 ml) for 16 h. T.l.c. analysis (ethyl acetate:cyclohexane, 1:4) indicated the disappearance of the intermediate triflate (R f 0.42) and the presence of a more polar compound (R f 0.40). The reaction solvent was removed in vacuo and the residue was partitioned between ethyl acetate and brine. The aqueous layer was extracted with ethyl acetate and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo. The resulting crude residue was purified by silica gel chromatography (ethyl acetate:cyclohexane, 0:1 to 1:4) providing 7-azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octono-1,4-lactone Qf as a colourless oil (3.026 g, 81%): δ H (CDCl 3 ) 0.11 (2×s, 6H, 2×CH 3 ), 0.91 (s, 9H, C(CH 3 ) 3 ), 1.30, 1.38, 1.41, 1.47 (4×s, 12H, 2×C(CH 3 ) 2 ), 3.41-3.45 (m, 1H, H-7), 3.87 (dd, 1H, J 8a,7 5.37 Hz J 8a,8b 10.81 Hz, H-8 a ), 3.92 (dd, 1H, J 8b,7 7.32 Hz, H-8 b ), 4.19-4.24 (m, 2H, H-5, H-6), 4.61 (br s, 1H, H-4), 4.75-4.79 (m, 2H, H-2, H-3); δ C (CDCl 3 ) −5.59, −5.56, 18.14, 25.54, 25.73, 26.09, 26.71, 26.98, 61.61, 63.19, 67.94, 74.84, 74.94, 75.47, 78.36, 78.66, 110.90, 113.37, 174.02; ν max (film) 1796, 2111; [α] D +36.7 (c 1, CHCl 3 ).
[0000] 7-Azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octitol Qg
[0301] 7-azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octono-1,4-lactone (Qf, 3.00 g, 6.6 mmol) was dissolved in tetrahydrofuran (40 ml) and was cooled to 0° C. Lithium borohydride (216 mg, 9.9 mmol) was added and the mixture was stirred at 0° C. to room temperature for 24 h. T.l.c. analysis (ethyl acetate:cyclohexane, 1:1) indicated the disappearance of the starting material (R f 0.76) and the presence of a more polar compound (R f 0.45). The reaction was quenched through the addition of ammonium chloride (sat. aq.) and the partitioned between ethyl acetate and brine. The aqueous layer was extracted with ethyl acetate (2×) and the combined organic layers were dried (MgSO 4 ), filtered and the solvent removed. The resulting crude residue was purified by silica gel chromatography (ethyl acetate:cyclohexane, 1:3 to 1:1) affording 7-azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octitol Qg as a colourless syrup (2.476 g, 82%): δ H (CDCl 3 ) 0.10 (s, 6H, 2×CH 3 ), 0.91 (s, 9H, C(CH 3 ) 3 ), 1.36, 1.41, 1.42, 1.48 (4×s, 12H, 2×C(CH 3 ) 2 ), 3.43-3.47 (m, 1H, H-7), 3.66 (br d, 1H, H-4), 3.79-3.92 (m, 4H, H-1, H-1 a , H-8, H-8 a ), 4.10-4.14 (m, 2H, H-2, H-3), 4.30-4.38 (m, 2H, H-5, H-6); δ C (CDCl 3 ) −5.61, −5.51, 18.14, 25.18, 25.71, 26.87, 27.07, 27.86. 60.65, 62.39, 63.66. 67.62, 75.90. 76.91, 77.18, 77.49, 108.63, 110.16; ν max (film) 2109, 3536; [α] D +46.6 (c 1, CHCl 3 ).
[0000] 7-Azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-1,4-di-O-methanesulphonyl-L-threo-L-talo-octitol Qh
[0302] 7-Azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-L-threo-L-talo-octitol (Qg, 2.4 g, 5.3 mmol) was dissolved in pyridine (20 ml) and was added to a solution of 4-dimethylamino pyridine (64 mg, 0.53 mmol) and methanesulfonyl chloride (4.814 g, 3.253 ml, 42 mmol) in pyridine (20 ml) and stirred for 2 h. T.l.c analysis (ethyl acetate:cyclohexane, 1:2, double elution) revealed the disappearance of starting material (R f 0.33) and the presence of a more hydrophobic product (R f 0.43). The solvent was removed under educed pressure and the residue was partitioned between ethyl acetate and brine. The aqueous layer was extracted with ethyl acetate and the combined organic layers were dried (MgSO 4 ), filtered and concentrated under reduced pressure. The resulting crude residue was purified by silica gel chromatography (ethyl acetate:cyclohexane, 1:2) giving 7-azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-1,4-di-O-methanesulfonyl-L-threo-L-talo-octitol Qh as a colourless oil (2.973 g, 92%): δ H (CDCl 3 ) 0.11, 0.12 (2×s, 6H, 2×CH 3 ), 0.91 (s, 9H, C(CH 3 ) 3 ), 1.41, 1.44, 1.46, 1.56 (4×s, 12H, 2×C(CH 3 ) 2 ), 3.08 (s, 3H, SO 2 CH 3 ), 3.21 (s, 3H, SO 2 CH 3 ), 3.49 (ddd, 1H, J 7,6 2.82 Hz, J 7,8 5.46 Hz, J 7,8a 7.94 Hz, H-7), 3.87-3.97 (m, 2H, H-8, H-8 a ), 4.19 (dd, 1H, J 6,5 2.30 Hz, H-6), 4.24-4.31 (m, 2H, H-1, H-5), 4.36 (dd, 1H, J 3,4 2.96 Hz, J 3,2 6.62 Hz, H-3), 4.49-4.53 (m, 1H, H-2), 4.69 (dd, 1H. J 1a,2 2.39 Hz, J 1a,1 10.83 Hz, H-1 a ), 5.11 (app t, 1H, H-4); δ C (CDCl 3 ) −5.56, 18.18, 25.76, 26.24, 26.78, 26.89, 27.56, 37.75, 39.02, 60.90, 63.57, 70.44, 76.00, 76.07, 76.46, 77.18, 77.32, 109.01, 110.68; ν max (film) 2113; [α] D −16.2 (c 1, CHCl 3 ).
[0000] 7-Azido-7-deoxy-1,4-di-O-methanesulphonyl-L-threo-L-talo-octitol Qi
[0303] 7-Azido-8-O-tert-butyldimethylsilyl-7-deoxy-2,3:5,6-di-O-isopropylidene-1,4-di-O-methanesulfonyl-L-threo-L-talo-octitol (Qh, 2.90 g, 4.7 mmol) was treated with a trifluroacetic acid:water mixture (1:1, 40 ml) for 3 h. T.l.c. analysis (ethyl acetate) showed the disappearance of starting material (R f 0.9) and the presence of a more polar product (R f 0.12). The solvent was removed under reduced pressure and the residue was co-evaporated with toluene and dried under vacuum. Purification by silica gel chromatography (ethyl acetate:cyclohexane, 1:1 to 1:0) yielded 7-azido-7-deoxy-1,4-di-O-methanesulphonyl-L-threo-L-talo-octitol Qi as a colourless oil (1.677 g, 85%): δ H (CD 3 OD) 3.12 (s, 3H, SO 2 CH 3 ), 3.21 (s, 3H, SO 2 CH 3 ), 3.61-3.71 (m, 2H, H-7, H-8), 3.78-3.82 (m, 2H, H-6, H-8 a ), 3.98-4.05 (m, 2H, H-2, H-3), 4.11-4.13 (m, 1H, H-5), 4.34 (dd, 1H, J 1,2 4.87 Hz, J 1,1a 10.44 Hz, H-1), 4.45 (dd, 1H, J 1,2 1.87 Hz, H-1 a ), 5.00 (dd, 1H, J 4,3 1.91 Hz, J 4,5 6.15 Hz, H-4); δ C (CD 3 OD) 36.17, 38.11, 61.84, 66.62, 69.09, 70.33, 70.45, 71.08, 72.55, 86.41; ν max (film) 2113; [α] D −9.1 (c 1, H 2 O).
[0000] (1R,2R,3S,6S,7R,7aR)-3-(Hydroxymethyl)-1,2,6,7-tetrahydroxypyrrolizidine Qi
[0000] [3,7-diepi-Casuarine]
[0304] 7-Azido-7-deoxy-1,4-di-O-methanesulphonyl-L-threo-L-talo-octitol (Qi, 1.6 g, 3.78 mmol) was dissolved in water (30 ml) and was treated with 10% palladium on carbon (400 mg) under an atmosphere of hydrogen for 16 h. T.l.c analysis (ethyl acetate:methanol, 9:1) indicated the disappearance of starting material (R f 0.75) and the presence of a more polar product (R f 0.05). Palladium was removed by filtration and the filtrate was treated with sodium acetate (930 mg, 11.34 mmol) at 60° C. for 16 h. The reaction mixture was cooled and the solvent removed in vacuo. The crude brown oil was purified by ion-exchange chromatography (Dowex 50WX8-100, eluting with 2M ammonium hydroxide) to afford (1R,2R,3S,6S,7R,7aR)-3-(hydroxymethyl)-1,2,6,7-tetrahydroxypyrrolizidine [3,7-diepi-Casuarine] Qj as a brown glass (671 mg, 87%): δ H (D 2 O) 2.81-2.92 (m, 2H, H-5, H-5 a ), 3.16 (dd, 1H, J 3,2 5.91 Hz, J 3,8 10.74 Hz, H-3), 3.30 (app t, 1H, J 3.78 Hz, H-7 a ), 3.76 (dd, 1H, J 8,8a 6.35 Hz, H-8), 3.87 (dd, 1H, H-8 a ), 4.01 (d, 1H, J 2,1 3.55 Hz, H-2), 4.04-4.12 (m, 2H, H-6, H-7), 4.29 (app t, 1H, H-1); δ C (D 2 O) 49.32, 57.29, 63.78, 70.41, 72.59, 72.65, 74.47, 78.25; [α] D −21.1 (c 0.5, H 2 O).
Equivalents
[0305] The foregoing description details presently preferred embodiments of the present invention. Numerous modifications and variations in practice thereof are expected to occur to those skilled in the art upon consideration of these descriptions. Those modifications and variations are intended to be encompassed within the claims appended hereto. | Isolated immunomodulatory (e.g. immunostimulatory) polyhydroxlated pyrrolizidine compounds having the formula
are disclosed. In these compounds R is selected from hydrogen, straight or branched, unsubstituted or substituted, saturated or unsaturated acyl, alkyl (e.g. cycloalkyl), alkenyl, alkynyl and aryl groups. The compounds are useful in therapy and prophylaxis, including increasing the Th1:Th2 response ratio, hemorestoration, alleviation of immunosuppression, cytokine stimulation, treatment of proliferative disorders (e.g. cancer), vaccination, stimulation of the innate immune response and boosting of the activity of endogenous NK cells. | 0 |
FIELD OF THE INVENTION
The invention relates to novel catalysts for use with a fiberglass non-woven binder. The catalyst can be a Lewis acid, an organic acid salt, a free-radical generator, or a mixture thereof. The catalyst provides stronger bonding, increased crosslinking density, reduced curing times, and reduced curing temperatures.
BACKGROUND OF THE INVENTION
Fiberglass insulation products generally consist of glass fibers bonded together by a cross-linked polymeric binder. An aqueous polymer binder is sprayed onto matted glass fibers soon after they have been formed, and while they are still hot. The polymer binder tends to accumulate at the junctions where fibers cross each other, to hold the fibers together at these points. The heat from the fibers causes most of the water in the binder to vaporize.
The polymeric binder has been a phenol-formaldehyde polymer. More recently formaldehyde-free polymer systems have been used to avoid formaldehyde emissions. The formaldehyde-free polymer system consists of 1) a polymer of a polycarboxyl, polyacid, polyacrylic, or anhydride; 2) an active hydrogen compound (hydroxyl or polyol group) such as trihydric alcohol (U.S. Pat. Nos. 5,763,524; 5,318,990), triethanolamine (U.S. Pat. No. 6,331,350; EP 0990728), beta-hydroxy alkyl amides (U.S. Pat. No. 5,340,868; or hydroxy alkyl urea (U.S. Pat. Nos. 5,840,822; 6,140,388); and 3) a catalyst or accelerator such as a phosphorous-containing compound (U.S. Pat. No. 6,136,916) or a fluoroborate compound (U.S. Pat. No. 5,977,232). The catalyst functions to decrease the cure time, to increase the cross-linking density, to reduce the cure time and/or to decrease the water sensitivity of the binder.
One problem with current catalysts is that they produce films that can discolor. Also the films may release phosphorous-containing vapors.
There is a need for a fiberglass binder system having a catalyst other than the phosphorous or fluoroborate catalysts currently used.
Surprisingly it has been found that Lewis acids, Lewis bases, and free-radical generators are effective catalysts for crosslinking polymeric binders for fiberglass non-wovens. The use of these catalysts produces a strong, yet flexible and clear, fiberglass insulation binder system.
SUMMARY OF THE INVENTION
The present invention is directed to a non-woven binder composition containing a polymer binder having an acid functionality, an active hydrogen crosslinker containing hydroxyl, polyol, or amine functionality, and a catalyst that is either a Lewis acid, an organic acid salt, or a free-radical generator.
The invention is also directed to a bonded fiberglass mat in which the mat is bound with a copolymer binder system having a catalyst that is either a Lewis acid, an organic acid salt, or a free-radical generator.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a non-woven binder composition containing a polymeric binder; an active hydrogen crosslinker; and a catalyst or accelerator that is a Lewis acid, a Lewis base, or a free radical generator. The catalyst or accelerator allows the crosslinking reaction between a carboxyl group on the polymer binder and an active hydrogen-containing compound to occur faster, at a lower temperature, and more completely.
In one preferred embodiment, the catalyst is a Lewis acid. Lewis acids useful in the present invention include, but are not limited to, dibutyltindilaurate, iron(III)chloride, scandium(III)trifluoromethanesulfonic acid, boron trifluoride, tin(IV)chloride, Al 2 (SO 4 ) 3 xH 2 O, MgCl 2 .6H 2 O, AlK(SO 4 ) 2 .10H 2 O, and Lewis acids having the formula MX n wherein M is a metal, X is a halogen atom or an inorganic radical, and n is an integer of from 1 to 4, such as BX 3 , AlX 3 , FeX 3 , GaX 3 , SbX 3 , SnX 4 , AsX 5 , ZnX 2 , and HgX 2 More preferably, the Lewis acid catalyst is selected from Al 2 (SO 4 ) 3 xH 2 O, MgCl 2 .6H 2 O, AlK(SO 4 ) 2 .10H 2 O . A combination of Lewis acid catalysts may also be used.
In another embodiment, the catalyst is a salt of an organic acid. Examples of organic acids are citric acid, tartaric acid, lactic acid, acetic acid, polyacrylic acid, and the like. The preferred salts of these acids are the alkaline earth salts, preferably the magnesium and calcium salts; titanates; and zirconates. The salts may be formed in situ by adding a base, such as Mg(OH) 2 .
In another embodiment, the catalyst could be a free-radical generator. By free-radical generator, as used herein is meant that the catalyst will produce free radicals during the curing process. Free radicals are generated by the use of one or more mechanisms such as photochemical initiation, thermal initiation, redox initiation, degradative initiation, ultrasonic initiation, or the like. Preferably the free-radical generators are selected from azo-type compounds, peroxide type compounds, or mixtures thereof. Examples of suitable peroxide compounds include, but are not limited to, diacyl peroxides, peroxy esters, peroxy ketals, di-alkyl peroxides, and hydroperoxides, specifically hydrogen peroxide, benzoyl peroxide, deconoyl peroxide, lauroyl peroxide, succinic acid peroxide, cumere hydroperoxide, t-butylhydroperoxide, t-butyl peroxy acetate, 2,2 di (t-butyl peroxy) butane di-allyl peroxide), cumyl peroxide, or mixtures thereof. Examples of suitable azo-type compounds include, but are not limited to azobisisobutyronitrile (AIBN), 2,2′-azobis (N,N′-dimethyleneisobutyramide) dihydochloride (or VA-044 of Wako Chemical Co.), 2,2′-azobis(2,4-dimethyl valeronitrile) (or V-65 of Wako Chemical Co.), 1,1′-azobis (1-cyclohexane carbonitrile), acid-functional azo-type initiators such as 4,4′-azobis (4-cyanopentanoic acid).
The catalyst is admixed with a polymer binder and an active hydrogen component to form a polymer binder composition. The catalyst is present at from 1 to 25 percent by weight, and preferably from 1 to 10 percent by weight, based on the weight of the polymer.
The polymer binder is synthesized from one or more acid monomers. The acid monomer may be a carboxylic acid monomer, a sulfonic acid monomer, a phosphonic acid monomer, or a mixture thereof. The acid monomer makes up from 1 to 99 mole percent, preferably from 50 to 95 mole percent, and most preferably from 60 to 90 mole percent of the polymer. In one preferred embodiment, the acid monomer is one or more carboxylic acid monomers. The carboxylic acid monomer includes anhydrides that will form carboxyl groups in situ. Examples of carboxylic acid monomers useful in forming the polymer of the invention include, but are not limited to acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, fumaric acid, maleic acid, cinnanic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, sorbic acid, alpha-beta-methyleneglutaric acid, maleic anhydride, itaconic anhydride, acrylic anhydride, methacrylic anhydride. Preferred monomers are acrylic acid and methacrylic acid. The carboxyl groups could also be formed in situ, such as in the case of isopropyl esters of acrylates and methacrylates that will form acids by hydrolysis of the esters when the isopropyl group leaves. Examples of phosphonic acid monomers useful in forming the copolymer include, but are not limited to, vinyl phosphonic acid.
Examples of sulfonic acid monomers useful in forming the copolymer include, but are not limited to styrene sulfonic acid, 2-acrylamido-2-methylpropane sulfonic acid, vinyl sulfonic acid, methallyl sulfonic acid, sulfonated styrene, and allyloxybenzenesulfonic acid.
Other ethylenically unsaturated monomers may also be used to form a copolymer binder, at a level of up to 50 mole percent, and preferably up to 30 mole percent based on the total monomer. These monomers can be used to obtain desirable properties of the copolymer, in ways known in the art. For example, hydrophobic monomers can be used to increase the water-resistance of the nonwoven. Monomers can also be use to adjust the Tg of the copolymer to meet the end-use application requirements. Useful monomers include, but are not limited to, (meth)acrylates, maleates, (meth)acrylamides, vinyl esters, itaconates, styrenics, acrylonitrile, nitrogen functional monomers, vinyl esters, alcohol functional monomers, and unsaturated hydrocarbons. Low levels of up to a few percent of crosslinking monomers may also be used to form the polymer. The extra crosslinking improves the strength of the bonding, yet at higher levels would be detrimental to the flexibility of the resultant non-woven material. The crosslinking moieties can be latent crosslinking where the crosslinking reaction takes place not during polymerization but during curing of the binder. Chain-transfer agents may also be used, as known in the art, in order to regulate chain length and molecular weight. The chain transfer agents may be multifunctional so as to produce star-type polymers.
The polymer is synthesized by known methods of polymerization, including solution, emulsion, suspension and inverse emulsion polymerization methods. In one preferred embodiment, the polymer is formed by solution polymerization in an aqueous medium. The aqueous medium may be water, or a mixed water/water-miscible solvent system, such as a water/alcohol solution. The polymerization may be batch, semi-batch, or continuous. The polymers are typically prepared by free radical polymerization but condensation polymererization may also be used to produce a polymer containing the desired moieties. The monomers may be added to the initial charge, added on a delayed basis, or a combination. The polymer is generally formed at a solids level in the range of 15 to 60 percent, and preferably from 25 to 50 percent, and will have a pH in the range of from 1–5, and preferably from 2–4. One reason a pH of above 2 is preferred is for the hazard classification it will be afforded. The polymer may be partially neutralized, generally with sodium, potassium, or ammonium hydroxides. The choice of base, and the partial-salt formed will effect the Tg of the copolymer. The use of calcium or magnesium base for neutralization, produces partial salts having unique solubility characteristics, making them quite useful, depending on the end-use application.
The polymer binder may be random, block, star, or other known polymer architecture. Random polymers are preferred due to the economic advantages, however other architectures could be useful in certain end-uses. Polymers useful as fiberglass binders will have weight average molecular weights in the range of 1,000 to 300,000, and preferably in the range of 2,000 to 15,000. The molecular weight of the copolymer is preferably in the range of 2500 to 10,000, and most preferably from 3000 to 6000.
Admixed with the polymer binder and catalyst is an active hydrogen-containing compound which serves to crosslink the polymer binder. The active hydrogen is preferably in the form of a hydroxyl group, an amine group, or an amide group. In one embodiment of the invention, Polyols and polyamines containing more than one hydroxyl or amine groups may be used. Useful hydroxyl compounds include, but are not limited to, trihydric alcohol; beta-hydroxy alkyl amides; polyols, especially those having molecular weights of less than 10,000; ethanol amines, such as triethanol amine; hydroxy alkyl urea; oxazolidone. Useful amines include triethanol amine, diethylenetriamine, tetraethylenepentamine, and polyethyleneimine. One embodiment of the invention, a polyamine, such as tetraethylenepentamine is used with an acid-containing polymer binder. This polyamine/polymer binder combination may be catalyzed with either the catalysts of the present invention, or may be catalyzed with other catalysts such as phosphorous-containing compounds and fluoroborate compounds.
In one embodiment, the catalyst of the invention is used in combination with a copolymer binder containing both acid-functionality and hydroxyl-, amine-, and/or amide-functionality. In this case, at least one monomer containing active hydrogen functionality is copolymerized with the acid-functional monomer to form a copolymer binder, eliminating the need for a separate source of active hydrogen. Additional external active hydrogen components may optionally be present in the copolymer binder composition, and may serve as a plasticizer as well as a cross-linker. The hydroxyl or amine monomer makes up from 0 to 75 mole percent, and preferably 10 to 20 mole percent of the copolymer. Examples of hydroxyl monomers useful in forming the copolymer of the invention include, but are not limited to hydroxy propyl (meth) acrylate, hydroxy ethyl (meth) acrylate, hydroxy butyl (meth) acrylate and methacrylate esters of poly(ethylene/propylene/butylene) glycol. In addition, one could use the acrylamide or methacrylamide version of these monomers. Also, monomers like vinyl acetate that can be hydrolyzed to vinyl alcohol after polymerization may be used. Preferred monomers are hydroxypropyl acrylate and methacrylate. Examples of amine-functional monomers useful in the present invention include, N, N dialkylaminoalkyl(meth) acrylate, N,N dialkylaminoalkyl (meth) acrylamide, namely dimethylaminopropyl methacrylate, dimethylaminoethyl methacrylate, tert-butylaminoethyl methacrylate and dimethylaminopropyl methacrylamide. In addition monomers like vinyl formamide and vinylacetamide that can be hydrolyzed to vinyl amine after polymerization may also be used. Furthermore, aromatic amine monomers such as vinyl pyridine may also be used. The copolymer could contain a mixture of both hydroxyl and amine functional monomers. It was found that copolymers containing lower levels of these functional monomers were more flexible than copolymers containing higher levels of these functional monomers. While not being bound to any particular theory, it is believed this may be related to the lower Tg copolymers that are formed. Amide-functional monomers could also be used to form the copolymer if a higher cure temperature is used in forming the finished non-woven. The mole ratio of acid-functional monomer to hydroxyl-, or amine-functional monomer is preferably from 100:1 to 1:1, and more preferably from 5:1 to 1.5:1.
The polymer binder may optionally be formulated with one or more adjuvants, such as, for example, coupling agents, dyes, pigments, oils, fillers, thermal stabilizers, emulsifiers, curing agents, wetting agents, biocides, plasticizers, anti-foaming agents, waxes, flame-retarding agents, and lubricants. The adjuvants are generally added at levels of less than 20 percent, based on the weight of the copolymer binder.
The copolymer binder composition is useful for bonding fibrous substrates to form a formaldehyde-free non-woven material. The copolymer binder of the invention is especially useful as a binder for heat-resistant non-wovens, such as, for example, aramid fibers, ceramic fibers, metal fibers, polyrayon fibers, polyester fibers, carbon fibers, polyimide fibers, and mineral fibers such as glass fibers. The binder is also useful in other formaldehyde-free applications for binding fibrous substances such as wood, wood chips, wood particles and wood veneers, to form plywood, particleboard, wood laminates, and similar composites.
The copolymer binder composition is generally applied to a fiber glass mat as it is being formed by means of a suitable spray applicator, to aid in distributing the binder composition evenly throughout the formed fiberglass mat. Typical solids of the aqueous solutions are about 5 to 12 percent. The binder composition may also be applied by other means known in the art, including, but not limited to, airless spray, air spray, padding, saturating, and roll coating. The residual heat from the fibers causes water to be volatilized from the binder, and the high-solids binder-coated fiberglass mat is allowed to expand vertically due to the resiliency of the glass fibers. The fiberglass mat is then heated to cure the binder. Typically the curing oven operates at a temperature of from 130° C. to 325° C. The fiberglass mat is typically cured from 5 seconds to 15 minutes, and preferably from 30 seconds to 3 minutes. The cure temperature will depend on both the temperature and the level of catalyst used. The fiberglass mat may then be compressed for shipping. An important property of the fiberglass mat is that it will return to its full vertical height once the compression is removed.
Properties of the finished non-woven (fiberglass) include the clear appearance of the film. The clear film may be dyed to provide any desired color. Another advantage of the copolymer binder composition is that it produces a flexible film. This is important in fiberglass insulation that needs to bounce back after one unwraps the roll and uses it in walls/ceilings. It was found that the use of the catalyst systems of the present invention could produce films that were not just flexible, meaning they could bend without breaking, but were also elastic in that they returned to the original shape after deformation.
The fiberglass, or other non-woven treated with the copolymer binder is useful as insulation for heat or sound in the form of rolls or batts; as a reinforcing mat for roofing and flooring products, ceiling tiles, flooring tiles, as a microglass-based substrate for printed circuit boards and battery separators; for filter stock and tape stock and for reinforcements in both non-cementatious and cementations masonry coatings.
The following examples are presented to further illustrate and explain the present invention and should not be taken as limiting in any regard.
EXAMPLE 1
Control
75.2 grams of a polyacrylic acid (ALCOSPERSE 602A from Alco Chemical) and 12.4 grams of triethanolamine (TEA) and 12.4 grams of water was mixed to form a homogenous solution.
EXAMPLE 2
Comparative
75.2 grams of a polyacrylic acid (Alcosperse 602A from Alco Chemical) and 12.4 grams of TEA and 5.0 grams of sodium hypophosphite (SHP) and 7.4 grams of water was mixed to form a homogenous solution.
EXAMPLES 3–17
The ingredients in the Table below were mixed to form a homogenous solutions. The solutions were made up to 100 percent by adding water.
TABLE 1
Wt %
poly(acrylic acid)
Alcosperse 602A
from Alco
Wt %
Wt %
Sample
Chemical
TEA
Catalyst
catalyst
Example 3
75.2
12.4
MgCl 2 , 6H 2 O
5
Example 4
75.2
12.4
MgCl 2 , 6H 2 O
2.5
Example 5
75.2
12.4
70% Tert-
5
butylhydroperoxide
Example 6
75.2
12.4
35% H 2 O 2
5
Example 7
75.2
12.4
Sodium salicylate
5
Example 8
75.2
12.4
Magnesium
0.5
zirconate
Example 9
75.2
12.4
Magnesium
0.5
titanate
Example 10
75.2
12.4
Tyzor 217
5
zirconium lactate
complex (from
Dupont)
Example 11
75.2
12.4
Mg(OH) 2
1
Example 12
75.2
12.4
Mg(OH) 2
2.5
Example 13
75.2
12.4
Mg(OH) 2 /citric acid
2.5/2.5
Example 14
75.2
12.4
MgSO4
2.5
Example 15
75.2
12.4
Mg(OH) 2 /acetic
2.5, 2.5
acid
Example 16
75.2
12.4
Mg(OH) 2 /tartaric
2.5/2.5
Example 17
75.2
12.4
ZnSO4
2.5
EXAMPLE 18
The testing protocol was as follows: 20 grams of each of solution was poured into PMP Petri dishes and placed overnight in a forced air oven set at 60° C. The film was then cured by being placed for 10 minutes in a forced air oven set at 150° C. After cooling, the resulting films were evaluated in terms of physical appearance, flexibility, and tensile strength.
TABLE 2
SAMPLE #
COMPOSITION
APPEARANCE
FLEXIBILITY
TENSILE
Example 1,
PAA/TEA
“Swiss cheese”,
Low flex, breaks
Breaks readily
control
yellow-brown color
easily
Example 2,
PAA/TEA/
“Swiss cheese”, slight
Slight flexibility,
Stretches, tensile
comparative
10% SHP
yellowing
breaks easily
slightly stronger than
Example 3
Example 3
PAA/TEA/
Very irregular surface
Very flexible but
Breaks readily
5% MgCl 2 .6H 2 O
from bubbling,
does break
yellow-brown color
Example 4
PAA/TEA/
Very irregular surface
Very flexible but
Breaks readily
10% MgCl 2 .6H 2 O
from bubbling,
does break
yellow-brown color
Example 5
PAA/TEA/
“Swiss cheese”
Flexible but does
Difficult to break, very
10% TBHP
appearance, very
break
little elasticity
slight yellowing
Example 6
PAA/TEA/
Clear, “Swiss
Breaks easily
Very strong tensile
10% H 2 O 2
cheese” appearance
Example 7
PAA/TEA/
“Swiss cheese”
Breaks easily
Not as strong as
10% sodium
appearance, slight
control
salicylate
yellowing
Example 8
PAA/TEA/1%
“Swiss cheese” from
low, breaks easily
similar to Example 2
magnesium
bubbling
zirconate
Example 9
PAA/TEA/1%
“Swiss cheese” from
low, breaks easily
slightly stronger than
magnesium
bubbling
Example 1, less than
titanate
Example 2
Example 10
PAA/TEA/
wrinkled, very
more than
similar to Example 1
10% Tyzor 217
irregular
Example 1, less
zirconium lactate
than Example 2
complex
Example 11
PAA/TEA + 2%
wrinkled, very
more brittle than
similar to Example 2
Mg(OH 2 )
irregular
Example 2
Example 12
PAA/TEA + 5%
wrinkled, very
more brittle than
similar to Example 2
Mg(OH 2 )
irregular
Example 2
Example 13
PAA/TEA + 5%
wrinkled, very
more brittle than
similar to Example 2
Mg(OH 2 ) + 5%
irregular
Example 2
citric acid
Example 14
PAA/TEA + 5%
wrinkled, irregular
slightly more
similar to Example 2
MgSO 4
surface
flexible than
Example 1
Example 15
PAA/TEA + 5%
wrinkled, very
more brittle than
similar to Example 2
Mg(OH 2 ) + 5%
irregular
Example 2
acetic
Example 16
PAA/TEA + 5%
wrinkled, very
more brittle than
similar to Example 2
Mg(OH 2 ) + 5%
irregular
Example 2
tartaric acid
Example 17
PAA/TEA + 5%
wrinkled, very
Similar to
similar to Example 2
ZnSO 4
irregular
Example 2
EXAMPLE 19
A blend of 75.2 g of polyacrylic acid (ALCOSPERSE 602A), 12.4 g of polyamine (tetraethylenepentamine), and 5 percent SHP were admixed to form a homogeneous solution. Films of the solution were made an tested as in Example 18. The results are shown in Table 3
TABLE 3 SAMPLE # COMPOSITION APPEARANCE FLEXIBILITY TENSILE Example 19 PAA/tetraethylene- Very irregular Slight Stretches, pentamine/5 % SHP surface from flexibility, tensile slightly bubbling, breaks easily stronger than Example 3
The data shows that a polyamine like tetraethylenepentamine can be used instead of a polyol and give similar benefits.
EXAMPLE 20
The polymers of Example 2 and 3 as well as a phenol formaldehyde resin were applied to a veneer with grain oriented at a 90 degree angle on successive layers. The plywood composite formed was cured by application of heat. The strength and dimensional stability of the plywood composites formed by using the binder of example 2 and 3 would be similar to that using the conventional phenol-formaldehyde resin. | The present invention relates to novel catalysts for use with a fiberglass non-woven binder. The catalyst can be a Lewis acid, an organic acid salt, a free-radical generator, or a mixture thereof. The catalyst provides stronger bonding, increased crosslinking density, reduced curing times, and reduced curing temperatures. Fiberglass mats made with polymer binder compositions containing the catalyst exhibit both flexibility and elasticity, allowing the mats to be compressed for storage, yet return to original thickness once the compressive forces are removed. Formaldehyde-free wood composites, such as plywood and fiberboard, may also be produced with polymer binder compositions containing the catalyst. | 3 |
FIELD OF THE INVENTION
This invention relates to an improved dusting blend and the use of such a blend in a baking process. The improvement resides in the addition of salt to the dusting blend to retard insect infestation while at the same time retaining good flowability characteristics.
DESCRIPTION OF THE PRIOR ART
In the baking process, dusting flour is applied to dough at various stages so that the dough does not stick to equipment, hands or other matter. Further, use of dusting flour makes handling easy, smooth and convenient. If dusting flour is not applied, the dough is likely to tear and be damaged in normal handling or in machinery.
Traditionally, bakers have used as dusting powder the same flour that is used in the baking process because it is easily available, has good handling characteristics and serves the purpose of avoiding damage to the dough. Conventional flour when used as dusting flour is a good media for growth of pest and insect life. Unless strict sanitation and house keeping practices are followed accumulation of dusting flour in the corners and crevices of equipment such as sheeters, rollers and proofers will serve as a refuge for infestation growth.
In a small bake shop, dusting flour may be employed by taking a handful from the flour bag and spreading it. In most bakeries the dusting flour is mechanically spread for uniform and economical usage of flour. Flour is stored in a hopper from where it flows over a shaking screen with perforated holes or a type of dusting machine which has a shaker arm. The flow of flour from this machine is controlled by proper selection of screen mesh, speed of shaking and/or rotation of shaker arm.
Some bakers have used starch as a dusting flour in the belief that it does not support insect life as much as baking flour does. Other have tried starch because it is felt that it has good functional properties. However, common starches are not sufficiently mobile and consequently starch has a tendency towards bridging. Some speciality starches on the other hand flow too rapidly from the screens commonly used by bakers. Moreover, starch has not proven to be an effective retardant for insect life. As a result of the foregoing, the disadvantages of using ordinary flour and ordinary starch has been of great concern to bakers.
As mentioned earlier, one of the objections of using ordinary flour as a dusting powder is that it is a good media for growth of infestation. There are many substances which are available in the marketplace that can be used to retard insect growth but care must be exercised in selecting one that can be used for food manufacturing use. Most bakeries control their infestation by frequent cleaning and spraying of chemical substances. However, the dusting flour currently used gets collected in the corners of equipment and these corners are difficult to clean. Even periodic cleaning of equipment and spraying has not proved to be very effective in the corners and the collection of flour has encouraged growth of insect life.
SUMMARY OF THE INVENTION
A purpose of this invention therefore has been to provide a dusting powder which will not support growth of insect life or at least retard insect growth and at the same time have flowability characteristics of uniformity and suitable rate of flow.
A further purpose of this invention has been to provide a product which has good flowability characteristics for use in a bakery and be substantially free of any tendency towards sticking, bridging or caking and capable of being used with standard dusting equipment.
This invention relates to an improved dusting blend for application to baking and cooking equipment and material, to prevent dough from sticking to said equipment the improvement residing in said dusting blend comprising salt in a quantity sufficient to retard insect infestation while at the same time not adversely affecting fermentation during the baking process.
The invention further relates to a method of retarding insect infestation in an area used for cooking or baking which method comprises using the dusting blend of this invention as a dusting powder for cooking or baking equipment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
There were several experiments conducted to determine the level of salt which does not undesirably affect the baking process or taste. The reason for this is that it was found that salt retards the fermentation process, can inhibit the desired effect of avoiding stickiness and can result in a salty tast being imparted to the finished baked goods. Testing indicated that up to 20% by weight of salt was functional and that a level of up to 12% salt did not show any noticeable differences in taste on the baked produce and use of salt up to a level of 12% in the dusting process was not detremental to the fermentation process.
In addition to mixing flour and salt to form the dusting powder, additional components can be added to enhance flowabiity or retard or inhibit the formation of mould. A component which may be added to the dusting powder of this invention to reduce stickiness and enhance flowability is starch. Starch can be used along with flour or salt or may even replace the flour such that a starch and salt mixture is used as a dusting powder. Suitable starches include corn starch or wheat starch. Suitable alternatives to starch could be rice flour.
A component which may be added to the dusting powder of the invention to inhibit mould formation is calcium or sodium propionate. Alternatives to these could be substances such as potassium sorbate, sodium diacetate, ascorbic acid and propionic acid.
The salt used in the dusting flour mix could be in almost any form although too coarse a salt could detract from good flowability characteristics. Fine salt at 325 mesh and flour salt of 60 mesh have been used with good results.
Dried flour is capable of working better in the dusting flour blend than undried flour because moisture in undried flour is absorbed by the salt resulting in more stickiness than if dried flour was used.
EXAMPLES RELATING TO FLOWABILITY CHARACTERISTICS
It is known that flowability characteristics depend upon type of product, moisture content, particle size and chemical properties particularly related to water holding and fat absorption. Flowability can be measured in terms of viscosity, mobility indexes and various other empirical means. A purpose of this invention is to provide a product that will flow uniformly through screens commonly used by bakers irrespective of other physical characteristics. It was decided to use an actual screen as the test media. A screen with an opening of 1/64th of an inch and a shaker arm rotating at 60 shakes per minute was chosen and installed in the lab to measure the rate of flow. A test model was set up and tried with flours actually used in the trade and by a comparison of results, establishing that a product which has a flow rate of 220-300 g per minute through the test model is the one that would be most suitable for use in bakeries as far as rate of flow is concerned.
EXAMPLE 1
Dusting blends were made up in the lab. These were made by blending flour, corn starch, sodium propionate and salt. Salt was used at 6%, 9% and 12% levels (all parts by weight).
These 3 mixtures were used to evaluate effect of salt on the baking process.
Bread dough was made using standard procedures and after mixing, dough was divided into 3 equal portions.
One portion was made up by using a dusting flour blend containing 6% salt, the second portion by using dusting flour blend containing 9% salt and the third portion by using dusting flour blend containing 12% salt.
Very liberal amounts of dusting flour were used at the following stages in the baking process:
(a) after scaling out of the mixer
(b) after dividing and rounding
(c) at moulding
(d) on pans at proofing
The breads made with the 3 above dusting flour blends were evaluated by an expert panel of 3 judges. The result of the tests indicated that 6 and 9% salt levels in the dusting blend did not show a substantial effect on the baking process or in the taste of the bread produced. It was observed that with 12% salt in the dusting blend, doughs were a little sticky and one of the judges noticed a little salty taste in the bread made with 12% salt in the dusting blend.
EXAMPLE 2
Regular Keynote™ flour (bakery patent flour) was used as a control for determining flowability characteristics. A regular bakery sifter with the following dimensions was used as a test model.
______________________________________Dimension 15" × 41/2"Screen Size 133/4" × 11/2"Mesh Opening 1/64"Shaker Arm Speed 60 shakes per minute______________________________________
2000 g of Keynote™ flour was put in the test model and the shaker arm started. Keynote™ flour (bakery patent flour) was allowed to flow. The flour was collected for 5 minutes to determine the rate of flow.
Several tests were done and a record of the amount of flour collected in 5 minutes was noted. Flour collected in 5 minutes varied from 1277 g to 1335 g or 255 g to 267 g per minute.
Field test experience indicated that flour with a flow rate significantly different from Keynote™ will not be preferred. Therefore it was established that a preferred flow rate target for the dusting blend of this invention, as measured by the test equipment, to be between 220-300 g per minute.
EXAMPLE 3
Larger scale batches were made to establish if the lab tests were confirmed by field tests regarding flowability. At the same time these batches were subjected to infestation studies. Keynote flour was used as control for both flowability and infestation studies. Two batches were made up with the only difference being the type of flour.
______________________________________Control Batch 1 Batch 2______________________________________Keynote Flour A (Dried) 91.75 Flour B (undried) 91.75Flour 100% Starch 3.00 Starch 3.00 Salt 5.00 Salt 5.00 Sodium Sodium Propionate 0.25 Propionate 0.25______________________________________ Control Batch 1 Batch 2______________________________________Rate of Flow in 1350 g 1255 g 1025 g5 minutes 1365 g 1160 g 1000 g 1350 g 1125 g 1025 g 1320 g 1100 g 1020 gAverage per min. 269 g 232 g 203 g______________________________________
These batches were put through field tests in a bakery. Observations indicated that Batch No. 1 performed well, had a uniform flow rate and had desirable rates of flow for dusting. Batch No. 2 flow rate was considered to be a little on the low side and Batch No. 1 was preferred. These field tests further confirmed that for good dusting flour, the flowability rate as measured by our test model should preferably be in the range of 220-300 g per minute.
The Effect of Salt on Retarding Insect Infestation in Dusting Blend
Having determined preferred flowability characteristics, tests were then conducted to examine the effect of salt and flour mixtures on retarding insect infestation in dusting flour. Different levels of flour salt were studied at various dosage levels (2, 4, 5, 6, 8, and 10 percent) in the dusting blends for their effectiveness in retarding the growth of the common insect pest, the confused flour beetle--Tribolium confusum. Under optimal environmental conditions, after seven weeks the artificially innoculated samples showed that population levels decreased by more than 50% at the 8 percent salt level. After 14 weeks the remaining insect level was approaching zero.
Dusting blends were prepared both in the laboratory and in the plant containing flour, corn starch, calcium propionate, and different levels (2, 4, 6, 8, and 10 percent) of salt. Tests were carried out innoculating both dried and undried flours. There was no significant difference between the two types as far as supporting insect life. That is to say the moisture level in the dried flour was not reduced to the extent that it affected the metabolic or reproductive abilities of the insects. Tests were conducted utilizing flour salt (60 mesh) and fine salt (325 mesh). As shown in the results a greater reduction in the number of insects occurred utilizing the fine salt in as much as the dispersibility factor was greater.
The initial population of insects was secured from the Research Station, Agriculture Canada, London, Ontario. Eggs, larva, and young adults (1 month old) of the Tribolium species were used to conduct these tests. Subsequent culturing, sub-culturing, transferring, etc was performed at Robin Hood Multifoods Inc. The confused flour beetle was chosen for this experimental work as it is a general feeder on farinaceous foods and is undoubtedly the worst insect pest as regards prepared cereal foods. It is commonly found in flour mills, warehouses, and bakeries and tends to infiltrate parts of equipment and machinery. The insects were reared on a medium containing whole wheat flour and brewer's yeast in a climatically controlled environment at 25° C. where sufficient quantities of air and moisture were prevalent. Sub-culturing was done every two to three months onto fresh media.
Both larva and young adults were artificially innoculated into dusting blends containing various levels of salt and enumerated at varying intervals (7, 8 and 14 weeks).
Table 1 representing a first experiment showed that a dusting flour blend with 10 percent salt present not only prevented the growth of insects but dehydrated them to the extent that a total kill was evident. In this case the control sample showed more than a 6-fold increase in the larva population (25 to 166), whereas the adult population remained relatively stable at 60 insects. The next experiment was designed to establish the threshold level of salt required to retard insect multiplication.
Table 2 shows the effect of salt on insect life at 2 percent increments from a level of 2 percent to 12 percent (by weight). From this table we can see the 8 percent salt level has a marked effect on the multiplication of the Tribolium species. After seven weeks the larva population also decreased (from 30 to 10) although it began to increase after that seven week period. This increase is not significant in that no additional salt was added whereas conditions in the bake shop would necessitate a daily application of salt such that the overall salt concentration over time would increase above 8 percent.
Table 3 shows that larva and adult populations at both 5 and 8 percent levels of salt were killed off. Neither flour salt (60 mesh) or fine salt (325 mesh) as a complete medium would support insect life. Calcium propionate, another component in the dusting flour blend would not support insect growth, whereas corn starch would support the growth of Tribolium species as shown by the increase in larva from 60 to more than 100 and adult level being marginally higher.
It will be understood that while in the foregoing specification, embodiments of the invention have been described in detail, these details are not limiting and changes may be made in these details, by those skilled in the art, without departing from the spirit of the invention, especially as defined in the following claims.
TABLE 1__________________________________________________________________________ Live Live Larva Flour Dead Larva Popula- Flour Beetle Beetle Flour Beetle Population tion at Population Population Population at T × 0 T × 8 wks at T × 0 at T × 8 wks at T × 8__________________________________________________________________________ wksI. Dusting Blend 25 0 60 0 66 10% salt undried flour - prepared in the laboratoryII. Dusting Blend 25 0 60 0 63 10% salt dried flour - prepared in the laboratoryIII. Dusting Blend 15 0 15 3 18 10% salt dried flour - PlantIV. Undried Flour - Control 15 166 60 60 7__________________________________________________________________________
TABLE 2__________________________________________________________________________DUSTING BLEND - RESULTS FOR INFESTATION INHIBITIONBlend 383-1 383-2 383-3 383-4 383-5 383-6 383-7 383-8 383-9__________________________________________________________________________Flour 1000 g 997.5 g 987.5 g 977.5 g 957.5 g 937.5 g 917.5 g 897.5 g 877.5 gCalciumPropionate 0 2.5 g 2.5 g 2.5 g 2.5 g 2.5 g 2.5 g 2.5 g 2.5 gSalt 0 0 10.0 g 20.0 g 40.0 g 60.0 g 80.0 g 100.0 g 120.0 gTotal 1000 g 1000 g 1000 g 1000 g 1000 g 1000 g 1000 g 1000 g 1000 gLarva Populationat T × 0 30 30 30 30 30 30 30 30 30Live Larva Pop.At T × 7 wks 58 60 35 32 26 54 10 20 15 T × 4 wks >1000 >2000 >2000 >1000 >1000 >800 80 150 51Live Flour BeetlePopulationat T × 0 60 60 60 60 60 60 60 60 60Live Flour BeetlePopulationat T × 7 wks 65 54 60 77 64 40 26 28 21 T × 14 wks 61 >100 >100 43 30 80 3 6 3Dead Flour BeetlePopulationat T × 7 wks 14 15 8 4 10 20 19 48 52 T × 14 wks 18 19 13 38 44 35 52 71 79__________________________________________________________________________
TABLE 3______________________________________ Live Dead Larva Flour Live Flour Popu- Beetle Flour Beetle Larva lation Popu- Beetle Popu- Pop. at lation Pop. at lation at T × 8 at T × 8 at T × 8 T × 0 wks T × 0 wks wks______________________________________1. Dusting Blend (8% salt) 60 0 60 0 1042. Dusting Blend (5% salt) 60 0 60 0 963. Dusting Blend (6.5% salt) 60 0 60 4 924. Flour Batch 5773 (control) 60 >1000 60 106 65. Flour Batch 5774 (control) 60 >1000 60 98 86. Corn starch 60 >100 60 64 227. Flour Salt (60 mesh) 60 0 60 0 1018. Salt (325 mesh) 60 0 60 0 609. Calcium Propionate 60 0 60 0 60______________________________________ | This invention relates to an improved dusting blend and the use of such a blend in a baking process. The improvement resides in the addition of salt to the dusting blend to retard insect infestation while at the same time retaining good flowability characteristics. The dusting blend is applied to cooking or baking equipment, as a dusting powder, to prevent food or dough from sticking to the equipment. The dusting blend of this invention controls insect infestation far better than known dusting blends comprising flour or starch. | 8 |
FIELD OF THE INVENTION
The present invention relates to the investment casting of metal in a mold made using a disposable pattern, more particularly, to investment casting in a manner to improve as-cast surface finish of the cast component as well as to provide an improved pattern material.
BACKGROUND OF THE INVENTION
Investment casting is widely used in the manufacture of myriad cast components including complex gas turbine engine components, such as blades and vanes made of nickel or cobalt base superalloys. In the investment casting process, a wax or other disposable pattern of the component to be cast is made typically by injecting molten wax into a pattern die cavity and solidifying the material in the die cavity. Ceramic mold material then is coated on or invested about the pattern to form a casting mold upon selective removal of the pattern by heating (melting), chemical dissolution or other conventional pattern removal technique. The ceramic investment mold typically is fired to develop mold strength, and then molten metal is cast into the mold and solidified to form the cast component, which will have the configuration of the pattern employed to make the mold.
Existing wax pattern materials normally contain a stable, solid filler material, such as for example only 4,4-isopropylidene diphenol available as Bisphenol A (BPA) or cross-linked polystyrene, which results in wax properties that limit dimensional distortion, reduce visual defects, control shrinkage, and improve dewax capabilities. Presently used filler material is a mechanically ground material that is characterized by angular surface configuration, such as an acicular particle configuration and/or fiber-like particle configuration. This filler morphology creates significant undesirable side effects which include rough and pitted casting surfaces that require extensive post-casting finishing operations and increased wax injection pressures into the pattern die cavity during pattern fabrication. Such increased wax injection pressures in the pattern die cavity can break fragile ceramic cores positioned in the die cavity and about which the wax is injected in the manufacture of wax/core pattern assemblies for use in casting hollow components, such as internally cooled turbine blades and vanes.
An object of the present invention is to provide an investment casting method conducted in a manner to improve as-cast surface of the cast component and to reduce the extent of post-casting surface finishing operations.
Another object of the present invention is to provide an improved pattern material and pattern for use in forming a refractory casting mold for use in investment casting methods.
SUMMARY OF THE INVENTION
The present invention provides an investment casting method in which a pattern material including one or more matrix constituents and substantially spherical filler particulates in a certain size range is formed into a pattern configuration of the component to be cast. The spherical filler particulate size range is selected effective to improve as-cast surface finish of the cast component by providing an improved, uniform pattern surface texture characterized by substantially reduced random, localized surface depressions and pits. The improved, uniform pattern surface is imparted to the component cast in a mold made using the pattern.
In particular, the component cast in the mold exhibits an improved as-cast surface finish with improved, much more uniform surface texture with reduced random, localized surface pitting and other gross surface defects so as to, in turn, reduce the extent of post-casting surface finishing operations. Moreover, the pattern material can be injected into a pattern die cavity at a lower injection pressure that reduces breakage of a ceramic core positioned in the die cavity in the manufacture of wax/core pattern assemblies for use in casting hollow components, such as internally cooled turbine blades and vanes.
In one embodiment of the present invention, the pattern material comprises one or more heat meltable wax and/or reisn matrix constituents and substantially spherical filler particulates within a particle size range of about 10 microns to about 70 microns particle diameter effective to improve as-cast surface finish of a nickel or cobalt superalloy casting. The aforementioned objects and advantages of the present invention will become more readily apparent from the following detailed description of the invention taken with the following drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photograph at 100X of ground BPA filler particulates used previously in prior art pattern material.
FIG. 2 is a photograph at 100X of substantially spherical BPA filler particulates used in pattern materials in accordance with the present invention.
FIG. 3 is a photograph at 10X of a wax pattern surface produced using a pattern material including the ground BPA filler particulates of FIG. 1 having acicular and/or fiber particle configuration.
FIG. 4 is a photograph at 10X of a pattern surface produced using a pattern including spherical BPA filler particulates of FIG. 2 pursuant to the invention.
FIG. 5 is a particle size distribution graph for the spherical filler particulates used in the example described herebelow.
FIG. 6 is a partial sectional view of an atomizer to make substantially spherical filler particulates.
DETAILED DESCRIPTION OF THE INVENTION
The present invention embodies an improved pattern material for use in investment casting methods. The pattern material comprises one or more matrix components or constituents, such as petroleum wax and/or natural or synthetic resins, and solid filler particulates having a susbtantially spherical particle shape and having a particle size in a range discovered effective to improve as-cast surface finish of metal components cast in investment molds made using the pattern material.
For purposes of illustration and not limitation, the invention will be described in detail herebelow with respect to a pattern material for use in forming patterns and investment casting shell molds by the conventional "lost wax" process for use in casting nickel base or cobalt superalloy components.
A pattern material in accordance with one embodiment of the present invention typically comprises one or more petroleum waxes (e.g. a paraffin wax and a microcrystalline wax) and a hydrocarbon resin such as Eastotac H-130 as the matrix constituents, stearic acid as a flow enhancer and adhesive agent, and substantially spherical solid filler particulates in a particle size range found effective to improve as-cast surface finish of the component cast in a refractory mold using the pattern material. An exemplary pattern material pursuant to a working embodiment of the invention comprises the following:
______________________________________hydrocarbon resin (Eastotac H-130) 29.25% by weightmicrocrystalline wax 6.50% by weightstearic acid 13.00% by weightparaffin wax 16.25% by weightspherical filler 35.00% by______________________________________ weight
The hydrocarbon resin (Eastotac H-130) is available as solid flake from Eastman Chemical Co., Kingsport, Tenn., and has a melting point of 130 Degrees C. as determined by ASTM standard E-28. The microcrystalline wax is available as a solid slab from Bareco Products, Rock Hill, S.C., and has a melting point of 180 degrees F. as determined by ASTM standard D-127-63. The paraffin wax is available as a solid slab from Moore & Munger-Marketing, Inc., Shelton, Conn., and has a melting point of 152 degrees F. as determined by ASTM standard D-127-63.
The spherical filler particulates comprise in the illustrative working embodiment Bisphenol A (BPA) available from Aristech Chemical Corporation, Pittsburgh, Pa., although the invention is not limited thereto and can be practiced using other spherical filler particulates such as cross-linked polystyrene and other suitable polymeric and/or organic crystalline materials. Importantly, the filler particles are made to have a substantially spherical shape with a particle size in the range of about 10 microns to about 70 microns particle diameter discovered to significantly improve the as-cast surface finish of superalloy castings made in ceramic shell molds produced using the pattern material. Filler particles having a particle diameter less than about 10 microns are not suitable because they produce visual quality defects such as flow lines and entrapped air (air locks) during pattern injection. Filler particles having a particle diameter greater than about 70 microns are not suitable because they cause unacceptably rough pattern surfaces, and high injection pressures.
A preferred size range for the substantially spherical filler particles comprises a median particle size that falls in a range from about 25 microns to about 35 microns diameter, and more preferably from about 27 microns to about 33 microns diameter, to provide a tight or relatively narrow particle size distribution that avoids localized, random pits or other surface depressions in the pattern surface.
An inert gas atomization method can be used to produce the substantially spherical shaped filler particles for practice of the invention. For example, the aforementioned bisphenol A (BPA) is heated to a liquid at 350 degrees F. for atomization by room temperature argon gas at a pressure of 240 psi using 30-45 cubic feet per minute argon for 100 pounds per hour of liquid resin. The liquid resin is discharged from a nozzle 1 having a resin discharge orifice 1a with a diameter of 1/8 inch and atomized by twenty (20) argon gas jets discharged from individual argon gas discharge orifices 2 each having a diameter of 0.030 inch and receiving argon from a gas manifold 3 communicated to a source of argon, FIG. 6. The argon gas discharge orifices 2 of the atomizer are disposed in a circle equally spaced apart about the resin discharge orifice 1a and axially spaced from it by a distance of about 0.125 inch, the gas jets being oriented at 45 degree angle to the longitudinal axis of nozzle 1 to form a spray of atomized droplets that are collected in a bin B, which is essentially purged of air over time by the argon atomizing gas, and that solidify as substantially spherical particles. The atomized generally spherical filler particles are collected and passed through a 120 mesh screen for blending or mixing with the pattern material. The invention is not limited to producing the generally spherical resin particles by inert gas atomization in the manner described since the substantially spherical filler particulates can be produced by other methods such as including, but not limited to, centrifugal atomization, water and steam atomization, and emulsification processes.
The substantially spherical resin particulates, FIG. 2, contrast to the typical acicular and fibrous type filler particles heretofore used and produced by grinding FIG. 1.
The filler particles may be present in the pattern material in amounts ranging from about 20 weight % to about 40 weight % of the total pattern material, although 35 to 40 weight % is preferred.
The aforementioned pattern components or constituents are blended together by mechanical mixing to yield a pattern material having the spherical solid filler particulates uniformly distributed in the matrix constituents. The resulting pattern material has a viscosity of about 200 cps to about 2000 cps (centipoise) suitable for injection under pressure into a conventional pattern die cavity.
The blended pattern material typically is injected into a metal pattern die cavity having the exact pattern shape (of the article to be cast) in the pressure range of 35 to 300 psi which is low enough to avoid breaking or cracking a ceramic core which may be present in the pattern die cavity to form a pattern/core pattern assembly for making hollow castings. For making solid airfoil components, these injection pressures are high enough to fill fine part features to be ultimately cast in the component. In particular, the ceramic core may be a relatively thin cross-section silica, alumina or other core of the type typically used in the casting of hollow gas turbine engine blades or vanes having as-cast internal cooling air passages. Such thin ceramic cores have experienced breakage or cracking in the past using the higher injection pressures needed for prior pattern materials having acicular solid filler particulates.
The disposable, heat meltable pattern formed by injection molding in the pattern die cavity can be coated or invested with a refractory mold material using conventional "lost wax" mold making procedures to form a casting shell mold about the pattern. For example, the injected molded pattern can be repeatedly dipped in an appropriate aqueous slurry of fine ceramic powder or flour and binder agent to build up a facecoat layer that contacts the molten metal cast in the mold. The pattern then is repeatedly dipped in an appropriate slurry of fine or coarse ceramic particles and dusted or stuccoed with coarse ceramic particles while the slurry is still wet to build up a ceramic shell mold of suitable wall thickness on the pattern. The particular ceramic particles for the mold materials are selected in dependence on the metal composition to be cast. The examples set forth below describe particular ceramic shell mold parameters for purposes of illustration and not limitation.
The pattern is selectively removed from the refractory or ceramic mold by melting, dissolution or other conventional pattern removal techniques. For example, the green ceramics shell mold with the pattern therein formed by the "lost wax" technique can be placed in a conventional furnace and heated to melt the pattern and allow it flow out of the mold. Alternately, microwave heating may be employed to selectively melt the pattern from the shell mold. During the pattern removal step, both the pattern matrix constituents and some or all of the spherical filler particulates are melted for removal from the green mold. Any unmelted spherical filler particles flow out of the green mold easily as compared to flow of acicular filler previously used.
Following the pattern removal step, the investment shell mold can be heated or fired in conventional manner at a suitable elevated temperature to develop sufficient mold strength for casting molten metal therein. The mold heating temperature will depend on the refractory or ceramic mold materials and binders employed in mold fabrication.
Molten metal, such as nickel and cobalt base superalloys, then can be conventionally cast into the investment shell mold and solidified therein to form a cast component. The casting technique can be selected from conventional, well known techniques to produce equiaxed grain casting, columnar grain casting or single crystal casting. Use of the pattern material in accordance with an embodiment of the invention yields a cast component having an as-cast surface finish that is an exact replicate of the pattern down to microscopic surface texture characteristics and is significantly improved in terms of having improved, much more uniform surface texture with reduced localized surface pitting so as to, in turn, reduce the extent of post-casting surface finishing operations. A comparison of FIGS. 3 and 4 reveals the improved pattern uniform surface texture and reduced random localized surface pitting and gross surface defects achieved by practice of the invention (FIG. 4).
The following example is offered to illustrate the invention in greater detail but not to limit the scope of the invention in any way.
EXAMPLE
The particle size distribution of the spherical BPA filler particles (Bisphenol A particles argon gas atomized as described hereabove) used in this example is shown in FIG. 5. A Malvern Instruments particle size analyzer, using laser scattering of particles suspended in dry air, was used to measure the filler particle size distribution. The results of the analysis showed that the median particle size of the generally spherical filler particles was about 28 microns diameter. The particle size under 10 percentile was about 10-15 microns, while particle size over 90 percentile was about 40-60 microns. The spherical BPA filler particles were screened and mixed with the pattern material components and in proportions described hereabove for the exemplary pattern material. The surface of a solid airfoil shaped pattern pursuant to the invention made using the exemplary pattern material injected into a pattern die at approximately 200 psi is shown in FIG. 4.
For comparison, in FIG. 3, the surface of an airfoil shaped pattern made using a pattern material having the solid acicular and angular BPA filler particles of FIG. 1 mixed with like pattern material components in like proportions as the exemplary pattern material is shown and characterized as including unacceptable gross or severe randomly located, localized surface depressions or pits and surface roughness measured in the range of 95 to 142 rms (root mean square). The noted random, localized surface depression and pit defects in the pattern surface will be reflected in a component cast in a mold made using the pattern. Such a casting would need extensive post-casting surface finishing operations to remove such severe random, localized deep surface defects.
In contrast, in FIG. 4, the surface of the pattern made using the exemplary pattern material including solid spherical filler particulates described hereabove pursuant to the invention is characterized as including reduced localized surface pitting and reduced surface roughness measured in the range of 75 to 130 rms. A more uniform pattern surface generally is evident in FIG. 4 with little or no gross or severe random, localized surface defects such as random deep depressions and pits that render casting finishing problematic. The more uniform surface of FIG. 4 imparted to a casting can be easily finished to bring the casting surface finish within customer specifications as a result of the avoidance of the gross or severe localized surface defects such as deep depressions and pits evident in FIG. 3.
That is, the pattern surface of FIG. 4 will produce a similarly improved as-cast surface on a component cast in an investment mold made using that pattern by conventional lost-wax procedures (e.g. as an as-cast surface having an improved surface texture with reduced severe random, localized surface depressions or pitting), thereby requiring much less extensive surface finishing operations, such as grinding, belting, and polishing, to remove surface defects and thus less removal of metal from the casting surface (as compared to a casting made in a mold using the pattern shown in FIG. 3). The improved, uniform pattern surface texture with reduced localized surface ptis and the like imparted to the cast component may enable the component to be used in the as-cast condition without traditional casting surface finishing. The invention can be used in conjunction with conventional investment casting techniques wherein a mold is formed about disposable pattern of a component to be cast, the pattern is removed, and molten metal is cast into the mold to form a cast component to produce equiaxed, columnar grain or single crystal castings of nickel and cobalt base superalloys as well as other metals and alloys with improved as-cast surface finish of the cast component.
The invention is advantageous to improve as-cast surface finish of a cast component so that the extent of post-casting surface finishing operations and metal removal from the casting is substantially reduced and possibly eliminated altogether so that casting can be used as-cast. Moreover, castings made using patterns with improved, more uniform surface texture pursuant to the invention can be surface finished using automated finishing operations, such as media finishing, that are less costly. Still further, castings made using patterns with improved, more uniform surface texture pursuant to the invention will exhibit a significant reduction in scrap due to wall scrap, which can result from excessive finishing operations to remove unacceptable surface defects. In particular, the more metal that is removed or modified in a post-casting operation to repair or remove surface pit defects on a hollow casting will result in greater wall thickness variation of the hollow casting. Since wall thickness specifications have become a critical quality characteristic in new high performance airfoil casting designs, the invention is advantageous in reducing the extent of post-casting finishing operations needed, wall thickness variations, and scrap due to out-of-specification wall thickness.
While the invention has been described in terms of specific illustrative embodiments thereof, it is not intended to be limited thereto. Moreover, although certain embodiments of the invention have been shown and decribed in detail hereabove, those skilled in the art will appreciate that changes, modifications and omissions can be made therein without departing from the scope of the invention as set forth in the appended claims. | The pattern material with substantially spherical filler particulates is used to produce investment cast components with improved surface quality, reduced finishing costs, and reduced core breakage. The pattern material comprises substantially spherical particles within the particle size range of about 10 microns to about 70 microns particle diameter, the use of which reduces the number of random, localized surface depressions and pits to improve pattern surface texture and uniformity. Patterns so formed inpart the same improvements to the surface of subsequent investment cast components. The resulting castings exhibit improved as-cast surface finish and reduced random, localized surface pitting, thereby reducing or eliminating expensive post casting surface finishing operations. Moreover, the spherical morphology of the filler particulates reduces injection pressures to fill a pattern die cavity as compared to non-spherical filler particulates. The lower injection pressures eliminate or reduce breakage of ceramic cores positioned in the die cavity for manufacture of hollow cast components, such as internally cooled turbine blades and vanes. | 1 |
TECHNICAL FIELD
[0001] The present disclosure relates generally to pillows, and more specifically to a hand pillow.
BACKGROUND
[0002] Pillows come in all shapes and sizes. They are primarily used on a bed when sleeping but may also be used as accents on a bed or couch. However, when one is traveling in a car or on an airplane, for example, it may not be convenient or desirable to bring a pillow. Furthermore, a pillow may be offered by the airlines; however, a person may not want to use a pillow that has been used by other passengers.
[0003] A pillow insert is comprised of an outer shell and fill material. The outer shell is typically comprised of material such as polyester or cotton. The fill material, which is also referred to as the stuffing, may be feathers, down, foam, recycled polyester, virgin polyester, or some other natural/synthetic materials.
[0004] The pillow insert is usually placed inside of a pillow case, which could be plain or decorative. The pillow case could be open on one end so that the user could remove the pillow insert, or the pillow case could be stitched closed as in the case of most accent pillows. Besides leaving the end open or stitching it closed, the manufacturer may also choose to finish the pillow by adding a zipper, buttons, or a flap.
[0005] Most pillows are too large to carry when traveling, or the users may not have the space to carry the pillow among their travel belongings. More importantly, the user usually does not have the room to lie down in a car or on a plane when traveling. A person may place a pillow in between the head and palm of the hand. However, this pillow may be oversized and is not suited for placing on the palm of the hand. As a result, the pillow may slide off the person's hand when sleeping simply because it is not properly sized and not suitable for such an application.
SUMMARY
[0006] Rather than use a standard pillow, the principles of the present disclosure allow the use of a pillow with a pocket in which the hand can be inserted into the pocket. The pillow has been resized to substantially accommodate a person's hand. With the addition of a pocket, the pillow does not slide off or roll off the person's hand when resting or sleeping.
[0007] In one aspect, a pillow having a pocket is provided, and in one embodiment, such a pillow may comprise a first side of said pillow, where the first side comprises a first outer layer and a first inner layer, and a first filling material located between the first outer and inner layers. In such an embodiment, the pillow may also comprise a second side having a second outer layer and a second inner layer, and having a second filling material located between the second outer and inner layers. Moreover, in such embodiments, said first side and said second side are attached to each other along at least a portion of their corresponding edges to create a pocket between the first and second sides.
[0008] In another embodiment of a pillow having a pocket, the pillow may comprise a first side having a first outer layer and a first inner layer, and having a first filling material located between the first outer and inner layers. In addition, this embodiment of a pillow may then simply have a second side, wherein said first side and said second side are attached to each other along at least a portion of their corresponding edges to create a pocket between the first and second sides.
[0009] In another aspect, methods of manufacturing pillows having a pocket therein are also disclosed herein. In one embodiment, such a method may comprise combining a first outer layer and a first inner layer, and having a first filling material located between the first outer and inner layers, to create a first side of said pillow. In such an embodiment, the method may also include providing a second side of said pillow, and then creating a pocket between the first and second sides by attaching said first side and said second side along at least a portion of their corresponding edges.
[0010] In sum, a pocket-containing hand pillow in accordance with the present disclosure is more suitable than a traditional pillow when the person does not have the luxury or space to lay down (e.g., as in a bed). Furthermore, a pocket hand pillow can be substantially smaller in size than a traditional pillow and could be placed in a hand bag, briefcase, pack back, purse, or computer bag when traveling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates one embodiment of a hand pillow according to the disclosed principles, which is comprised of four layers, each with substantially the same lengths and widths;
[0012] FIG. 2 a illustrates the four layers of the hand pillow illustrated in FIG. 1 , which are attached along two and/or four edges to form a hand pillow constructed according to the disclosed principles;
[0013] FIG. 2 b illustrates a front view of pocket of the hand pillow of FIG. 1 ;
[0014] FIG. 2 c illustrates a side view of the hand pillow of FIG. 1 ;
[0015] FIG. 2 d illustrates a hand that has been inserted into the pocket of the hand pillow of FIG. 1 ;
[0016] FIG. 3 illustrates another embodiment of a hand pillow according to the disclosed principles, which is comprised of three layers, each with substantially the same lengths and widths;
[0017] FIG. 4 illustrates the four layers of the hand pillow illustrated in FIG. 3 , which are attached along two and/or four edges to form a hand pillow constructed according to the disclosed principles;
DETAILED DESCRIPTION
[0018] FIG. 1 illustrates an exemplary embodiment for a hand pillow 100 constructed according to the disclosed principles.
[0019] FIG. 2 a illustrates items of hand pillow 100 in this embodiment, with different layers:
Layer 110 Layer 120 Layer 130 Layer 140
Hand pillow 100 is comprised of layers 110 , 120 , 130 , and 140 , each of which has substantially the same dimensions along their widths and lengths, as illustrated in FIG. 2 a . In addition, in this embodiment, layer 110 has four sides or edges ( 110 a , 110 b , 110 c and 110 d ), layer 120 has four sides or edges ( 120 a , 120 b , 120 c and 120 d ), layer 130 has four sides or edges ( 130 a , 130 b , 130 c and 130 d ), and layer 140 has four sides or edges ( 140 a , 140 b , 140 c and 140 d ). Each of the layers 110 , 120 , 130 , 140 , 150 , 160 having four sides is merely illustrative, and thus layers have any number of sides, no sides per se such as with round- or elliptical-shaped hand pillows, or even pillows substantially shaped like the outline of a user's hand, are also envisioned and fall within the scope of the present disclosure.
[0024] A fill material such as polyester, down, or feathers may be placed between layers 110 and 120 or 130 and 140 . Another option may be to put fill material between layers 110 and 120 and between 130 and 140 . A manufacturer may also choose to use a pillow insert, in which case the pillow insert would be placed between layers 110 and 120 or 130 and 140 . The manufacturer may also have pillow insert between 110 and 120 and another pillow insert between 130 and 140 .
[0025] FIG. 2 a illustrates the individual layers 110 , 120 , 130 , and 140 and the exemplary areas of attachment. The “X” represents the area of attachment. FIG. 2 a shows the area of attachment substantially along certain edges of the pillow 100 . Specifically, sides 110 a , 120 a , 130 a , and 140 a are attached together. Sides 110 b and 120 b are attached together in order to keep the fill material within layers 110 and 120 . If a pillow insert is used, then sides 110 b and 120 b may, but are not required to, be attached together. Sides 130 b and 140 b are attached together. Sides 110 c , 120 c , 130 c , and 140 c are attached together. Sides 110 d , 120 d , 130 d , and 140 d are attached together. Attaching the layers as described above creates a pocket 150 .
[0026] FIGS. 2 b and 2 c illustrate a front view and side view of the hand pillow 100 , respectively. FIG. 2 d illustrates a hand 160 that has been inserted into pocket 150 of the hand pillow 100 . The palm of the person's hand 160 is substantially in contact with the bottom side of layer 120 . The person's face would be substantially in contact with the top side of layer 110 .
[0027] The attached edges substantially prevent the hand pillow 100 from sliding off the person's hand 150 . The preferable method of attachment along the appropriate edges is sewing, although other methods to secure the layers together could also be used. A traditional pillow does not have a pocket and may slide off its resting place when the person is resting.
[0028] Of course, the above description of the embodiment illustrated in FIG. 1 is illustrative only, and variations to the above-described approach may also be included in a hand pillow constructed according to the disclosed principles.
[0029] FIG. 3 illustrates another exemplary embodiment for a hand pillow 200 constructed according to the disclosed principles.
[0030] FIG. 4 illustrates items of hand pillow 200 in this embodiment, with different layers:
Layer 210 Layer 220 Layer 230
Hand pillow 200 is comprised of layers 210 , 220 , and 230 , each of which have substantially the same dimensions along their widths and lengths, as illustrated in FIG. 4 . In addition, in this embodiment, layer 210 has four sides or edges ( 210 a , 210 b , 210 c and 210 d ), layer 220 has four sides or edges ( 220 a , 220 b , 220 c and 220 d ), and layer 230 has four sides or edges ( 230 a , 230 b , 230 c and 230 d ). Each of the layers 210 , 220 , and 230 having four sides is merely illustrative, and thus layers have any number of sides, no sides per se such as with round- or elliptical-shaped hand pillows, or even pillows substantially shaped like the outline of a user's hand, are also envisioned and fall within the scope of the present disclosure.
[0034] A fill material such as polyester, down, or feathers may be placed between layers 210 and 220 or between layers 220 and 230 . A manufacturer may also choose to use a pillow insert in which case the pillow insert would be placed between layers 210 and 220 or between layers 220 and 230 . Pillow 200 may have one insert/filled material since it is comprised of three layers whereas pillow 100 may have one or two inserts/filled materials since it is comprised of four layers.
[0035] FIG. 4 illustrates the individual layers 210 , 220 , and 230 , and the exemplary areas of attachment. The “X” represents the area of attachment. FIG. 4 shows the areas of attachment substantially along certain edges of the pillow 200 . Specifically, sides 210 a , 220 a , and 230 a are attached together. Sides 210 b and 220 b are attached together. Sides 210 c , 220 c , and 230 c are attached together. Sides 210 d , 220 d , and 230 d are attached together. Attaching the layers as described above creates a pocket 250 for a user's hand to be inserted therein.
[0036] A fill material such as polyester, down, or feathers may be placed between layers 210 and 220 . The amount of fill material can be determined by the manufacturer. A manufacturer may also choose to have a pre-made pillow of the correct size and dimensions inserted between layers 210 and 220 .
[0037] Like hand pillow 100 , the person inserts his or her hand into the pocket 250 of pillow 200 that is created along edges 210 b , 220 b , and 230 b . The palm of the person's hand is substantially in contact with the bottom side of layer 220 . The person's face would be substantially in contact with the top side of layer 210 .
[0038] The attached edges substantially prevent the pocket hand pillow 200 from sliding off the person's hand. The preferable method of attachment along the applicable edges is sewing, although other methods to secure the layers together could also be used. A traditional pillow does not have a pocket and may slide off of its resting location when the person is resting.
[0039] Since pocket hand pillow 200 is comprised of three layers, it may be less expensive to manufacture than pocket hand pillow 100 .
[0040] Of course, the above description of the embodiment illustrated in FIG. 3 is illustrative only, and variations to the above-described approach may also be included in a hand pillow constructed according to the disclosed principles.
[0041] The physical dimensions of the layers and method of attachment are for illustrative purposes only. The embodiments in the present disclosure illustrate 4-sided polygon layers and resulting pillows. However, one may also choose to use other multi-sided polygon, elliptical, or circular layers, or even layers substantially shaped like the outline of a user's hand, to construct pillow of corresponding shape. Also, the method of attaching the layers and area of attachment can be determined by the designer or manufacturer. Although we have shown three layers or four layers in our illustrations, a hand pillow constructed in accordance with the present disclosure should be comprised of at least three or more layers. The material of the hand pillow, dimensions, spacing, and the fill material of the hand pillow, can be determined by the designer or manufacturer.
[0042] Each layer of hand pillow 100 and 200 may be comprised of different materials or thicknesses. Hand pillows 100 and 200 may have layers comprised of various thicknesses of cotton, fur or faux fur. The fill material (polyester, feathers, down, etc.) which determines the softness or firmness of the pillow can be decided by the manufacturer.
[0043] In U.S. Pat. No. 4,375,809, Meals describes an inflatable hand pillow used to elevate the hand during a healing period. Meals pillow has inflatable chambers and cushions for the arm and forearm. The disclosed hand pillow has no inflatable chambers and is intended to enclose a substantial portion of the hand and not the arm or forearm.
[0044] In U.S. Pat. No. 6,526,612, Zarella claims a pillow comprised of a cushion which rests in the palm of the user and a strap used to affix the pillow to the hand. The disclosed hand pillow uses no straps to secure the pillow to the hand. Instead the disclosed hand pillow forms a pocket into which the hand is inserted thereby keeping the pillow on the hand. In an alternate embodiment, Zarella also claims a pillow comprised of a cushion which rests in the palm of the user and sheaths which in which one or more fingers is inserted. The disclosed hand pillow uses a pocket instead of a sheath to hold the pillow on the hand of the user. The Zarella pillow is open at both ends while the disclosed hand pillow is open only at one end. The Zarella pillow is intended to provide cushion for just the palm of the user while the disclosed hand pillow offers cushion for the entire hand.
[0045] Additionally, the section headings herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein. | Disclosed herein are embodiments of a pillow with a pocket in which the hand can be inserted into the pocket, as well as related methods of manufacturing such a pillow. In embodiment, such a pillow may comprise a first side of said pillow, where the first side comprises a first outer layer and a first inner layer, and a first filling material located between the first outer and inner layers. In such an embodiment, the pillow may also comprise a second side having a second outer layer and a second inner layer, and having a second filling material located between the second outer and inner layers. Moreover, in such embodiments, said first side and said second side are attached to each other along at least a portion of their corresponding edges to create a pocket between the first and second sides. With the addition of a pocket, the pillow does not slide off or roll off the person's hand when resting or sleeping. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-307576, filed Oct. 22, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a system which uses collected information for data mining or the like while maintaining privacy of personal information included in the collected information.
[0004] 2. Description of the Related Art
[0005] In recent years, computers are existing everywhere without being noticed. Ubiquitous computing which assists daily life and ubiquitous networks that connect ubiquitous computers are extensively being studied (“Toward Realization of a Ubiquitous Network”, Study Group on Future Prospects of Ubiquitous Network Technology in Ministry of General Affairs, <URL: http://www.soumu.go.jp/s-news/2002/pdf/020611 — 4 — 1.pdf>).
[0006] A scale having an IrDA is commercially available. When the user weighs himself/herself, the scale automatically transmits the measured weight and body fat percentage to a personal computer through a network. A home healthcare system is also under development, in which when the user uses the toilet, the weight, blood pressure, pulse, and blood glucose level are measured and transmitted to a health control center or the like through a network.
[0007] As size reduction of acceleration sensors progresses, high-performance pedmeters are becoming commercially available. There are some commercially available pedmeters which can cause a personal computer to manage measured data through a USB (Universal Serial Bus).
[0008] A railway company introduced 2002 a service that uses a combination of a pass and a prepaid card using a noncontact IC card with extensive advertisements. In the service that combines a pass and a noncontact IC card, the holder of each noncontact IC card pass can be specified. The service provider, i.e., the railway company can grasp the movement of the holder of each noncontact IC card pass and the time of his/her action although the follow-up range is limited to the railway network of that company.
[0009] To cope with the increase in number of heinous crimes, there are installed many security/monitor cameras in bank ATMs, convenience stores, amusement centers, and elevator halls or cages of multistoried apartments. The monitor cameras continuously sense images at an interval of 1 to 10 sec on a 24-hour basis. In case of an actual offense, recorded images are offered to the police and the like.
[0010] Images sensed by monitor cameras which are installed to observe the water levels of rivers or rainfalls are open to the public through cable TVs or Web. Cable TVs are exclusive services for only subscribers and are therefore charged for. However, there are some images that can be seen at an interval of 10 min in real time without charge (top page of Keihin Office of River, <URL: http://www.keihin.ktr.mlit.go.jp/index_top.html>).
[0011] That is, for various purposes such as crime prevention and health control, various kinds of sensing devices such as cameras and vital or living-body sensors are installed at public sites including banks, stations, convenience stores, and amusement centers, or private locations including homes, or worn by individuals.
[0012] On the other hand, medical facilities want to not only manage the blood glucose levels of diabetics but also collect and mine enormous quantity of data about even reserves of “lifestyle” diseases and make use of the data for medical treatments and health instructions. All patients want only themselves and their doctors to browse their data. Even when the patients know that the data is useful for preventive medicine, they do not want their names revealed. If the data is to be used for study of preventive medicine, the patients wish that information related to the patient's privacy should be completely deleted, and only abstract information necessary for studies should be made open, like “female, age: 35, height: 163 cm, weight: 48 kg, blood pressure: 116-72, . . . .”
[0013] Currently, however, such work for keeping personal information secret is mainly done by doctors who use the data for studies. Only few doctors have knowledge about information protection such as firewall or can do programming to keep information secret. Even when doctors have such knowledge or ability, most of them have no sufficient time to handle and manage information.
[0014] In the distribution industry including convenience stores and supermarkets, it is required to know the merchandise buying tendency of each age group and gender and make use of the information for the next purchase of merchandise. In convenience stores, presently, a clerk looks at a customer and estimates and inputs, e.g., “middle-aged, man”. If settlement using a point card or a portable cellular phone is introduced, the data can automatically be acquired.
[0015] On the other hand, the railway company can grasp the flow of passengers who use the noncontact IC card passes. On the basis of the data, the company can make a train service schedule or improve the station facilities. However, every noncontact IC card pass user expects that the personal information is protected even if his/her data is used.
[0016] An enormous quantity of information including personal information or private information such as images of street cameras, available railway information, personal vital data, and personal purchase information, which have not been handled as contents with clear awareness, can be processed as electronic data and distributed through networks. Every person wants to protect the information including personal information. On the other had, companies, railway companies, medical facilities, and distribution industry want to mine data and use them as fundamental data for marketing or investment on plants and equipment. There is a bottleneck of interests between the two parties.
[0017] As described above, conventionally, there is no environment for effectively using information including personal information or information such as vital data or purchase information corresponding to personal information for different purposes while protecting the personal information.
[0018] It is therefore an object of the present invention to provide an information sharing method and information sharing system, which allow a third party to effectively use information including personal information while protecting the personal information.
BRIEF SUMMARY OF THE INVENTION
[0019] (1) According to first aspect of the present invention, there is provided an information sharing apparatus, which communicates with at least one terminal corresponding to a first user of users, comprising: an acquiring unit configured to acquire a first information item which includes an anonymous information item and a personal information item, the personal information item corresponding to an informant of the anonymous information item; a separating unit configured to separate the personal information item from the first information item, to obtain the anonymous information item; a first storing unit configured to store the personal information item and the anonymous information item; a second storing unit configured to store a first access level which is assigned to a first group of users of the users who can access only the anonymous information item out of the anonymous information item and the personal information item, and to store a second access level which is assigned to a second group of users of the users who can access both of the anonymous information item and the personal information item; a receiving unit configured to receive a request message for accessing the first information item, the request message being transmitted from the terminal; a first transmitting unit configured to transmit only the anonymous information item out of the anonymous information item and the personal information item to the terminal in response to the request message, when an access level predetermined to the first user is equal to the first access level; a second transmitting unit configured to transmit both of the anonymous information item and the personal information item in response to the request message, when the access level of the first user is equal to the second access level.
[0020] (2) According to second aspect of the present invention, there is provided an information sharing apparatus, which communicates with at least one terminal corresponding to a first user of users, comprising: an acquiring unit configured to acquire a second information item which includes a personal information item; an extracting unit configured to extract the personal information item from the second information item, to obtain extracted personal information item; a generating unit configured to generate an anonymous information item by deleting the personal information item in the second information item; a first storing unit configured to store the extracted personal information item and the anonymous information item; a second storing unit configured to store a first access level which is assigned to a first group of users of the users who can access only the anonymous information item out of the anonymous information item and the personal information item, and to store a second access level which is assigned to a second group of users of the users who can access both of the anonymous information item and the personal information item; a receiving unit configured to receive a request message for accessing the second information item, the request message being transmitted from the terminal; a first transmitting unit configured to transmit only the anonymous information item out of the anonymous information item and the personal information item to the terminal in response to the request message, when an access level predetermined to the first user is equal to the first access level; a synthesizing unit configured to synthesize the personal information item with the anonymous information item, to obtain a regenerated second information item; a second transmitting unit configured to transmit the regenerated second information item in response to the request message, when the access level of the first user is equal to the second access level.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0021] [0021]FIG. 1 is a block diagram schematically showing a configuration of an information anonymizing system according to the first embodiment of the present invention;
[0022] [0022]FIG. 2 is a view showing the outer appearance of a terminal corresponding to a sensing unit shown in FIG. 1;
[0023] [0023]FIG. 3 is a block diagram showing the schematic arrangement of the sensing unit shown in FIG. 1;
[0024] [0024]FIG. 4 is a graph showing a detailed example of vital data;
[0025] [0025]FIG. 5 is a table showing an example of storage of vital data and additional information in the storing unit;
[0026] [0026]FIG. 6 is a view showing an example of storage of personal information in the storing unit;
[0027] [0027]FIG. 7 is a sequence chart for explaining the processing operation of the information anonymizing system shown in FIG. 1 in recording information;
[0028] [0028]FIG. 8 is a block diagram showing another arrangement of the sensing unit shown in FIG. 1;
[0029] [0029]FIG. 9 is a view for explaining a method of extracting an information portion corresponding to personal information from acquired information;
[0030] [0030]FIG. 10 is a view for explaining another method of extracting an information portion corresponding to personal information from acquired information;
[0031] [0031]FIG. 11 is a view showing a detailed example of image information including personal information, which is acquired by the sensing unit;
[0032] [0032]FIG. 12 is a view showing the personal information included in the image shown in FIG. 11;
[0033] [0033]FIG. 13 is a view showing anonymous information obtained by deleting the personal information from the image shown in FIG. 11;
[0034] [0034]FIG. 14 is a sequence chart for explaining another processing operation of the information anonymizing system shown in FIG. 1 in recording information;
[0035] [0035]FIG. 15 is a sequence chart for explaining the processing operation of the information anonymizing system shown in FIG. 1 in using information;
[0036] [0036]FIG. 16 is a view showing an example of a report created on the basis of information provided from the information anonymizing system shown in FIG. 1;
[0037] [0037]FIG. 17 is a block diagram schematically showing another configuration of the information anonymizing system according to the first embodiment of the present invention;
[0038] [0038]FIG. 18 is a view showing an example of anonymous information; and
[0039] [0039]FIG. 19 is a view for explaining the mechanism of an information use service using the information anonymizing system described in the first embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The embodiments of the present invention will be described below with reference to the accompanying drawing.
[0041] (First Embodiment)
[0042] [0042]FIG. 1 shows the schematic configuration of an information anonymizing system 100 according to the first embodiment. A sensing unit 1 is, e.g. a camera installed on a street or a terminal apparatus (FIG. 2) which measures user's vital data (pulse, GSR (Galvanic Skin Reflex), acceleration that represents a user's motion state, and the like). When the sensing unit 1 is a camera, an image (including both a still image and a moving image) sensed by the camera is transmitted to a transceiver unit 4 . When the sensing unit 1 is a terminal apparatus shown in FIG. 2, vital data measured from the user who is wearing the terminal apparatus is transmitted to the transceiver unit 4 .
[0043] The terminal apparatus shown in FIG. 2 mainly comprises a main unit 51 and a PDA (Personal Digital Assistant) 53 . A sensor module head 52 to be wound around a user's finger is connected to the watch-like main unit 51 that the user wears. The sensor module head 52 has sensors to measure GSR, pulse, acceleration, and the like. These sensors measure GSR, pulse, acceleration, and the like every msec. The measurement result is transmitted to the PDA 53 by short-distance wireless communication (e.g., Bluetooth) every, e.g., 50 msec.
[0044] GSR is the resistance value between two points on the skin surface. Generally, when man sweats on the skin surface, the skin resistance value decreases. When getting tense, the skin becomes sweaty. Since GSR indicates the degree of tense, it is used in a polygraph or the like.
[0045] The PDA 53 analyzes these pieces of vital data transmitted from the main unit 51 and determines the type of user's action such as walking, running, working, keeping rest, or taking a meal. The PDA 53 also gives the user an advice such as “30 minutes after meal. Take medicine!” or “Have you measured the blood glucose level?”
[0046] [0046]FIG. 3 shows the functional arrangement of the terminal apparatus shown in FIG. 2, i.e., the sensing unit 1 . The sensing unit 1 is constituted by a vital data measuring unit 11 and a communication unit 15 . The vital data measuring unit 11 comprises a GSR measuring unit 12 which measures GSR and skin temperature, a wave measuring unit 13 which causes a photoelectric pulse wave sensor or the like to measure pulse, and an acceleration measuring unit 14 which causes a biaxial acceleration sensor to measure acceleration. The communication unit 15 wirelessly transmits the result. For example, the vital data measuring unit 11 shown in FIG. 3 corresponds to the main unit 51 including the sensor module head 52 shown in FIG. 2. The communication unit 15 corresponds to the PDA 53 shown in FIG. 2.
[0047] [0047]FIG. 4 shows vital data such as the skin temperature, pulse, GSR, and acceleration measured by the measuring units. The plurality of kinds of vital data are transmitted from the communication unit 15 to the transceiver unit 4 shown in FIG. 1 as sensing information.
[0048] [0048]FIG. 4 is a graph of actually measured skin temperature, pulse, GSR, and acceleration. The skin temperature, pulse, GSR, and acceleration are chronologically stored in correspondence with each measurement time. As shown at the lower portion of
[0049] [0049]FIG. 4, the types of action such as “PC work”, “sit”, “stand”, “walk”, and “run” are determined from the acceleration.
[0050] In the above description, the sensing unit 1 acquires vital data as sensing information. However, the present invention is not limited to this. Information other than vital data may be acquired.
[0051] Vital data generally is used in a set of the vital data and additional information that makes it possible to identify the person to whom the vital data belongs. More specifically, such information (e.g., personal information such as a personal ID or name) that can be used to identify an individual is always integrated with vital data and managed. However, in the information anonymizing system according to this embodiment, such information (a kind of “information to be kept secret”) that is used to specify an individual is separated from vital data and stored such that the vital data can be used for data mining or the like later.
[0052] Personal information includes pieces of information that specify an individual, i.e., the name, address, telephone number, photograph of face, insurance number, and bank account number of an individual and other private information that must be kept secret from a third party. Such personal information can be regarded as secret information that must be held in confidence, i.e., “information to be kept secret”.
[0053] An information processing unit 2 adds, to information (sensing information) collected by the sensing unit 1 , information to be used to access the sensing information later. When “information to be kept secret” is included in or associated with the sensing information itself, the information processing unit 2 separates the “information to be kept secret” from the sensing information to generate recording information to be recorded in a structured accessible information storing unit 3 . The information processing unit 2 includes an adding unit 21 , information associating unit 22 , and anonymous information structuring unit 23 .
[0054] When the sensing unit 1 outputs a plurality of kinds of sensing information, the information associating unit 22 associates the plurality of kinds of sensing information with each other in the order of measurement times, as shown in FIG. 4.
[0055] The adding unit 21 generates additional information (i.e., additional information including the type indicator of sensing information, information acquisition date/time, sensing information encryption method, information (level information) representing the level of the access right that limits access users who can access the sensing information, and information about the source of the sensing information) to be added to each sensing information. The adding unit 21 also generates recording information including vital data and additional information. The recording information generated here still includes both the “information to be kept secret” and information that need not to do so. The anonymous information structuring unit 23 . separates the “information to be kept secret” (especially the personal information) from the recording information. After that, the recording information is stored in the structured accessible information storing unit 3 in, e.g., the format shown in FIG. 5.
[0056] Referring to FIG. 5, identifiers “B 1 ”, “B 2 ”, . . . are added to the sensing information items. The sensing information items themselves are encrypted and stored in the structured accessible information storing unit 3 independently of the additional information.
[0057] The recording information shown in FIG. 5 will be described. “Information type” indicates the type of information and the manner of storage of the information. For example, it can immediately be determined on the basis of the information type whether the information is useful for marketing. “Access right” is defined in advance in accordance with each recording information items to limit users (accessible users) of the recording information. Vital data included in the recording information item s assigned an access right of high level. When there are access rights of three levels, i.e., “low”, “medium”, and “high”, the highest level, “high”, is assigned to the vital data.
[0058] “Region ID” indicates the region where the source of information lives. “Encryption type” indicates the encryption method used to encrypt the sensing information. Not only public key encryption or secret key encryption but also partial encryption, total encryption, or a combination of a plurality of kinds of encryption may be employed. “Encryption type” means such type of encryption. In FIG. 5, a type indicated by a numerical value.
[0059] Since vital data is a kind of “information to be kept secret”, it is encrypted and stored. Personal information of each individual, including the name and address of the source of information who has provided vital data, is also “information to be kept secret”. Hence, the personal information is also encrypted and stored in the structured accessible information storing unit 3 . The personal information is separated from recording information including vital data and additional information shown in FIG. 5 and separately stored as independent information. Hence, the recording information shown in FIG. 5 is anonymized information, i.e., anonymous information. As shown in FIG. 5, each vital data stored in the structured accessible information storing unit 3 is stored separately from personal information (anonymized). Hence, the vital data is anonymous information.
[0060] [0060]FIG. 6 is a view for explaining an example of storage of personal information in the structured accessible information storing unit 3 . Each personal information has an ID (personal ID) used to identify it. The personal IDs are indicated by “P 1 ”, “P 2 ”, . . . in FIG. 6. FIG. 6 shows only the personal IDs as personal information for the sake of simplicity. In fact, each personal information also includes data items such as the name and address (the data items are not illustrated in FIG. 6).
[0061] Only a temporary ID assigned to each recording information as shown in FIG. 5 makes personal information shown in FIG. 6 correspond to (associate with) vital data and other additional information shown in FIG. 5. A temporary ID is made to correspond to a personal ID (the ID (identifier) of personal information) by the information associating unit 22 . Temporary IDs are given to pieces of recording information at random. Only the information associating unit 22 knows the correspondence between the temporary IDs and the personal IDs. That is, the information which indicates correspondence between the temporary IDs and the personal IDs is recorded in the information associating unit 22 so that only the information associating unit 22 can read out the information.
[0062] Of the pieces of recording information shown in FIG. 5, the information type, access right, region ID, sex, age, and acquisition date are not encrypted. These pieces of information can be referred to even without any special access right (even when, for example, an accessible user has an access right of lowest level).
[0063] The information anonymizing system shown in FIG. 1 also has the transceiver unit 4 , an authentication unit 5 , and an information anonymizing unit 7 .
[0064] The transceiver unit 4 receives a recording request for sensing information transmitted from an information source side or an access request from an accessible user who wants to use sensing information recorded in the structured accessible information storing unit 3 . The transceiver unit 4 also transmits information requested by an accessible user to that accessible user at the request source.
[0065] The authentication unit 5 authenticates authentication information which is transmitted from an accessible user side and received by the transceiver unit 4 . The anonymizing unit 7 processes portions to be anonymized of the pieces of information stored in the structured accessible information storing unit 3 in accordance with the access right of the accessible user authenticated by the authentication unit 5 .
[0066] The anonymous information structuring unit 23 in the information processing unit 2 separates “information to be kept secret” from recording information including information provided (sent) from an information source side.
[0067] [0067]FIG. 7 is a sequence chart for explaining the processing operation of the information anonymizing system until recording information including information (e.g., vital data) obtained by the sensing unit 1 is anonymized and stored in the structured accessible information storing unit 3 .
[0068] An example will be described, in which the sensing unit 1 constituted by the terminal apparatus shown in FIG. 3 acquires vital data and sends the vital data as shown in FIG. 4 to the transceiver unit 4 through the communication unit 15 . In this case, before transmission of vital data, the sensing unit 1 transmits an authentication request including authentication information first. The authentication request is transmitted to the authentication unit 5 through the transceiver unit 4 (step S 1 ). The authentication information may be, e.g., a fingerprint or a photograph of face of the source of information, vital data such as an iris serving as authentication information, or authentication data (e.g., an authentication number or password) on an IC card incorporated in the terminal apparatus corresponding to the sensing unit 1 shown in FIG. 3.
[0069] On the basis of the authentication information included in the authentication request, the authentication unit 5 executes personal authentication. If the authentication request is authentic, the authentication unit 5 transfers an authenticated ID (or pass ID) (the value of the authenticated ID is “x1”) to the information associating unit 22 . Simultaneously, the authentication unit 5 returns an authenticated ID having the same value as that of the authenticated ID to the sensing unit 1 (steps S 3 and S 4 ). If the authentication request is inauthentic, the authentication unit 5 gives no authenticated ID, and the processing is interrupted.
[0070] In parallel to the authentication request, a recording request and anonymizing request to record the vital data from the sensing unit 1 in the information anonymizing system through the transceiver unit 4 are sent to the information associating unit 22 through the transceiver unit 4 (step S 2 ). The information associating unit 22 receives the determination result from the authentication unit 5 . If the determination result is “authentic”, the information associating unit 22 holds the authenticated ID sent from the authentication unit 5 and waits for vital data sent from the sensing unit 1 . If the authentication result is “inauthentic”, the information associating unit 22 discards the recording request and anonymizing request without waiting for vital data from the sensing unit 1 , and the processing is interrupted.
[0071] Upon receiving the authentication result that indicates “authentic”, the sensing unit 1 sends the received authenticated ID and vital data to the transceiver unit 4 again through the communication unit 15 (step S 5 ). The sensing unit 1 may also transmit, together with the vital data, personal information such as a personal ID to be used to identify the source of the vital data. The personal information is registered in advance in, e.g., the terminal (e.g., the PDA shown in FIG. 3) corresponding to the sensing unit 1 .
[0072] Assume that vital data added with personal information is transmitted from the sensing unit 1 . For example, in the information anonymizing system, the personal information of the source of information is registered in the structured accessible information storing unit 3 in advance. Vital data added with a personal ID is sent from the sensing unit 1 . For example, the information associating unit 22 obtains, from the personal ID, other pieces of personal information such as the name corresponding to the personal ID. The pieces of personal information are made to correspond to the vital data transmitted from the sensing unit 1 .
[0073] The transceiver unit 4 sends the personal information, vital data, and authenticated ID to the information associating unit 22 . The information associating unit 22 determines whether the held authenticated ID (“x1”) coincides with the received authenticated ID.
[0074] When the authenticated IDs coincide with each other, a temporary ID corresponding to the personal ID included in the personal information is generated at random. Data representing the correspondence between the generated temporary ID and the personal ID is stored in a table (step S 6 ). If no personal ID is present, an ID that identifies the personal information may be generated and used as the personal ID. The generated temporary ID, vital data, personal information, recording request, and anonymizing request are sent to the adding unit 21 (step S 7 ).
[0075] The personal information is defined in advance as “information to be kept secret”. The access right for it has the highest level (preferably a level higher than the access right for vital data).
[0076] The adding unit 21 generates level information that defines the level of the access right that limits accessible users who can access the vital data and additional information (by referring to information included in the recording request or the personal information of the source of the vital data, as needed) in correspondence with the temporary ID. The adding unit 21 outputs recording information including the additional information, vital data, and personal information.
[0077] The temporary ID, recording information, recording request, and anonymizing request are sent to the anonymous information structuring unit 23 to anonymize the recording information (step S 8 ).
[0078] The anonymous information structuring unit 23 separates the “information to be kept secret” from the recording information. The “information to be kept secret” means personal information and vital data. Of the recording information, pieces of information except the vital data and personal information are “information that need not be kept secret”.
[0079] Of the pieces of “information to be kept secret” included in the recording information, information (i.e., personal information) to be integrated with the personal ID is separated from the recording information. Of the pieces of “information to be kept secret”, information (i.e., vital data) other than the personal information is encrypted and sent to the structured accessible information storing unit 3 together with the temporary ID (step S 9 ). At this time, the pieces of “information that need not be kept secret” are also sent to the structured accessible information storing unit 3 .
[0080] The anonymous information structuring unit 23 sends the personal information separated from the recording information to the information associating unit 22 together with the temporary ID such that the personal information is integrated with the personal ID (step S 10 ). The information associating unit 22 obtains the personal ID corresponding to the temporary ID from the table that stores the information item which represents the correspondence, integrates the personal information with the personal ID, encrypts the personal information, and sends it to the structured accessible information storing unit 3 (step S 11 ).
[0081] The structured accessible information storing unit 3 stores the encrypted personal information (including the personal ID) sent from the information associating unit 22 , as shown in FIG. 6. The structured accessible information storing unit 3 stores the temporary ID sent from the anonymous information structuring unit 23 , and anonymous information including the encrypted vital data and the pieces of “information that need not be kept secret” in the format shown in FIG. 5 (step S 12 ). Actually, since the vital data and personal information are encrypted, the contents of these pieces of information cannot easily be read. In addition, the processing for encrypting and storing the personal information in steps S 10 and S 11 need not always be executed if the personal information has already been stored in the structured accessible information storing unit 3 . More specifically, in step S 9 , the personal information is separated from the recording information, the vital data is encrypted, and anonymous information including the encrypted vital data and other pieces of “information that need not be kept secret” and the temporary ID are stored in the structured accessible information storing unit 3 . In this case, steps S 10 to S 12 may be omitted.
[0082] When the anonymous information is recorded, the structured accessible information storing unit 3 returns a reply representing the end of recording to the sensing unit 1 through the associating unit 22 (step S 13 ).
[0083] With the above processing, the sensing information that is sent together with corresponding personal information is separated from the personal information and recorded in the structured accessible information storing unit 3 .
[0084] In the above example, the vital data itself includes no information that specifies the individual. However, when the sensing unit 1 comprises an imaging unit 16 and the communication unit 15 , as shown in FIG. 8, an image acquired by the imaging unit 16 can include personal information such as the face of the person, which can identify the individual. When the information sensed by the sensing unit 1 includes “information to be kept secret”, which is related to the privacy of an individual, a personal information extracting unit 24 extracts the “information to be kept secret”.
[0085] In paragraphs [0155] and [0156] of Jpn. Pat. Appln. KOKAI Publication No. 2000-311251, a method of extracting an object from an image using fractal is described. For example, two extracting methods as shown in FIGS. 9 and 10 are used. FIGS. 9 and 10 show examples wherein the contour of buildings is extracted from the same image. An image A 1 in FIG. 9 and an image B 1 in FIG. 10 have the same initial contour (thick line) in the same image. An image A 2 in FIG. 9 indicates the contour of buildings, which is extracted from the initial contour in the image A 1 by using a fractal method. An image B 2 in FIG. 10 indicates the contour of buildings, which is extracted from the initial contour in the image B 1 by using a snake method.
[0086] [0086]FIG. 10 shows a method called snake, which extracts the contour (the white curved line that surrounds the buildings in FIG. 10) of an object with a minimum energy. In this case, since the energy is minimum, the contour is rounded, as indicated in the image B 2 . It is therefore difficult to accurately extract the contour of the sharp portions of the buildings.
[0087] To the contrary, the fractal method shown in FIG. 9 can extract even the contour of sharp portions by increasing the fractal value (the degree of repetition of similar shapes). Hence, even the contour of the sharp portions of the buildings can be accurately extracted, as indicated in the image A 2 , unlike the snake method.
[0088] Only a portion (“information to be kept secret”) associated with the privacy of an individual can be extracted from, e.g., the image shown in FIG. 11 by using the above extracting method.
[0089] [0089]FIG. 12 shows the image information of a person, which is obtained as personal information extracted by the personal information extracting unit 24 from the image shown in FIG. 11. FIG. 13 shows anonymous information obtained by deleting or mosaicing the personal information in the image shown in FIG. 11 to make the personal information (the image of the person shown in FIG. 12) secret.
[0090] [0090]FIG. 14 is a sequence chart for explaining another processing operation of the information anonymizing system. FIG. 14 shows the processing operation after the personal information extracting unit 24 extracts “information to be kept secret” (personal information) from information (image information) acquired by the sensing unit 1 until the information acquired by the sensing unit 1 is anonymized and stored in the structured accessible information storing unit 3 . The personal information in the image information is the image of an individual. Hence, in this case, the personal information is included in advance in the image acquired by the sensing unit 1 as sensing information. This case is the same as the case shown in FIG. 7 wherein part of vital data acquired by the sensing unit 1 as sensing information is personal information. Processing in steps S 1 to S 8 in FIG. 14 is the same as in FIG. 7, and a description thereof will be omitted. In step S 6 in FIG. 14, a personal ID is generated and stored in correspondence with a temporary ID.
[0091] Processing from step S 8 in FIG. 14 will be described. More specifically, in step S 8 , the temporary ID, recording information including additional information and image information including personal information and the like, an recording request, and an anonymizing request are sent to the anonymous information structuring unit 23 . The recording information and temporary ID are sent to the personal information extracting unit 24 together with a request to extract the personal information from the recording information (step S 9 a).
[0092] The personal information extracting unit 24 extracts, from the image information in the recording information, the image portion of the person, i.e., personal information as “information to be kept secret” by using the fractal method (step S 9 b). The extracted personal information (image portion of the person) and the temporary ID are sent to the information associating unit 22 to be integrated with the personal ID by the anonymous information structuring unit 23 (steps S 9 c and S 10 ).
[0093] On the other hand, the personal information extracting unit 24 converts the image information in the recording information into anonymous information. More specifically, the personal information extracting unit 24 executes anonymizing processing for the image information by deleting or mosaicing a portion corresponding to the personal information extracted from the image information. For example, the personal information extracting unit 24 deletes a portion corresponding to the personal information extracted from the image information by overwriting the personal information portion with arbitrary symbols. Anonymous information obtained by this anonymizing processing is transferred to the structured accessible information storing unit 3 together with the temporary ID (step S 9 d). The anonymous information may be encrypted. The adding unit 21 in the information processing unit 2 adds, as additional information, level information that defines the level of the access right that limits accessible users to the personal information extracted from the image information.
[0094] The information associating unit 22 integrates the personal information with the personal ID on the basis of the correspondence between temporary ID and personal ID, which is stored in advance in the table. The information associating unit 22 then encrypts the personal information and sends it to the structured accessible information storing unit 3 (step S 11 ).
[0095] The structured accessible information storing unit 3 stores the encrypted personal information sent from the information associating unit 22 and the anonymous information (the anonymous information may be encrypted) and the temporary ID which are sent from the anonymous information structuring unit 23 in, e.g., the formats shown in FIGS. 5 and 6 (step S 12 ). After that, the structured accessible information storing unit 3 returns a reply representing the end of recording to the sensing unit 1 (step S 13 ).
[0096] The processing operation of the information anonymizing system when an access request is received from an accessible user will be described next with reference to FIG. 15.
[0097] Assume that an accessible user wants to know how the degree of concentration during PC work changes in accordance with the work time in one week. In this case, the degree of concentration can be known from the GSR value. Hence, e.g., the following search request text is described in the XML (extensible Markup Language) format and sent. {category: males & females, item 1: PC work time/week, item 2: degree of concentration}
[0098] For the search request text, the terminal side of the access user or, e.g., an information management unit 6 of the information anonymizing system that has received the search request text may convert the name of “item” representing the type of information to be searched in the search request text to a name representing the type of information actually stored in the structured accessible information storing unit 3 such that the search request text itself can be adapted to the information anonymizing system. For example, the search request text is converted to {category: males & females, item 1: PC work time/week, item 2: GSR}
[0099] Before the terminal of the accessible user issues an access request including the search request text, an authentication request including authentication information is sent to the authentication unit 5 through the transceiver unit 4 (step S 21 ). After that, the access request is transmitted (step S 22 ). The authentication unit 5 confirms whether the access of the accessible user is permitted. Permission of use of information in the system is given by an authentication department separately provided. An accessible user who is permitted in advance to use the information in the system is authenticated using a given public key.
[0100] If the public key is not correct, the authentication unit 5 gives no authenticated ID. Hence, the accessible user cannot use the information anymore.
[0101] When the accessible user is successfully authenticated by the authentication unit 5 , an authenticated ID including level information that defines the level of the access right defined for the accessible user is transferred to the transceiver unit 4 (step S 23 ). Alternatively, the authenticated ID is temporarily transmitted to the terminal of the accessible user through the transceiver unit 4 . The authenticated ID transmitted from the terminal of the accessible user may be received (step S 24 ).
[0102] The transceiver unit 4 sends the access request sent from the accessible user and the authenticated ID returned from the authentication unit 5 (or transmitted from the terminal of the accessible user) altogether to the information anonymizing unit 7 (step S 25 ).
[0103] On the basis of the received access request, the information anonymizing unit 7 sends a read request to the structured accessible information storing unit 3 to read out the requested information (e.g., information corresponding to the search request text included in the access request) (step S 26 ). The structured accessible information storing unit 3 separately stores the anonymous information and personal information, as shown in FIGS. 5 and 6.
[0104] Information to be searched by the search request text having a designated “category”, like the above search request text, is irrelevant to personal information. For this reason, on the basis of the level of the access right of the accessible user, information with level that can be made open to the accessible user is provided to him/her.
[0105] The category is “males & females”. All the pieces of information shown in FIG. 5 belong to this category. Hence, all the pieces of information (including pieces of encrypted vital data that are separately recorded) shown in FIG. 5 are read out and sent to the anonymizing unit 7 (step S 27 ).
[0106] When the readout information includes information to be anonymized in accordance with the level of the access right included in the authenticated ID, the anonymizing unit 7 anonymizes the information. When the readout information includes information that should not be made open to the accessible user, the anonymizing unit 7 deletes the information (step S 28 ). For example, each information shown in FIG. 5 has no information to be kept secret because personal information has already been separated. However, the temporary ID used to associate the personal information still remains. Hence, in this example, the temporary ID is deleted from each readout anonymous information.
[0107] The access right is defined for each accessible user in advance. The access right is information that specifies the level of usable information for each accessible user. In the above example, an accessible user who can receive vital data from the search request text must have in advance a permission of access to at least vital data. Even when the accessible user is permitted to access vital data, he/she cannot know the person to whom the vital data belongs if he/she is not permitted to access personal information. When the physician in charge of the source of the vital data is the accessible user, the access right may be defined such that the accessible user can access both the vital data and personal information of the source of the vital data.
[0108] In addition, in recording “information to be kept secret” such as vital data, the access right (“low”, “medium”, and “high”) defined for the “information to be kept secret” to be recorded may be used as the access right of the accessible user. For example, when the access right to vital data is “medium”, the access right of an accessible user who can access vital data may have to be “medium” or one of “medium” and “high”. When the access right to personal information is “high”, the access right of an accessible user who can access personal information may have to be “high”.
[0109] The information (anonymous information) that has undergone necessary processing by the information anonymizing unit 7 is transmitted to the terminal of the accessible user (step S 29 ).
[0110] Upon receiving the anonymous information transmitted from the information anonymizing system, the terminal of the accessible user arranges the data in the anonymous information, as shown in, e.g., FIG. 16, so that a report including the PC work time per week, the ratio of doers who are doing that action, the average degree of concentration of all persons, and the average degree of concentrate of only males can be obtained.
[0111] The accessible user pays the compensation for information use to the charging management unit (step S 30 ). The authentication department that permits information use also serves as the charging management unit. Payback corresponding to the information providing amount may be done for each source of information. Alternatively, a banking agency that has a contract with the source of information may serve as the charging management unit such that a remittance can be made to the banking agency.
[0112] Assume that an access request to information such as the above-described image information is issued. Image information is anonymized in advance and recorded. If the level of the access right given to the accessible user is too low to access the personal information in the image information, only anonymous information stored in the structured accessible information storing unit 3 is provided. If the level of the access right given to the accessible user permits access to personal information in the image information, anonymous information is read out from the structured accessible information storing unit 3 . Simultaneously, a personal ID corresponding to the (temporary ID of) anonymous information is obtained from the table stored in the information associating unit 22 . Then, personal information corresponding to the personal ID is read out from the structured accessible information storing unit 3 . For example, the information anonymizing unit 7 synthesizes the readout personal information with the anonymous information to generate the original image information. The original image including the synthesized personal information is transmitted to the accessible user at the information request source through the transceiver unit 4 . In this way, the anonymizing unit 7 also executes processing for returning the processed portion in the anonymous information, i.e., the portion corresponding to the personal information to the original state.
[0113] In the above embodiment, the sensing unit 1 is independently arranged as a terminal apparatus. The sensing unit 1 transmits/receives data to/from the information anonymizing system incorporated in a home server or the like via wireless communication. The present invention is not limited to this arrangement. As the small device technology is developed, a large memory capacity can be ensured as in a current home server. A portable sensing unit 1 that is incorporated in the information anonymizing system, as shown in FIG. 17, may be available.
[0114] The same reference numerals as in FIG. 1 denote the same parts in FIG. 17. FIG. 17 is different from FIG. 1 only in that the sensing unit 1 is incorporated in the information anonymizing system.
[0115] The above embodiment assumes that medical facilities are accessible users, and individuals are sources of information. However, the present invention is not limited to this. For example, individuals may be accessible users, and the police and the like may be sources of information.
[0116] For example, a personal user who wants to know the current state of Roppongi requests images sensed by a camera installed on a street of Roppongi. The user issues an access request including a search request text {category: not designated, item 1: Roppongi, item 2: real time} The National Police Agency that controls cameras installed in Roppongi provides, e.g., anonymized image information (anonymous information) as shown in FIG. 18, i.e., information obtained by removing personal information (e.g., the image information of face portions) from a sensed image (by using the personal information extracting unit 24 ).
[0117] As described above, according to the above embodiment, first information including anonymous information (such as vital data including pulse and body temperature related to that person) and personal information (e.g., a personal ID) is acquired. The personal information is separated from the first information to obtain anonymous information (that is not added or associated with the personal information). Each of the anonymous information and personal information is assigned level that defines the level of the access right that limits accessible users. The anonymous information and personal information are separately stored in the structured accessible information storing unit 3 as independent information. Only a temporary ID makes the two pieces of information correspond to each other. The information item that represents the correspondence between the temporary ID and the personal ID that identifies the personal information is stored in the associating unit 22 .
[0118] When an access request to access the first information is received, and the level of the access right defined in advance for the user who has sent the access request allows access to the anonymous information of the first information, the anonymous information is provided to the user at the request source. When the level of the access right also allows access to the personal information, the anonymous information is provided to the user at the request source together with the personal information.
[0119] When second information including personal information is acquired, the personal information is separated from the second information to generate anonymous information (that doesn't include personal information). Each of the anonymous information and personal information is assigned the level of the access right that limits accessible users. The anonymous information and personal information are separately stored in the structured accessible information storing unit 3 as independent information. Only a temporary ID makes the two pieces of information correspond to each other. The information item that represents the correspondence between the temporary ID and the personal ID that identifies the personal information is stored in the associating unit 22 .
[0120] When an access request to access the second information is received, and the level of the access right defined in advance for the user who has sent the access request inhibits access to the personal information, the anonymous information of the second information corresponding to the access request is read out and provided. When the level of the access right allows access to the personal information, the original second information is generated from the personal information and anonymous information corresponding to the second information. The generated original second information is provided to the user at the request source.
[0121] In the above way, when information added with personal information or information including personal information is acquired, the personal information added to or included in the information is separated from the acquired information to generate anonymous information. The generated anonymous information and personal information are separately stored as individual information. The anonymous information and personal information are separated in advance and stored. For this reason, when the anonymous information (“information that need not be kept secret”) is provided to another user, it is impossible to search for the personal information (“information to be kept secret”) on the basis of the provided information. Hence, even information including vital data and personal information or information (e.g., image information) including personal information can be used by a third party without being accessed by him/her.
[0122] The information anonymizing system according to this embodiment facilitates use of information while protecting the privacy of individuals and can therefor greatly contribute to research and development in medical facilities and the like. Since an access right is defined in advance for “information to be kept secret” such as personal information, any user who has an access right of level that allows access to the information can refer to even the “information to be kept secret” such as personal information.
[0123] Hence, an information sharing environment can be realized in which while protecting important information such as personal information from being open to a third party without permission, anonymized information can be actively used such that data mining can easily and effectively be done.
[0124] (Second Embodiment)
[0125] The mechanism of an information use service using the information anonymizing system 100 described in the first embodiment will be described next as the second embodiment.
[0126] [0126]FIG. 19 is a view for explaining the mechanism of the information use service using the information anonymizing system 100 . Referring to FIG. 19, the information anonymizing system 100 according to the first embodiment acquires information such as information including vital data and personal information or image information including personal information through a sensing unit 1 attached to a user as a source of information. When “information to be kept secret” such as personal information is included in the acquired information, the “information to be kept secret” (e.g., personal information that can specify an individual) is separated from the acquired information, and the anonymous information and personal information are separately stored, as described in the first embodiment. Only a temporary ID that is valid in the information anonymizing system serves as a link key for the two pieces of information. (The two pieces of information the anonymous are information and personal information.)
[0127] On the other hand, an access request including a search request text transmitted from the terminal of an accessible user such as a doctor is received by a server apparatus 101 serving as a proxy agent. The server apparatus 101 transfers the access request to the information anonymizing system 100 . On the basis of obtained anonymous information, the server apparatus 101 creates a report suitable for the search request text as shown in, e.g., FIG. 15.
[0128] The server apparatus 101 pays, to the source of information, information fees corresponding to the information provided by the source of information. The server apparatus 101 collects, from the accessible user, information fees for use of the information.
[0129] According to the information providing service system shown in FIG. 19, anonymous information obtained by separating personal information in advance from information added with or including the personal information is provided. Hence, even information including “information to be kept secret” such as personal information provided from an individual can smoothly and effectively be used by a third party while reliably holding the “information to be kept secret” in confidence.
[0130] The method of the present invention described in the embodiments of the invention can be stored in a recording medium such as a magnetic disk (e.g., a floppy disk or hard disk), optical disk (e.g., a CD-ROM or DVD), or semiconductor memory and distributed as a program to be executed by a computer.
[0131] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | An information sharing apparatus comprises extracting unit extracting personal information item from acquired information item which includes personal information item, generating unit generating anonymous information item by deleting personal information item from acquired information item, storing unit storing personal information item and anonymous information item, storing unit storing first access level assigned to group of users who can access only anonymous information item, and to store second access level assigned to group of users who can access both of anonymous information item and personal information item, receiving unit receiving request message for accessing acquired information item, transmitting unit transmitting only anonymous information item when access level predetermined to user is equal to first access level, synthesizing unit synthesizing personal information item with anonymous information item, transmitting unit transmitting regenerated second information item, when access level of user is equal to second access level. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/673,657 filed Apr. 20, 2005 entitled “Fabric for the Production of High Bulk Tissue and Towel and Nonwovens”, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the papermaking arts. More specifically, the present invention relates to through-air-drying (TAD) fabrics used in the manufacture of bulk tissue and towel, and of nonwoven articles and fabrics on a paper machine.
2. Description of the Prior Art
Soft, absorbent disposable paper products, such as facial tissue, bath tissue and paper toweling, are a pervasive feature of contemporary life in modern industrialized societies. While there are numerous methods for manufacturing such products, in general terms, their manufacture begins with the formation of a cellulosic fibrous web in the forming section of a paper machine. The cellulosic fibrous web is formed by depositing a fibrous slurry, that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric.
The cellulosic fibrous web is then transferred to a through-air-drying (TAD) fabric or belt by means of an air flow, brought about by vacuum or suction, which deflects the web and forces it to conform, at least in part, to the topography of the TAD fabric or belt. Downstream from the transfer point, the web, carried on the TAD fabric or belt, passes through a through-air dryer, where a flow of heated air, directed against the web and through the TAD fabric or belt, dries the web to a desired degree. Finally, downstream from the through-air dryer, the web may be adhered to the surface of a Yankee dryer and imprinted thereon by the surface of the TAD fabric or belt, for further and complete drying. The fully dried web is then removed from the surface of the Yankee dryer with a doctor blade, which foreshortens or crepes the web and increases its bulk. The foreshortened web is then wound onto rolls for subsequent processing, including packaging into a form suitable for shipment to and purchase by consumers.
As noted above, there are many methods for manufacturing bulk tissue products, and the foregoing description should be understood to be an outline of the general steps shared by some of the methods. For example, the use of a Yankee dryer is not always required, as, in a given situation, foreshortening may not be desired, or other means, such as “wet creping”, may have already been taken to foreshorten the web.
It should be appreciated that TAD fabrics may take the form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous process which proceeds at considerable speeds. That is to say, the fibrous slurry is continuously deposited onto the forming fabric in the forming section, while a newly manufactured paper sheet is continuously wound onto rolls after it is dried.
Those skilled in the art will appreciate that fabrics are created by weaving, and have a weave pattern which repeats for flat weaving in both the warp or machine direction (MD) and the weft or cross-machine direction (CD). Woven fabrics take many different forms. For example, they may be woven endless, or flat woven and subsequently rendered into endless form with a seam. It will also be appreciated that the resulting fabric must be uniform in appearance; that is, there are no abrupt changes in the weave pattern that result in undesirable characteristics in the formed paper sheet. Due to the repeating nature of the weave patterns, a common fabric deficiency is a characteristic diagonal pattern in the fabric. In addition, any pattern marking, desired or not, imparted to the formed tissue will impact the characteristics of the paper.
Contemporary papermaking fabrics are produced in a wide variety of styles designed to meet the requirements of the paper machines on which they are installed for the paper grades being manufactured. Generally, they comprise a base fabric woven from monofilament and may be single-layered or multi-layered. The yarns are typically extruded from any one of several synthetic polymeric resins, such as polyamide and polyester resins, used for this purpose by those of ordinary skill in the paper machine clothing arts.
The present application is concerned, at least in part, with the TAD fabrics or belts used on the through-air dryer of a bulk tissue machine. More specifically, the present application is concerned with a TAD fabric of the variety disclosed in U.S. Pat. No. 6,763,855 to Rougvie (which is incorporated herein by reference). Rougvie discloses a TAD fabric comprising a woven base fabric having a coating of a polymeric resin material. Although the present fabric does not have a resin coating, many of the teachings of Rougvie relating to TAD fabrics are relevant.
Fabrics of this kind may also be used in the forming section of a bulk tissue machine to form cellulosic fibrous webs having discrete regions of relatively low basis weight in a continuous background of relatively high basis weight. Belts of this kind may also be used to manufacture other nonwoven articles and fabrics by processes such as hydroentangling, which have discrete regions in which the density of fibers is less than that in adjacent regions.
The properties of absorbency, strength, softness, and aesthetic appearance are important for many products when used for their intended purpose, particularly when the fibrous cellulosic products are facial or toilet tissue, paper towels, sanitary napkins or diapers.
Bulk, cross directional tensile, absorbency, and softness are particularly important characteristics when producing sheets of tissue, napkin, and towel paper. To produce a paper product having these characteristics, a fabric will often be constructed so that the top surface exhibits topographical variations. These topographical variations are often measured as plane differences between strands in the surface of the fabric. For example, a plane difference is typically measured as the difference in height between a raised weft or warp yarn strand or as the difference in height between MD knuckles and CD knuckles in the plane of the fabric's surface. Often, the fabric surface will exhibit pockets in which case plane differences may be measured as a pocket depth.
The present invention provides a TAD fabric which exhibits favorable characteristics for the formation of tissue paper and related products.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a TAD fabric, although it may find application in the forming, pressing and drying sections of a paper machine. As such, it is a papermaker's fabric which comprises a plurality of warp yarns interwoven with a plurality of weft yarns.
The present invention is preferably a TAD fabric comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce a paper-side surface pattern characterized by alternating first pockets and second pockets. The first and second pockets are bounded by raised warp yarns and raised weft yarns produced by knuckles in the fabric pattern. The first pockets are preferably larger in area than the second pockets. The fabric base in the interior of the first pocket is preferably a plain weave pattern. The interior of the second pocket may also be bisected by a raised weft yarn.
The present invention will now be described in more complete detail with frequent reference being made to the drawing figures, which are identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:
FIG. 1 shows a paper side view and a machine side view illustrating the paper side and machine side surface weave patterns for a preferred embodiment of the present invention;
FIG. 2 is a surface depth view highlighting the relative pocket sizes on the paper side surface of the fabric shown in FIG. 1 ;
FIG. 3 is a surface depth view highlighting the raised wefts and warps in the paper side surface of the fabric shown in FIG. 1 ;
FIG. 4 is a schematic plan view of the paper side surface weave pattern for the fabric shown in FIG. 1 ;
FIG. 5 shows the warp yarn contour patterns for the fabric pattern shown in FIG. 4 ;
FIG. 6 shows the weft yarn contour patterns for the fabric pattern shown in FIG. 4 ;
FIG. 7 shows cross-sectional views in the CD illustrating different weft yarn contour patterns for the fabric shown in FIG. 1 ; and
FIG. 8 shows cross-sectional views in the MD illustrating different warp yarn contour patterns for the fabric shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is preferably a TAD fabric having at least two different sized pockets which alternate on the paper-side surface. The pocket sizes are a function of the weave pattern, mesh count, and yarns used in the pattern. Pocket sizes can be characterized by an MD/CD dimension and/or by a pocket depth. The pockets are formed/bounded by weft yarns and warp yarns which are raised from the base plane of the fabric surface. The raised weft yarns and warp yarns are produced by long knuckles in the weave pattern. The fabric base weave inside each pocket can be a plain weave pattern or any other suitable pattern. In addition, a pocket may include one or more raised or semi-raised warp yarns or weft yarns inside the pocket perimeter. For example, one size pocket may have a raised weft yarn bisecting the pocket area.
Fabrics according to the present invention may have mesh/end counts in the range of 12-20 yarns/cm in the MD and 10-18 yarns/cm in the CD. The pocket depth of the present fabrics may range between 300 and 500 μms.
Advantages of the present fabric are a relatively high percentage of open area resulting in a high air permeability as compared to other TAD fabrics. The present fabric produces a distinct and visible pattern in the tissue paper while limiting manufacturing stresses to maintain tensile strength and prevent ruptures. As a result, the present fabric may reduce or not cause pinholes in the tissue paper, as seen with other highly structured TAD fabrics.
A preferred embodiment of the present fabric may be produced with a 10-shed pattern comprising 3 different warp yarn contours and 3 different weft yarns contours. This pattern forms two sizes of pockets (or depressions) on the fabric surface. The smaller pocket encompasses an area which is between 45% and 65% of the area encompassed by the larger pocket. Both the large and small pockets are surrounded by higher out of plane long knuckles created by warp yarns and weft yarns. The interior of the large pocket has a plain weave surface pattern. The interior of the small pocket is bisected by a raised weft yarn across its center. This raised weft yarn may or may not be in-plane with the high long knuckles forming the pocket. Other embodiments alternatively may have a raised warp yarn bisecting the pocket.
FIG. 1 shows a paper side view and a machine side view illustrating the paper side and machine side surface weave patterns for the preferred embodiment of the present invention. In this preferred embodiment all MD yarns are 0.35 mm in diameter and all CD yarns are 0.40 mm in diameter. The mesh count is 18.9 yarns/cm in the MD and 13.0 yarns/cm in the CD. The pocket depth for this fabric is approximately 430-440 μms. This pattern also has shute runners on the machine side of the present fabric for abrasion resistance.
FIG. 2 is a surface depth view of the preferred embodiment taken with a MarSurf TS 50 high-precision optical 3D measuring instrument manufactured by Mahr GmbH Gottingen, Gottingen, Germany, and the relative pocket sizes on the paper side surface are highlighted. FIG. 2 provides a close-up view of the paper side surface shown in FIG. 1 . The fabric shown in FIG. 2 has two different sized pockets: a small pocket 200 and a large pocket 210 , 220 . The small pocket 200 has an area of approximately 4.03 mm 2 . The large pocket has a minimum area measurement of 7.84 mm 2 (as shown by highlighted pocket 210 ) and a median area measurement of 10.52 mm 2 (as shown by highlighted pocket 220 ).
FIG. 3 is a surface depth view of the preferred embodiment also taken with a MarSurf TS 50 high-precision optical 3D measuring instrument manufactured by Mahr GmbH Gottingen, Gottingen, Germany, showing the raised wefts and warps on the paper side surface. The pockets are formed/bounded by raised weft yarns 330 and raised warp yarns 310 . Note the interiors of the large pockets have a plain weave pattern, while the interiors of the small pockets have a raised weft yarn 320 which bisects the pocket. This raised weft yarn 320 may or may not be in the same plane as the raised weft yarns and warp yarns which bound the pockets.
FIG. 4 is a schematic plan view of the paper side surface weave pattern for the fabric shown in FIG. 1 . In FIG. 4 , the MD runs vertically and the CD runs horizontally. Each column corresponds to a warp yarn and each row corresponds to a weft yarn. The numbered boxes indicate knuckles where that numbered warp yarn is on the top (paper) surface of the fabric. Accordingly, the empty boxes indicate locations where a warp yarn passes under a weft yarn.
FIG. 5 shows the warp yarn contour patterns for the fabric pattern shown in FIG. 4 . The numbers to the right of each warp yarn contour pattern indicate the number of the warp yarn followed by the contour pattern number for that warp yarn. For example, warp yarns 1 , 4 , 6 , and 9 each weave a staggered/shifted version of contour pattern number 1. Note, the present fabric pattern incorporates 3 different warp yarn contours in a 1, 2, 2, 1, 3 sequence which repeats twice in one pattern repeat. Each warp yarn corresponds to a column in FIG. 4 . For example, warp yarn 1 corresponds to the pattern shown in the first column in FIG. 4 . As shown by the contour pattern for warp yarn 1 , the warp yarn passes under weft yarns 1 - 3 , over weft yarn 4 , under weft yarn 5 , over weft yarns 6 and 7 , under weft yarn 8 , over weft yarn 9 , and under weft yarn 10 . Accordingly, in column 1 of FIG. 4 , the boxes corresponding to weft yarns 4 , 6 , 7 , and 9 indicate that warp yarn 1 forms knuckles where it passes over the weft yarns in the contour pattern. Alternatively, the boxes in FIG. 4 are blank where the warp yarn passes under the weft yarn.
FIG. 6 shows the weft yarn contour patterns for the fabric pattern shown in FIG. 4 . As in FIG. 5 , the numbers to the right of each weft yarn contour pattern indicate the number of the weft yarn followed by the contour pattern number for that weft yarn. For example, weft yarns 1 , 4 , 6 , and 9 each weave a staggered/shifted version of contour pattern number 1. Note, the present fabric pattern incorporates 3 different weft yarn contours in a 1, 2, 2, 1, 3 sequence which repeats twice in one pattern repeat. Each weft yarn corresponds to a row in FIG. 4 . For example, weft yarn 1 corresponds to the pattern shown in the first row in FIG. 4 . As shown by the contour pattern for weft yarn 1 , the weft yarn passes over warp yarn 1 , under warp yarn 2 , over warp yarn 3 , under warp yarn 4 , over warp yarn 5 , and under warp yarns 6 - 10 . Accordingly, in row 1 of FIG. 4 , the boxes corresponding to warp yarns 2 , 4 , and 6 - 10 indicate those warp yarns form knuckles where they pass over weft yarn 1 in the contour pattern. As above, the boxes in FIG. 4 are blank where the warp yarn passes under the weft yarn.
FIG. 7 shows cross-sectional views in the CD illustrating two of the three different weft yarn contour patterns for the fabric shown in FIG. 1 . FIG. 8 shows cross-sectional views in the MD illustrating two of the three different warp yarn contour patterns for the fabric shown in FIG. 1 .
The present invention is intended to cover other fabric patterns having different sizes and shapes of pockets, different pocket depths, and different yarn contours. Accordingly, the present invention should not be construed as being limited to the preferred embodiment disclosed above.
The fabric according to the present invention preferably comprises only monofilament yarns, preferably of polyester, polyamide, or other polymers. Any combination of polymers for any of the yarns can be used as identified by one of ordinary skill in the art. The CD and MD yarns may have a circular cross-sectional shape with one or more different diameters. For example, the raised weft yarns and warp yarns may be a different diameter than the weft yarns and warp yarns forming the base fabric (i.e. the pocket interiors). The weft yarn and warp yarn diameters may range from 0.20 mm to 0.55 mm, and are preferably between 0.35 mm and 0.45 mm. However, any combination of diameters can be used and these exemplary diameters should not be construed as limiting the invention in any way. Further, in addition to a circular cross-sectional shape, one or more of the yarns may have other cross-sectional shapes such as a rectangular cross-sectional shape or a non-round cross-sectional shape.
Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the present invention. The claims to follow should be construed to cover such situations. | A through-air-drying (TAD) fabric for producing tissue paper and related products on a papermaking machine comprising a plurality of warp yarns interwoven with a plurality of weft yarns to produce a paper-side surface pattern characterized by alternating first pockets and second pockets. The first and second pockets are bounded by raised warp yarns and raised weft yarns produced by knuckles in the fabric pattern. The first pockets are preferably larger in area than the second pockets. The fabric base weave in the interior of the first pocket is preferably a plain weave pattern. The interior of the second pocket may also be bisected by a raised weft yarn. | 3 |
CROSS REFERENCES TO RELATED APPLICATIONS
The Present application is a divisional application of U.S. patent application Ser. No. 11/846,402, filed on Aug. 28, 2007, which claims priority to U.S. Provisional Patent Application No. 60/824,118, filed Aug. 31, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a golf ball. More specifically, the present invention relates to a golf ball having a metallic ink printing thereon.
2. Description of the Related Art
Large particle size metallic inks have processing issues, and the luster and sheen of the inks is unappealing.
Heretofore, for the purpose of obtaining written marks with metallic luster such as gold and silver, aqueous ink using glittering pigments have been proposed. For example, Japanese Unexamined Patent Publication Hei 7-118592 proposes an aqueous ink using an aluminum powder pigment. Japanese Unexamined Patent Publication Hei 8-151547 proposes an ink using a pearlescent pigment. Japanese Unexamined Patent Publication Hei 11-29734 proposes an aqueous metallic ink prepared by coloring an aluminum powder with an organic pigment fixed.
Aluminum pigments are used widely in coatings as special-effect pigments. The term special-effect pigments is used to denote pigments which have a directed reflection at oriented, metallic or highly light-refractive particles of a predominantly flat configuration (German Standard DIN 5594). They are always of a plate-like or flake-like configuration and have very large particle diameters compared with dye pigments. Their optical properties are determined by reflection and interference. Depending on transparency, absorption, thickness, single-layer or multi-layer structure, the special-effect pigments exhibit a metallic shine, a pearl shine, interference or interference reflection. The main area of use is in cosmetics and the automobile sector, and in addition in coloring plastic materials, paints, leather coatings, the printing industry and the ceramic industry. (For a comprehensive representation of the technical background, see W. Ostertag, Nachr. Chem. Tech. Lab. 1994, 9, 849).
The aluminum pigments which are most frequently used are aluminum flakes or pigments based on flake-like Cu/Zn-alloys and coated mica flakes, wherein aluminum pigments exhibit a typical metal shine whereas coated mica flakes exhibit a typical pearl shine.
In recent years the need for colored special-effect pigments has increased greatly. Therefore for example oxide-covered copper and brass flakes, substrates which are coated with transition metal oxides such as muscovite, phlogopite or glass, guanine single-crystals (fish silver), BiOCl-single crystals, flake-form haematite single-crystals, flake-form phthalocyanines, micronized titanium dioxide, polished aluminum shot, iron oxide or crushed thin multi-layer films with a Fabry-Perot-structure were used as special-effect pigments.
In comparison, by coloring aluminum pigments, it is possible to produce colored pigments with improved covering capability, compared with pearl shine pigments, and good coloristic options. In that respect, the coloring action is produced either by fixing color pigments by means of polymers, by coating with oxides of different metals using a very wide range of different processes, by coating with a color pigment-bearing oxide layer or by oxidation.
In accordance with U.S. Pat. No. 4,328,042 and EP-A-0 033 457 aluminum flakes are colored by the deposition of iron oxide from iron pentacarbonyl, using a technically very expensive fluidized bed process. That procedure gives rise to gold-colored aluminum pigments.
In accordance with U.S. Pat. No. 5,037,475 color pigments are fixed on the metal surface by carboxyl group-bearing polymers. The pigments obtained however have only a low level of color intensity.
Aluminum pigments are colored in accordance with WO 91/04293 (PCT/US90/05236) by the fixing of polymer-coated color pigments on the metal surface by means of electrostatic forces.
In accordance with EP-A-0 238 906 metal pigments are covered with a titanium dioxide layer by the controlled hydrolysis of an organic titanate ester compound. Various color shades can be achieved by varying the thickness of the oxide layer. For that purpose it is necessary to observe accurately controlled reaction conditions such as pH-value and the rate of adding material by dropping. In order to achieve color effects, it is also necessary to perform a calcination operation which however can only be carried out with difficulty, because of the low melting point of aluminum.
U.S. Pat. No. 4,978,394 describes the production of titanium dioxide-coated aluminum pigments by chemical vapor deposition (CVD) which is technically highly expensive.
U.S. Pat. No. 4,158,074 discloses the production of colored aluminum pigments by coating with a film of hydrated metal oxide. The film is produced by the treatment of fine aluminum flakes or plate portions in an alkaline solution of an iron, nickel, cobalt, zinc or copper salt at elevated temperature by electrochemical reaction of the metal salts.
U.S. Pat. No. 5,261,955 discloses a sol-gel process for the production of colored metal pigments, wherein the metal flakes are dispersed in a sol of an inorganic salt, dispersed after filtration in a solution of an inorganic compound, for example cobalt nitrate, in an organic solvent and finally a sol-gel layer is formed on the flakes by heating.
In accordance with DE 1 95 01 307.7 (Eckart-Werke) aluminum pigments can be colored in a very wide range of different color shades such as for example blue, red, violet and gold, in accordance with a process which is simple from the point of view of the apparatus used, by the controlled hydrolysis of metal acid esters in the presence of color pigments in an organic solvent.
JP-A-61-130375 discloses a gold-colored aluminum pigment, produced by the treatment of aluminum powder with dichromate, sodium fluoride and surface-active agents in acid solution, drying and treatment with a fatty acid derivative. Color shades other than gold cannot be achieved with that process. In addition the toxicity of the chemicals used and their high price represent a major disadvantage of the process.
U.S. Pat. No. 3,067,052 describes colored aluminum pigments which are produced by the oxidation of aluminum powder with KMnO 4 -solution, possibly with the addition of a reducing agent. The color shade of these pigments is golden, possibly also with a greenish or reddish shade, depending on the respective reducing agent used. In this case also the toxicity of the oxidizing agent has a detrimental effect.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a vacuum-metallized pigmented ink printed on a golf ball as an indicia. The golf ball may have an additional indicia composed of a non-metallized ink.
One aspect of the present invention is a golf ball including a core and a cover formed over the core. The cover has an aerodynamic surface. A first coating layer covers the aerodynamic surface of the cover. An indicia is printed on the first coating layer. The indicia is composed of a vacuum metallized pigmented ink having a particle size ranging from 10 microns to 12 microns. The vacuum metallized pigmented aluminum based ink comprises a plurality of aluminum flakes all oriented in one direction. A second coating layer is disposed over the indicia and the first coating layer.
Another aspect of the present invention is a golf ball including a core, a cover, a first coating layer, a second coating layer, a first indicia and a second indicia. The cover is formed over the core and has an aerodynamic surface. The first coating layer covers the aerodynamic surface of the cover. The first indicia is printed on the first coating layer. The first indicia is composed of a vacuum metallized pigmented ink having a particle size ranging from 10 microns to 12 microns. The second indicia is printed on the first coating layer in proximity to the first indicia. The second indicia is composed of a non-metallic ink. A second coating layer is disposed over the indicia and the first coating layer.
Yet another aspect of the present invention includes an intermediate layer composed of an ionomer material, an HPF material, a polyurethane material, windings, polybutadiene or a mixture thereof.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a golf ball.
FIG. 2 is a cross-sectional view of the coating layers and indicia for a golf ball of the present invention.
FIG. 3 is a cross-sectional view of the coating layers and indicia for a golf ball of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a golf ball 20 has a core 12 , an intermediate layer 16 and a cover 14 . The golf ball 20 may also be a two piece golf ball with only a core 12 and cover 14 . The cover 14 has an aerodynamic pattern 18 and is preferably composed of an ionomer material or a polyurethane material. The core 12 is preferably composed of a polybutadiene material. As shown in FIG. 2 , a first coating layer 26 is placed on the surface of the cover 14 . The first coating layer 26 is preferably a paint layer. A first indicia 30 is printed on a surface of the first coating layer 26 . A second coating layer 28 is coated over the first coating layer 26 and first indicia 30 . The second coating layer 28 is preferably a clear coat layer. An alternative embodiment is illustrated in FIG. 3 wherein a second indicia 32 is printed in proximity to the first indicia 30 . The first indicia 30 is composed of a novel metallic ink of the present invention. The second indicia is preferably composed of a non-metallic ink.
The following U.S. patents are owned by Callaway Golf Company, the assignee of the present application, and are hereby incorporated by reference in their entirety: U.S. Pat. Nos. 5,885,173; 6,179,730; 5,459,220; 5,409,233; 6,191,185; 6,638,185; 5,971,870; 6,419,594; 6,958,020; and 6,855,073.
One embodiment of the ink composition may comprise approximately 5 to 30% by weight of a metallic dispersion component comprising a dispersion solvent and metallic particles, wherein the metallic particles comprise approximately 5% to 15% by weight of the metallic dispersion component; and approximately 70 to 95% by weight of a solvent based ink component comprising an ink solvent, said dispersion solvent and said ink solvent being compatible with each other; wherein the ink composition provides a metallic appearance when evaporatively cured onto a surface of the golf ball.
Generally, in commercial ink printing operations, the lowest operational costs, the greatest operational efficiencies and the highest ink printing speeds, are obtained by operations that utilize an ultraviolet (“UV”) curing process to cure or dry ink compositions onto substrates. For example, in a typical in-line commercial printing operation utilizing UV curing, a particular substrate is printed with a “UV based” ink, and transported or conveyed in-line to a UV curing unit where the ink is cured onto the substrate nearly instantaneously by UV radiation. Conventional UV curing units are typically one foot in length and the substrates travel through the unit at a speed of about one foot per second or greater. Thus, the processing speed of an W curing unit consuming approximately one foot of in-line processing space is on the order of one unit per second (60 units per minute) or greater. In comparison, in a typical in-line commercial printing operation utilizing an evaporative curing process, the substrate is printed with a solvent based ink and transported or conveyed in-line through a hot air drying oven. The curing time for a solvent based ink depends primarily on the temperature of the drying oven and the evaporation rate of the particular solvent; however, the curing time is generally significantly slower than that required for UV curing. This in turn requires the processing space or length of the drying oven to be longer than the one foot length of a typical UV curing unit. Thus, to achieve processing speeds competitive with those utilizing UV curing, the hot air drying ovens or units for evaporative curing typically consume ten feet or more of in-line processing space. Thus, commercial printing operations utilizing evaporative curing requires substantially more in-line processing space than operations utilizing UV curing, thereby resulting in significantly lower space utilization efficiencies.
Further, commercial printing operations utilizing evaporative curing are subject to increasing governmental regulations regarding the amount, containment and disposal of solvents and solvent emissions used in the printing process. Commercial printing operations utilizing UV curing and “UV based” inks, are typically subject to significantly fewer, if any, government regulations.
Thus, for the above reasons, among possible others, UV curing of ink compositions onto substrates has become the preferred curing process for most commercial printing operations. Indeed, in the commercial screen printing industry, and various other printing industries as well, operations utilizing evaporative curing have become somewhat of a historical relic. Thus, in any new printing application, the primary focus is on UV curing, with little if any attention being given to processes utilizing evaporative curing.
In formulating a metallic ink composition and a method for applying a desired metallic appearance to a plastic substrate, it was first discovered that metallic ink compositions behaved quite differently when applied to plastic substrates as when applied to paper or paperboard substrates. Specifically, it was unexpectedly discovered that, the desired metallic appearance utilizing certain metallic ink compositions could not be readily obtained with printing operations utilizing UV curing, but could be obtained with printing operations utilizing evaporative curing. More specifically, it was discovered that to obtain the desired metallic appearance, (1) a minimum period of time was required during the curing process for the metallic particles within the metallic ink compositions described herein to “cure down” or settle into a generally horizontal position relative to the plastic substrate, and into a substantially parallel position relative to one another, and (2) a solvent based ink, as opposed to a “UV based” ink, was required for the metallic ink composition to properly adhere to the plastic substrate. In other words, it was unexpectedly discovered that if the curing process cures the metallic ink composition onto the plastic substrate too quickly, such as in a UV curing process, the metallic particles “cure up” or settle in a random manner and the desired metallic appearance is not obtained. Thus, one aspect of the present invention is the discovery and recognition that the generally accepted and commonly used UV curing process generally will not work in applying a metallic ink composition onto a plastic substrates in accordance with the present invention, with any hope of achieving the desired metallic appearance. In contrast, it has been discovered that the relatively slower curing processes, such as evaporative curing, will achieve not only a metallic appearance, but an unexpectedly shiny and reflective metallic appearance similar to that obtained by hot foil stamping.
The solvent based ink component of the process and the metallic ink composition may be generally characterized as follows. The resin of the solvent based ink component should be compatible with the plastic substrate and should also provide adhesion for the metallic printing ink to the plastic substrate. Additionally, the solvent of the solvent based ink component should be compatible with the solvent of the metallic dispersion component, which should also be compatible with the plastic substrate. Optionally, the solvent based ink component may be comprised of one or more pigments of various colors that act to provide a colored hue to the metallic appearance ultimately obtained. As used herein, the term “compatible” or “compatible with” is synonymous with solubility or miscibility. In other words, a component which is compatible with a second component means that such component is miscible with or is capable of dissolving in such second component. Components that are compatible may be mixed without reacting chemically or interfering with each components characteristics. Various solvent based ink components will be acceptable for use in the present invention provided they meet the above qualifications. Preferred solvent based ink compositions include the solvent based ink of Coates Screen, Inc. sold under the trademark MONOCAT, the solvent based inks sold by Nazdar Corporation as the 9600 or the 9700 Series, the solvent based inks sold by Coates Screen, Inc. under the trademarks HG 480 Series and FLEXIFORM Series C37 and the solvent based ink sold by Summit Screen Ink under the trademark ZEPHYR-JET. More detailed compositions for some of these inks are set forth in the examples below.
The metallic dispersion component of the process and ink composition may be generally characterized as follows. The metallic dispersion component should be comprised of a solvent compatible with the solvent of the ink and the plastic substrate to which it is to be applied. Further, the dispersion component should be comprised of a percentage by of metallic particles weight of metallic particles sufficient to achieve the desired metallic appearance. Generally, a metallic dispersion component comprised of between about 5% to 15% by weight is preferred, with a metallic dispersion comprised of approximately 10% by weight of metallic particles being most preferred. The metallic particles can be comprised of a variety of metals such as copper, silver and aluminum; however aluminum is the metal preferred.
The metallic particles should preferably have a particle size distribution, defined as the percentage of particles within a range of particle lengths, such that the desired metallic appearance may be ultimately obtained. It has been found that a metallic dispersion component having a particle size distribution of approximately 15% aluminum particles having a length of 3.600 microns to 4.900 microns, approximately 18% aluminum particles having a length of 4.908 microns to 7.950 microns, approximately 15% aluminum particles having a length of 7.957 microns to 10.630 microns, approximately 14% aluminum particles having a length of 10.633 microns to 14.208 microns, approximately 19% aluminum particles having a length of 14.209 microns to 18.980 microns, approximately 13% aluminum particles having a length of 18.986 microns to 27.940 microns, approximately 2% aluminum particles having a length of 27.945 microns to 37.340 microns, and approximately 3% aluminum particles having a length of 37.342 microns to 45.300 microns, is preferred. Similarly, the metallic particles should have an aspect ratio, defined as the ratio of the length of the metallic particles to the width of the metallic particles, such that the desired metallic appearance may be ultimately obtained. It has been found that a metallic dispersion component having an aspect ratio with a minimum of approximately 1.0, a maximum of approximately 5.2 with a mean aspect ration of approximately 1.507 is preferred.
Metallic dispersion components manufactured by various sources will be acceptable provided they have a compatible solvent and a metallic particle concentration and size distribution which results in the desired metallic appearance when printed.
The metallic printing ink is made by mixing the solvent based ink component and the metallic dispersion component and may be generally characterized as follows. The percentage by weight of the metallic dispersion component to the solvent based carrier component should be such that the desired metallic appearance is ultimately obtained. It has been found that a metallic printing ink comprised preferably of approximately 5 to 30% by weight, and more preferably 10 to 25% by weight, of the metallic dispersion component is needed to obtain the desired metallic appearance. Generally, metallic printing inks comprised of more than 30% by weight of the metallic dispersion component results in the appearance of the printed substrate being dark and “muddy” and does not provide the desired metallic appearance. Metallic printing inks comprised of less than approximately 5% by weight of the metallic dispersion component results in the appearance being relatively non-metallic and also does not provide the desired metallic appearance.
It has also been found that if it is desired that the metallic appearance be a purely metallic or silverish appearance, a metallic printing ink comprising approximately 23% by weight of the metallic dispersion component is preferred. If, however, a metallic appearance with a colored hue is desired (e.g., a reddish metallic appearance), a metallic printing ink comprising approximately 12% by weight of the metallic dispersion component is preferred.
The viscosity of the metallic printing ink is dictated primarily by the process by which the ink is printed. For the preferred commercial screen printing process, the viscosity of the metallic printing ink should preferably be above about 300 centipoise, less than about 2000 centipoise and most preferably about 1000 centipoise. While the desired metallic appearance may be achieved with metallic printing inks with viscosities around 300 centipoise, in some cases, bubbling of the metallic printing ink on the plastic substrate tends to occur at these viscosity levels.
For the reasons explained below, the combined solvents of the metallic dispersion component and the solvent based carrier component should have a boiling point such that substantially all of the solvent is evaporated when exposed to oven temperatures from about 150 to 300° F. for about 10 to 15 seconds.
A preferred pigment is SDF-6 series metal pigments available from Eckart America of Painsville, Ohio. Another preferred material is Eckart Aluminum Metalure, L055350. The metalure is mixed with blue UV ink in an amount of 15 parts of the blue UV ink to 3 parts of the metalure.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims. | A golf ball having an indicia composed of a novel metallic ink is disclosed herein. The first indicia is preferably composed of a vacuum metallized pigmented ink having a particle size ranging from 10 microns to 12 microns. The ink is preferably an aluminum based ink. The golf ball is preferably a two-piece solid golf ball or a three-piece solid golf ball. The novel ink preferably has a viscosity above about 300 centipoise. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of international application PCT/EP2004/002494, filed 11 Mar., 2004, and which designates the U.S. The disclosure of the referenced application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a process and apparatus for spinning and laying a synthetic yarn sheet for the production of non-woven fabrics or mats.
[0003] In the production of non-woven fabrics or mats, freshly spun endless filaments are laid on a perforated belt or a perforated drum, which works together with a suction device in order to obtain uniform laying of the filaments and thus a uniform non-woven formation, and to effect a cooling of the melt-spun filaments. The non-wovens produced through the laying of filaments are as a rule made flat and through the application of one side on the perforated support the surface quality is made different on the lower side from the upper side.
[0004] In order to improve the forming of non-wovens, DE 42 04 366 A1 discloses a prior device and process in which the yarn sheet after the spinning and before the laying on the perforated support, is first fed through a collecting gap formed between two feed rollers. Therein the feed rollers are used essentially to spread the yarn sheet. The formation of the non-woven is done on the perforated support. With this, the distribution of the individual filaments within the non-woven can be influenced. The forming of the non-woven is however still influenced. The forming of the non-woven is however still determined by the single side application on the perforated support as before. Thus as a rule, one side of the non-woven is always smooth and the opposite side has a more or less structured form of a wave.
[0005] It is accordingly an objective of the invention to provide an apparatus and a process of the type stated initially with which a homogeneous, uniformly formed non-woven fabric or mat can be produced.
[0006] An additional objective of the invention lies in providing an apparatus and a process with which a non-woven having as high a volume as possible can be produced.
SUMMARY OF THE INVENTION
[0007] The invention deviates from the known practice in which the production of the non-woven is conducted essentially by laying a sheet of filaments on the horizontally aligned perforated support. In contrast, the present invention uses the collection of the yarn sheet right after the drawing off from a spinning device to form a non-woven oriented laid material. For this, the yarn sheet is fed through a collecting gap which is formed by two feed belts disposed opposite one another.
[0008] The feed belts can be driven at a surface speed where the feed rate of the feed belts is less than the draw-off rate of the yarn sheet. Thus, for example, the laying of the yarn sheet in the collecting gap can be influenced by the feed rate of the feed belts in such a manner that, for example, higher laying densities can be produced.
[0009] The invention distinguishes itself in particular by the fact that the non-woven can be formed with two sides. Furthermore, the invention has the advantage that a spatial laying structure of the filaments in the non-woven is produced, said laying structure being suited in particular to the production of voluminous non-wovens. In this case the thickness of the non-woven can be determined in a simple manner by the width of the collecting gap.
[0010] In order to obtain an oriented laying already in the collection of the yarn sheet, in a particularly advantageous extension of the invention, the feed rollers are made with a feed jacket permeable to air and with a suction device disposed in the interior of the feed jacket. In this case the suction device suctions a segmental circumferential section of the feed jacket in the area of the entrance to the collecting gap. In this way there is a uniform distribution of the filaments on the application surfaces of the feed rollers. In this case the feed rollers and the feed belts are preferably driven at the same feed rate and form a common collecting gap.
[0011] Through the invention's advantageous embodiment in which the suction device is formed in such a manner that it can be displaced in the circumferential direction of the feed rollers, the start of the forming of the non-woven can be offset to a desired area.
[0012] Along with this a sufficient and intensive suction flow is achieved by the feed jacket of the feed rollers comprising an open surface of >75%, preferably >90%.
[0013] Advantageously the orientation of the yarn sheet as well as the forming of the non-woven to be formed can be influenced in such a manner that the suctioning of the application surfaces is done at different intensities at the entrance of the collecting gap. For this, the suction devices are formed so that they can be controlled independently of one another.
[0014] An additional possibility for influencing the laying of the yarn sheet by the suction flow is provided by the feed jacket of the invention, which comprises, in its interior below an exterior application surface, partition walls which are each aligned in the radial direction. Such partition walls influence the course of the flow of the suctioned air flow and thus the collecting and laying of the yarn sheet.
[0015] Through the possibility of changing both feed rollers in their horizontal distance from one another, a desired thickness or a desired volume of the non-woven can be set.
[0016] By changing the positions of the feed rollers in the running direction of the yarn sheet, the spinning length can in addition be set to a desired optimum.
[0017] Basically the feed rollers and the feed belts can be formed and driven by separate means. In practice however a particularly advantageous embodiment of the invention has proven itself, in which the feed belts are formed so that they are permeable to gas and, as endless belts, each encircle one of the feed rollers and a deflecting roller which works together with the feed roller in question. In this way, one ensures continuous collecting of the filaments, laying of the filaments on a perforated support, and transporting of the resulting fabric or mat on a perforated support. In particular, it is possible to realize good and stable forming of the non-woven of both sides until the perforated support is reached.
[0018] The forming can also be advantageously supported by the feed belts being disposed relative to one another in such a manner that the collecting gap has a greater width at its entrance than at its exit. Thus, the thickness of the non-woven is determined by the width of the collecting gap at its exit.
[0019] For a reliable transfer of the non-woven from the feed belts to the perforated support, the embodiment of the invention is particularly preferred in which the perforated support includes a suction device in the area of the exit of the feed belts so that a transfer zone of the perforated support can be suctioned.
[0020] The perforated support is preferably formed by a running collecting belt which is responsible for the transport of the non-woven for further treatment and further processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Additional advantages of the process according to the invention and the apparatus according to the invention are described in more detail in the following, with the aid of several embodiments as shown in the accompanying figures, in which:
[0022] FIG. 1 is a schematic view of a first embodiment of the device according to the invention,
[0023] FIG. 2 is a schematic cross-sectional view of the embodiment of FIG. 1 , without showing a spinning device and draw-off device,
[0024] FIG. 3 is a schematic cross-sectional view of an additional embodiment of the device according to the invention without showing a spinning device and draw-off device, and
[0025] FIG. 4 is a schematic cross-sectional view of an additional embodiment of the device according to the invention, without showing a spinning device and draw-off device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] In FIG. 1 and FIG. 2 a first embodiment of the apparatus according to the invention for carrying out the process according to the invention is represented schematically. FIG. 1 shows a schematic view of the complete device. In FIG. 2 a cross-sectional view is shown schematically, where representation of the spinning device and the draw-off device is omitted. In the absence of an express reference to one of the figures being made, the following description applies to both figures.
[0027] The device according to the invention comprises spinning device 1 , through which a yarn sheet 3 consisting of a plurality of individual filaments are melt spun. In this case the spinning device 1 can comprise means for melting polymeric granules, means for feeding a polymer melt, means for conveying a polymer melt, means for extruding the polymer melt, and means for cooling the freshly extruded filaments. Spinning devices of this type are generally known, so that a detailed representation and description can be omitted.
[0028] Below the spinning device 1 a draw-off device 2 is provided through which the yarn sheet 3 is drawn off from the spinning device 1 and accelerated. As draw-off device 2 , suction nozzles or suction channels, preferably compressed air-driven, are used. In principle however, any of the known draw-off systems for drawing off and accelerating a yarn sheet can be used.
[0029] Below the draw-off device 2 two feed rollers 6 . 1 and 6 . 2 are disposed in parallel adjacent to one another in such a manner that a collecting gap 7 is formed between the feed rollers 6 . 1 and 6 . 2 . The feed rollers 6 . 1 and 6 . 2 thus represent an entrance 20 to the collecting gap 7 .
[0030] The feed rollers 6 . 1 and 6 . 2 are each encircled by a feed belt 8 . 1 and 8 . 2 . The feed belts 8 . 1 and 8 . 2 are formed to be endless and are each fed in an extension of the collecting gap 7 up to a deflecting roller 9 . 1 and 9 . 2 . As endless belts the feed belt 8 . 1 is thus led around the feed roller 6 . 1 and the deflecting roller 9 . 1 while the feed belt 8 . 2 is led around the feed roller 6 . 2 and the deflecting roller 9 . 2 . In so doing, the feed belts 8 . 1 and 8 . 2 extend essentially over the entire width of the feed rollers 6 . 1 and 6 . 2 . The deflecting rollers 9 . 1 and 9 . 2 form an exit 21 from the collecting gap 7 , which is disposed at a short distance from a perforated support 4 which extends in the horizontal direction. The perforated support 4 is implemented as a collecting belt 16 , which is conducted or driven via a belt roller 17 . The collecting belt 16 has a width which corresponds at least to the width of the feed belts 8 . 1 and 8 . 2 . In the area of the exit 21 a suction device 10 is disposed adjacent the collecting belt 16 , by means of which, in a transfer zone for picking up a non-woven, a suction flow which penetrates the collecting belt 16 can be generated.
[0031] In the embodiment represented in FIGS. 1 and 2 of the device according to the invention, a yarn sheet 3 is spun by means of the spinning device 1 . The yarn sheet 3 is drawn off by the draw-off device 2 and fed with acceleration to the feed rollers 6 . 1 and 6 . 2 .
[0032] As is shown in FIG. 2 , the feed rollers 6 . 1 and 6 . 2 each comprise in their interior a suction device 14 . 1 and 14 . 2 . The suction devices 14 . 1 and 14 . 2 each have a suction opening 15 which is turned toward the entrance 20 to the collecting gap 7 . The suction opening 15 of the suction device 14 . 1 or 14 . 2 is formed in such a manner that the feed jacket 11 of the feed rollers 6 . 1 and 6 . 2 in question is suctioned in a circumferential section in the form of a segment. The segment like circumferential section is held in the area of the entrance 20 to the collecting gap 7 . Along with this, the suction openings 15 can be displaced by rotation within the feed rollers 6 . 1 and 6 . 2 , in order to change the circumferential section to be suctioned. Each of the feed rollers 6 . 1 and 6 . 2 has an identical structure of the feed jacket 11 . The feed jacket 11 consists of an exterior application surface 12 , which is formed by the respective feed belts 8 . 1 and 8 . 2 . Below the application surface 12 the feed jacket 11 comprises in its interior several partition walls 13 aligned at a distance from one another and extending in the radial direction. The partition walls 13 can be formed to be straight, curved, or inclined so that by turning of the feed jacket 11 an additional effect of the suction flow is possible. The feed belts 8 . 1 and 8 . 2 are formed so as to be permeable to gas, where the open surface of the feed belts 8 . 1 and 8 . 2 is in the range of 75%-98%.
[0033] The feed rollers 6 . 1 and 6 . 2 and the deflecting rollers 9 . 1 and 9 . 2 are held in such a manner that they can be moved, in a frame (not shown). In this case the feed rollers 6 . 1 and 6 . 2 as well as the deflecting rollers 9 . 1 and 9 . 2 can be displaced to adjust the width of the collecting gap 7 in the horizontal direction.
[0034] Likewise, a vertical displacement of the feed rollers 6 . 1 and 6 . 2 and the deflecting rollers 9 . 1 and 9 . 2 is possible in order to change in particular the distance between the draw-off device 2 and the collecting gap 7 . In this case, between the feed rollers 6 . 1 and 6 . 2 and the respective deflecting rollers 9 . 1 and 9 . 2 , a belt-tensioning device can advantageously act, through which a desired tension of the feed belts 8 . 1 and 8 . 2 continues to be ensured.
[0035] After the yarn sheet 3 is fed with acceleration through the draw-off device 2 in the direction of the collecting gap 7 the individual filaments of the yarn sheet 3 are, due to the suction flow, laid on the application surfaces 12 of the feed rollers 6 . 1 and 6 . 2 or the feed belts 8 . 1 and 8 . 2 and fed into the collecting gap 7 . In so doing, a non-woven 5 is formed. The feed belts 8 . 1 and 8 . 2 are driven via the feed rollers 6 . 1 and 6 . 2 in the running direction of the filaments at a predetermined feed rate. The feed rates of the feed belts 8 . 1 and 8 . 2 are preferably made to be identical and essentially less than the draw-off rate generated by the draw-off device 2 . By the relationship between the draw-off rate and the feed rate the density of the fiber non-wovens 5 can essentially be defined. The greater the difference between the draw-off rate and the feed rate is, the higher the density of the non-woven 5 for a constant collecting gap 7 .
[0036] Collected and laid in the entrance 20 to the collecting gap 7 , the filaments of the yarn sheet 3 produce a non-woven 5 formed with two sides. Due to the bilateral suctioning of the application surface 12 , a spatial laying structure of the filaments within the non-woven 5 results so that a voluminous non-woven 5 is formed. The volume of the fiber non-woven 5 can be set essentially by the width of the collecting gap 7 .
[0037] The non-woven 5 produced in this manner is fed via the feed belts 8 . 1 and 8 . 2 to the exit 21 and laid on the collecting belt 16 . Due to the suction device 10 disposed at the collecting belt 16 there is a controlled and uniform laying of the filaments on the collecting belt 16 . The belt rate of the collecting belt 16 is essentially equal to the feed rate of the feed belts 8 . 1 and 8 . 2 so that no additional compression or loosening of the non-woven develops. It is however possible to achieve special effects in the non-woven by different settings of the belt rate of the collecting belt 16 in relationship to the feed rates of the feed belts 8 . 1 and 8 . 2 . The non-woven 5 is transported by the collecting belt 16 for further processing and further treatment.
[0038] The device according to the invention and the process according to the invention are thus particularly suitable for steadily producing voluminous non-wovens formed with two sides. Here all the customary types of polymers, e.g., polyester, polyamide, polypropylene, or modifications and mixtures of these types of polymers, can be used. A non-woven with predetermined density, uniform surfaces, and three-dimensional orientation can be produced.
[0039] In FIG. 3 an additional embodiment of the device according to the invention is represented schematically in a cross-sectional view. In the embodiment represented in FIG. 3 the representation of the spinning device of the draw-off device is omitted. To that extent, reference is made to the previous embodiment. Likewise, the formation of the perforated support 4 is identical to the previous embodiment. For this, reference is made to the description of the previous embodiment.
[0040] To collect and lay the yarn sheet, the embodiment comprises two feed rollers 6 . 1 and 6 . 2 which form the entrance 20 to the collecting gap 7 . Two feed belts 8 . 1 and 8 . 2 are disposed after the feed rollers 6 . 1 and 6 . 2 , each of said feed belts being led over a drive roller 19 . 1 and 19 . 2 and a deflecting roller 9 . 1 and 9 . 2 . Between the feed rollers 6 . 1 and 6 . 2 as well as between the feed belts 8 . 1 and 8 . 2 the collecting gap 7 is formed. The transfer area of the collecting gap 7 between the feed rollers 6 . 1 and 6 . 2 and the feed belts 8 . 1 and 8 . 2 is bordered by two guide plates 18 . 1 and 18 . 2 disposed opposite one another.
[0041] The feed rollers 6 . 1 and 6 . 2 are identical in their structure to the previous embodiment so that at this point reference can be made to the previous description. For collecting the yarn sheet 3 baffles 22 . 1 and 22 . 2 are disposed at the sides of the entrance 20 to the feed rollers 6 . 1 and 6 . 2 , where the suctioning of the ambient air is prevented by the baffles. Baffles 22 . 1 and 22 . 2 of this type can preferably be formed in such a manner that a direct transfer from the draw-off device to the feed rollers can be shielded from the environment. Baffles of this type can, for example, also be used in the embodiment according to FIG. 1 .
[0042] The collecting and laying of the yarn sheet in the collecting gap 7 is done in the same manner as already explained in the previous embodiment. In contradistinction to the previous embodiment according to FIGS. 1 and 2 however the possibility now exists that the feed rate of the feed rollers 6 . 1 and 6 . 2 and the feed rate of the feed belts 8 . 1 and 8 . 2 can be set to be different. Thus, for example, the density of the resulting non-woven can be increased by a lower feed rate of the feed belts 8 . 1 and 8 . 2 . It is however also possible to achieve a loosening of the fiber non-woven by the feed rate of the feed belts 8 . 1 and 8 . 2 being set higher than the feed rate of the feed rollers 6 . 1 and 6 . 2 . In order to produce certain effects in the non-wovens 5 the feed rate of the feed rollers 6 . 1 and 6 . 2 and the feed rate of the feed belts 8 . 1 and 8 . 2 can also be operated with a certain difference in rates. For this, each feed roller 6 . 1 and 6 . 2 and each feed belt 8 . 1 and 8 . 2 is driven separately.
[0043] In FIG. 4 an additional embodiment of the device according to the invention is represented schematically where once again the representation of the spinning device of the draw-off device is omitted.
[0044] The spinning device, the draw-off device, and the represented perforated support 4 are identical to the previous embodiments.
[0045] To collect and lay the yarn sheet 3 two feed rollers 6 . 1 and 6 . 2 and feed belts 8 . 1 and 8 . 2 disposed after the feed rollers 6 . 1 and 6 . 2 are provided according to the embodiment of FIG. 4 . The feed rollers 6 . 1 and 6 . 2 are disposed at a distance from one another so that a collecting gap 7 is formed. The feed rollers 6 . 1 and 6 . 2 have no suction device so that the yarn sheet 3 can be fed through the collecting gap 7 without laying it on the application surfaces of the feed rollers 6 . 1 and 6 . 2 . Below the feed rollers 6 . 1 and 6 . 2 the feed belts 8 . 1 and 8 . 2 are each led between the drive rollers 19 . 1 and 19 . 2 and the deflecting rollers 9 . 1 and 9 . 2 . The feed belts 8 . 1 and 8 . 2 are disposed relative to one another in such a manner that a collecting gap 7 formed between the feed belts 8 . 1 and 8 . 2 has a greater width on the side of the entrance 20 than at the exit 21 . On their side facing the collecting gap 7 the feed belts 8 . 1 and 8 . 2 are each combined with a suction device 14 . 1 and 14 . 2 . The feed belts 8 . 1 and 8 . 2 are thus essentially suctioned over the entire length of the collecting gap 7 .
[0046] The collecting and laying of the individual fiber strands of the yarn sheet 3 is thus done essentially by the feed belts 8 . 1 and 8 . 2 . In this case the feed rates of the feed rollers 6 . 1 and 6 . 2 and the feed belts 8 . 1 and 8 . 2 can be made very different. The non-woven 5 is produced essentially in the collecting gap 7 formed by the feed belts 8 . 1 and 8 . 2 . By the extended suctioning of the feed belts 8 . 1 and 8 . 2 and the V-shaped arrangement of the feed belts 8 . 1 and 8 . 2 non-wovens with high densities can preferably be produced.
[0047] In order to be able to implement the process according to the invention, the yarn sheet could, in the embodiment represented in FIG. 4 , be fed immediately through the draw-off device to the feed belts 8 . 1 and 8 . 2 .
[0048] Furthermore, the feed rollers could be formed so that they can be moved in the horizontal direction in order to make possible the collecting of the yarn sheet predominantly on a drum. Thereby non-woven layings with lower non-woven masses can be produced.
[0049] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | An apparatus and process for producing a non-woven fabric or mat, wherein a downwardly advancing sheet of polymeric filaments is produced by a melt spinning device, and a draw-off device serves to withdraw the sheet from the spinning device and advance the sheet into a collecting gap which is formed by two feed rollers which are positioned a short distance above a perforated support. In order to obtain a desired configuration on both surfaces of the web, the collecting gap is extended by two opposing feed belts which cooperate with the feed rollers to shape the sheet upstream of the perforated support. | 3 |
FIELD OF THE INVENTION
[0001] The invention relates in general to methods of processing lignocellulosic biomass and to methods of pre-treatment of lignocellulosic biomass. In particular, the invention provides methods which fix moisture levels in lignocellulosic biomass to levels near the inherent water holding capacity of the material.
BACKGROUND
[0002] Bioethanol offers a promising alternative to fossil fuels, providing renewable and “carbon neutral” energy sources that do not disrupt global atmospheric carbon dioxide balance. Amongst other possible sources of bioethanol precursors, lignocellulosic biomass can be enzymatically hydrolysed to provide fermentable carbohydrates. However, because of its complex chemical structure, lignocellulose can only be efficiently hydrolysed by presently known enzyme activities after some pre-treatment that renders cellulose fibers accessible to enzyme catalysis. Such pre-treatment processes typically involve heating to comparatively high temperatures, between 100 and 250° C. Large scale bioethanol production from lignocellulosic biomass requires large scale pre-treatment and processing. Accordingly, an intense interest has arisen in methods of biomass pre-treatment and processing that reduce costs or otherwise increase commercial viability of bioethanol on production scale.
[0003] Two factors which heavily influence overall costs of bioethanol production from lignocellulosic biomass are energy costs of ethanol distillation from fermentation mixtures and energy costs of biomass pre-treatment.
[0004] Energy costs of ethanol distillation can be greatly reduced where ethanol content of fermentation mixtures exceeds 4%. However, to achieve these high ethanol levels in fermentation mixtures, without requiring costly and inefficient additional process steps, enzymatic hydrolysis of pre-treated lignocellulosic biomass should be conducted at relatively high dry matter content (DM)—at least about 15-20%. Previous attempts to achieve high DM content in fermentation mixtures have been hampered by accumulation of fermentation inhibitors generated during pre-treatment and by other problems arising during enzyme hydrolysis and fermentation. See e.g. refs. 1 - 7 .
[0005] Recently, however, production scale methods for enzyme hydrolysis of pre-treated lignocellulosic biomass have been reported that are efficient and effective at DM greater than 20%. These methods provide liquefaction and saccharification of biomass using “free fall” mixing, as described by WO 2006/56838 (ref. 8 ), which is hereby incorporated by reference in entirety.
[0006] Energy costs of pre-treatment can be reduced where biomass is pre-treated at high DM. Greater dry matter content of biomass corresponds with reduced aqueous content. Thus, the greater the dry matter content of biomass during pre-treatment, the less energy is wasted heating aqueous content. It is, thus, generally advantageous during pre-treatment to achieve the highest possible DM levels (lowest possible aqueous levels) of lignocellulosic biomass that do not contribute to eventual reduction of ethanol yield (% theoretical) from fermentation mixtures.
[0007] Optimal pre-treatment conditions require that biomass have some aqueous content. Eventual ethanol yield (% theoretical) from lignocellulosic biomass is generally improved to the extent that it is pre-treated under conditions in which cellulose fibers do not contain air. Biomass that is simply exposed to moisture can, eventually, with time, achieve homogenous aqueous saturation of cellulose fibers. However, such an “impregnation” approach is slow, and accordingly unsuitable for production scale pre-treatment. Aqueous content of biomass has been previously optimized on production scale by soaking and pressing prior to pre-treatment, for example, as described by WO 2007/009463 (ref. 9 ), which is hereby incorporated by reference in entirety. After soaking in an excess of aqueous solution, then pressing to remove as much aqueous content as possible, lignocellulosic biomass will typically comprise a “saturation level” of aqueous content corresponding to DM greater than about 30%.
[0008] While such soaking and pressing methods are effective, they require additional energy for pressing, time delays for soaking, as well as additional process steps. These introduce additional costs and production inefficiencies.
[0009] Accordingly, it is advantageous to provide methods of processing lignocellulosic biomass, suitable for use in continuous processing on production scale, that provide homogenous, aqueous saturation of cellulose fibers quickly, with low energy cost, and with the fewest possible process steps.
SUMMARY OF THE INVENTION
[0010] In some embodiments, the invention provides methods of processing lignocellulosic biomass whereby biomass is wetted with an amount of aqueous solution sufficient to provide moisture levels near the inherent water holding capacity of the material then thoroughly mixed, optionally using a mixer that massages water content into lignocellulosic fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a mixer used in preferred embodiments to massage water content in lignocellulose fibers.
[0012] FIG. 2 shows alternative arrangements of water or aqueous solution addition and a mixer suitable for practice of embodiments of the invention in a continuous pre-treatment process.
[0013] FIG. 3 shows cellulose conversion (%) as a function of time of enzymatic hydrolysis of lignocellulosic biomass pre-treated by methods of the invention at fixed dry matter content from 20 to 50%.
[0014] FIG. 4 shows the effect of mixing time (from 10-30 minutes) on cellulose conversion (%) as a function of time of enzymatic hydrolysis of lignocellulosic biomass processed by methods of the invention to fixed dry matter content of 35%.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] As used herein, the following terms have the following meanings:
(i). Lignocellulosic Biomass
[0016] Lignocellulosic biomass refers to material derived from plants or other organisms in which carbohydrate content is substantially cellulose and hemicellulose and which comprises more than 5% lignin. Cellulose is a polysaccharide composed of D -glucose monomers linked by β-1,4-glucosidic bonds with a degree of polymerisation up to 10,000. Hemicellulose is a complex heterogeneous polysaccharide comprising different monomer residues including : D -glucose, D -galactose, D -mannose, D -xylose, L -arabinose, D -glucuronic acid and 4-O-methyl- D -glucuronic acid having a degree of polymerisation below 200. Lignin is a complex aromatic network formed by polymerisation of phenyl propane and comprising monomers including: ρ-coumaryl alcohol, coniferyl alcohol and sinapyl alcohol, typically linked through arylglyceryl-β-aryl ether bonds. The term as used herein includes processed materials, such as papers, as well as primarily natural materials, such as agricultural wastes. Lignocellulosic biomass will typically comprise water content. A mixture of water and/or other agents and/or solvents comprising lignocellulosic biomass as the predominant solid component can also be referred to as “a” lignocellulosic biomass within the meaning of the term as used. The carbohydrate composition of a lignocellulosic biomass may be changed during pre-treatment.
(ii). Dry Matter
[0017] Dry matter refers to insoluble material. Typically, dry matter comprises insoluble fibers.
[0000] (iii). Inherent Water Holding Capacity of the Biomass.
[0018] Inherent water holding capacity of the biomass refers to the amount of water, or aqueous solution, that remains after repeated “pressing” in a biomass that has been “soaked” in a “soaking and pressing” process such as that described in WO 2007/009463.
(iv). Fixed Dry Matter Content and Thorough Mixing
[0019] Fixed dry matter content refers to moisture content of lignocellulosic biomass adjusted prior to pre-treatment and/or enzymatic hydrolysis. The dry matter content is adjusted or “fixed” by adding a quantity of water, or aqueous solution comprising one or more chemical additives, sufficient to provide moisture levels between 80-120% of the inherent water holding capacity of the biomass then thoroughly mixing. Mixing is “thorough” where substantially all of the dry matter of the lignocellulosic biomass is wetted by added water or aqueous solution. Dry matter content is “fixed” where substantially all of the water, or aqueous solution, is incorporated within fibers with substantially no excess water, or aqueous solution, that is not incorporated within fibers, except an amount not exceeding an amount of water, or aqueous solution, added in excess of 100% of the inherent water holding capacity of the biomass. Soaking typically involves excess water, >120% of the inherent water holding capacity of the biomass, that is not incorporated within fibers and does not provide fixed dry matter content as used herein.
(v). Massages Water Content
[0020] Water content is massaged into wetted biomass fibers by subjecting them to a form of mixing that acts to alternately compress fibers then restore them to a relaxed state. An example of a mixer that massages water content into wetted biomass fibers is the Cormall Multimix MTX two auger livestock feed mixer.
(vi). Pre-Treatment
[0021] Pre-treatment refers to a manipulation of lignocellulosic biomass that renders its cellulosic component more accessible to enzymes that convert carbohydrate polymers into fermentable sugars. Heat pre-treatment refers to a pre-treatment in which biomass is heated to temperatures of 100° C. or more.
[0000] (vii). Enzymatic Hydrolysis
[0022] Enzymatic hydrolysis refers to treatment of a lignocellulosic biomass with a mixture of enzyme activities comprising one or more cellulytic enzyme in such manner as to convert cellulose content to carbohydrates with at least 20% theoretical yield.
[0023] Some embodiments provide a method of processing lignocellulosic biomass comprising;
providing a lignocellulosic biomass adding an amount of water or aqueous solution sufficient to provide moisture levels between 80-120% of the inherent water holding capacity of the biomass, and mixing in a mixer that imparts a combination of shear and/or pressing forces such that the biomass is mixed thoroughly within 60 minutes, or, optionally, within 30 minutes, or, optionally, within 20 minutes, or, optionally within 10 minutes wherein said mixed biomass having fixed dry matter content is subsequently subject to heat pre-treatment and/or enzymatic hydrolysis.
[0027] Other embodiments provide a method of processing lignocellulosic biomass comprising;
providing a lignocellulosic biomass an amount of water or aqueous solution sufficient to provide moisture levels between 80-120% of the inherent water holding capacity of the biomass, and mixing thoroughly in a mixer that massages water content into lignocellulosic fibers wherein said mixed biomass having fixed dry matter content is subsequently subject to heat pre-treatment and/or enzymatic hydrolysis.
[0031] Embodiments of the invention may be practiced in batch, semi-continuous or continuous modes of operation.
[0032] In preferred embodiments, the dry matter content is fixed to levels corresponding to moisture content of greater than 85% but less than 100% of the inherent water holding capacity of the biomass. In more preferred embodiments, the dry matter content is fixed to levels corresponding to moisture content of greater than 95% but less than 100% of the inherent water holding capacity of the biomass. In still more preferred embodiments, other embodiments, the dry matter content is fixed to levels corresponding to moisture content about 100% of the inherent water holding capacity of the biomass.
[0033] In preferred embodiments, dry matter content of lignocellulosic biomass is fixed on a large scale, having dry matter mass at least 40 kg, or having dry matter mass greater than 50 kg, or greater than 100 kg, or greater than 1000 kg, or greater than 10,000 kg.
[0034] In the practice of some embodiments, any suitable lignocellulosic biomass feedstock having intrinsic dry matter content greater than about 50% may be used including at least corn stover, wheat straw, rice straw, bagasse, corn fiber, hardwood bulk, softwood bulk, nut shells, corn cobs, grasses, including but not limited to coastal Bermuda grass and switch grass, paper, including newspaper, waste papers and paper from chemical pulps, sorted refuse, cotton seed hairs, empty fruit baskets and other materials well known in the art.
[0035] The lignocellulosic biomass may be pre-processed by chopping, grinding, ball milling, or other mechanical treatment processes.
[0036] In preferred embodiments, a lignocellulosic biomass will have a distribution of particle sizes prior to pre-treatment having 80% falling within the range of 1 to 10 cm. In other embodiments, a lignocellulosic biomass will have a distribution of particle sizes having 80% falling within the range of 0.5 to 15 cm.
[0037] In practice of preferred embodiments, it is helpful to determine the inherent water holding capacity of a lignocellulosic biomass, for example, by measuring the moisture content that remains after “pressing” in a biomass that has been “soaked” in a “soaking and pressing” process such as that described in WO 2007/009463. For example, wheat straw typically has an inherent water holding capacity corresponding to about 42% DM.
[0038] In preferred embodiments, intrinsic DM content of a lignocellulosic biomass is first determined by means of drying to no loss of weight or by any method known in the art. A quantity of water, or aqueous solution, sufficient to provide moisture levels between 80-120% of the inherent water holding capacity of the biomass can then be readily determined based on the dry mass of the lignocellulosic biomass. For example, for 10,000 kg of wheat straw having dry matter content 92.0%, 30,000 liters of water or aqueous solution should be added to provide dry matter content of about 30% (moisture content about 120% of the inherent water holding capacity). For the same lignocellulosic biomass, to provide dry matter content of about 40% (moisture content about 103% of the inherent water holding capacity), only 23,000 liters of water or aqueous solution need be added.
[0039] In other embodiments, dry matter content of a lignocellulosic biomass can be estimated visually, or based upon reference materials or prior experience.
[0040] In other embodiments, an appropriate amount of water or aqueous solution can be approximated or added in amounts that may vary within constraints of some process limitations such as water availability. For example, dry matter content may be fixed imprecisely at between 30-40% by adding an amount of water or aqueous solution that is not precisely measured, although sufficient, in that it does not exceed the amount required for 30% dry matter.
[0041] Aqueous solutions suitable for practice of some embodiments may comprise acids, bases, salts, metals, or other chemical additives, enzymes or microorganisms. In preferred embodiments, a mildly acidic solution is added. Optimum pH is typically between 3.5-4.0. This lowers heat requirements for pre-treatment and prevents sticking of “cooked” biomass to reactor vessels or communication lines. Wash effluent or extracts of pre-treated biomass, typically containing acetic acid, may be added as aqueous solutions suitable for practice of some embodiments.
[0042] In preferred embodiments, the lignocellulosic biomass and added water or aqueous solution may be mixed thoroughly using a mixer that massages water content into lignocellulosic fibers. One such mixer, suitable for practice of preferred embodiments, is illustrated in FIG. 1 . The mixer is mounted with a series of augers, in this example 5 . FIG. 1 (A) provides an end view while FIG. 1 (B) provides a side view of a preferred mixer. As shown in FIG. 1 (B), the mixer comprises a series of augers, in this example 5, mounted perpendicular to the flow of biomass. As shown in FIG. 1 (A), each auger has blades that are situated to provide, along the same axis, counterposing helical motion from each end, such that biomass from either end is transported towards the center of the auger. At the center of the auger, biomass is “shot” up, in what can be described as a “molehill” of water. Added biomass is “shot” up then naturally falls back down into the augers. Some of the biomass from each “molehill” moves forward through the mixer to the next auger in series. A steady state flow of biomass into and out of the mixer is established by constant flow of biomass into one end of the mixer and constant removal of thoroughly mixed biomass from an outlet situated at the opposite end of the mixer. The time of mixing can be adjusted by adjusting the rate of removal of thoroughly mixed biomass, and thus the rate of introduction of unmixed biomass. Other suitable mixers that massage water content into lignocellulosic fibers include at least mixers similar to any of the mixers described in WO8002458, US20070274151, WO07089144, WO07083998, US20050105390, US20050094486, and US20030169639 (refs. 10 - 16 ).
[0043] In other embodiments, the lignocellulosic biomass and added water or aqueous solution may be mixed thoroughly using a mixer that imparts a combination of shear and/or pressing forces such that the biomass is mixed thoroughly within 60 minutes, or, optionally, within 30 minutes, or, optionally, within 20 minutes, or, optionally, within 10 minutes. In still other embodiments, the lignocellulosic biomass and added water or aqueous solution may be mixed by any means that provides that, within 60 minutes, or, optionally, within 30 minutes, or, optionally, within 20 minutes, or, optionally, within 10 minutes, substantially all of the water, or aqueous solution, is incorporated within fibers with substantially no excess water, or aqueous solution, that is not incorporated within fibers.
[0044] In practice of some embodiments, water or aqueous solution may be added as cold liquid, which is typically absorbed in a shorter time, or as steam or a combination of steam and liquid. In practice of some embodiments, water or aqueous solution may be added directly in the mixer. Alternatively, water or aqueous solution may be added within a vertical column through which biomass is falling, by force or gravity or conveyance, into the mixer. Other possible arrangements can be readily imagined. FIG. 2 illustrates two alternative arrangements of water or aqueous solution addition and a mixer suitable for practice of embodiments of the invention in a continuous pre-treatment process. In the most preferred embodiment, biomass is added to the mixer simultaneously with an appropriate quantity of water or aqueous solution. Alternatively, biomass may be sprayed, for example, as it is falling through a column that transports biomass.
[0045] After processing by embodiments of the invention, the biomass can be pre-treated by any heat pre-treatment and, further, to any post pre-treatment processing.
[0046] In some embodiments, a biomass that does not require pre-treatment may be used. For example, waste paper and other paper pulp feedstocks, do not require heat pre-treatment but can be used directly in enzymatic hydrolysis.
Example 1
[0047] These data origin from the IBUS pilot plant of Inbicon in Fredericia, Denmark. Cut wheat straw and liquid were mixed in a KUHN Euromix II type 1460 feed mixer. The dry matter content of the wetted straw after mixing was varied from 20 to 50% DM, which corresponds with moisture levels of between 138 to 86% of the inherent water holding capacity of the biomass.
[0048] 500 kg of cut (2-10 cm in length) wheat straw was added to the mixer. Liquid in an adjusted amount was sprayed on the straw. Then the mixer was started, and the liquid was massaged in to the straw. Residence time in the mixer was 30 minutes. After mixing the dry matter content was measured in the wetted straw and it was found to be in agreement with the calculated. In this way samples of wetted wheat straw with a content of 20, 30, 40 and 50±1% DM were prepared. Two samples were prepared at 40% DM, which corresponds with moisture levels of about 103% of the inherent water holding capacity of the biomass.
[0049] These samples were loaded in to the pilot pre-treatment facilities of Inbicon. In this pilot plant the wetted wheat straw in a continuously way was steam treated at 185° C. for 10 minutes.
[0050] As a reference, for comparison with the “fixed dry matter” samples, soaked and pressed wheat straw was also pre-treated. In the reference sample,s cut straw was soaked for 5-10 minutes in 80° C. hot liquid. After the soaking the straw was pre-treated at a dry matter content of 18-22%, which corresponds with moisture levels of between 141 to 134% of the inherent water holding capacity of the biomass.
[0051] The pre-treatment must ensure that the structure of the lignocellulosic content is rendered accessible for enzymatic hydrolysis, and at the same time the concentrations of harmful inhibitory by-products such as acetic acid, furfural and hydroxymethyl furfural remain substantially low. Therefore, after heat pre-treatment, the pre-treated straw is washed by water or condensate then pressed. After post-pre-treatment washing and pressing, the cellulosic fibres have a dry matter content of app. 25-35%. The pre-treated straw was collected in plastic bags and stored at 1-5° C. until use.
[0052] The pre-treated wheat straw samples were evaluated regarding convertibility of cellulose in a shake flask set up at 12% DM, where the samples were simultaneous saccharified and fermented (SSF). The pre-treated fibre fraction was diluted with an acetic acid buffer, pre-hydrolysed 6 hours with Novozym 188 and Celluclast 1.5 FG at 50° C. using an enzyme loading of 5.0 FPU (g DM) −1 then simultaneously saccharified and fermented (SSF) 144 hours at 30-33° C. with common bakers yeast (Baker's yeast, De Danske Spritfabrikker).
[0053] FIG. 3 shows that fixing dry matter of biomass prior to steam pre-treatment at levels of dry matter from 30-40% corresponding to from 120 to 103% of the water holding capacity of the biomass provides equivalent yields in cellulose conversion compared to soaking, typically 18-22% dry matter, corresponding to from 141 to 134% of the inherent water holding capacity.
[0054] Accordingly, by practice of embodiments of the invention, it is possible to reduce energy consumption, stream line process steps, and reduce process time without loss of yield, by reducing the water content of the biomass during pre-treatment. However, as shown in FIG. 1 , at dry matter content 50%, corresponding to only about 86% of the water holding capacity of the biomass, yields in cellulose conversion are reduced considerably relative to soaking.
Example 2
[0055] These data origin from the IBUS pilot plant of Inbicon in Fredericia, Denmark. Cut wheat straw and liquid were mixed in a KUHN Euromix II type 1460 feed mixer. The dry matter content of the wetted straw after mixing was 35%, which corresponds to about 112% of the water holding capacity of the biomass.
[0056] 500 kg of cut (2-10 cm in length) wheat straw was added to the mixer. A pre-determined amount of aqueous solution, sufficient to provide dry matter content of about 35%, was sprayed on the straw. Then the mixer was started, and the liquid was massaged in to the straw. Residence time in the mixer was varied from 10 to 30 minutes. After mixing the dry matter content was measured in the wetted straw and it was found to be in agreement with the calculated. In this way samples of wetted wheat straw with a content of 35±1% DM were prepared.
[0057] These samples were loaded in to the pilot pre-treatment facilities of Inbicon. In this pilot plant the wetted wheat straw in a continuously way was steam treated at 185° C. for 10 minutes.
[0058] The pre-treatment must ensure that the structure of the lignocellulosic content is rendered accessible for enzymatic hydrolysis, and at the same time the concentrations of harmful inhibitory by-products such as acetic acid, furfural and hydroxymethyl furfural remain substantially low. Therefore, after heat pre-treatment, the pre-treated straw is washed by water or condensate then pressed. After post-pre-treatment washing and pressing, the cellulosic fibres have a dry matter content of app. 25-35%. The pre-treated straw was collected in plastic bags and stored at 1-5° C. until use.
[0059] The pre-treated wheat straw samples were evaluated regarding convertibility of cellulose in a shake flask set up at 12% DM, where the samples were simultaneous saccharified and fermented (SSF). The pre-treated fibre fraction was diluted with an acetic acid buffer, pre-hydrolysed 6 hours with Novozym 188 and Celluclast 1.5 FG at 50° C. using an enzyme loading of 5 FPU (g DM) −1 then simultaneously saccharified and fermented (SSF) 400 hours at 30-33° C. with common bakers yeast (Baker's yeast, De Danske Spritfabrikker).
[0060] FIG. 4 shows that residence times between 10 and 30 minutes in a fixed dry matter mixer before steam pre-treatment ensures equal yield in cellulose conversion.
[0061] Accordingly, by practice of embodiments of the invention, it is possible to reduce energy consumption, stream line process steps, and reduce process time without loss of yield, by reducing the water content of the biomass during pre-treatment, through a processing that provides thorough mixing within 60 minutes, or, optionally, within 30 minutes, or, optionally, within 20 minutes, or, optionally within 10 minutes.
Example 3
[0062] These data origin from the IBUS pilot plant of Inbicon in Fredericia, Denmark. Dried empty fruit bunches (EFB) of oil palm and liquid were mixed in a KUHN EUROMIX II™ type 1460 feed mixer.
[0063] 500 kg of EFB (average fibre length of app. 5-10 cm) was added to the mixer. Liquid in an adjusted amount was sprayed on the EFB. Then the mixer was started, and the liquid was massaged in to the EFB. Residence time in the mixer was 60 minutes. After mixing the dry matter content was measured in the wetted EFB and it was found to be in agreement with the calculated. In this way samples of wetted EFB with a content of 25 and 35±1% DM were prepared.
[0064] These samples were loaded in to the pilot pre-treatment facilities of Inbicon. In this pilot plant the wetted EFB in a continuously way was steam treated at 200° C. for 12 minutes.
[0065] The pre-treatment must ensure that the structure of the lignocellulosic content is rendered accessible for enzymatic hydrolysis, and at the same time the concentrations of harmful inhibitory by-products such as acetic acid, furfural and hydroxymethyl furfural remain substantially low. Therefore, after heat pre-treatment, the pre-treated EFB is washed by water or condensate then pressed. After post-pre-treatment washing and pressing, the cellulosic fibres had a dry matter content of app. 25-35%. The pre-treated EFB was collected in plastic bags and stored at 1-5° C. until use.
[0066] The pre-treated EFB samples were evaluated regarding convertibility of cellulose in a shake flask set up at 12% DM, where the samples were simultaneously saccharified and fermented (SSF). The pre-treated fibre fraction was diluted with an acetic acid buffer, pre-hydrolysed 6 hours with ACCELLERASE 1500™ (Genencor) at 50° C. using an enzyme loading of 0.21 ml (g cellulose)-1 then simultaneously saccharified and fermented (SSF) 144 hours at 30-33° C. with common bakers yeast (Baker's yeast, De Danske Spritfabrikker). In these experiments a cellulose conversion of 88% was reached.
[0067] The examples and descriptions provide representative examples of particular embodiments and are not intended to limit the scope of the invention.
REFERENCES
[0000]
1 P. Sassner et al., “Bioethanol production based on simultaneous saccharification and fermentation of steam-pre-treated Salix at high dry matter content,” Enzyme and Microbial Technology (2006) 39:756;
2 M. Alkasrawi et al., “Influence of strain and cultivation procedure on the performance of simultaneous saccharification and fermentation of steam pre-treated spruce,” Enzyme and Microbial Technology (2006) 38:279;
3 A. Rudolf et al., “A comparison between batch and fed-batch simultaneous saccharification and fermentation of steam pre-treated spruce,” Enzyme and Microbial Technology (2005) 37:195;
4 M. Ballesteros et al., “Ethanol production from paper material using a simultaneous saccharification and fermentation system in a fed-batch basis,” World Journal of Microbiology & Biotechnology (2002), 18:559.
5 Charlotte Tengborg, Mats Galbe, and Guido Zacchi: Influence of Enzyme Loading and Physical Parameters on the Enzymatic Hydrolysis of Steam-Pre-treated Softwood Biotechnol. Prog. 2001, 17, 110-117;
6 Hanne R. Sørensen,†,‡ Sven Pedersen,† and Anne S. Meyer*,‡: Optimization of Reaction Conditions for Enzymatic Viscosity Reduction and Hydrolysis of Wheat Arabinoxylan in an Industrial Ethanol Fermentation Residue Biotechnol. Prog. 2006, 22, 505-513;
7 Eniko Varga, Helene B. Klinke, Kati Reczey, Anne Belinda Thomsen: High Solid Simultaneous Saccharification and Fermentation of Wet Oxidized Corn Stover to Ethanol BIOTECHNOLOGY AND BIOENGINEERING, VOL. 88, NO. 5, Dec. 5, 2004;
8 WO 2006/56838
9 WO 2007/009463
10 WO8002458
11 US20070274151
12 WO07089144
13 WO07083998
14 US20050105390
15 US20050094486
16 US20030169639 | The invention relates in general to methods of processing lignocellulosic biomass and to methods of pre-treatment of lignocellulosic pretreated with steam biomass. In particular, the invention provides methods which fix moisture levels in lignocellulosic biomass to levels near the inherent water holding capacity of the material. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ink jet type recording apparatus and more particularly to such recording apparatus comprising two recording liquid containing tanks having different capacities and a recording head mounted on a carriage. According to the present invention, the smaller capacity one of the two tanks and the recording head are united together into a single unit which is mounted on the carriage. In response to the running of the carriage, the recording liquid is automatically supplied to the smaller tank from the larger one.
2. Description of the Prior Art
The basic form of conventional ink jet recording apparatus having an open ink feed system is schematically shown in FIG. 1. The recording head 1 is composed of, for example, a piezo-electric element in a manner known per se and has a supply line 2 connected to one end part of the head. Recording liquid(ink) is fed to the recording head 1 from a tank 3 through the supply line 2. To maintain the atmospheric pressure within the tank 3 there is provided a vent hole 5 in the upper wall of the tank. The recording liquid 4 is always allowed to reach the tip end of the head 1. In response to electric signals applied to the piezo-electric element of the head 1, droplets of recording liquid are jetted from the tip end of the head 1, that is, the jet orifice 1A to effect printing of characters, marks etc. on a recording paper. The recording liquid consumed as jet droplets 6 at the recording head 1 is successively supplied from the tank 3 through the supply line 2 owing to the surface tension at the orifice 1A and the difference in liquid level between the liquid level in the tank 3 and that in the head 1. Therefore, the recording head 1 can always retain a sufficient amount of recording liquid at its orifice 1A.
The known ink jet type of recording apparatus described above involves the following problems:
One of the problems concerns the arrangement of the tank 3 and the recording head 1. When the above mentioned type of known recording apparatus is incorporated into a portable table computer or a portable typewriter, there is the possibility that the body of the apparatus may be inclined while being carried in one's hand. In this case, since the tank 3 and the tip end of the recording head 1 are arranged distant from each other, the difference between the liquid level in tank 3 and that in jet orifice 1A may be deviated from the proper value. Such a change of the liquid level difference, if occurred, will lead to retrogradation of the meniscus of recording liquid or leaking of the recording liquid from the orifice 1A. For ink jet printing it is essential to keep the meniscus formed by the jet orifice 1A at a right position. If the meniscus is moved backward into the supply line 2, the operator has to restore it to the right position. This may be done, for example, by applying a pressure to the recording liquid from the side of the tank 3. However, leakage of the recording liquid brings about some unrecoverable trouble. The leakage recording liquid will make the inner part of the apparatus dirty. In any case, these unfavorable phenomenons give the operator much trouble. Every time after transportation of the table computer or portable typewriter, the operator must do the work of restoring the retrograded meniscus or worry about any leak of recording liquid which may make the apparatus dirty.
The above mentioned unfavorable phenomenons of leaking of recording liquid or retrogradation of the meniscus will be enhanced when vibration or impact is applied to the apparatus or when the recording head 1 is struck against another member at the end of every printing at a high speed. As is well known to those skilled in the art, the meniscus at the jet orifice 1A is very sensitive to vibration or impact. If some vibrating force or impact force is applied to the body of apparatus, the recording head 1 or the supply line 2, then the meniscus is easily broken away which may result in inward retrogradation of the meniscus into the supply line 2 or leaking of droplets outward. In this case, if the difference in liquid level between tank 3 and head 1 is higher than the proper value, the meniscus once broken can not be restored to its original right position at once. The recording liquid continues to flow out from the orifice or the meniscus continues to move backward into the supply line 2 up to the position in which the liquid level difference and the surface tension get balanced finally. These vibrations and impacts are inevitable for such type of apparatus in which printing is carried out by reciprocating a recording head 1 relative to a recording medium such as printing paper. Therefore, it may be said that such sensitiveness of recording head 1 to vibration and/or impact constitutes a fatal drawback of the apparatus. For this reason, the reciprocating speed of recording head 1 is limited very much, which constitutes an obstacle against the speed-up of printing with this type of recording apparatus.
Another problem concerns air bubbles occasionally introduced into the supply line 2. Occasionally a bubble enter the supply line 2. The bubble will not particularly hinder liquid droplets from jetting from the orifice of head 1 so long as it remains in the supply line 2. However, when the bubble moves toward the head 1 accompanied by the recording liquid and enters the head, there occurs a serious problem. The bubble prevents liquid droplets from smoothly jetting out from the orifice. This trouble becomes much more serious in particular when the deformation effect of an electric-mechanical converter is used as the jet driving source of the recording head 1. In this case, energy produced by the deformation is absorbed and lost by the bubble and no energy can be transmitted to the recording liquid. Thus, the jet of the recording liquid is completely stopped and therefore a continuous and stable printing is no longer assured.
FIGS. 2A and B schematically show an example of an ink jet type recording apparatus which has been proposed to solve the problems described above. Designated by 10 is a recording head and 11 is tank. The head 10 and tank 11 are united together into a unitary component encased in a container 12. The container 12 is fixedly mounted on a carriage 13 which is in turn slidably mounted on a shaft 14. To effect printing, the carriage 13 moves along the width of a printing paper not shown. The recording head 10 is composed of a piezo-electric element 15, nozzle part 16, jet orifice 17 and supply pipe 18. The supply pipe 18 is L shaped and extends from the main body of the head 10 into the tank 11 containing recording liquid 19. The recording head 10 receives the recording liquid 19 through the supply pipe 18. To prevent the supply pipe 18 from being moved by vibration or impact, it is fixed to a wall 20 so provided as to cover the container 12. The tank 11 has a vent hole 21 to maintain the pressure within the tank 11 at atmospheric pressure. Designated by 22 and 23 are connectors for externally applying electric signals to the piezo-electric element 15 of the head 10. While not shown, the piezo-electric element 15 and the connectors 22, 23 are connected by signal lines. The orifice 17 is provided at the tip end of the nozzle part 16 and the supply pipe 18 terminates at 18A. In the shown example, the distance between 17 and 18A can be adjustably preset to a most appropriate value.
As will be seen from the foregoing, the arrangement of the apparatus shown in FIG. 2 is featured in that the recording head 10 and tank 11 are united together into a unitary member encased in a container 12 and also in that the supply pipe 18 for feeding the recording liquid to the head 10 is introduced into the tank 11 with the length of the pipe being preset to a most appropriate value. Owing to these features, the previously mentioned troubles of leakage of recording liquid from the head and retrogradation of the meniscus formed at the orifice into the supply pipe can be eliminated even when the apparatus is subjected to inclination, vibration or impact.
While the improved apparatus shown in FIG. 2 has appreciable advantages over the conventional ones, it has been found that the ink jet recording apparatus shown in FIG. 2 still involves some problems as hereinafter described.
In the case of a miniature computer or other instruments for which high speed printing is required, it is desirable to lessen the weight of the reciprocating carriage part as much as possible in view of the power of driving motor useful for driving the carriage. To meet the requirement, the amount of recording liquid to be stored in the liquid tank of the apparatus must be limited in term of weight. As an example, in case of such printer with which one character is composed of 5×7 dot matrix, it has been proved by experiments that when the recording head has a jet orifice of 50 to 100 μm in inner diameter, only 1 cc of recording liquid is sufficient enough to print 150 to 200 thousand characters. This means that if the ink jet recording apparatus is provided with a task capacity of about 3 cc, then there can be obtained an electronic machine equipped with an ink jet recording apparatus such as a table computer with printer which is useful for a long time without any need of supply or exchange of the recording liquid. It may be possible to design such a recording liquid containing tank for which exchange of tank or supply of recording liquid is required only once every half year. However, this exchange of tank or supply of liquid to the tank brings forth a problem no matter how small the frequency of tank exchange or ink supply may be. For a table computer or other similar electronic devices there may be caused some operational troubles by the work necessary for exchange of the tank or supply of recording liquid even when the work is simplified to the utmost extent.
Another problem is caused by change of weight load on the carriage carrying the tank. As the recording liquid in the tank is consumed, the weight load on the carriage changes gradually with time. Assuming that there is used a tank having 3 cc capacity, the change of tank weight will reach about 3 g when comparison is made between the weight of the tank being full and that being vacant. When a linear motor or the like is used as the carriage driving motor, this change of weight loaded on the carriage will cause a change of carriage driving speed and also a change of printing speed. Since the printing speed varies from time to time, it is no longer possible to keep the print quality at a desired level.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the invention to solve the problems involved in the ink jet type recording apparatus according to the prior art as mentioned above.
It is a still more specific object of the invention to provide an ink jet type recording apparatus which has two separate recording liquid containing tanks one of which is smaller in capacity than the other and in which the recording liquid is automatically supplied to the smaller tank from the larger one every time when the carriage carrying a recording head and the smaller tank is moved to effect printing.
To attain the objects according to the present invention, the recording head and the smaller tank are united together into a unitary unit which is encased in a container. The container is mounted on the carriage. The smaller tank is connected with the larger capacity tank through a recording liquid supply line formed by a flexible tubing material so that the recording liquid can be automatically supplied to the smaller tank from the larger one through the supply line in response to the movement of the carriage.
Other and further objects, features and advantages of the invention will appear more fully from the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an ink jet type recording apparatus according to the prior art;
FIGS. 2A and B show an example of an improved ink jet type recording apparatus;
FIGS. 3 and 4 show an embodiment of ink jet type recording apparatus according to the invention;
FIG. 5 illustrates the manner of operation of the embodiment; and
FIG. 6 shows a concrete form of head/tank unit used in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the invention is described in detail with reference to FIGS. 3 and 4.
In FIG. 3, a recording head 32 and a subsidiary tank 33 are united together to form a unitary unit, head/tank unit 31 which is mounted on a carriage 34. The carriage 34 is slide movably mounted on a shaft 35 and is driven by a carriage driving motor not shown. Thus, the carriage 34 can move along the shaft in a reciprocating motion under the control of the driving motor. The subsidiary tank 33 has a liquid inlet 36 provided at the lower portion of one side wall of the tank. A flexible supply line 37 is connected with the inlet 36 at its one end. The other end of the supply line 37 is connected with another supply line 39 via a fixed point 38. The supply line 39 extends to a main tank 40 and is connected with a liquid outlet 41 provided at the lower portion of one side wall of the main tank. The tanks 33 and 40 have each one vent hole 42, 43 provided in the respective top walls so that the pressure within the tanks remains unchanged at atmospheric pressure irrespective of change in volume of the recording liquid in the respective tanks.
The ink jet type recording apparatus shown in FIG. 3 operates in the following manner:
The recording head 32 receives a print instruction signal externally put in. In response to the signal, droplets of the recording liquid are jetted from the head 32 toward a printing paper not shown. At the same time, the carriage driving motor (not shown) controlled by the signal drives the carriage 34 carrying thereon the head/tank unit 31. Thus, the carriage 34 is moved along the shaft 35 to effect printing of a desired character such as letter, numeral, symbol etc. on the printing paper. As shown in FIG. 4, since the carriage 34 and therefore the head/tank unit 31 move along the shaft 35 rightward and leftward as viewed on the drawing, the supply line 37 connected with the head/tank unit 31 is also moved to and for describing circular arcs the center of which is the fixed point 38. As a result of this circular arc motion of the supply line 37 about the fixed point 38, there is produced a centrifugal force acting on the recording liquid with the supply line 37. Thus, so-called a pumping effect is obtained which produces an ink feeding force in supply line 37. Owing to this ink feeding force, the recording liquid is effectively supplied to the subsidiary tank 33 from the main tank 40 as the recording liquid in the subsidiary tank is consumed by printing.
In an ink jet type recording apparatus formed as shown in FIGS. 3 and 4 according to the invention there is produced a pumping pressure in the liquid supply line extending from the main tank to the subsidiary tank in the manner described above. Generally, the value of the pumping pressure can be found mathematically, which is described hereinafter with reference to FIG. 5.
For the purpose of explanation, the subsidiary tank 33 of the head/tank unit 31 in FIG. 5 is shown to be connected with the main tank 40 directly by the supply line 37 without and intermediate fixed point. In FIG. 5, the head/tank unit 31 is moved along the shaft 35 at an angular velocity of ω (speed: Vl). The supply line 37 extending from the main tank 40 to the head/tank unit 31 is measured to be in length and S in cross-sectional area. Let ρ denote the specific weight of the recording liquid, g the gravitational acceleration, Vr the velocity of the supply tank 37 at a point r distant from the side wall of the main tank, dr a minute area of the supply line at the distance r from the main tank, dp the pressure difference between the upstream and downstream sides of the recording liquid at the area dr and f the centrifugal force acting on the recording liquid at dr resulted from the swing (circular arc) motion about the main tank 40 (center), then F, that is the force which the recording liquid at dr receives by the pressure difference dp, can be represented by F=f. The force F and the centrifugal force f can be represented as follows: ##EQU1## From F=f ##EQU2## Therefore, the pressure P can be represented by the following equation: ##EQU3##
Let this pressure P be the pumping pressure, then it will be understood that the pumping pressure P is proportional to the square of the speed of carriage 34, namely to the square of Vl.
In this manner, every time the carriage 34 is moved, there is produced a centrifugal force acting on the recording liquid in the supply line 37. The centrifugal force depends upon the running speed of the carriage and brings about a pumping effect by which the recording liquid is effectively supplied to the subsidiary tank 33 from the main tank 40.
For high speed printing it is desired to reduce the weight and size of the head/tank unit 31 as much as possible. FIG. 6 shows a preferred embodiment of such head/tank unit satisfying the requirement.
In FIG. 6, the recording head generally designated by 50 is constituted of piezo-electric element 51, nozzle part 52, jet orifice 53 and supply tube 54. Designated by 55 is a subsidiary tank which has a projection part 55A. The projection part 55A is formed by extending one side wall (left-hand side wall as viewed on the drawing of FIG. 6) of the subsidiary tank and bending it toward the carriage 34 nearly at right angles relative to the upper surface side of the tank 55. The projection part 55A is fixed to the carriage 34 and the recording head 50 is fixed onto the projection part 55A. Thus, the carriage 34 supports the head on its upper surface and the subsidiary tank on its one side surface. As compared with the structure shown in FIG. 2, it is readily seen that the structure shown in FIG. 6 is smaller in size, lighter in weight and flatter in shape.
To keep the pressure within the subsidiary tank 55 at the same value as to the atmospheric pressure, again a vent hole 56 is provided in the top wall of the tank. It is preferred to form the top wall by using polyethylene, fluororesin or silicone resin. A plural number of vent holes 56 having an inner diameter less than 100 μm may be provided in such top surface. Alternatively, a membrane filter may be used. The subsidiary tank 55 has also a liquid inlet 57 provided at the lower portion of its one side wall (right-hand side wall as viewed on the drawing of FIG. 6). A supply line 37 is connected to the liquid inlet 57 to supply the recording liquid to the subsidiary tank 55.
As is understood from the foregoing, the present invention has may advantages over the prior art.
While the head/tank unit 31 according to the invention has basically the same structure as that of the prior art unit shown in FIG. 2, the former is smaller in size, lighter in weight and flatter in shape than the latter. Like the previously described embodiment shown in FIGS. 3 and 4, the embodiment shown in FIG. 6 is insensitive to tilt, vibration and impact of the main body of apparatus. There is no fear of the recording liquid leaking out from the tip of the recording head 50 or the meniscus at the orifice 53 being retrograded into the supply tube 54 by such tilt, vibration or impact. Also, the aforementioned trouble caused by air bubbles is eliminated by the present invention. Even when bubbles come into the supply lines 37 and 39, they can not enter the recording head 50 unlike the conventional cases where a bubble can go on directly into the recording head. In the apparatus according to the invention, the bubbles in the supply line are not allowed to directly enter the recording head but enter the subsidiary tank 55. Since the subsidiary tank 55 is provided with vent hole 56, the bubbles disappear there and never come into the recording head 50. Therefore, the trouble of orifice blockage is eliminated and a stable and reliable printing operation is assured. Furthermore, since the subsidiary tank serves also as a buffer to the pumping pressure, the trouble of leakage ink from the orifice is eliminated. This enables driving of the carriage at a higher speed than in the conventional apparatus shown in FIG. 1.
As previously described in detail with reference to FIGS. 3 and 4, feeding of ink to the subsidiary tank is accomplished by a pumping effect. This feature of the invention allows the bottom surface of the main tank 40 to lie on a level lower than the bottom of the subsidiary tank 33. Therefore, it is made possible to shape the apparatus thinly as a whole and use a larger capacity of main tank. In this case, when the liquid level of the recording liquid in the main tank 40 sinks down to a level lower than the bottom surface of the subsidiary tank 33, the recording liquid may flow backward from the subsidiary tank 33 to the main tank 40. To prevent such counter flow of the recording liquid there may be provided a check valve in the supply line 39 as a preferred modification of the above embodiment.
In summary, the important feature of the present invention resides in that a subsidiary tank whose capacity is smaller than a main tank and a recording head are united together to form a unitary unit which is mounted on a carriage and that said subsidiary tank and main tank are connected by a flexible tubing directly or via a fixed point. With this structure, the flexible tubing supply line is swingably moved to describe circular arcs every time the carriage is moved. As a result of this swing motion, the recording liquid in the supply line is subjected to a centrifugal force which produces a pumping effect. Therefore, the recording liquid is automatically supplied to the subsidiary tank from the main tank without use of any particular pumping device.
The above feature of the invention enables use of a very small capacity subsidiary tank mounted on the carriage. Since the capacity of the subsidiary tank is extremely small, the change of weight load on the carriage becomes negligibly small. Therefore, there is caused no change of carriage running speed by change of weight even when a linear motor or the like is used as the carriage driving motor. All of the impacts which may be produced when the carriage running at a high speed is struck against the guide end, are absorbed by the subsidiary tank itself and also the recording liquid contained therein. Therefore, the trouble of leakage of ink at the end part can be minimized as compared with the known apparatus in which such impact force acts on the recording head directly. Thus, according to the invention there is provided an ink jet type recording apparatus which assures a high quality and high speed printing. | An ink jet type recording apparatus is disclosed which includes a main tank containing recording liquid, a subsidiary tank receiving a supply of recording liquid from the main tank through a supply line, a recording head to which the recording liquid is fed from the subsidiary tank through a feeding pipe and a carriage carrying thereon the subsidiary tank and recording head. The recording liquid is supplied to the subsidiary tank from the main tank by a pumping pressure produced in the supply line when the carriage is running. The supply line is fixed at an optionally selected point in such manner than the segment of the supply line extending from the selected point to the subsidiary tank may swing move above the fixed point describing a circular arc in accordance with the running of the carriage. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a double-clutch transmission having hydraulic shift cylinders and a control device for controlling the operation of the shift cylinders.
2. Description of the Related Art
A device for controlling hydraulic shift cylinders is disclosed in published German Patent Application No. DE 10 2005 019 516 A1. The device includes a first slide valve with a control inlet that is pressurizable with a control pressure, and a system pressure inlet that is pressurizable with system pressure, as well as two outlets and at least one return outlet. Depending upon the pressure present at the control inlet optionally one of the two outlets is connected to the system pressure, possibly through a pressure regulating mechanism, and at the same time the other outlet is connected to the return outlet. A valve device by means of which the shift cylinders are selectively actuatable is connected to the outlets of the slide valve.
In addition, a hydraulic control for actuating a double-clutch transmission is known, wherein a plurality of shift cylinders are actuated hydraulically to shift gears. The shift cylinders can be pressurized by means of a selector valve system by connecting the hydraulic cylinders for actuating the two clutches and the shift valve system to the pressure side of a pressure apparatus. To initiate a shift process, a rotary valve selects the shift rail that is to be moved. The selector valve system, which includes a two-stage pressure-regulating valve, is actuated by means of a proportional electromagnet. In a middle region of the controlling magnetic flux, the selector valve system opens its two outlet ports, which are connected to the tank, so that those ports become depressurized. For high control currents, the selector valve system regulates the pressure in the first outlet port, while the second outlet port remains connected to the tank. For low control currents, on the other hand, the selector valve system regulates the pressure in the second outlet port, while the first outlet port remains connected to the tank. By means of a rotary slide valve, the two pushers are guided on both sides of the double-acting cylinder of the correspondingly selected shift rail. At the same time, the shift cylinders for the inactive shift rails are pressurized on both sides with the same pressure, so that they do not move.
To adjust a desired shift rail position, the selector valve system must be regulated back and forth quickly by means of the magnetic flux, between the low pressure region at the first outlet port and the low pressure region at the second outlet port. That means that for the movement of the valve piston in the selector valve system, the piston must move back and forth very rapidly between the two control edges of the outlet ports. To prevent leakage and consequent loss of system pressure, the two positions must be located relatively far apart from each other, so that the overlap at the two control edges is as large as possible, because the valve piston must be between those two control edges as long as no gear is selected, so that there is no pressure in the two outlet ports.
However, that long travel of the valve piston between the two control edges means that the controllability of the selector valve system is limited, particularly at low temperatures, at which high viscous friction occurs in the valve due to the viscosity of the hydraulic fluid. Likewise, that long distance from the respective rest positions until one of the control edges is reached also results in delays in purely force-controlled or pressure-controlled engagement of a gear.
An object of the present invention is therefore to provide a device for controlling a plurality of hydraulic shift cylinders, in which the viscosity of the hydraulic fluid has no influence on the controllability of the actuation of the shift cylinders even at low temperatures, and with which the speed of engaging a gear is improved.
SUMMARY OF THE INVENTION
Briefly stated, in accordance with one aspect of the present invention, a double-clutch transmission for providing a plurality of output speeds includes at least three shift cylinders for actuating shift rails associated with respective gear stages of the transmission; and a control device for selectively actuating respective shift cylinders, wherein the control device includes at least three electromagnetically switchable directional valves for actuating respective ones of the shift cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and advantages of the present invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a hydraulic circuit diagram in accordance with an embodiment of the present invention;
FIG. 2 is a graph showing the pressure distribution at the control edges of directional valve A of FIG. 1 as a function of the magnetic flux present at the valve or on the valve position; and
FIG. 3 is the hydraulic circuit diagram of FIG. 1 with modified shift allocations of directional valve B.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hydraulic circuit diagram for actuating four shift cylinders 1 , 2 , 3 , and 4 of a double-clutch transmission. As is known, a double-clutch transmission is made up of two divided transmissions, each of which is controlled hydraulically by a respective associated actuation arrangement. The actuation arrangement is composed essentially of a corresponding number of shift rails for selecting gears. In that example two shift rails S U 1 , S U 2 are needed for divided transmission with the odd-numbered gears and two shift rails S G 1 , S G 2 for the even-numbered gears. Each of the four shift rails S U 1 , S U 2 , S G 1 , S G 2 is controlled by a hydraulic or shift cylinder 1 , 2 , 3 , or 4 , which has two end positions, as is known, so that it is possible with those four shift rails S U 1 , S U 2 , S G 1 , S G 2 to select 8 gears, i.e., 7 forward gears and one reverse gear.
The individual gears are selected by shift cylinders 1 , 2 , 3 , and 4 . In that exemplary embodiment, shift cylinder 1 shifts gears seven and five, shift cylinder 2 shifts gears three and one, shift cylinder 3 shifts gears two and four, and shift cylinder 4 shifts gear six and reverse. As mentioned earlier, shift cylinders 1 , 2 , 3 , and 4 are actuated hydraulically and have two end positions, which are always associated with one of the two corresponding gears 1 through 8 , as well as a middle position in which neither of the two associated gears is selected.
It can be seen from FIG. 1 that the odd-numbered gears 7 , 5 , 3 , and 1 operate together with a first transmission input shaft (not shown) and with a first hydraulically operated clutch (not shown). Correspondingly, the even-numbered gears 2 , 4 , and 6 and the reverse gear operate together with a second transmission input shaft (not shown) and with a second hydraulically operated clutch (not shown).
By means of a pump, not shown in FIG. 1 , a system pressure p is produced in a conduit and in a line routed through a pilot valve. It can be seen from the hydraulic circuit diagram in FIG. 1 that a pressure regulator is formed by a directional valve A, with any number of intermediate positions, between the system pressure p and the unpressurized state by the connection to a tank. The system pressure p is present at an input to the directional valve A, and the other input is connected to the tank.
With the help of directional valve A, either of the two inputs can be pressurized alternately, while the respective other input is unpressurized. In addition, directional valve A has two outputs and a middle position M in which there is no pressure at any of the outputs. In that relatively narrow middle position M the control edges are designed for a minimal overlap, so that in the middle position M all four control edges, system pressure p—p 1 , p 1 —tank, system pressure p—p 2 as well as p 2 —tank are active without appreciable additional travel. That results in good controllability and only short delays when engaging a gear.
However, because directional valve A has significant leakage in that middle position M, and the pressure difference between the two outputs equals zero, it can only be regulated with difficulty. For that reason, two-way valves B and C are connected at the outlet side. In that case, directional valve B assumes the function of the inactive shift of the corresponding gear actuator, and therewith the function of the gear positioner, because directional valve B has three positions that are controlled by means of a proportional electromagnet.
Without current, the divided transmission with the odd-numbered gears is selected; with full current the divided transmission with the even-numbered gears is selected. The arrangement can also equally well be the opposite. But with medium current, both the two feed lines to gear actuator B and the two inputs are blocked. The directional valve C, controlled by means of a shift electromagnet, in turn selects within the divided transmission selected by directional valve B the corresponding active shift rail S U 1 , S U 2 , S G 1 , S G 2 . That control functions as follows.
In order to move a particular shift rail S U 1 , S U 2 , S G 1 , S G 2 , directional valve C is first set to the appropriate position, then directional valve A is set to the middle position, or to engage a gear it is set immediately to the desired pressure level. Next, the corresponding divided transmission is unlocked with directional valve B, which remains in its middle position as long as no shift motion is necessary. If the gear engaging or disengaging process, in which the pressure and possibly the travel distance are regulated by means of directional valve A, has ended, i.e., if the intended position of the shift rail S U 1 , S U 2 , S G 1 , S G 2 has thus been reached, directional valve B is first set to its middle position. Now the active shift rail S U 1 , S U 2 , S G 1 , S G 2 can not momentarily move. Next the current to directional valves A and C is switched off, on the one hand to save power and on the other hand to minimize the leakage at directional valve A, since the latter has the greatest overlap with the tank in the rest position or with full current. Directional valve B must be designed so that the overlaps with the tank and the adjacent positions are as large as possible in its middle position M.
In FIG. 1 the pressure p 1 coming from directional valve A pressurizes shift cylinder 1 , so that fifth gear is selected. In all of the other shift cylinders 2 , 3 , and 4 the same pressure level p 2 exists at both inputs or outputs, so that shift cylinders 2 , 3 , and 4 remain in their middle position M.
FIG. 2 illustrates the control of the closing body to form the control edges within directional valve A, and thus system pressure p by means of a magnetic flux φ, so that it is divided into two different high pressures p 1 and p 2 . In the middle position M of directional valve A, in which the overlap of the control edges is minimal and the two pressures p 1 and p 2 are briefly superimposed, all four control edges are active.
FIG. 3 shows another possibility for shift occupancy of directional valve B, in which both pressures p 1 and p 2 are connected to the tank and thus there is no flow in the system.
Although particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit of the present invention. It is therefore intended to encompass within the appended claims all such changes and modifications that fall within the scope of the present invention. | A double-clutch transmission having at least three and preferably four, hydraulic shift cylinders, and a control device to actuate the hydraulic shift cylinders. To improve the speed of operation when selecting a gear, the shift cylinders needed for gear shifting are actuated with the aid of at least three electromagnetically shiftable directional valves. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
BACKGROUND
[0002] 1. Field of Invention
[0003] This invention relates to hinges, specifically to hinges used for doors.
[0004] 2. Description of Prior Art
[0005] For years, door hinges have operated much the same way. A notch is made on the edge of a door as well as the door jamb to accommodate the hinge leafs and allow the hinge leafs to sit flush with the door edge and jamb. Once the hinge is mounted into place, there is very little room for adjustment and if adjustment is needed, further machining of the door and jamb must be made in order for the door to fit properly into the door jamb. Several attempts at solving this problem have been made such as displayed in U.S. Pat. Nos. 7,350,272, 994,196, 2,940,115, 5,799,370 and 6,202,255. These solve the problem, but with considerable retooling of the door and door jamb. The closest invention to this one is U.S. Pat. No. 928,760 (W. F. Hunter) Hunter's hinge solves the problem, but again because of the thickness of his hinge, it would require re-machining a door and door jamb. U.S. Pat. No. 2,373,955 shows a similar mechanism, but requires the hinge pin to be turned in order to adjust the height of the door. This is impractical because the hinge pin should stay rigid in relation to one of the hinge leafs to be stable. This invention solves this problem by providing a mechanism which allows a hinge to be adjusted vertically after the hinge has been mounted and without the need for re-machining the door or door jamb.
SUMMARY
[0006] This invention is a hinge with a mechanism allowing for vertical adjustment of the hinge leafs.
OBJECTS AND ADVANTAGES
[0007] Several objects and advantages of the present invention are:
a) to provide a mechanism for adjusting a door vertically after its hinges have been installed. b) to provide a means for said mechanism to adjust a door vertically with out further machining of a door or its jamb. c) to provide said mechanism to the marketplace in a way that it can replace existing hinges without further machining of a door or its jamb
[0011] FIG. 1 is an exploded view of an Adjustable Hinge
[0012] FIG. 2 is a view of an Adjustable Hinge attached to a door and a door jamb.
[0013] FIG. 3 is a detail top and orthographic view of an adjusting nut and adjusting nut set screw.
[0014] FIGS. 4 and 5 show an alternate embodiment of my invention.
REFERENCE NUMERALS IN DRAWINGS
[0000]
10 adjustable hinge
15 jamb leaf
20 threaded hinge pin
25 jamb leaf pin barrel
30 jamb leaf pin barrel
35 jamb leaf pin barrel
40 door leaf
45 door leaf pin barrel
50 door leaf pin barrel
55 threaded adjusting nut
60 threaded adjusting nut
65 jamb leaf mounting holes
68 jamb leaf mounting screws
70 door leaf mounting holes
72 door leaf mounting screws
75 adjusting nut set screw
80 adjusting nut set screw
85 door edge
90 door jamb
95 smooth hinge pin
100 shaft collar
105 shaft collar
110 shaft collar set screw
115 shaft collar set screw
DESCRIPTION
[0039] FIGS. 1 , 2 and 3 Preferred Embodiment
[0040] A preferred embodiment of the mechanism is illustrated in FIGS. 1 (exploded view of an adjustable hinge), 2 (view of an adjustable hinge mounted to a door and respective door jamb) and 3 (detail of adjusting nut and adjusting nut set screw showing top and orthographic views).
[0041] A jamb leaf 15 is connected to pin barrels 25 , 30 , and 35 . A door leaf 40 is connected to pin barrels 45 and 50 . A jamb leaf 15 and a door leaf 40 are connected to one another by a threaded hinge pin 20 which penetrates pin barrels 25 , 45 , 30 , 50 and 35 . Adjusting nuts 55 and 60 are threaded onto a threaded hinge pin 20 in such a manner that adjusting nut 55 resides between the bottom of door leaf pin barrel 45 and the top of jamb leaf pin barrel 30 and adjusting nut 60 resides between the bottom of door leaf pin barrel 50 and the top of jamb leaf pin barrel 35 . A threaded hinge pin 20 is rigidly attached to jamb leaf pin barrels 25 , 30 and 35 in such a manner that said threaded hinge pin 20 does not pivot within pin barrels 25 , 30 and 35 . Openings of door leaf pin barrels 45 and 50 are made large enough to allow pin barrels 45 and 50 and thus door leaf 40 to pivot freely about threaded hinge pin 20 . Door leaf pin barrel 45 is penetrated by a threaded hinge pin 20 in such a manner that it resides between jamb leaf pin barrel 25 and adjusting nut 55 . Door leaf pin barrel 45 is made short enough in relation to the space between jamb leaf pin barrels 25 and 30 as to allow for vertical movement along a threaded hinge pin 20 . Likewise door leaf barrel 50 is penetrated by a threaded hinge pin 20 in such a manner that it resides between jamb leaf pin barrels 30 and adjusting nut 60 . Door leaf pin barrel 50 is made short enough to allow for vertical movement along a threaded hinge pin 20 . Adjusting nut 55 is held in place along a threaded hinge pin 20 by the threads of adjusting nut 55 attached to the threads of threaded hinge pin 20 and by set screw 75 . Adjusting nut 60 is held in place along a threaded hinge pin 20 by the threads of adjusting nut 60 attached to the threads of threaded hinge pin 20 and by set screw 80 . Door leaf pin barrels 45 and 50 are held in place at the desired location along a threaded hinge pin 20 by adjusting nuts 55 and 60 and respective set screws 75 and 80 . An adjustable hinge 10 is attached to a door and respective door jamb by door leaf mounting screws 72 penetrating door leaf screw holes 70 anchoring a door leaf jamb 40 to a door 85 and jamb leaf mounting screws 68 penetrating jamb leaf holes 65 anchoring a jamb leaf 15 to a door jamb 90 .
[0042] FIG. 4 —Additional Embodiment
[0043] An additional embodiment is shown in FIG. 4 . A jamb leaf 15 is connected to pin barrels 25 , 30 , and 35 . A door leaf is connected to pin barrels 45 and 50 . A jamb leaf 15 and a door leaf 40 are connected to one another by a smooth hinge pin 95 which penetrates pin barrels 25 , 45 , 30 , 50 and 35 . Shaft collars 100 and 105 are penetrated by a smooth hinge pin 95 in such a manner that shaft collar 100 resides between the bottom of door leaf pin barrel 45 and the top of jamb leaf pin barrel 30 and shaft collar 60 resides between the bottom of door leaf pin barrel 50 and the top of jamb leaf pin barrel 35 . A smooth hinge pin 95 is rigidly attached to jamb leaf pin barrels 25 , 30 and 35 in such a manner that said smooth hinge pin 95 does not pivot within pin barrels 25 , 30 and 35 . Openings of door leaf pin barrels 45 and 50 are made large enough to allow pin barrels 45 and 50 and thus door leaf 40 to pivot freely about a smooth hinge pin 95 . Door leaf pin barrel 45 is penetrated by a smooth hinge pin 95 in such a manner that it resides between jamb leaf pin barrel 25 and shaft collar 100 . Door leaf pin barrel 45 is made short enough in relation to the space between jamb leaf pin barrels 25 and 30 as to allow for vertical movement along a smooth hinge pin 95 . Likewise door leaf pin barrel 50 is penetrated by a smooth hinge pin 95 in such a manner that it resides between jamb leaf pin barrels 30 and shaft collar 105 . Shaft collar 100 is held in place on a smooth hinge pin 95 by a set screw 110 . Shaft collar 105 is held in place on a smooth hinge pin by a set screw 115 . Door leaf pin barrels 45 and 50 are held in place at the desired location along a smooth hinge pin 95 by shaft collars 100 and 105 and respective set screws 110 and 115 . Door leaf pin barrel 50 is made short enough to allow for vertical movement along a smooth hinge pin 95 . An adjustable hinge 10 is attached to a door and respective door jamb by door leaf mounting screws 72 penetrating door leaf screw holes 70 anchoring a door leaf jamb 40 to a door 85 and jamb leaf mounting screws 68 penetrating jamb leaf holes 65 anchoring a jamb leaf 15 to a door jamb 90 .
[0044] Operation—FIGS. 1 , 2 and 3
[0045] The manner in which one uses an adjustable hinge 10 consists first of attaching the jamb leaf 15 to the door jamb 90 using jamb leaf mounting screws 68 inserted through jamb leaf mounting holes 65 . The jamb leaf mounting screws 68 are subsequently driven into the door jamb 90 holding the jamb leaf 15 firmly against the surface of the door jamb 90 . The door leaf 40 is attached to the edge of a door 85 by first inserting the door leaf mounting screws 72 through the door leaf mounting holes 70 . The door leaf mounting screws 72 are subsequently driven into the edge of the door 85 holding the door leaf 40 firmly against the door 85 . Adjusting nuts 55 and 60 , being threaded onto the threaded hinge pin 20 , will move vertically along the length of the threaded hinge pin 20 by turning them in a clockwise or counter-clockwise direction, depending on the bias of the threads. After the adjustable hinge 10 is mounted to the door 85 and door jamb 90 , the height of the door 85 can be adjusted by turning the adjusting nuts 55 and 60 in the direction that facilitates the desired vertical motion, either up or down , of the door. Pressure from the top surfaces of the adjusting nuts 55 and 60 against the bottoms of the door leaf pin barrels 45 and 50 causes the door leaf 40 and thus the attached door 85 to be moved vertically in the same direction as the vertical motion of the adjusting nuts 55 and 60 . Once the desired height of the door 85 is reached by turning the adjusting nuts 55 and 60 , the adjusting nuts 55 and 60 can be secured by driving the set screws 75 and 80 into the adjusting nuts 55 and 60 and against the threaded hinge pin 20 .
CONCLUSION, RAMIFICATIONS AND SCOPE
[0046] The reader will see the mechanism of the invention provides the user with a useful method of adjusting the height of a door without the need for additional machining of the door or door jamb.
[0047] While my above description contains many specificities, these should not be construed as limitation on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible. For example, the adjustable hinge can be reversed. It can be installed with the jamb leaf attached to the door and the door leaf attached to the door jamb.
[0048] The size and shape of the invention should not be construed to be limited to the preferred embodiment, but may be of any size or shape that would be useful for a particular implementation. For example the size of the adjustable hinge could be scaled down to be useful for small cabinet doors, or scaled up to accommodate large barn doors. The shape could be made in any form that is practical and/or aesthetically pleasing. The adjustable hinge could also be used on lids where the adjustment is needed in the horizontal, instead of the vertical direction. | A mechanism for providing a means of adjusting the vertical height of a hinged door having a jamb leaf ( 15 ) with jamb leaf pin barrels ( 25 ), ( 30 ) and ( 35 ) attached to a door leaf ( 40 ) with door leaf pin barrels ( 45 ) and ( 50 ) by means of a threaded hinge pin ( 20 ) penetrating leaf pin barrels ( 25 ), ( 30 ),( 35 ),( 45 ) and ( 50 ). A means ( 55 ) and ( 60 ), containing set screws ( 75 ) and ( 80 ), of adjusting the vertical height of one leaf ( 40 ) in relation to the other leaf ( 15 ). A means ( 70 ),( 72 ), ( 65 ) and ( 68 ) of mounting said adjustable hinge to a door ( 85 ) and door jamb ( 90 ). | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of international application PCT/DE2004/001162 filed Jun. 7, 2004, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for processing mailpieces that have been dropped into mail drop boxes, whereby a plurality of mailpieces are collected and then transported in transportation containers to postal centers and are sorted in the postal centers by means of sorting devices according to postal categories.
2. Description of Related Technology
Methods of this generic type are being used by postal service providers worldwide for millions of letters daily.
One prior-art method of this type is known from EP 1 072 328 A2. This method involves sorting mailpieces during their transportation on conveyor belts according to postal categories. During the transportation of the mailpieces on the conveyor belt, the weight and the dimensions of the mailpieces are ascertained. Subsequently, on the basis of the determined weight and the determined dimensions, the mailpieces are classified in postal categories and systematically ejected from the area of the conveyor belt.
FR 2 637 823 relates to a device for automatically sorting envelopes with which envelopes of various formats are delivered in a container, aligned in a special manner, and are then removed from the container in groups and fed to the sorting device. After a singulation step, the size of the envelopes is determined by means of specially arranged light barriers and the envelopes are diverted into different containers on the basis of their size.
U.S. Pat. No. 4,136,780 describes a singulation and sorting system with which the mailpieces are first placed into an input hopper and then separated by an inclined conveyor. Via a controllable receiving station, the mailpieces then reach one of several singulation sections which are followed by a device in which photocells ascertain the dimensions of the mailpieces. Subsequently, the mailpieces are diverted and stacked according to their dimensions.
U.S. Pat. No. 6,126,017 discloses a device for sorting mailpieces with which the mailpieces, sorted according to address, are diverted into buffer receptacles in which the mailpieces become arranged in stacks. Once a buffer receptacle is filled, the mailpieces are emptied in an output receptacle.
Moreover, EP 0 436 521 A2 describes a method and a device for identifying mailpieces in order to mark “zip-code” segments in stacks of mailpieces. Here, stacks of mailpieces are placed into a hopper and then singulated. A reader then ascertains the “zip code” and the mailpieces are provided with a first identification mark at a certain position, which is changed when the “zip code” is changed, and they are likewise provided with an identification mark whose position is changed every time the first three digits of the “zip code” changes. Subsequently, the mailpieces are stacked.
With the known methods of this type, the contents of the transportation containers are tipped out, immediately placed onto conveyor belts and ejected on the conveyor belts from a predefined conveying sequence according to postal categories.
Methods are likewise known with which mailers of mailpieces sort the mailpieces according to sorting criteria specified by the particular postal service provider and then mail them according to this sorting. The mail that has been presorted in this manner is subsequently taken directly to an appropriate processing station according to the complete presorting that was systematically undertaken by the mailer.
Moreover, in the state of the art, several non-generic product recognition systems are known. The prior-art product recognition systems allow the recognition of objects preferably by means of computer-aided optical scanning devices.
A known non-generic product recognition system is described in European patent EP 0 685 814 B1 and in its German counterpart DE 695 18 947 T2. This known product recognition system allows the identification, classification, evaluation and verification of objects. By using computer systems that make evaluations on the basis of target object images, it is possible to achieve teachable object recognition and consequently to depict numerous objects. This known non-generic method is especially well-suited for distinguishing between various kinds of fruit.
Moreover, numerous automatic control systems for robots are known in the state of the art.
A non-generic automatic control system with a robot-controlled manipulation means is known from EP 0 251 441 B1 and in its German counterpart DE 37 88 596 T2. This known automatic control system allows the guidance of a manipulation means as a function of determined information. Its use in laboratory systems is explained here by way of an application example for this automatic control system.
GENERAL DESCRIPTION OF THE INVENTION
The invention is provides a method that is suited for bulk sorting of mailpieces according to postal categories at a high processing speed in bulk operations in postal centers with minimal processing effort.
According to the invention, a processing method is carried out in such a way that the mailpieces are filled into the transportation containers, the transportation containers filled with the mailpieces are transported to unloading stations in the postal centers, during the filling of the transportation containers and/or during transport of the transportation containers to the postal center, a partial presorting of the mailpieces according to postal categories occurs, and subsequently, at the unloading stations, the mailpieces are removed in stacks from the transportation containers, utilizing the presorting according to postal categories, and the mailpieces are conveyed to subsequent processing stations as a function of the postal category.
The invention utilizes the surprising realization that an essentially coincidence-based presorting occurs during the filling and/or the transportation of mailpieces, so as to achieve a systematic processing of the mailpieces, in that the mailpieces are removed from the transportation containers according to the resultant presorting and are subsequently brought to the processing stations corresponding to the individual postal categories.
The mail drop boxes can be designed in many different ways. These can be post office branches, or postal agencies as well as mailboxes or receptacles in the area of customers of a postal service provider.
Previously, it has been assumed in technical circles that mailpieces are dropped into mailboxes completely at random and that they are thoroughly mixed up by the subsequent transport and handling procedures. In spite of handling several million letters every year, so far, no person skilled in the art has become aware of the fact that a presorting occurs through simple handling procedures of the mailpieces, especially their filling into transportation containers and the transport of the preferably box-shaped transportation containers.
Based on the conviction firmly held in technical circles that the mailpieces are unsorted, until now, mailpieces collected in mailboxes have been tipped out directly onto conveyor belts at the postal centers.
According to the invention, the mailpieces are removed from the transportation containers in stacks corresponding to the existing presorting, and the sorting effort is considerably reduced.
The invention can be implemented with various transportation containers. However, it is especially advantageous to use box-shaped transportation containers.
It has been found that a presorting takes place, especially when mailpieces are dropped into box-shaped transportation containers as well as during the transport in box-shaped transportation containers.
The nature of the partial presorting results from the dropping of the mailpieces into the transportation containers, from the structure of the mailpiece, from the transportation conditions and from the relationship between the dimensions of the transportation container and the mailpieces dropped into it.
In particular, partial presorting of the mailpieces results if the mailpieces are transported predominantly while lying flat.
The presorting procedures resulting from the transportation enhance the partial presorting that results during the previous filling of the mailpieces into the transportation containers.
In a preferred embodiment of the invention, at least some of the transportation containers are set up in drop-off places where, at least from one side, the mailpieces can be dropped off in a way that promotes an essentially horizontal position. This embodiment of the method according to the invention allows a faster processing of the mailpieces in the receiving stations.
The fundamentally desirable filling of mailpieces of different postal categories into different transportation containers—including the placement of the mailpieces in the transportation containers in a vertical position that enhances this complete arrangement—can thus be replaced by a much simpler and faster filling of the transportation containers. This is associated with a substantial reduction in time and effort at post offices or other mail receiving stations such as postal agencies.
This handling for some of the transportation containers can be combined at will with a suitable handling of other transportation containers.
A measure that further improves the presorting of the mailpieces according to the invention is characterized in that at least some of the transportation containers are conveyed in transporters means to mailers of mailpieces so that, in the area of the mailer of mailpieces, the mailpieces can be dropped essentially horizontally into the transportation containers.
Such handling is especially well-suited for collecting mailpieces from postal customers. Fundamentally, such a pick-up technique can be carried out for all postal customers, but it is advantageous to implement this pick-up technique especially for those customers who normally mail multiple mailpieces every day.
Mailing methods used so far required the mailers to tediously presort the mailpieces themselves according to postal categories and other sorting criteria or else required the employee of the particular postal service provider who was picking up the mailpieces to place them into the transportation containers arranged according to postal categories. These known methods are associated with the drawback that the mailer or the person picking up the mail has to presort the mailpieces. This calls for a certain amount of time for the mailer or for the person picking up the mail.
In an especially preferred embodiment of the invention, this drawback is avoided in that the mailpieces are placed into the transportation containers in a way that utilizes an essentially coincidentally occurring presorting. This embodiment of the invention takes advantage of the realization that many mailers already stack up the mail by size in a sorted arrangement when they are preparing the mailpieces for pick-up, for example, in order to enhance their overview.
When the transportation containers are filled with the mailpieces that are already presorted in this manner, it is advantageous to first deposit the smaller mailpieces so that the larger mailpieces come to lie on top of the smaller mailpieces.
However, it is likewise advantageous to conversely first deposit the larger mailpieces so that the smaller mailpieces come to lie on top since surprisingly, this, too, results in a partial presorting of the mailpieces.
With other methods of depositing mail, it is also advantageous to drop the mailpieces in a way that enhances such a presorting.
In this manner, a resultant presorting process of the mailpieces according to size is enhanced.
With numerous embodiments of the invention, it has been found that at least some of the largest mailpieces tend to accumulate in the upper part of the postal containers during the processing procedures. This phenomenon is a self-organizing process that enhances the presorting of mail and that has remained unrecognized until now.
Advantageously, other embodiments of the invention also utilize this mechanism of action.
Surprisingly, the partial presorting of the mailpieces that is utilized according to the invention and that arises coincidentally, but statistically reproducibly, also occurs when the mailpieces are dropped into other mail drop boxes such as, for example, mailboxes.
In an especially advantageous embodiment of the invention, this occurs in that at least some of the transportation containers are placed into mailboxes in such a way that mailpieces dropped into the mailboxes end up directly in the transportation containers.
However, it is equally advantageous that at least some of the transportation containers are filled by emptying collecting containers located in mailboxes.
The transportation containers filled with the mailpieces—preferably as a function of their filling level—are transported to additional mail drop boxes or to postal centers.
In a simple and advantageous embodiment of the invention, at least some of the transportation containers are taken directly to the unloading stations. In this manner, the structural requirements for carrying out the method are further reduced.
It is especially advantageous to carry out the invention in such a way that at least some of the transportation containers are taken to the unloading stations by means of a conveyor section. As a result, the feed of the mailpieces to the unloading stations can be adapted to the unloading capacities.
Moreover, it is advantageous for the transportation containers to be conveyed to the unloading means intermittently.
The intermittent feed of the transportation containers is advantageously carried out in such a way that, after a container has been emptied, another container is automatically conveyed to the unloading means. In this manner, the processing speed is further increased.
In an especially preferred embodiment of the invention, the transportation containers are conveyed to the unloading stations in such a way that, at least at times, at least two transportation containers are located in the area of an unloading station.
In this manner, the removal of the mailpieces from the transportation containers can be sped up. In particular, this embodiment of the invention allows the removal of mailpieces from a transportation container during the change-over of another transportation container.
In an especially advantageous embodiment of the invention, stacks of mailpieces of different postal categories are first removed from the transportation containers and, subsequently, mailpieces of one postal category remaining in the transportation containers are tipped out of the transportation container.
These process steps further increase the unloading speed. In particular, this makes it possible to utilize the resulting presorting of the mailpieces for the further simplification of the unloading of the mailpieces. In particular, during the execution of the method involving mailpieces of varying sizes, the smaller-format mailpieces—especially standard format letters—tend to accumulate in the bottom part of the transportation container. In this manner, stacks of mailpieces of different—preferably larger—postal categories can be removed first and subsequently, the mailpieces remaining in the transportation containers after the large mailpieces have been removed can be quickly removed by tipping over the transportation container.
Moreover, it is advantageous that in at least some of the unloading stations, stacks of mailpieces are recognized by at least one optical detection means. In this way, the method can be further sped up and automated.
Additional measures for speeding up and automating the method are described below:
The mailpieces can fundamentally be detected by any suitable detection, whereby product recognition systems, in particular teachable product recognition systems, are especially well-suited.
In another advantageous embodiment of the invention, in at least some of the unloading stations, the mailpieces are removed from the transportation containers by a robot.
The use of one or more robots for the stackwise removal of the mailpieces further increases the unloading speed.
The term “robot” is to be understood in the broadest sense of the word as a programmable manipulator. In particular, this means a reprogrammable multifunctional manipulator for executing changeably programmable movement sequences as set forth in the definition of the term “robot” according to The Robotics Institute of America.
In an especially preferred embodiment of the invention, mailpieces of at least one of the postal categories are fed to a subsequent processing station by means of a conveyor belt. With this embodiment of the invention, at least some of the mailpieces that have been removed from the transportation containers can be transported quickly to one or more of the processing stations located downstream.
Moreover, it is advantageous to equip the unloading stations in such a way that, below one or more transportation containers, there is a—preferably additionally installed—conveyor belt. Thanks to this conveyor belt, mailpieces that have been removed from the transportation containers can be dropped directly onto this conveyor belt, as a result of which they are automatically carried away. This further increases the processing speed.
In terms of the devices, this is advantageously realized in that the unloading station is configured in such a way that it has a holding device for one or more transportation containers and that two conveyor belts for conveying in different directions are provided below the site where the transportation containers are placed.
In this manner, mailpieces of a first postal category can be removed directly from the transportation containers and dropped directly above the suitable conveyor belt.
This is advantageously achieved in that a removal (i.e. manipulation) arm reaches into the mail container, removes a stack of mailpieces of the same postal category, drops them onto a conveyor belt located in front of and/or below the transportation containers and immediately thereafter reaches into the transportation container again and systematically removes more mailpieces of the same postal category.
Additional conveyor belts as well as additional transportation containers can likewise be used to further transport mailpieces of other postal categories.
Advantageously, different types of further transportation are provided for mailpieces of different postal categories so that the type of further transportation can be adapted to the number of mailpieces of a given postal category.
Thus, for example, when the method is carried out with mailpieces involving the postal categories of standard letters, compact letters, large letters and oversize letters, it is advantageous to convey machine-processable standard letters on one conveyor belt, machine-processable large and oversize letters on another conveyor belt and to drop the mailpieces of other postal categories into other transportation containers.
Furthermore, it is advantageous to carry out at least a partial singulation of the mailpieces on at least one of the conveyor belts.
In an especially preferred embodiment of the invention, the type of singulation is adapted to the postal category in question and to the mailing volume.
Thus, for example, it is advantageous for letters of a frequently occurring postal category—preferably machine-processable standard letters—to be subjected to one or more processing steps that promote their singulation while they are being transported on the conveyor belt.
When the method is carried out with an especially high mailing volume, the singulation steps yield an at least approximately continuous mail flow when the mailpieces are placed onto the conveyor belt essentially in stacks.
Mailpieces present in such a mail flow can be completely singulated in various suitable ways. For example, horizontal-vertical repositioning devices with a down-stream fast-running separation section can be used for this purpose.
In the case of mailpieces located on other conveyor belts—for example, for machine-processable compact and large letters—it is advantageous to carry out a complete singulation on the conveyor belt and to cancel the mailpieces during a pass on the conveyor belt.
An especially advantageous embodiment of such a canceling procedure is referred to below as rolling belt canceling.
In the rolling belt canceling procedure, the large and oversize letters that are to be canceled can be fed on a rolling belt. After being canceled, the oversize letters can then be taken from the belt and placed into prepared containers. An especially advantageous aspect is the possibility to adjust the speed of the rolling canceling belt. The throughput increases due to the simple activity of the rolling canceling (large and oversize) and of the removal of the oversize letters. As a result, the processing speed is increased as compared to manual sorting. Moreover, the mailpiece does not have to be picked up or rotated individually in order to be canceled.
Moreover, it is advantageous to carry out the method in such a way that at least some of the mailpieces are canceled while they are being transported on the conveyor belt.
This embodiment of the invention contributes to a further acceleration of the method. Although carrying out the canceling is fundamentally advantageous for all of the mailpieces that are further transported on conveyer belts, it is especially advantageous to carry out the canceling during the transportation on the conveyor belt for mailpieces with a relatively small mailing volume—for example, for large and oversize letters.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages, special features and practical refinements of the invention can be gleaned from the subordinate claims and from the presentation below of preferred embodiments making reference to the drawings.
FIG. 1 illustrates a schematic representation of a device that is suitable for carrying out the removal of the mailpieces and their subsequent processing;
FIG. 2 illustrates a section through the device shown in FIG. 1 along the line A-A;
FIG. 3 illustrates a section through the device shown in FIG. 1 along the line B-B; and
FIG. 4 illustrates a section through the device shown in FIG. 1 along the line C-C.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Below, the invention will be described with reference to especially advantageous embodiments.
The described embodiments are especially advantageous since they are suitable for the bulk processing of many mailpieces.
The representation is only to be understood by way of an example and can be used in a plurality of methods for processing mailpieces.
In particular, the described postal categories are only to be understood by way of examples. The selected postal categories can be adapted to the operational requirements in each case. However, it is especially advantageous to use known postal categories since then the method is compatible with other processing steps for mailpieces.
The designations of the postal categories can correspond to the postal categories used by the applicant as well as to other operational requirements of postal centers.
Moreover, the invention can also be realized in a myriad of structural ways.
In particular, the invention does not depend on a specific embodiment of the sorting devices 110 , 210 , 310 of FIGS. 1-3 , separately.
Before the mailpieces are processed in the sorting devices 110 , 210 , 310 , large numbers of mailpieces 100 , 200 , 300 that have been dropped into mail drop boxes are collected and subsequently transported in transportation containers 120 , 220 , 320 to postal centers.
Advantageously, the transportation containers are transported in the postal centers directly to the sorting devices 110 , 210 , 310 .
In order to ensure that at least one transportation container 120 , 220 , 320 filled with mailpieces is present in the sorting devices 110 , 210 , 310 at each of unloading stations 130 , 230 , 330 during the processing of the mailpieces, it is advantageous to transport the transportation containers 120 , 220 , 320 filled with the mailpieces 100 , 200 , 300 intermittently to the unloading stations 130 , 230 , 330 .
In an especially preferred embodiment, the transportation containers 120 , 220 , 320 are transported by a conveyor section 140 , 340 .
The structure of the conveyor section is shown in FIG. 1 as well as in FIG. 3 .
Transportation containers 120 , 320 filled with mailpieces 100 , 300 are placed onto conveyor section 140 , 340 in the area of loading stations 105 , 305 .
The conveyor section 140 , 340 contains suitable devices for transporting the transportation containers 120 , 320 . The devices (not shown here for the sake of clarity) are, for example, a suitably driven conveyer belt or a roller conveyor with driven rollers.
The conveyor section 140 , 340 serves to transport the transportation containers 120 , 320 to the unloading stations 130 , 330 .
The transportation containers 120 , 320 can be transported to the unloading stations 130 , 330 either directly or else via other transportation means.
An integration of additional transportation means allows an adaptation to different physical situations and thus considerable space savings.
Such an especially substantial space savings is achieved in the embodiment shown in FIG. 1 and FIG. 3 in that a repositioning device 135 , 335 is located at the end of the conveyor section 140 , 340 opposite from the loading station 105 , 305 .
The repositioning device 135 , 335 allows a transfer of the transportation containers 120 , 320 to an additional conveyor section 145 .
In an especially preferred embodiment, an additional conveyor section 145 extends essentially perpendicularly to the first conveyor section 140 .
The embodiment with a first conveyor section 140 , 340 and a second conveyor section 145 entails the advantage that the subsequent removal of the mailpieces 100 , 300 from the transportation containers 120 , 320 is largely uncoupled from the feed of the transportation containers 120 , 320 .
This advantageous uncoupling is also retained when a repositioning device 135 , 335 is located between the first conveyor section 140 , 340 and the second conveyor section 145 . However, the repositioning device 135 , 335 is associated with the additional advantage that the transportation containers 120 , 320 can be taken to the unloading stations 130 , 330 more quickly and with relatively few structural requirements.
Details of the unloading stations 130 , 230 , 330 are shown in FIGS. 1 , 2 , and 3 .
In particular, it is advantageous for two transportation containers to be situated next to each other, at least at times, at each of the unloading stations 130 , 230 , 330 .
Advantageously, the transportation containers 120 , 220 , 320 are taken to the unloading stations 130 , 230 , 330 in such a way that the transportation containers have an adjustable tilt angle of preferably about 50° to about 70° with respect to the horizontal.
In the area of the unloading stations 130 , 230 , 330 , a suitable product recognition system of the type known, for example, from EP 0 685 814 B1, the disclosure of which is incorporated herein by reference, is used to recognize stacks of mailpieces of the same postal category. Immediately after the recognition of the stack, or especially advantageously, essentially simultaneously with the recognition of the stack of mailpieces of the same postal category, a manipulation arm reaches into the transportation container 120 , 220 , 320 that is located in the area of the unloading station 130 , 230 , 330 and removes from the transportation container 120 , 220 , 320 the previously recognized stack of mailpieces 100 , 200 , 300 of the same postal category.
The manipulation arm is configured in different ways here. An implementation example is disclosed in EP 0 251 441 B1.
Immediately after the removal of the stack of mailpieces, the manipulation arm drops the stack of mailpieces 100 , 200 , 300 onto a conveyor belt that, if possible, is in the immediate vicinity of the transportation container.
The conveyor belt conveys standard letters and compact letters to another conveyor belt 170 , 175 , 250 , 280 , 350 , 380 .
Large letters are transported by another conveyor belt located in the area of the unloading stations 130 , 230 , 330 to another conveyor belt 150 , 160 for the conveyance of large letters.
At a mail volume of about 30,000 to 42,000 mailpieces per hour—of which about 30,000 to 36,000 are standard or compact letters and, for the rest, large or oversize letters—for large letters as well as two conveyor belts for standard letters, a singulation already occurs for the large letters through the selection of the conveying speed of the conveyor belts.
An additional singulation is carried out for standard letters and compact letters during the transportation on the conveyor belts 170 , 175 , 250 , 280 , 350 , 380 .
In order to further accelerate the method and to save more space, it is advantageous that an outgoing conveyor section 290 , 390 is arranged underneath the conveyor section 140 , 340 and/or underneath the conveyor belts 170 , 175 , 250 in order to return the emptied transportation containers 120 , 220 , 320 .
For purposes of achieving a rapid further transportation of the mailpieces that have been processed in the area of the sorting device 110 , 210 , 310 , it is advantageous to provide a means for automatically feeding additional transportation containers 195 , 395 .
In an especially preferred embodiment, the feed device for additional transportation containers 195 , 395 is configured in such a way that the additional transportation containers 195 , 395 are arranged directly underneath the end of conveyor belts 150 , 160 that are transporting processed mailpieces.
In an especially advantageous embodiment, the mailpieces slide directly via a chute 198 into the additional transportation container 195 .
Although the additional transportation containers 195 , 395 can have the same dimensions as the transportation containers 120 , 220 , 320 for the transport of the unsorted mailpieces, it is especially advantageous to configure the additional transportation containers 195 , 395 with smaller dimensions—especially with a smaller footprint.
In an especially preferred embodiment, the additional transportation containers 195 , 395 have dimensions that are slightly larger than the maximum size of the mailpieces being transported on the conveyor belts 150 , 160 .
In this manner, an orientation of the mailpieces that was achieved during the transfer of the mailpieces to the conveyor belts 150 , 160 can be retained.
An especially advantageous configuration of the feed means for the additional transportation containers 195 , 395 is configured in such a way that, at least over certain sections, the transportation containers 195 , 395 are transported parallel to the conveyor belts 150 , 160 .
In an especially advantageous embodiment, this is done in that, at least over certain sections, the conveying means for the additional transportation containers 195 , 395 are located parallel to the conveyor belts 150 , 160 for the mailpieces that are to be put into the additional transportation containers 195 , 395 .
An especially advantageous configuration of this is characterized in that the conveying means is configured as a conveyor section 199 , 399 .
In an especially preferred embodiment, the conveyor section 199 , 399 , which preferably extends parallel to the conveyor belts 150 , 160 and advantageously in the same direction but at a much lower transportation speed, is arranged directly below a conveyor belt 150 , 160 .
In this manner, the mailpieces conveyed on the conveyor belt 150 , 160 can reach the additional transportation containers 195 , 395 directly, for example, via a chute 198 .
Such a further transport of the mailpieces into the additional transportation containers 195 , 395 calls for very little processing effort and is also very space-saving so as to allow the feeding of the additional transportation containers 195 , 395 to be well integrated into the sorting devices.
Moreover, this also reduces the space requirement for the further transport of the additional transportation containers 195 , 395 as well as the required storage space for additional transportation containers 195 , 395 to be fed.
In the manner presented, the described sorting device can be integrated into existing postal centers.
In the postal centers, standard letters are canceled in automatic canceling machines. Address reading machines read the address and encode the mailpiece. In fine sorting machines, the letter is sorted in terms of the individual deliverer, parcel compartment systems/large customers, and then the mail volume intended for the deliverer is sorted so as to correspond to the delivery sequence (street number by street number) in the delivery sequence sorting machines. The machine throughput rate is, for example, 36,000 mailpieces per hour=10 letters per second.
This throughput rate relates to the number of standard mailpieces processed with the sorting device. Moreover, mail of additional postal categories can be present among the processed mailpieces, but the above-described process steps subject these mailpieces to a different processing operation than the standard letters.
In particular, it is advantageous to subject so-called machine-processable mailpieces to different processing steps than other mailpieces. The machine-processable mailpieces are especially standard letters. In particular, mailpieces that are flexible and that have standard dimensions are processed here. Mailpieces that are stiff or that have inflexible inserts and/or thickened edges on one side, or rounded edges or other deviations from standardized dimensions are fed to special processing means by the depicted sorting devices.
LIST OF REFERENCE NUMERALS
100 mailpieces
105 loading station
110 sorting device
120 transportation container
130 unloading stations
140 conveyor section
145 conveyor section
150 conveyor belt
160 conveyor belt
170 conveyor belt
175 conveyor belt
195 additional transportation container
198 chute
199 conveyor section
200 mailpieces
210 sorting device
220 transportation container
230 unloading stations
250 conveyor belt
290 outgoing conveyor section
300 mailpieces
305 loading station
310 sorting device
320 transportation container
330 unloading stations
340 conveyor section
390 outgoing conveyor section
395 additional transportation container
399 conveyor section | A method for processing mail, wherein a plurality of mailing items inserted into insertion places are collected and subsequently transported in a container to postal centers where they are sorted in sorting devices according to postal categories. The invention is characterized in that the mail is placed in transport containers which are transported to unloading areas in postal centers. When the transport container is filled and/or during the transportation of the container to the postal centers, random partial pre-sorting of mail takes place according to postal categories so that, when, the mail is removed from the containers at the unloading areas, it is in the form of piles formed by the predetermined pre-sorting method and sorted according to the postal categories, whereupon it is guided to subsequent processing stations according to said postal categories. | 1 |
This application is a division of application Ser. No. 07/936,625 filed Aug. 28, 1992, now U.S. Pat. No. 5,425,082.
BACKGROUND OF THE INVENTION
This invention relates to a communication processing apparatus, a communication processing system and a communication processing method, in which the communication processing apparatus has a telephone, which serves as an audio input/output unit, a facsimile device equipped with an image/text input/output unit, a communication unit, an enciphering unit, a display unit and a touch-panel dial input unit, as well as an external storage device such as a hard disk, a photomagnetic disk or a digital audio tape.
In our information-oriented society which has seen remarkable progress in recent years, the existence of the facsimile machine is of growing importance in that it has the ability to transmit information accurately, rapidly and in mixed form. In terms of the transmission of information in mixed form, a so-called multimedia function, through which audio and images are capable of being sent and received by a single apparatus, is important in the sense that complex, diversified information may be processed in a skillful manner.
In a case where it is desired to record received audio or image data in advance or to edit audio data that has already been recorded even when a function for this purpose is not available, it is necessary to create audio data using a device such as a tape recorder.
More specifically, with a device such as the conventional facsimile machine, it is possible to send and receive audio using the attached telephone, and to send and receive images using a facsimile device. Thus, these two different media can be handled by a single device.
In recent years, however, the diversification of communication media has been accompanied by increasing demand for achieving an interrelationship between audio data and image data such as facsimile image data.
The enciphering of image data has long been known. Specifically, a value serving as a code is decided by negotiation prior to transmission of image data between the sending and receiving sides. This value is preset on the sending and receiving sides. On the sending side, the value serving as the code is scrambled with the image data before the transmission is made. On the receiving side, the received data that has been enciphered based upon the value serving as the code is converted to reproduce the original image.
When audio and image data are communicated in interrelated form in the prior art described above, an absolute requirement is that the receiving party be present at the facsimile machine at the time that the image data are transmitted. This places a severe restriction upon the side receiving the data.
If the received audio and image data are stored in a memory device in inter-related form, a tape recorder is required in addition to the facsimile machine, and the separately recorded or stored data must be properly arranged and managed on the receiving side. This is a very troublesome task.
In a case where transmitted audio data are recorded in advance or already recorded audio data are edited, a tape recorder is required besides the facsimile machine. This is highly inconvenient.
Thus, in the prior art, the user is not furnished with a useful function through which audio, namely a voice message for supplementing an image, and the image are processed in interrelated form.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method through which the foregoing drawbacks of the prior art can be eliminated.
Another object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which it is unnecessary to limit the actions of the receiving party and a tape recorder is no longer required, and in which audio and images can be interrelated with ease and stored and the audio can be edited.
Another object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which a voice message can be appended in order to supplement the contents of transmitted image data.
Still another object of the present invention is to provide a communication processing apparatus in which the contents of image data that have been transmitted can be discriminated before the data are outputted, thereby making it possible to utilize paper resources effectively, as by excluding output of unwanted images sent by wrongful use of facsimile transmission.
A further object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which, when a questionnaire or the like is transmitted, responses having greater accuracy can be gathered by offering guidance through voice messages.
A further object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which, by converting audio into code data, the code data are stored in an external device and a voice message is capable of being edited by using the stored data.
Yet another object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which effective utilization can be made of voice messages that the user has recorded in the past, and in which a voice message sent from another party is stored and this voice message is appended to a voice message or image data to be transmitted for the purpose of replying, whereby the replying party can be notified more clearly as to the nature of the matter requiring a reply.
Yet another object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method through which it is possible to manage a history of responses and agreements by accumulating and consolidating audio and images sent in combined form.
A further object of the present invention is to provide a communication processing apparatus, a communication processing system and a communication processing method in which the enciphering not only of images as in the prior art but also of audio from a telephone makes it possible to improve the reliability of communication in terms of maintaining the confidentiality of communication data.
Another object of the present invention is to provide a communication processing apparatus comprising first converting means for converting audio into digital data, second converting means for converting the digital data, which has been converted by the first converting means, into code data, and transmitting means for uniting and transmitting the code data converted by the second converting means and document data prepared in advance.
Another object of the present invention is to provide a communication processing apparatus comprising first converting means for converting audio into digital data, second converting means for converting the digital data, which has been converted by the first converting means, into code data, third converting means for converting the code obtained by the second converting means into enciphered data, and transmitting means for uniting and transmitting the enciphered data converted by the third converting means and document data prepared in advance.
Another object of the present invention is to provide a communication processing system for performing communication processing between a transmitting apparatus and a receiving apparatus via a line, wherein the transmitting apparatus has first converting means for converting audio into digital data, second converting means for converting the digital data, which has been converted by the first converting means, into code data, and transmitting means for uniting and transmitting the code data converted by the second converting means and document data prepared in advance, and the receiving apparatus has receiving means for receiving data from the transmitting apparatus, third converting means for converting, into digital data, code data corresponding to audio in the data received by the receiving means, fourth converting means for converting the digital data, which has been converted by the third converting means, into analog data, and output means for producing an audio output based upon the analog data converted by the fourth converting means.
Another object of the present invention is to provide a communication processing method comprising a first step of converting audio into digital data, a second step of converting the digital data, which has been converted by the first converting step, into code data, a transmitting step of uniting and transmitting the code data converted by the second converting step and document data prepared in advance, a receiving step of receiving data transmitted by the transmitting step, a third converting step of converting, into digital data, code data corresponding to audio in the data received by the receiving step, a fourth converting step of converting the digital data, which has been converted by the third converting step, into analog data, and a step of producing an audio output based upon the analog data converted by the fourth converting step.
Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the construction of a facsimile apparatus according to a first embodiment of the present invention;
FIGS. 2A and 2B are diagrams illustrating examples of communication procedures according to recommendation T62 in accordance with this embodiment;
FIG. 2C is a diagram showing an example of a control document according to this embodiment;
FIG. 3 is a flowchart for describing a voice-code converting procedure according to this embodiment;
FIG. 4 is a flowchart for describing a first communication control procedure by a CPU according to this embodiment;
FIG. 5 is a flowchart for describing a second communication control procedure by a CPU according to this embodiment;
FIG. 6 is a flowchart for describing a third communication control procedure by a CPU according to this embodiment;
FIG. 7 is a flowchart for describing a fourth communication control procedure by a CPU according to this embodiment;
FIG. 8 is a flowchart for describing a fifth communication control procedure by a CPU according to this embodiment;
FIG. 9 is a flowchart for describing a sixth communication control procedure by a CPU according to this embodiment;
FIG. 10 is a flowchart for describing a seventh communication control procedure by a CPU according to this embodiment;
FIG. 11 is a flowchart for describing a eighth communication control procedure by a CPU according to this embodiment;
FIG. 12 is a flowchart for describing a ninth communication control procedure by a CPU according to this embodiment; and
FIGS. 13A, 13B, 14 and 15 are diagrams for giving a supplementary explanation of the eighth communication control procedure according to this embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 1 is a block diagram illustrating the construction of a facsimile apparatus embodying the present invention. As shown in FIG. 1, the facsimile apparatus includes a CPU 1 comprising a microprocessor or the like. The elements described below are connected to a system bus 14 comprising address and data buses of the CPU 1, and the CPU 1 controls these elements to carry out a facsimile communication operation.
Specifically, a ROM 2 and a RAM 3, which serves as a working area, are connected to the system bus 14. The control program of the CPU 1 is stored in the ROM 2, and the RAM 3 is employed as the working area of the CPU 1.
The apparatus further includes a handset 4 for converting a voice into an audio signal (analog data) and sending the analog data to the system bus 14. The analog data are inputted, converted into a voice and outputted via the system bus 14. The audio signal is inputted to an audio converter 5 via the system bus 14, and the audio converter 5 converts the audio signal into digital data by a PCM (pulse-code modulation) conversion and sends the digital data to the system bus 14. The digital data are inputted via the system bus 14 and subjected to a reverse PCM conversion so as to be converted into an audio signal (analog data), and the analog data are sent to the system bus 14.
The digital data are inputted to a code converter 6 via the system bus 14. The code converter 6 converts the digital data into a code and sends the code data to the system bus 14. The code data are inputted via the system bus 14 and converted into digital data, and the digital data are sent to the system bus 14.
A reader 7 reads image data, performs code compression into an MH (modified Huffman) code, an MR (modified read) code or MMR (modified-modified read) code and sends the compressed data to the system bus 14. The compressed image data or text data are inputted to a print output unit 8 via the system bus 14, and the unit 8 outputs the data on paper.
A display unit 9 comprises a liquid-crystal device (LCD) for displaying various messages illustrated in FIG. 15. Further, the display unit 9 serves as a touch panel which displays "NO" and "YES" buttons. By pressing the "NO" button, a "NO" operation can be selected; pressing the "YES" button selects a "YES" operation.
A dial input unit 10, which is used when inputting another party's number, is capable of inputting numerals ("1", "2", "3", . . . ). A key input unit 11, which is used when creating text data, is capable of inputting English characters as well as hiragana and katakana characters of the Japanese syllabary. A communication controller 12 comprises a modem, an NCU (network control unit) and a call-signal detector, etc. The communication controller 12 interfaces the facsimile apparatus with a line 13, such as a telephone or ISDN (integrated service digital network). An enciphering converter 15, by coding audio data, is capable of being applied to audio data as well. Numeral 16 denotes a data storage unit which uses a hard disk or a photomagnetic disk.
By way of example, in a G4 facsimile machine which employs recommendation T62 of the CCITT (International Telegraph and Telephone Consultative Committee), a system employing a control document is employed as the system for transmitting character data. It is possible to distinguish the control document by a document-identifier parameter of a CDs command defined in recommendation T62.
FIGS. 2A and 2B are diagrams illustrating examples of communication procedures in recommendation T62 according to this embodiment, and FIG. 2C is a diagram showing an example of a control document according to this embodiment.
FIGS. 2A and 2B illustrate two types of methods for a case where coded audio data are transmitted and received in multidocuments. Communication Method 1 shown in FIG. 2A is a multidocument transceiving method in which audio data initially are transmitted/received in a control document, after which, in the next document, image data are transmitted/received in a normal document. Communication Method 2 shown in FIG. 2B is a multidocument transceiving method in which image data initially are transmitted/received in a normal document, after which, in the next document, audio data are transmitted/received in a control document.
In FIG. 2C, the control document is recommended in CCITT. T62. The data placed in this control document is divided according to domestic standards and company standards (a manufacturer's own mode). In this embodiment, a transmission is made in which an identifier (90), which indicates voice mail, and data are placed in application capability within the company standards. Text data also can be placed in the above-mentioned application capability as an identifier (80).
A method of communication according to this embodiment will now be described.
FIG. 3 is a flowchart for describing a voice-code converting procedure according to this embodiment.
The procedure illustrated in FIG. 3 shows the details of a voice-code converting procedure in first through ninth communication control procedures described below. First, at step S30 in FIG. 3, processing is executed for sampling analog data at a predetermined sampling rate and converting the data into digital data. This is followed by step S31, at which processing is executed for compressing the data based upon the continuity of the digital data obtained at step S30. For one example of a compressing method, see "A Technique for High. Performance Data Compression" by Terry A. Welch, IEEE Computer, vol. 17, No. 6 (June, 1984), pp. 8˜19.
Since compressed data are data which possess no meaning as code data, these data cannot be transmitted. Accordingly, at step S32, the compressed data are converted into a character code by a UNIX UU encoding method, and the character code is stored in the RAM 3. It should be noted that even if a character code is converted into a character, audio is not put into the form of documentation.
FIG. 4 is a flowchart for describing a first communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 4 is a processing procedure for a case where audio data, image data or text data are transmitted by a facsimile machine.
Step S41 calls for a voice message from the handset 4 to be stored in the RAM 3 as audio data. The above-mentioned voice-code conversion of FIG. 3 is performed at step S42. This is followed by step S43, at which the code data of RAM 3 are accumulated in the RAM 3 upon being consolidated in the form of a control document capable of being transmitted by facsimile.
At step S44, a document that has been set in place is read by the reader 7 and converted into image data thereby. Next, at step S45, the inputted image data are code-compressed into an MH code or MR, MMR codes capable of being transmitted by facsimile, and the compressed data are accumulated in the RAM 3. Step S46 calls for data inputted from the key input unit 11 to be stored in the RAM 3 as text data. This is followed by step S47, at which the text data in RAM 3 are accumulated in the RAM 3 upon being consolidated in the form of a control document capable of being transmitted by facsimile. At step S48, the control document for the voice message created at step S43, the normal document based upon compressed data created at step S45 and the control document for text data created at step S47 are combined in the form of a multidocument and accumulated in the RAM 3. This is followed by step S49, at which the multidocument created at step S48 is transmitted to line 13 via the communication controller 8.
FIG. 5 is a flowchart for describing a second communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 5 is a processing procedure for a case where audio data, image data or text data are received by a facsimile machine.
Step S50 in FIG. 5 calls for the multidocument data received from line 13 to be stored in the RAM 3 using the communication controller 12. Next, at step S51, the attributes of the documents are verified from the multidocument data of RAM 3, the audio data are extracted and these data are again stored in the RAM 3. This is followed by step S52, at which the audio data (code data) stored in the RAM 3 are reverse-code converted by UU encode using the code converter 6. Then, at step S53, the reverse-code converted digital data are decompressed, and the decompressed digital data are converted into analog data by a PCM conversion and then stored again in the RAM 3 at step S54.
Step S55 calls for the audio data in RAM 3 to be outputted as audio using the handset 4. Next, at step S56, the attributes of the documents are verified from the multidocument data of RAM 3, the image data are extracted and these data are again stored in the RAM 3. The image data stored in the RAM 3 are printed out at step S57 using the print output unit 8. Next, at step S58, the attributes of the documents are verified from the multidocument data of RAM 3, the text data are extracted and these data are again stored in the RAM 3. The text data stored in the RAM 3 are printed out at step S59 using the print output unit 8.
FIG. 6 is a flowchart for describing a third communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 6 is a processing procedure for a case where audio data is enciphered and transmitted by a facsimile machine.
Step S61 calls for a voice message from the handset to be stored in the RAM 3 as audio data. At step S62, the audio data are subjected to the above-mentioned voice-code conversion of FIG. 3.
This is followed by step S63, at which the code data of RAM 3 are accumulated in the RAM 3 upon being enciphered using the enciphering converter 15. The enciphered audio data (code data) created at step S63 are transmitted to line 13 via the communication controller 8 at step S64.
The enciphering of code data is carried out through a method of scrambling predetermined data in the code data, as is well known in the enciphering of image data in the prior art.
FIG. 7 is a flowchart for describing a fourth communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. In image and text data, the data classification and method of reception employ the same method as shown in FIG. 5. FIG. 7 is a processing procedure for a case where enciphered audio data are received by a facsimile machine.
Step S70 in FIG. 7 calls for the enciphered data received from line 13 to be stored in the RAM 3 using the communication controller 12. Next, at step S71, the enciphered data in RAM 3 are restored to the original audio data (code data) using the enciphering converter 15, and the restored data are again stored in the RAM 3.
Here the predetermined data that have been scrambled are eliminated from the received data, whereby a conversion which is the reverse of enciphering is executed.
This is followed by step S72, at which the audio data (code data) stored in the RAM 3 are reverse-code converted by UU encode using the code converter 6. Then, at step S73, the reverse-code converted digital data are decompressed, and the decompressed digital data are converted into analog data by a PCM conversion and then stored again in the RAM 3 at step S74.
The audio data in RAM 3 are outputted as audio using the handset 4 at step S75.
FIG. 8 is a flowchart for describing a fifth communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 8 is a method of rapidly putting audio data, image data and text data into the form of a multidocument and then transmitting the same by a facsimile machine.
At step S81 in FIG. 8, the system waits for the handset 4 to be raised (to attain the "UNHOOKED" state). The program proceeds to step S82 if the handset 4 has been unhooked. Step S82 calls for a voice message from the handset 4 to be stored in the RAM 3 as audio data. At step S83, the audio data are subjected to the above-mentioned voice-code conversion of FIG. 3.
Next, at step S84, the code data in RAM 3 are transmitted in the form of one control document to the line 13 via the communication controller 12. This is followed by step S85, at which it is determined whether a document has been set for the reader 7 to read. If a document has been set in place, the program proceeds to step S86, at which the set document is read by the reader 7 and converted into image data thereby. Next, at step S87, the inputted image data are code-compressed into an MH code or MR, MMR codes capable of being transmitted by facsimile, and the compressed data are transmitted, as a second normal document of a multidocument, to the line 13 via the communication controller 12. The system then waits for an input from the key input unit 11 at step S88, and the program proceeds to step S89-1 if an input is made. Step S89-1 calls for the data inputted from the key input unit 11 to be stored in the RAM 3 as text data. This is followed by step S89-2, at which the text data in RAM 3 are transmitted, as a third control document of a multidocument, to the line 13 via the communication controller 12.
FIG. 9 is a flowchart for describing a sixth communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 9 is a method of extracting audio data, image data and text data from stored data, putting the extracted data into the form of a multidocument and then transmitting the same by a facsimile machine.
At step S90 in FIG. 9, audio data stored in the data storage unit 16 are displayed on the display unit 9 in the order in which they were inputted, and an item of audio data is selected by a cursor. The selected voice message is outputted as audio from the handset 4 at step S91. Next, it is determined at step S92 whether the outputted voice message is the one sought. If it is ("YES" at step S92), the program proceeds to step S93. If the voice message is not the one sought, the program returns from step S92 to step S90. At step S93, the selected audio data are registered in the data storage unit 16 as one control document. Then, at step S95, the text data stored in the data storage unit 16 are displayed on the display unit 9 in the order in which they were inputted, and an item of text data is selected by a cursor and registered in the data storage unit 16.
This is followed by step S96, at which the control document for the voice message created at step S93, the normal document based upon compressed data created at step S94 and the control document for text data created at step S95 are combined in the form of a multidocument and registered in the storage unit 16. Next, at step S97, the multidocument created at step S96 is transmitted to line 13 via the communication controller 12.
FIG. 10 is a flowchart for describing a seventh communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 10 is a processing procedure for a case where audio data, image data and text data are received and rapidly outputted by a facsimile machine.
Step S100 calls for multidocument data received from the line 13 to be stored in the RAM 3 using the communication controller 12. Next, at step S101, the attributes of the documents are verified from the document data in the multidocument data of RAM 3, and the audio data are removed. This is followed by step S102, at which information reading "With voice message" is appended to header information. Next, at step S103, the attributes of the documents are verified from the multidocument data of RAM 3, and the image data are extracted. Then, at step S104, the header information created at step S102 is appended to the extracted image data, after which the image is printed out using the print output unit 8. Next, at step S105, the attributes of the documents are verified from the multidocument data of RAM 3, and the text data are extracted. Then, at step S106, the header information created at step S102 is appended to the extracted text data, after which the text is printed out using the print output unit 8.
FIG. 11 is a flowchart for describing an eighth communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 11 is a processing procedure for a case where audio data, image data and text data are received and stored temporarily in the data storage unit by a facsimile machine.
Step S110 calls for multidocument data received from the line 13 to be stored in the data storage unit 16 using the communication controller 12. Next, at step S111, a directory for document storage is created in the data storage unit 16. At step S112, the attributes of the documents are verified from the multidocument data of storage unit 16, and the audio data are extracted. This is followed by step S113, at which the audio data extracted at step S112 are stored in the directory of step S111. Next, at step S114, the attributes of the documents are verified from the multidocument data of storage unit 16, and the image data are extracted.
The image data extracted at step S114 are stored in the directory of step S115. Next, at step S116, the attributes of the documents are verified from the multidocument data of storage unit 16, and the text data are extracted. Then, at step S117, the text data extracted at step S116 are stored in the directory of step S115.
The structure of the directory and the procedure for referring to it are illustrated in FIGS. 13 through 15.
FIG. 12 is a flowchart for describing a ninth communication control procedure executed by the CPU 1 of this embodiment. The illustrated procedure is stored in the ROM 2 as a control program of the CPU 1. FIG. 12 is a processing procedure for a case where audio data, image data and text data are received and only the audio data are stored temporarily in the data storage unit by a facsimile machine.
Step S120 calls for multidocument data received from the line 13 to be stored in the data storage unit 16 using the communication controller 12. Next, at step S121, consecutive numbers are created in order to identify each of the documents. At step S122, the attributes of the documents are verified from the multidocument data of storage unit 16, and the audio data are extracted. This is followed by step S123, at which the audio data extracted at step S122 are stored in the data storage unit 16 with consecutive numbers attached to them. The consecutive numbers are subsequently retrieved and outputted.
Next, at step S124, the attributes of the documents are verified from the multidocument data of storage unit 16, and the image data are extracted. After the consecutive numbers created at step S121 are attached to the extracted image data, the image data are printed out at step S125 using the print output unit 8. Next, at step S126, the attributes of the documents are verified from the multidocument data of storage unit 16, and the text data are extracted. After the consecutive numbers created at step S121 are attached to the extracted text data, the text data are printed out at step S127 using the print output unit 8.
FIGS. 13 through 15 are diagrams for giving a supplementary explanation of the eighth communication control procedure according to this embodiment. These diagrams illustrate the structure of the directory and the method of referring to it.
The data storage unit 16 is partitioned into directory units (see FIG. 13), each of which has a label such as "Multidocument A". Under the label, a plurality of files in document units, namely as audio, image and text files, are present. In the case of a label "Multidocument B", a plurality of files in document units, namely audio, image and text files, are present under the label.
In terms of structure, the data of the label "Multidocument A" (FIG. 14) is composed of the time received (the time at which a facsimile transmission was received), the other party's dial number (the dial number of the party that made the transmission), the other party's abbreviated name (the abbreviated name of the party that made the transmission), the receiving party's abbreviated name (there are instances where the abbreviated name of the receiving party is included when the sending party specifies the receiving party), and a related-document pointer (a pointer which indicates a multidocument sent to another party or a multidocument sent previously from another party). These are used in order to refer to the directory.
The information displayed by the LCD of the display unit 9 when the directory is referred to is the content of the multidocument of each directory. Instances of reception are indicated at 1, 2, 3, . . . in descending order starting from the most recent. Reception time, the other party's abbreviated name, the other party's dial number and the content of the reception (sound: voice mail; picture: image data; document: text data) are displayed for each instance of reception, and selection is made by entering a number using a key or by employing the cursor for the selection.
Thus, in accordance with the present embodiment, as described above, means for converting audio (analog data) into digital data and means for converting the digital data into code data are provided. As a result, a voice message inputted from a telephone or the like is converted into code data and it is possible to transmit this data upon unifying it with facsimile image and/or text data.
The foregoing makes it possible to append a voice message in order to supplement the content of transmitted image data. Furthermore, applying this feature makes it possible to distinguish the content of image data by a voice message before the image data are outputted. This enables paper resources to be utilized effectively, as by enabling the user to exclude output of an unwanted image sent by wrongful use of facsimile transmission. In addition, when a questionnaire or the like is transmitted, responses having greater accuracy can be gathered by offering guidance through voice messages.
Further, by converting audio into code data, the code data may be stored in an external device and a voice message is capable of being edited by using the stored data.
As a result of the foregoing, effective utilization can be made of voice messages that the user has recorded in the past. In addition, a voice message sent from another party is stored and this voice message is appended to a voice message or image data to be transmitted for the purpose of replying, whereby the replying party can be notified more clearly as to the nature of the matter requiring a reply.
Further, it is possible to manage a history of responses and agreements by accumulating and consolidating audio and images sent in combined form. This makes it possible to verify the progress of agreements or transactions by storing telephone responses, which are transitory in nature, together with the associated image data and managing this information.
Further, the enciphering not only of images as in the prior art but also of audio from a telephone makes it possible to improve the reliability of communication in terms of maintaining the confidentiality of communication data. A combination of image and/or text data with coded audio raises the value of the individual items of information makes it possible to respond more accurately to the needs of a multimedia-information culture.
As a modification of the foregoing embodiment, identifiers for audio and for images/text can be set in the content of a document, thereby making possible transmission to the line 13 in the form of a single document instead of using the multidocument of step S110.
The present invention is not limited to the above-described embodiment but can be modified in various ways within the scope of the claims.
It should be noted that the present invention may be applied to a system composed of a plurality of devices or to an apparatus comprising one device. It goes without saying that the present invention can be applied also to a case where the above-mentioned effects are attained by supplying a program to a system or apparatus. | In a communication processing apparatus, communication processing system and communication processing method for performing communication processing between a transmitting unit and a receiving unit via a line, the transmitting unit converts audio into digital data, converts the resulting digital data into code data, units the resulting code data and document data prepared in advance and transmits the united data. The receiving unit receives the data from the transmitting unit, converts, into digital data, code data which corresponds to audio contained in the received data, converts the resulting digital data into analog data, and produces an audio output based upon the resulting analog data. | 8 |
This is a continuation of application Ser. No. 663,392, filed Oct. 22, 1984, which was abandoned upon the filing hereof.
RELATED APPLICATIONS
U.S. application Ser. No. 665,063, entitled TWIN-ROLL LAMINATED PACKAGING PROCESS AND APPARATUS, filed Oct. 26, 1984, (based on German P33 39 337.0) describes and claims an invention in the same general art area.
BACKGROUND OF THE INVENTION
The invention relates to apparatus for wrapping objects such as packs or bundles in a stretch foil, whereby the foil is drawn off from at least one delivery spool under tractive force and is then led around a winding cross-section. A transition conveyor is covered with foil and includes at least two conveyor belts arranged parallel one on top of the other. The lower one of these is designed as an actively driven conveyor belt with an outer side which is covered with the wrapping foil upon passing through the wrapping area, to form a tube of foil through which the objects to be wrapped pass. The upper conveyor belt is designed as a transport device for the packs of bundles.
Shaped, after-shrunk foils, i.e. so-called stretch foils, have made a far-reaching impact on wrapping technology in recent years. A feature of these foils is that an object wrapped in them is pressed together as a result of the remaining foil tension without the foil tearing. Thus, wrapping technology with the type of shaped, after-shrunk foil differs significantly from the using heat-shrunk foils.
In U.S. Pat. No. 4,050,220, an apparatus for wrapping packages is set forth with two conveyor belts arranged in a V-form for transporting objects to be wrapped to the wrapping station. Fixed guide rails are provided for the transport through the wrapping station. These guide rails are wrapped with foil, whereby the foil slides along the outer side of the guide rails as the packages move forward, and then slips off the guide rails at the end without any interruption. Because of the inherent tension, the foil then places itself onto the surface of the package units. The disadvantage of the fixed guide rails is that the foil clings to the guide rails as a results of the static electricity and cling effect, which then causes problems with the foil sliding off.
The concept set forth in U.S. Pat. No. 4,050,220, has been further developed (compare DE-OS No. 31 19 657). In the more advanced device, a transition conveyor has been provided which extends through the track of the winding tape lead apparatus and extends all the way through the lead apparatus without interruption. The transition conveyor consists of at least two conveyor bands arranged in a parallel position one above the other; the lower of these is designed as an actively driven conveyor with an outer side which is covered with the wrapping foil upon passage through the wrapping area, bringing the foil out. The upper conveyor belt is designed as a transport device for the packages. This permits a uniform forward movement of both packages and foil. The invention set forth here distinguishes itself from the familiar, above mentioned device.
In the apparatus described in DE-OS No. 31 19 657, the package units are always pushed in a certain direction through the wrapping in coils; thus, in the case of cartons loosely piled onto each other, which are to be grouped into a larger bundle, the positioning can slip and can even be grouped into a larger bundle, the positioning can slip and can even result in the dislodging of individual packages. In addition, a package unit can become damaged in its construction.
SUMMARY OF THE INVENTION
An objective of the invention is to improve on the above-described apparatus so that loosely layered bundles or package units can be wrapped reliably using a stretch foil.
This objective is accomplished by providing a second transition conveyor with the same design as the first to support the packages or bundles from above, whereby the inside conveyor is designed as a gliding plane or as a passively driven rolling plane for the packages or bundles.
The two transition conveyors should preferably be arranged horizontally and parallel to one another; some deviation, however, can be made from the horizontal position to a slight diagonal placement.
The arrangement of the invention deviates markedly from both the fixed guide rails in U.S. Pat. No. 4,050,220 and from the principle of the double conveyor belt as set for the in DE-OS No. 31 19 657. In particular, the transfer of power from the conveyor belt surface to the package units and the resulting, surprisingly uniform transport of the packges and the covering of them with foil is a significant step which simplifies the device and improves the operation.
The two transition conveyors forming the transition bridge are arranged above and below the package units, which is a reliable way to prevent the sliding and displacement of loosely piled pieced in a bundle. In addition, varying bundle sizes can be accomodated simply by altering the distance between the transition conveyors (means for altering not shown).
It is possible to make the gliding or roller plane wider than the conveyor belt when viewed from a diagonal to the direction of movement. In this case, during the actual wrapping process, the wrapping foil is already positioned at the sides of the package unit and is still in contact with the conveyor belt at the upper and lower sides.
The terms "gliding plane" and "roller plane" refer generally to so-called rolling conveyor planes equipped with positioned ball bearings or parallel roller rods, as in common in conveyor technology.
Above all, when adjustable roller rods housed in split bearings are used, it is possible to alter the width of the roller planes. In so doing, one might choose, for example, a dovetailing, overlapping roller rod arrangement, whereby one half of the roller rods can be shifted to one side and the other half to the other side.
It is also possible to connect at least two of the roller rods, positioned next to each other in split bearings, on their outer side over a crossover and to tape bore mount (i.e., and journal-bearing mounted) them on the outside.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently preferred emobidment will be described with reference to the figures, which depict the following:
FIG. 1 is a perspective view of the present invention;
FIG. 2 is a perspective view of the significant parts of the transition bridge including two conveyors in an enlarged illustration;
FIG. 3 is a cross section through the upper part of the transition bridge;
FIG. 4 is a detail of the mounting of the roller rods of the transition bridge conveyors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 there is shown a perspective drawing of an apparatus, according to the invention, to wrap package units 1. A wrapping foil leading device 2, is wrapped with a foil 3, which consists of a stretch foil strip. This is achieved with the help of a chain drive 5, which is lead around a rim 4 and which rotates during the wrapping on the fixed track of the rim 4 around the package 1 at a distance from the package. In order to increase the wrapping speed, a second rotating chain drive 5' of the same design is provided, with which a foil 3' can be wrapped.
In the area of a wrapping station 6, there is provided a belt feeder 8, a line conveyor belt 10 and an extension driving band 11, and two transition conveyors 9 and 19. The two transition conveyors together form the transition bridge. As is clear from the diagram, transition conveyor 9 is positioned below package unit 1, while the other transition conveyor 19 is above it. Both transition conveyors together form the transition bridge, which supports the package units; the foil tape 3, 3' is under tension and is wrapped around the transition bridge to form a tube with an inside diameter which is larger than the axial projection of the package unit 1 to be wrapped. Details as to the transition bridge are illustrated further below.
The constantly incoming package units 1 are placed in the continually forming tube, whereby the coiler tube places itself next to the package unit after the running over of the transition bridge under remaining foil tension, which is illustrated roughly. That is, the constantly incoming package units 1 are placed in the continually forming tube, whereby the tube adheres itself to the package unit as above-described and as illustrated in the Figures. In addition, lateral boundary belts 20, 21 are provided in order to guide the package units more precisely in the transition region from the belt feeder 8 to the wrapping station 6. Between the line conveyor belt 10 and the extension driving band 11, there is also a cutting station 22 equipped with a drop knife. The severing of the foil tube is relatively uncomplicated, since the tube is under tension and moves up to and joins the package unit as soon as it has been cut. Nonetheless, there are other pinching, cutting and refining devices which have been proven in the technology of wrapping devices, and these can also be used here advantageously.
The two transition conveyors 9 and 19 correspond to those which are illustrated in detail in FIGS. 2 and 3. They are hung in a cantilevered manner on a frame section 23.
Referring now to FIG. 2, the transition bridge consists of two transition conveyors 9, 19; each one of these has two parallel conveyance sections, i.e. an external conveyor belt 14, each with an outer and inner side. The conveyor belts 14 of the transition conveyors are actively driven. The speed of movement on the conveyor belt also determines the feeding of the package units. In addition, each transition conveyor 9, 19 consists of an internal, passively driven gliding or roller plane 17, which is equipped with roller rods 18, 18' and 28, 28' in the operational example. The roller rods can be, for example, polypropylene cylinders, which are moveable axially and are housed in split bearings.
Referring now to FIG. 4, there is shown an enlarged detail showing a type of split bearing 29 which is fastened onto a frame with a clamp 30. The package unit 1 is supported and guided in the wrapping area between the roller planes formed by the roller rods. The wrapping foil 3 places itself on the outer side 15 of the transition conveyor 9 or 19. By means of the tube which forms as well as the wrapping foil placed against the sides of the package units, the power from the conveyor belt is transferred and the package unit is thus propelled over the roller plane.
As shown in FIGS. 2 and 3, the roller rods form cogged configurations, with dovetailing formed by the roller rods and a cog ridge formed by the crossover 31. Inside the split bearing 29, the roller rods can be shifted to overlap axially toward the direction of transport, whereby the width of the roller plane is adjustable.
Normally, the width of the roller plane is greater than that of the conveyor belt. The roller rods are connected at the outer side to the crossover 31 and are also tape bore mounted to it, as can be seen in FIG. 2.
All this results in an apparatus which exhibits reliability in wrapping loose bundles without shifting the structure. Slippage can not occur between the advanced conveyor and the package units to be transported since the package units move foreward only on a passively driven roller conveyor.
Other embodiments and modifications of the present invention will be apparent to those of ordinary skill in the art having the benefit of the teaching presented in the foregoing description and drawings. It is therefore, to be understood that this invention is not to be unduly limited and such modifications are intended to be included within the scope of the appended claims. | A stretch foil wrapping arrangement for wrapping objects. The objects are conveyed to a transition bridge around which a stretch foil tube is wrapped. As the objects are conveyed through the transition bridge they pass inside of the tube which is out after the object and tube portion in which it is wrapped leave the transition bridge. The transition bridge includes upper and lower conveyors each having an outer actively driven belt and an inner passively driven roller plane in contact with the objects. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 09/089,033 filed on Jun. 2, 1998, now U.S. Pat. No. 5,953,345, entitled “Reduced Pin-Count 10Base-T MAC to Transceiver Interface” and co-pending U.S. patent application Ser. No. 09/088,956 filed on Jun. 2, 1998 entitled “Serial Media Independent Interface” which are incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a system and method for providing an interface between an Ethernet PHY and a MAC. More specifically, the present invention relates to a reduced pin count media independent interface (MII).
2. Relationship to the Related Art In computer network systems there is typically a natural division between chips handling the physical layer, which is responsible for transmitting data on the network, and the system chips, which perform logical operations with data transmitted on the network. Ethernet hubs, routers and switches are composed of multiple ports, and may be generically referred to as multi-port Ethernet devices. Each port is typically composed of a system chip, which includes a media access controller (“MAC”) layer, and a physical layer or “PHY.” Modern multi-port Ethernet devices typically integrate multiple MACs into one system chip (MAC chip) as well as multiple PHYs into another chip (PHY chip). An interface is required on each chip to transfer signals between the MACs and the PHYs.
IEEE standard 802.3u defines a media independent interface between a MAC layer and a PHY that includes 16 pins used for data and control. As noted above, in devices that include multiple ports that each have a MAC and a PHY, it is common to implement multiple MACs on one chip and multiple PHYs on another chip. If the standard MII, which includes 16 pins for data and control, is used for each MAC and PHY on the MAC chip and the PHY chip, the number of pins required for each chip becomes very large as multiple MACs and PHYs are included on single chips.
For example, typical switches available today may offer 24 ports in a single device. If all of the MACs were to be implemented on one chip and all of the PHYs were to be implemented on another chip then 384 pins would be required just to provide the interface between the MACs and the PHYs of the two chips. Obviously this is impractical. Thus, the requirement of 16 pins for data and control in the standard MII specification adds to the expense of MAC and PHY interfaces both by increasing the number of pins required on chips and by reducing the number of MACs and PHYs which may be combined on a single chip.
FIG. 1A is a block diagram illustrating a standard MAC to PHY interface. A MAC 100 is connected to a PHY 102 via a 16 wire MII. PHY 102 is connected to a physical medium that transmits data over a network 104 . MAC 100 is connected to a network device 106 in a device that is using the MAC and the PHY to communicate. The device may be a switch, a repeater, a hub or any other network device that includes ports for communication using the Ethernet 802.3u standard.
FIG. 1B is a block diagram illustrating the problem caused by the number of pins required in the standard MII MAC to PHY interface. A MAC chip 110 includes four MACs 112 a , 112 b , 112 c , and 112 d . Each of the four MACs must have 16 pins on the outside of the chip so that it can communicate with a PHY according to the MII standard. Similarly, a PHY chip 120 includes four PHYs 122 a , 122 b , 122 c , 122 d . Each of the PHYs must have 16 pins on the outside of the PHY chip so that it may communicate with the MAC via a standard 16 pin MII. Each PHY chip is also connected to a physical medium that is used to communicate over a network 130 .
It would be extremely useful if an alternative standard to the MII standard could be developed which would allow for communication between a MAC and a PHY using a reduced number of lines between the MAC and the PHY. This would reduce the number of pins per MAC or PHY included on a chip, reduce the cost of the chip, and allow more MACs or PHYs to be included on a single chip. An alternative interface to the Mil should include all of the control signals and the same data capacity as the Mil so that such an interface could continue to be interoperable with all systems that are intended to operate with an MII as described in IEEE standard 802.3u.
FIG. 2 is a block diagram illustrating the functions of the sixteen lines specified in the MII standard. A MAC 200 is connected to a PHY 202 using the 16 wire MII standard interface. The interface includes a transmit clock line 210 that provides a clock signal for clocking the transmitted data. A transmit enable line 212 indicates when data is being transmitted on the transmit data lines. A transmit error line 214 indicates an error should be forced onto the network. This line is used, for example, by repeaters to propagate errors that have been detected. A set of four lines 215 are used to transmit data. Since the overall data transfer rate between the MAC and the PHY is 100 MHz in a 100 Base-T system, each of the four data wires transmits at 25 MHz.
The MII also includes a carrier sense line 2 /which indicates that data is being either received or transmitted. In addition, a collision line 220 is included which indicates that a collision has been detected, i.e., data is being both received and transmitted simultaneously. A receive clock line 222 is used to provide a clock for clocking the received data. A set of four receive data lines 224 each transfer data at 25 Mhz for an overall data rate of 100 MHz. A receive data valid line 226 indicates that valid data is being transferred on the receive data lines. A receive error line 228 indicates when an error has been detected in the received data, such as when an illegal symbol is detected by the PHY.
An MII is commonly used with a 100Base-TX PHY, for example, where data is transmitted across the physical medium of the network from PHY to PHY at a data rate of 125 MHz. Bits of data are grouped into individual symbols which include five bits each. The PHY receives each five bit symbol and translates it into a four bit nibble of data. Thus, the five bit symbol is used to transmit only four bits of data, with the remaining possible information states of the symbol used for error detection or other purposes. When errors are detected by the PHY, they are propagated to the MAC using the receive error line. Certain devices, such as repeaters, may use the transmit error line to propagate errors to other devices on a network. It should be noted that the receive data valid line differs from the carrier sense line in that the receive data valid line does not go high as soon as data begins to be received. Instead, the receive data valid line goes high after an entire five bit symbol corresponding to a nibble of valid data has been received and decoded, and remains high after data has stopped being received between PHYs to allow decoding of all four bits of the nibble corresponding to the last symbol transmitted. MIIs may also be used to connect a MAC to another type of PHY, such as a 100Base-T4 PHY using other data transfer formats.
One approach to reducing the number of pins required for the MAC to PHY interface has been proposed by the Reduced Media Independent Interface™ (RMII™) consortium. The RMII provides a six pin interface between a MAC and a PHY. In addition to the six wires required for each MAC to PHY interface, a single synchronous clock signal is provided for both transmit data sent from the MAC to the PHY and the receive data sent from the PHY to the MAC. In the six pin RMII, two pins are used to transmit data and two pins are used to receive data. Each of the data transmit and the data receive lines runs at 50 Mhz. This provides a total bandwidth of 100 MHz for sending and a 100 MHz for receiving data across the MAC to PHY interface.
Thus, the RMII reduces the number of pins required to transmit and receive data from eight to four by doubling the clock speed of the data lines. The RMII reduces the eight pins required to send the remaining six control signals to only two pins by combining certain control signals and deriving other control signals in the manner described below. The transmit clock and the receive clock lines are eliminated for each individual MAC to PHY interface because a single synchronous clock is used for all of the interfaces on a single chip. The remaining six control signals are combined and derived from only two control lines as is described below.
The carrier sense and receive data valid control signals are combined on a single line by the RMII. As described above, the carrier sense signal differs from the receive data valid single in that the carrier sense signal goes high as soon as the PHY begins to receive data. The receive data valid signal goes high only after the PHY has received the first complete symbol of data and decoded the first nibble of data. Also, the receive data valid symbol remains high until the last nibble corresponding to the last symbol has been transferred to the MAC. The RMII combines the two signals into one on a single line as follows: the combined signal asserts with carrier sense and remains asserted while both carrier sense and receive data valid are both asserted. The signal alternates between the asserted and deasserted state while carrier sense is not asserted, but receive data valid is still asserted, so that carrier sense and received data valid are time-division multiplexed. The signal becomes deasserted while both carrier sense and receive data valid are deasserted.
On the second and last control line provided by the RMII, a transmit enable signal is provided. The collision signal is derived from the transmit enable signal and the carrier sense portion of the carrier sense data valid signal. When both are asserted, the RMII determines that a collision has occurred. The last two control signals, the receive error signal and the transmit error signal are transferred across the interface by altering the data sent when an error is detected. When an illegal symbol is detected, the rest of the data is filled with a specific data pattern such as alternating ones and zeros. When the specific data pattern is read, then it is determined that an error has occurred. There is a finite probability that good data may match the specific data pattern causing the MAC's to determine that an error has occurred when, in fact, no error has occurred. However, the RMII is designed so that the probability of such mistakes occurring is acceptably small to the system designers.
It should also be noted that the IEEE MII specification requires backward compatibility with a 10base-T Ethernet interface so that data may be transferred between the MAC and the PHY at either 100 Mhz or 10 Mhz. When data is transmitted at 10 Mhz, then each bit is repeated ten times so that the 10 Mhz data may be recovered by sampling every tenth bit. It is necessary, therefore, to indicate to the MAC or the PHY whether data is being transmitted at 100 Mhz or 10 Mhz so that proper sampling of the data may be implemented. The RMII accomplishes determining the correct data rate by using an out-of-band communication between the MAC and the PHY. The MAC queries a designated PHY register using the MII management bus to determine the selected data rate. It would be useful if an alternative to this out-of-band communication could be developed since the out-of-band communication is slow and there is a possibility that the out-of-band communication may not be accomplished before data is transmitted.
In view of the foregoing, it would be useful if the number of wires between a MAC and a PHY could be even further reduced to less than six wires. Furthermore, it would be useful if a simpler method of combining the control signals on a control line could be developed.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a reduced pin count Mini-MI interface that requires only four wires for the interface between a MAC and a PHY. The Mini-MII interface includes four lines, a transmit data line, a transmit control line, a receive data line, and a receive control line. The transmit data line, the transmit control line, the receive data line and the receive control line run at 100 Mhz. All of the data may be transferred across the data lines. The transmit control line conveys the transmit enable and transmit error information using time-division multiplexing. The receive control line conveys the receive data valid, receive error and carrier sense control information using time-division multiplexing. Furthermore, the transmit error and receive error signals are provided without requiring the data to be altered and interpreted. The transmit control and receive control lines are used to synchronize the time-division multiplexed data. The speed at which the PHY is transferring data to the MAC is indicated on the receive data line when the receive control line sends a certain bit pattern. Therefore, no out-of-band communication is required between the MAC and the PHY to determine whether the PHY is sending a data stream to the MAC at 10 Mbit/sec or 100 Mbit/sec.
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 method of communicating between a MAC and a PHY includes sending a 100 MHz time-division multiplexed signal on a receive data line and sending a time-division multiplexed receive control signal on a receive control line. A 100 MHz time-division multiplexed signal is sent on a transmit data line and a time-division multiplexed transmit control signal is sent on a transmit control line. In another embodiment, an interface between a first MAC and a second MAC consists essentially of a time-division multiplexed receive data line, a time-division multiplexed receive control line, a time-division multiplexed transmit data line and a time-division multiplexed transmit control line. In another embodiment, a MAC to PHY interface consists essentially of a common clock, a time-division multiplexed receive data line, a time-division multiplexed receive control line, a time-division multiplexed transmit data line and a time-division multiplexed transmit control line.
These and other features and advantages of the present invention will be presented in more detail in the following specification of the invention and the accompanying figures which illustrate 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, wherein like reference numerals designate like structural elements, and in which:
FIG. 1A is a block diagram illustrating a standard MAC to PHY interface.
FIG. 1B is a block diagram illustrating the problem caused by the number of pins required in the standard MI MAC to PHY interface.
FIG. 2 is a block diagram illustrating the functions of the sixteen lines specified in the MII standard.
FIG. 3 is a block diagram illustrating how Mini-MII (“MMII”) designed according to the present invention is used between a chip containing a MAC and a chip containing a PHY.
FIG. 4 is a sequence diagram illustrating how data and control are transferred using the receive data and receive control lines.
FIG. 5 is a sequence diagram illustrating how data and control are transferred on the transmit data and transmit control lines.
FIG. 6 is a flow chart illustrating how a MAC that is receiving data synchronizes to the first bit of a four bit data segment using the pattern transferred (or received) on the receive control line.
FIG. 7 is a block diagram illustrating how the four wires of the MMII are connected between a first MAC and a second MAC.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiment of the invention. An example of the preferred embodiment is illustrated in the accompanying drawings. While the invention will be described in conjunction with that preferred embodiment, it will be understood that it is not intended to limit the invention to one preferred embodiment. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
FIG. 3 is a block diagram illustrating how Mini-MII (“MMII”) designed according to the present invention is used between a chip 300 containing a MAC 302 and a chip 310 containing a PHY 312 . The sixteen standard MII lines from MAC 302 are connected to an MMII shim 304 which converts the data signals and the control signals on the sixteen lines to MMII signals that are conveyed across four lines. The four MMII lines include a transmit data line 322 , a transmit control line 324 , a receive data line 326 , and a receive control line 328 . These lines are connected to an MMII shim 314 on PHY chip 310 that converts the signals on those lines to the signals on a standard sixteen wire MII interface to PHY 312 . It should be noted that in FIG. 3 the MMII interface is shown as a shim between a standard MII interface and a MAC or PHY. In certain embodiments the MMII is implemented as a shim and in other embodiments, the MMII is implemented directly as part of the MAC or the PHY without translating signals to an actual 16 wire MII interface. The MMII provides a reduced number of wires for communication between the MAC and the PHY.
The MMII Receive Path
The MII receive path includes the receive data line and the receive control line. Receive data and control information are signaled in four bit segments. The data rate is one bit per 100 MHz clock cycle. In 100 Mbit/sec mode, each segment represents a new nibble of data. In 10 Mbit/sec mode, each segment is repeated ten times so every ten segments represents a new nibble of data. The MAC samples one of every ten segments when data is sent in 10 Mbit/sec mode. FIG. 4 is a sequence diagram illustrating how data and control are transferred using the receive data and receive control lines. A reference clock signal 400 is shown. In one embodiment, a common reference clock signal is used by both the MAC and the PHY chip. In order to send data to the MAC on the receive line that is synchronous to the MAC reference clock, the PHY must pass the data through an elasticity FIFO buffer to handle any difference between the reference clock rate and the clock rate at the packet source.
The Ethernet specification calls for packet data to be referenced to a clock with a frequency tolerance of 0.01%. However, it is not uncommon to encounter Ethernet stations with clocks that have frequency errors up to 0.1%. Thus, it is preferable that a FIFO be designed which allows communication with an end station that has a frequency error of up to 0.1% instead of the 0.01% required by the standard. Accordingly, the present invention in one embodiment provides an elasticity FIFO that is at least twenty-seven bits long. The size of the FIFO is determined according to the following formula:
# of bits=2*(max frame in bits)*(end station error+local error)=2*(1518*8)*(0.1%+0.01%)=26.7 bits
A receive control signal 402 is time-division multiplexed to include each of the MII receive control signals in a four bit segment. The first segment 402 a is a sync pulse. The sync pulse is always a one and it is used to synchronize the MAC to the data stream. The MAC monitors the received control signal and looks for a one followed by three zeros. A one followed by three zeros indicates that data is not being transferred from the PHY but the 1000 pattern can be used by the MAC to determine the beginning of the four bit segment. The remaining three bits in each receive control signal segment correspond to the IEEE MII receive control signals. These include a receive data valid signal 402 b , a receive error signal 402 c , and a carrier sense signal 402 d . Thus, the receive control line contains all of the information found on the receive side of the standard MII.
A receive data signal 403 is shown. The received data signal has four bits in each segment. The four bits are synchronized to the four control bits in the receive control signal. As described above, the MAC is able to synchronize to the beginning of the four bit control segment by monitoring the receive control line and looking for the 1000 pattern. Once the MAC is synchronized to the MMII control stream, the three control bits, RX_DV, RX_ER and CRS, and the four data bits, RXD 0 , RXD 1 , RXD 2 and RXD 3 , have the same purpose as the commonly designated signals in MII.
When receive data valid is zero, receive error is zero, and carrier sense is zero, the four bit receive control signal segment is 1000. The MAC can then synchronize to the 1 as being the first bit in the four bit segment. In addition, in one embodiment, when the 1000 pattern is received on the control line, the received data line is used to convey the PHY status. In one embodiment, when a 1000 is received on the receive control line, the first bit of the data segment is used to indicate the speed of the interface with a zero indicating 10 Mbits/sec and a 1 indicating 100 Mbits/sec. The other three bits in the data segment may be used to convey other data about the PHY status. In one embodiment, the second bit is used to indicate duplex with a zero indicating half and a one indicating full. The third bit is used to indicate whether the link is up or down with a zero indicating down and a one indicating up. The fourth bit is used to indicate jabber with a zero indicating okay and a 1 indicating an error. In other embodiments, the bits may be used for other signals. Also, the order of the bits may be changed.
Thus, it has been shown that all of the control signals and the data provided by the MII interface from the PHY to the MAC are included in the time-division multiplexed receive control and receive data lines of the Mini-MII interface. Next, it will be shown that the control signals and data from the MAC to the PHY are all included in the transmit control line and the transmit data line of the Mini-MII interface.
The MMII Transmit Path
FIG. 5 is a sequence diagram illustrating the signals on the transmit control and transmit data lines of the Mini-MII. Just as in the receive path, transmit data and control information are signaled in four bit segments. A clock signal 500 is provided by a clock source. In one embodiment, the clock source for the MAC and the PHY is a common clock. Thus, for each MAC and PHY chip a single pin is required to provide a clock for all of the MAC's or Phy's included on the chip. In other embodiments, a clock may be internally generated on a MAC or PHY chip. The data rate is 1 bit/100 MHz clock cycle.
Control signals and data are transmitted in 4 bit segments. In 100 Mbit/sec mode, each segment represents a nibble of data. In 10 Mbit/sec mode, each segment is repeated 10 times so that every ten segments represents a new nibble of data and the PHY can sample 1 of every 10 segments in 10 Mbit mode. A transmit control signal 502 contains the transmit control information provided on the transmit side of the standard MII. The transmit control segment contains a sync pulse 502 a , a transmit enable signal 502 b and a transmit error signal 502 c . The fourth bit in the transmit control segment is not needed to provide standard MII information. In one embodiment it is held at zero in other embodiments it may be used to convey other information from the MAC to the PHY.
As on the receive path, a 1000 pattern on the transmit control segment is used by the PHY to synchronize to the data stream, with the 1 generated by the sync pulse being used to mark the beginning of the segment. Once the PHY is synchronized to the MII data stream, when the transmit enable bit goes high, the PHY can sample data on a transmit data line 504 . Transmit data line 504 includes four bits per segment which are time-division multiplexed, just as the receive data line.
It is generally not necessary to pass status information from the MAC to the PHY because the PHY is able to detect the data rate. Therefore, in one embodiment, no status information is passed using the transmit data line in a manner that status information is passed using the receive data line. However, in other embodiments, this may be done if desired.
Collisions are detected when the transmit enable signal and the carrier sense signal are both high. For this method of detecting collisions to work, the PHY must ensure that CRS is not affected by its transmit path. When transmit enable is high and carrier sense is asserted, then a collision has occurred.
Synchronization Process
FIG. 6 is a flow chart illustrating how a MAC that is receiving data synchronizes to the first bit of a four bit data segment using the 1000 pattern transmitted on the receive control line. A similar process is implemented on the PHY to synchronize to the first bit of a transmit data segment using the transmit control bit pattern 1000. The process starts at 600 . In a step 602 , the MAC or PHY device detects a loss in synchronization. The device then enters a state of ignoring data in a step 604 . In a step 606 , the device checks the control line for a 1000 pattern. When the pattern is detected, control is transferred to a step 608 and the device synchronizes to the beginning of the 1000 segment. The process then ends at 610 and the process is executed again if another loss in synchronization is detected.
In addition to being used as a MAC to PHY interface, the MMII may also be used as a full duplex link to connect two MAC's directly. FIG. 7 is a block diagram illustrating how the four wires of the MMII are connected between a first MAC 700 and a second MAC 702 . The receive control line and the transmit data line of MAC 700 are connected to the transmit control line and the transmit data line of MAC 702 , respectively. The transmit control line and the transmit data line of MAC 700 are connected to the receive control line and receive data line of MAC 702 , respectively. The receive control and transmit control segments have nearly a bit to bit correspondence. The sync signal sent from one MAC can be used as a sync signal by the other MAC. The transmit enable signal sent from one MAC can be interpreted as a received data valid signal by the other MAC and the transmit error signal from one MAC can be used as a receive error signal by the other MAC. The fourth bit in the transmit control segment sent from one MAC is always deasserted and can be interpreted as a carrier sense by the other MAC.
Status information is included in the transmit path when transmit enable and transmit error are both zero. The first bit of the transmit data line is used to indicate speed, with zero indicating 10 Mbits/sec and 1 indicating 100 Mbits/sec. The second bit indicates duplex mode with 1 indicating full duplex. The third bit indicates link status with 1 indicating that the link is up and the fourth bit indicates jabber with a zero indicating no jabber. In other embodiments, these conventions may be changed. When transmit enable is 1, then the information on the transmit data segment is interpreted as being an MII data nibble. When the transmit error bit is 1, then the information on the transmit data segment is assumed to be an error.
Thus, it has been shown that a four wire Mini-MII interface using time-division multiplexed control and data signals can be used to convey all of the data and control information transferred by the standard IEEE MII interface. A common clock signal is used for both the MAC and the PHY and the time-division multiplexed segments are synchronized using a synchronization pulse on the receive control and the transmit control lines. Thus, the number of wires required for a MAC to PHY interface can be reduced, enabling more MAC's or Phy's to be implemented on a single chip.
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. It should be noted that there are many alternative ways of implementing both the process and apparatus of the present invention. For example, the Mini-MI interface can be used with other physical layers. 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 system and method are disclosed for providing a method of communicating between a media access control (MAC) layer and a physical (PHY) layer. The method includes sending a 100 MHz time-division multiplexed signal on a receive data line and sending a time-division multiplexed receive control signal on a receive control line. A 100 MHz time-division multiplexed signal is sent on a transmit data line and a time-division multiplexed transmit control signal is sent on a transmit control line. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to methods of patient diagnosis through processing of electrocardiogram (ECG) data, and particularly to methods and apparatus for evaluating the autonomic nervous system control of the heart through novel processing of ECG data.
2. Description of Background Art
The cardiovascular system responds to various demands of the body under control of the autonomic nervous system, which consists of the parasympathetic and sympathetic limbs. Certain pathologic conditions such as diabetic autonomic neuropathy and post-myocardial infarction can impair the autonomic control of the heart, which could result in various arrhythmias such as ventricular fibrillation, ventricular tachycardia, sinus bradycardia, atrioventricular block, and sudden asystole, among others. An imbalance between the sympathetic autonomic control and the parasympathetic autonomic control may predispose a patient to sudden cardiac death.
A conventional practice for evaluation of the autonomic nervous system control of the heart is the study of heart period variability (in both the time and frequency domains) under various conditions of autonomic stimulation including deep breathing, exercise, rest, mental and pharmacological stress testing, and various other autonomic maneuvers. However, clinical data has shown that heart period variability is predominantly representative of parasympathetic tone only, and that the ratio of low to high frequency spectral power of heart rate variability is not always reliable as a measure of sympathetic autonomic activity. As a result, analysis of heart period variability alone cannot detect adequately imbalances between the parasympathetic and sympathetic autonomic controls of the heart. Furthermore, heart rate variability cannot directly reflect ventricular response to autonomic stimuli, which may be a critical determinant of the susceptibility of a patient to ventricular arrhythmias and sudden cardiac death.
SUMMARY OF THE INVENTION
The present invention overcomes the deficiencies in the conventional autonomic evaluation by providing a novel method and apparatus for distinguishing between the parasympathetic and sympathetic control inputs to the heart. The present invention thus provides the cardiologist with a direct method for evaluating imbalances between the parasympathetic and sympathetic controls of the autonomic nervous system.
The present invention is based on the discovery by the present inventors that the variability of the QT interval of the heart activity wave is a direct indicator of sympathetic autonomic control of the heart, and thus QT interval variability complements heart period (RR) variability for a complete evaluation of the autonomic nervous system control of the heart. The present invention provides a method and apparatus for analyzing the QT interval variability simultaneously with the heart period (RR) variability. Through such simultaneous analysis, it becomes possible for the first time to better identify patients with autonomic imbalance.
In particular, the present invention provides a method for testing the autonomic nervous system of a mammal, comprising the steps of obtaining electrocardiographic (ECG) data from the mammal under a selectable state of autonomic stimulation for a predetermined period of time; calculating heart period (RR) intervals and QT intervals for a predetermined number of normally conducted heart beats represented in the ECG data, and outputting the calculated RR and QT intervals in the form of electrical data signals; calculating power spectral densities of the RR and QT intervals; and analyzing the calculated RR and QT interval power spectral densities with respect to each other as an indication of the state of balance between parasympathetic and sympathetic controls of the autonomic nervous system of the mammal. In another aspect, the present invention further provides apparatus for testing the autonomic nervous system of a mammal.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow in conjunction with the accompanying drawings, which are given by way of illustration only and are not limitative of the present invention, and wherein:
FIG. 1 is a graphic representation of a typical electrocardiograph (ECG) tracing with normal cardiac activation;
FIG. 2 is a block diagram of apparatus for carrying out the improved method according to one embodiment of the present invention;
FIG. 3 is a flow chart diagram of the processing steps for data acquisition according to one embodiment of the present invention;
FIG. 4 is a flow chart diagram of the processing steps for data analysis according to one embodiment of the present invention;
FIGS. 5A and 5B are graphs of the obtained RR and QT interval variabilities in the time and frequency domains for a normal subject and a pathological subject, respectively;
FIGS. 6A and 6B are graphs illustrating the relationship between corresponding QT and RR intervals as measured, and as normalized QT for a predetermined value of RR; and
FIGS. 7A and 7B are graphs illustrating circadian variations of heart rate and normalized QT intervals for control subjects and pathological subjects before and after treatment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a typical ECG tracing for a healthy individual. The letters P, Q, R, S, T and U refer to the conventional labelling of different waves during one complete cardiac cycle. The U wave is usually not present in healthy individuals. The letter J refers to the point where the slope of the terminal portion of the S wave abruptly changes toward the horizontal axis, and marks the beginning of the ST segment of the cardiac cycle. Under conditions of normal cardiac activation the R wave represents the conducted sinus beat of the heart, and the interval between the apexes of consecutive R waves represents the heart period in units of time, with the heart rate being the reciprocal of the RR interval expressed as beats per minute.
The QT interval is conventionally measured from the beginning of the Q wave to the end of the T wave (also known as QeT), or from the beginning of the Q wave to the apex of the T wave (also known as QaT). The end of the T wave is approximated by performing a linear regression analysis on the points in the steepest segment of the terminal portion of the T wave, and finding the intersection of the resultant regression line with the isoelectric line (not shown) of the electrocardiogram. Prior to the present invention, the normalized QT interval (QTc), normalized using Bazett's formula, was typically evaluated for prolongation, because an abnormally prolonged QTc interval under certain disease conditions is associated with a risk of sudden cardiac death.
In the present invention, the QT interval is normalized differently, since the QT interval often exhibits an exponential relationship to the RR interval, as shown in the graph of FIG. 6A. The solid exponential curve was obtained by fitting the data points of QT intervals plotted against corresponding RR intervals, measured every 5 minutes over a 24 hour period, with an exponential function through nonlinear regression analysis. The corresponding values of the exponential curve were subtracted from each data point and the value of the QT interval corresponding to RR=1000 msec on the curve was then added to resulting array of data points to obtain the heart rate normalized (corrected) QT interval, QTc, which is plotted against RR in the graph of FIG. 6B. Note that QTc is independent of RR, as the data points are randomly scattered above and below a line parallel to the horizontal axis. During autonomic manipulation over a short period, usually a few minutes, the QT interval may not exhibit a clear relationship to the RR interval. Under such conditions QT normalization is not needed.
FIG. 2 illustrates one embodiment of apparatus for carrying out the bi-variate spectral analysis according to the present invention. Electrocardiograms are recorded by an ECG recorder 21, via electrical leads placed on the subject. The ECG recorder 21 may be a magnetic tape FM recorder/player such as for example Hewlett Packard Model 3964A connected to the subject through an ECG amplifier, or any equivalent thereof for short-term tests, or a 24 hour ambulatory electrocardiographic recorder for circadian data evaluation.
The recorded electrocardiograms are outputted by the recorder 21 into a programmable waveform analyzer 22, which may be implemented by a Norland 3001 Programmable Waveform Analyzer or any equivalent thereof. For electrocardiograms recorded on a 24 hour ambulatory recorder, the recorded ECG data may be outputted into the waveform analyzer at 240 times recording speed using a Holter scanning system. ECG data recorded on the FM tape recorder may be outputted at the original recording speed.
The recorded ECG data is processed in the waveform analyzer 22 to acquire RR and QT interval data, and the acquired RR and QT interval data is then outputted from the waveform analyzer into a host personal computer 23, which may be an IBM-compatible personal computer or any equivalent thereof, over a suitable communication bus. The measured RR and QT interval data is processed and analyzed in the computer 23, and outputted in the form of high resolution graphics or statistical data.
The data acquisition and processing in the waveform analyzer and computer will now be described in detail with reference to the diagrams of FIGS. 3 and 4. However, it will be recognized that the data acquisition and analysis of the RR and QT intervals can be integrated into a single dedicated system based on a high performance computer platform with data acquisition hardware and software, without the need for a waveform analyzer.
Referring to FIG. 3, the waveform analyzer digitizes incoming ECG data and holds a predetermined length of the ECG in memory. At step S1, a segment of the ECG waveform containing at least two QRS complexes is displayed on the display screen of the waveform analyzer, with the first R wave positioned at the left of the display screen 1/8 the distance of the screen trace from the edge of the screen display. In addition to stored data the displayed data can be from a direct analog input to the analyzer. At step S2 the segment is calibrated by entering the time and voltage coordinates of the first QRS complex into memory registers of the analyzer.
The waveform analyzer has two movable cursors, c1 and c2, which are visible on the display screen and which can be moved via programming to seek various characteristic points on the displayed ECG waveform signal. At step S3, the first cursor c1 is moved to the apex of the first R wave and the second cursor c2 is positioned at the apex of the second R wave, through peak voltage level detection. At step S4 it is determined whether the current measurement is the first measurement for the particular ECG being processed. If so, the program pauses at step S5 to allow the user to visually observe the cursor positioning and either confirm the accuracy thereof or manually adjust the cursor position to the desired locations through the keyboard of the analyzer. If so adjusted, the positions and voltage levels will be memorized for calibration of subsequent measurements. At step S6, the RR interval in msec is determined as the distance between the cursors c1 and c2, and is stored in a memory register of the analyzer. At step S7, the c1 cursor is advanced (i.e., moved to the right) by 0.25 times the measured RR interval, and c2 is retarded (i.e., moved to the left) by the same distance. At this time, referencing FIG. 1, c1 and c2 are located on either side of the T wave between the adjacent R waves. At step S8, a seek command is issued for c1 to seek the minimum voltage point and for c2 to seek the maximum voltage point between the two cursors. Thus, c2 will now be positioned at the apex of the T wave (appropriate modification of the seek command is made in the case of inverted T waves). At step S9, c1 is moved to the beginning coordinates of the QRS complex as stored in memory. Similar to steps S4 and S5, steps S10 and S11 enable the user to visually and manually confirm or adjust the proper positioning of the cursors for the first measurement. At step S12, the distance between c1 and c2 is calculated to determine the QaT interval, and this interval is stored in a memory register.
At step S13, c2 is advanced to the right by 10 milliseconds and c1 is moved to a location 15 milliseconds to the right of c2, so that c1 and c2 are now positioned on the steepest segment of the terminal portion of the T wave. Appropriate adjustments can be made in the event of abnormal T waves. Next, at step S14, a linear regression is performed on the points between c1 and c2 to obtain a fitted regression line through such points. At step S15 the intersection of the regression line with the isoelectric line of the ECG signal is determined. The isoelectric line is determined by the voltage level at the beginning of the QRS complex (PQ segment). This intersection point is then taken as the termination point of the T wave.
At step S16, c1 is moved back to the beginning of the QRS complex, and c2 is moved to the intersection point. At step S17, the user visually confirms the positioning of the cursors and manually adjusts the positions if necessary. At step S18, the QeT interval is determined by calculating the distance between c1 and c2, and is stored in memory. Next, as represented at step S19, the measured RR, QaT, QeT, and initial time coordinates of the QRS complex are uploaded to the host computer 23, by issuing an interrupt over the bus connecting the waveform analyzer to the computer. The computer then receives the data values and places them into appropriate arrays in memory for further processing. At step S20, it is determined whether additional QRS complexes exist in the ECG waveform for processing. If so, the program resets to step S1 (step S21) and repeats the data acquisition procedure for the next QRS complex. If not, at step S22, the waveform analyzer communicates the completion of data acquisition to the computer 23, indicating that analysis of the data in the computer may begin. For subsequent measurements, the data acquisition program will pause for user confirmation only if the new measurement differs from the previous measurement by a predetermined percentage. This provides a means of rejecting non-sinus beats and the two or three immediately following beats.
Data processing in the computer 23 will now be explained with reference to FIG. 4. At step S100, the acquired RR and QT interval values stored in an array in the computer 23 are linearly interpolated to obtain samples equally spaced in time. At step S101, the data is smoothed by subtracting for baseline drift, and at step S102 the time domain RR and QT interval data is multiplied by a Hanning window function in order to minimize spectral leakage. At step S103, the evenly spaced linearly interpolated data samples are subjected to fast Fourier analysis to obtain frequency power spectra of the RR and QT intervals (either of the QaT or QeT calculated intervals may be used selectively). Preferably, the power spectra are calculated from more than 64 consecutive sinus beats. The lowest frequency capable of being studied is dependent on the total time duration of the data samples, while the highest frequency depends on the sampling interval. Thus, the total duration of the ECG used for power spectral analysis should contain at least 3 cycle lengths corresponding to the lowest frequency of interest, and at least 5 samples should exist within one cycle length of the highest frequency of interest.
At step S104, the frequency range of interest from the frequency domain data obtained through the fast Fourier analysis is divided into bands of 0.05 Hz each. At step S105 the square root of the area under the power spectral density (PSD) curves within each 0.05 Hz band is calculated, and at step S106 the square root is determined as a measure of the frequency specific variability at the determined central frequency.
FIGS. 5A and 5B illustrate graphs representing the time and frequency domain data of the measured RR and QT interval variability in units of milliseconds and voltage level, respectively. The graphics representation can be generated using commercially available graphics software such as Stanford Graphics Software or its equivalent. The processed frequency spectra data can be transferred to statistical format files such as Lotus files to facilitate statistical analysis and imported to the graphics software from the Lotus files.
The obtained power spectral densities of the RR and QT intervals as shown in FIGS. 5A and 5B are analyzed for coherence, relative phase and gain. The spectral coherence is a measure of the linear association between the RR and QT variables at various frequencies. FIG. 5A shows time and frequency domain RR and QT data obtained from a normal subject during a deep breathing autonomic maneuver. The RR PSD peak is several times larger than the QT PSD peak. In contrast, FIG. 5B shows the time and frequency domain RR and QT data for a subject with diabetic autonomic neuropathy (DAN). While the subject exhibits a reduced heart period variability (note that the RR PSD peak is abnormally small), the QT PSD peak is normal. Thus, the spectral power ratio between the RR interval and the QT interval is very small, suggesting a severe autonomic imbalance between the parasympathetic and sympathetic controls on the heart which may predispose the patient to sudden cardiac death, which is common among DAN patients.
FIGS. 7A and 7B illustrate changes in circadian patterns of heart rate (A) and QTc (rate-normalized QT) interval (B) in hypothyroid patients before treatment (HYPO) and after treatment under euthyroid conditions (EUTH). The heart rate in beats per minute is computed as the inverse of the RR interval, expressed in minutes. The circadian pattern of a healthy control subject (CONT) is also presented for comparison. The data points represent hourly mean values. As shown in the graph, after treatment the heart rate became almost normal; however, QTc was only moderately shortened after treatment, being still substantially prolonged as compared to the normal control QTc.
The RR and QT interval variability analysis of the present invention can be performed on electrocardiogram data recorded under many different conditions of autonomic stimulation, including rest, exercise, post-exercise, mental stress testing, pharmacological stress testing, ambulatory electrocardiography, tilt-table testing, programmed breathing, valsalva maneuver, cold presser testing, hyperventilation, sustained hand grip, face immersion, and drug intervention for directly or indirectly affecting the autonomic nervous system or cardiac repolarization. Patient groups likely to benefit from the present invention include patients with coronary artery disease, heart failure, diabetes, long QT syndrome, hypertension, unexplained syncope, or neurological disorders. As will be recognized from the above description, the present invention provides a novel technique for evaluating the autonomic system to detect imbalances between the parasympathetic and sympathetic controls of the cardiac function, which heretofore has not been possible.
The invention having been thus described, it be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit and scope of the invention. Accordingly, any and all such modifications are intended to be covered by the following claims. | Apparatus and method for testing the autonomic nervous system of a mammal through bi-variate analysis of heart period (RR) and QT interval variability obtained through data processing of electrocardiographic data. The method and apparatus enables both the parasympathetic and sympathetic controls on the heart to be evaluated for imbalances therebetween, which may indicate a predisposition for sudden cardiac death. | 6 |
FIELD OF THE INVENTION
This invention relates to an applicator system and method for distributing biodegradable and non-biodegradable matter. Specifically, the current invention is a method and apparatus for creating a plurality of shallow trenches and depositing matter in the trenches. In the preferred embodiment, poultry litter is deposited in the trenches.
BACKGROUND OF THE INVENTION
Approximately 8.5 billion broilers are raised and harvested by the domestic poultry industry every year. The manure by-product of the industry is mixed with absorbent materials such as pine shavings, rice hulls, or peanut hulls to create a biodegradable product commonly known as “poultry litter”. The industry generates approximately 17 million tons of poultry litter per year. The litter is high in nitrogen and phosphorous and consequently makes an excellent fertilizer, however there are problems and issues associated with the agricultural application of the litter.
The most common method of applying the litter to farmland is to simply broadcast the litter across the surface of the soil. Although this method is relatively quick and inexpensive, it is inefficient and may damage the environment. To be beneficial, the nutrients within the litter must vertically penetrate the soil to reach the root systems of the associated crops. However, heavy rains may dissolve the soluble materials within the litter and carry the nutrients away from the crops and into the area watershed, thereby contaminating local lakes and streams. Further, in areas where litter is applied repeatedly to the soil surface, the chemical nutrients within the litter may become concentrated on the soil's surface so that associated crops are damaged or otherwise adversely affected. Consequently state and federal guidelines may prohibit further surface application of litter until levels of some of the potentially damaging chemicals have decreased and normalized.
An alternative approach is to trench a field and simultaneously place the litter (or other materials) into a relatively deep trench so that a greater amount of material can be deposited without the environmental problems associated with surface applications. This approach is described and exemplified by U.S. Pat. No. 5,401,119 to Washington et al (hereinafter “Washington”). However, the dimensions of the trench described in Washington preclude this method from being employed in close proximity to the root systems of crops, which could be damaged by the deep trenching process. Further, the deep trenching process is relatively slow and a significant amount of power is required to tow the Washington placement device, particularly in applications in which multiple trenching devices are employed simultaneously.
The need exists for an apparatus capable of placing poultry litter (or any other matter) at a sufficient depth so that the nutrients associated with the matter are not easily lost to runoff. The biodegradable matter should be placed at a sufficient depth to facilitate the penetration of the soil by the fertilizing elements of the matter, but shallow enough not to disturb row crops. The current invention allows the placement of biodegradable matter in multiple trenches that are two to three inches in depth and allows a side-dress application that is compatible with row crops.
SUMMARY OF THE INVENTION
The current invention comprises an applicator system and method for distributing matter. In the preferred embodiment, the applicator system distributes poultry litter in an agricultural application. The current invention includes a hopper that at least partially encloses the matter. An agitator rotor is in communication with the hopper so that the matter from the hopper is engaged by the agitator rotor. A grating means adjacent to the agitator rotor grates and abrades the matter until it precipitates out of the reservoir and onto a supply conveyor.
The supply conveyor conveys the matter away from the agitator rotor and the associated grating means and into a distribution device. A sweeping means within the distribution device sweeps the matter into a plurality of apertures in the base of the distribution device.
At least two distribution conveyors receive the matter from the distribution device and transport the matter laterally away from the distribution device. Distribution funneling assemblies receive the matter from the respective distribution conveyers and direct the matter downwardly. Individual trenching assemblies receive the matter from each of the respective distribution funneling assemblies. Each of the trenching assemblies opens a trench in the ground so that the matter from the associated funneling assembly is directed into the trench. A trench closing assembly associated with each trenching assembly directs soil displaced by the trenching assembly back into the trench and compresses the surface of the soil.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental aspect view of the current invention.
FIG. 2 is a schematic of the process described in the current invention.
FIG. 3 is a front perspective view (from above) of the agitator assembly and hopper of the current invention in accordance with the preferred embodiment.
FIG. 4 is a front perspective view of the agitator and hopper showing a truncated rotor and a pivoting frame assembly.
FIG. 5 is a front perspective view of the agitator of FIG. 4 showing the frame pivoted upwardly.
FIG. 6 is a front perspective partial sectional view of an alternative embodiment of the agitator and storage reservoir.
FIG. 7 is a front perspective view (from above) of the material distribution device.
FIG. 8 is a front perspective view (from above) of the distribution conveyor assembly.
FIG. 9 is a front perspective partial sectional view (from above) of the trenching assembly of the current invention.
FIG. 10 is a rear perspective view (from below) of the primary components of the trenching assembly.
FIG. 11 is a front perspective view (from above) of the trenching assembly with the proximal inwardly cambered wheel removed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention comprises an applicator system for the agricultural distribution of biodegradable matter. Although biodegradable matter is preferred, matter which does not degrade (such as fly ash) should also be considered within the scope of the invention.
FIG. 1 is a functional environmental perspective view of the applicator system AS of the current invention. In the preferred embodiment, the applicator system AS is towed across a cultivated or non-cultivated area behind a tractor T, via a tool bar 10 , however, the motive force may be provided by any type of vehicle, and may include a self-propelling means.
FIGS. 1 and 2 provide a general operational overview of the applicator system AS. As the applicator system AS moves forward, the hopper assembly 30 delivers biodegradable matter to a supply conveyor 50 . The supply conveyor 50 transports the matter in the direction of the arrow 52 ( FIG. 2 ) and deposits the matter into a carousel-type distribution device 60 . The distribution device rotation assembly 66 sweeps the biodegradable matter in the direction of the arrow 62 so that portions of the matter are deposited through the passages 76 and on to one of four distribution conveyor systems 80 . At the end of the distribution conveyor system 80 the biodegradable matter is deposited into a trench created by a trenching assembly 90 . A trench closing assembly 110 directs the soil back into the trench after the biodegradable matter has been deposited. Each of the major components of the applicator system AS will be described in greater detail in the following paragraphs.
As best shown in FIG. 3 , in the preferred embodiment, the hopper assembly 30 is comprised of a storage reservoir 32 with generally angular walls 34 so that the biodegradable matter is gravity-fed to a rotor assembly 36 that is positioned at the vertex of the reservoir's angular walls 34 . The rotor assembly 36 includes a rotating shaft 38 with a plurality of rotor blades 40 positioned adjacent to a grating screen 42 . Specifically, the grating screen 42 is oriented to be concentric with the lower perimeter of the arc of the rotor blades 40 . Opposite edges of the grating screen 42 are connected to the lower edge of each of the reservoir's angular walls 34 .
As shown in FIG. 3 , in operation, biodegradable matter is gravity-fed by the reservoir's angular walls 34 into the rotor assembly 36 . As the rotor shaft 38 turns in the direction of the arrow 39 , the rotor blades 40 force the biodegradable matter downwardly against the grating screen 42 . As the matter is forced downwardly, it is sifted through the screen 42 and precipitates out of the storage reservoir 32 . Large aggregations or masses of biodegradable matter that are not initially small enough to pass through the screen 42 are grated and abraded as the rotor blades 40 force the matter against the grating screen 42 . Eventually the churning and abrading process breaks up and disperses any remaining clumps of the biodegradable material.
Occasionally a relatively large, hardened, non-abradable mass is inadvertently mixed with the biodegradable matter in the storage reservoir 32 . The introduction of a large rock or metal object (for example) into the rotor assembly 36 may cause severe damage to the assembly 36 . Consequently, one aspect of the current invention is a pivoting frame mechanism 44 , as best shown in FIGS. 4 and 5 . The pivoting frame mechanism 44 is comprised of a base member 46 and a pivoting member 48 that are joined at pivot point 47 .
FIG. 4 shows the rotor system 36 in the normal operating position. However, as best shown in FIG. 5 , when the rotor assembly 36 encounters a large non-abradable object, the pivoting member 48 may rotate upwardly in the direction of the arrow 49 so that the gap between the arc of the rotor blades 40 and the grating screen 42 is increased, thereby allowing the non-abradable object to pass.
In an alternative embodiment, the pivoting member 48 may have a shock-absorber type configuration so that the pivoting member 48 may contract and/or elongate as required to relieve the stress at the pivot point 47 . In a further embodiment, the pivoting member 48 may be spring-biased downwardly toward the grating screen 42 to increase the pressure on the biodegradable matter between the rotor blades 40 and the screen 42 , and thereby enhance the effectiveness of the grating screen 42 .
FIG. 6 shows an alternative embodiment of the hopper assembly 30 . In the alternative embodiment, the interior of the storage reservoir 32 has a generally conical shape so that the biodegradable material is funneled downwardly. At least two wing members 31 and a vertical agitator shaft 29 extend into the conical reservoir 32 .
The agitator shaft 29 is driven by a hydraulic motor or the like (not shown) positioned at the top of the shaft 29 . The agitator shaft 29 extends downwardly along the vertical centerline of the conical storage reservoir 32 . The wing members 31 are attached to the lower end of the agitator shaft 29 via a linkage assembly 45 and a pivotable pin joint 33 . Wheels 35 mounted to the upper end of each wing member 31 allow each wing member 31 to sweep close to the inner surface of the angular walls 34 of the storage reservoir 32 without dragging on the surface of the walls 34 . Agitator pegs 37 extend from each of the wing members 31 to facilitate the abrasion process. An aperture 41 in the bottom of the reservoir 32 allows biodegradable matter to flow out of the storage reservoir 32 .
In operation, the wing members 31 are initially positioned vertically so that the wheels 35 are adjacent the agitator shaft 29 . As the wing members 31 begin to rotate, they move outwardly toward the angular walls 34 of the reservoir 32 . As the wing members 31 continue to rotate, they abrade the biodegradable matter in the storage reservoir 32 so that abraded matter precipitates through the aperture 41 and out of the reservoir 32 . A base rotary component 43 attached to the lower end of the vertical agitator shaft 29 rotates with the agitator shaft 29 and reduces any tendency for clumps of matter to bridge and clog the aperture 41 . In the preferred embodiment, the base rotary component 43 has an inverted U-shape.
In further alternative embodiments, the hydraulic motor may be positioned below the reservoir 32 and the agitator shaft 29 may extend upwardly into the reservoir.
As best shown in FIGS. 2 and 3 , the biodegradable matter passes through the hopper assembly 30 and is deposited on the supply conveyor 50 . In the preferred embodiment, the supply conveyor 50 extends the length of the grating screen 42 and deposits the biodegradable matter into the distribution device 60 . The supply conveyor 50 of the preferred embodiment is a belt-type conveyor with flow-enhancing projections 54 extending laterally across the conveyor belt 56 . In alternative embodiments, the supply conveyor 50 may be of any type known in the art consistent with the function of moving the biodegradable material from the hopper assembly 30 to the material distribution device 60 .
As shown in FIG. 7 , in the preferred embodiment, the distribution device 60 is an oval carousel-type mechanism. Biodegradable matter is deposited in the receiving end 64 of the distribution device 60 and swept around the oval base 65 in the direction of the arrow 62 by the distribution device rotation assembly 66 . The rotation assembly 66 is comprised of at least two sprockets 68 connected by an endless chain 70 . The rotation assembly 66 also includes a plurality of sweeping bars 72 that extend from the chain 70 .
As shown in FIG. 7 , the sweeping bars 72 are spaced around the oval orbit of the chain 70 . The inwardly facing end of each sweeping bar 72 is connected directly to support link 71 in the chain 70 so that each sweeping bar 72 extends normal to the associated support link 71 . In the preferred embodiment, the sweeping bars 72 are linear pieces of inverted “L” shaped angle iron.
The leading edge of the sweeping bars 72 may include a plastic extension 73 that slides across the distribution device base 65 as the sweeping bars 72 rotate. The plastic extension 73 reduces the frictional drag on the sweeping bars 72 and also reduces adhesion of the biodegradable matter to the sweeping bars 72 . The device 60 may also include a housing (not shown) that covers the sprockets 68 and chain 70 and prevents the biodegradable material from interfering with the sprockets 68 and chain 70 and generally accumulating in the center of the base 65 .
As shown in FIG. 7 , the distribution device 60 also includes a retaining wall 74 disposed around the perimeter of the base 65 . The outer edge of the sweeping bars 72 pass adjacent to the retaining wall 74 . The function of the retaining wall is to ensure that the biodegradable material is retained within the distribution device 60 . As the sweeping bars 72 rotate, the biodegradable matter is swept into one of a plurality of passages 76 and out of the distribution device 60 .
In alternative embodiments, the sweeping bars 72 may be rotated by any means known in the art, and the shape of the bars 72 may be modified to enhance the sweeping process. For example, the sweeping bars 72 may have a “V” or a semicircular shape so that the matter at the edges of the bars 72 is directed toward the center portion of the bars 72 . The shape of the bars' 72 cross section may also be modified as required.
Further, although the passages 76 are shown as rectangular and positioned to coincide with the center of the sweeping bars, in alternative embodiments the shape and position of the passages 76 may be modified. The shape of the passages 76 may include any shape known in the art, and the size of the passages 76 may be enlarged or contracted as required by a specific application. Additionally, the specific position of the passages 76 may also be varied so that an individual passage 76 may be positioned adjacent the retaining wall 74 , adjacent the chain 70 , or in an intermediate area between the retaining wall 74 and the chain 70 .
After the biodegradable material passes through the passage(s) 76 , it is deposited onto one of the distribution conveyor systems 80 . FIG. 2 shows the position of the distribution device 60 relative to the distribution conveyor system 80 in accordance with the preferred embodiment. FIG. 8 shows the configuration of one of the individual distribution conveyor systems 80 . Although the preferred embodiment includes four distribution conveyor systems 80 corresponding with four passages 76 , a greater or lesser number of conveyors 80 and corresponding passages 76 should be considered within the scope of the invention.
As shown in FIG. 8 , the distribution conveyor system 80 includes a mesh chain conveying assembly 81 . The mesh chain conveying assembly 81 comprises two sets of conveyor sprockets 82 that rotate a mesh chain 84 . The mesh chain conveying assembly 81 primarily operates within an elongated trough 86 . A strike-off plate 85 extends laterally across the trough 86 and essentially limits the depth (and consequently the volume) of the biodegradable matter traveling down the conveyor system 80 .
As the matter leaves the delivery end 88 of the mesh chain conveying assembly 81 , it is directed downwardly by a distribution funneling assembly 83 shown in FIG. 8 . The distribution funneling assembly 83 is comprised of a retaining shield 87 and a flexible curtain 89 . The retaining shield 87 is attached to the elongated trough 86 on the delivery end 88 of the mesh chain conveying assembly 81 . The retaining shield 87 directs the flow of the biodegradable matter downwardly into the flexible curtain 89 . The flexible curtain 89 is appended to the lower edge of the retaining shield 87 and directs the material further downwardly into the trench created by the trenching assembly 90 .
FIG. 9 shows the specific configuration of the trenching assembly 90 . As the applicator system AS is propelled in the direction of the arrow 92 , the leading edge of a coulter disc 94 initially breaches the soil. The coulter disc 94 is immediately followed by a trenching blade 96 which slides into the fissure created by coulter disc 94 . The lower edge of the coulter disc 94 is generally positioned just below the lower edge of the trenching blade 96 so that the trenching blade 96 will not snag on rocks and other solid objects. This configuration enables the trenching blade 96 to ride up over obstacles and prevents damage to the trenching assembly 90 .
The leading edge of the trenching blade 96 is contoured to be concentric with the lower trailing edge of the coulter disc 94 . In the preferred embodiment, there is an approximately one sixteenth-inch gap between the leading edge of the trenching blade 96 and the trailing edge of the coulter disc 94 . The relatively close positioning of the coulter disc 94 to the trenching blade 96 serves to minimize accumulation of crop residue (particularly corn stalks) and soil on the leading edge of the trenching blade 96 . Although a gap of one-sixteenth inch is preferred, a larger or smaller gap should be considered within the scope of the current embodiment.
As shown in FIG. 9 , the trenching blade 96 is generally planar and extends away from the coulter disc 94 so that the trailing edged of the trenching blade 96 is disposed between two vertically extending trench enlargement plates 98 . The trench enlargement plates 98 are angled outwardly so that they further increase the width of the trench created by the trenching blade 96 and the coulter disc 94 as the trenching assembly 90 moves in the direction of the arrow 92 .
FIG. 10 shows a perspective view of the underside of the forward portion of the trenching assembly 90 . A plastic insert 106 that extends across the bottom portion of the trench enlargement plates 98 so that soil and plant residue does not become lodged in the crevice between the trailing portion of the trenching blade 96 and the trench enlargement plates 98 .
As shown in FIG. 9 , a matter receiving section 100 is attached to the trailing edges of the trench enlargement plates 98 . The matter receiving section 100 is comprised of two vertically extending receiving plates 102 and corresponding angular funnel plates 104 . The angular funnel plates 104 direct biodegradable matter from the supply conveyor system 80 (see FIG. 8 ) into the trench between the receiving plates 102 .
In the preferred embodiment, the funnel plates 104 are comprised of plastic or a similar flexible material. The plastic construction of the funnel plates 104 prevents damage to the plates 104 or the components of the supply conveyor system 80 if the trenching assembly 90 is unexpectedly deflected upwardly into the body of the applicator system AS.
After the matter is deposited in the trench, a trench closing assembly 110 closes the trench. The trench closing assembly 110 comprises a pair of inwardly cambered closing wheels 112 , a pivoting closing wheel frame 114 , and a tail wheel mechanism 116 .
The inwardly cambered closing wheels 112 are positioned and angled to correspond with the location of the soil displaced by the trenching assembly 90 . Specifically, the wheels 112 are positioned to contact the displaced soil on the lateral edges of the trench and direct the soil back into the trench. The wheels 112 are mounted on a pivoting frame 114 that extends longitudinally from the matter receiving section 100 of the trenching assembly 90 . The frame 114 pivots downwardly and may be spring-biased so that the inwardly cambered closing wheels 112 remain in contact with the soil as the applicator system AS moves over uneven terrain.
As shown in FIGS. 9 and 11 , a tail wheel mechanism 116 follows the inwardly cambered wheels 112 . The tail wheel mechanism 116 flattens and compresses the surface of the soil that has been directed into the trench. The tail wheel mechanism may also incorporate a pivoting frame assembly 115 (see FIG. 11 ) that maintains the tail wheel 116 in contact with the soil.
As shown in FIG. 2 , a toolbar 10 extends across the front portions of the trenching assemblies 90 . As shown in FIGS. 9 and 11 four-bar parallel linkages 93 connect the trenching assemblies 90 to the toolbar 10 . The linkages 93 allow the position of the trenching assemblies 90 to be adjusted laterally. Similarly, the mesh chain conveying assemblies 81 may be laterally adjusted so that the delivery ends 88 of the mesh chain conveying systems 81 correspond with the positions of the respective trenching assemblies 90 .
In operation, as shown in FIGS. 2 , 8 , and 9 , as the applicator system AS is propelled forward via the tool bar 10 , the coulter disc 94 slices through the soil creating a narrow crease. The trenching blade 96 immediately follows the coulter disc 94 . Vertically-extending trench enlargement plates 98 attached to the trenching blade 96 enlarge the trench. The biodegradable matter leaves the conveying assembly 81 and is directed downwardly by the distribution funneling assembly 83 into the matter receiving section 100 . As the applicator system AS continues to move forward, the inwardly cambered closing wheels 112 direct the displaced soil back into the trench, thereby covering the deposited matter. A tail wheel mechanism 116 levels and compresses the backfilled soil.
For the foregoing reasons, it is clear that the invention provides an effective and innovative means of applying matter (preferably biodegradable poultry litter) to a planted field or in other agricultural applications. The current invention may be modified in multiple ways and applied in various technological applications. The current invention may be modified and customized as required by a specific operation or application, and the individual components may be modified, as required, to achieve the desired result. Although the materials of construction are generally not described, they may include a variety of compositions consistent with the function of the associated component. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | The applicator system is designed to distribute agriculturally beneficial matter across a field. The system includes a supply reservoir and an agitator assembly that grates and abrades matter in the supply reservoir until the abraded matter precipitates out of the supply reservoir and onto a supply conveyor. The supply conveyor conveys the matter to a distribution device. The distribution device meters the matter onto at least two lateral distribution conveyors. At the end of each of the distribution conveyors the matter is funneled downwardly into an open trench created by a trenching device associated with each distribution conveyor. After the matter is deposited into the trench, a trench closing assembly directs soil back into the trench and compresses the soil surface. | 8 |
FIELD OF THE INVENTION
This invention relates to gas-separators used for recycling of drilling fluid, and especially, to gas-separators used for separating trapped gases from recycled drilling fluid.
BACKGROUND
Crude oil and natural gas deposits generally are deep within the earth. To extract oil and gas, a well-bore is drilled into the earth and then crude oil is pumped up using submersible pumps, often in a series.
A well-bore is drilled from an oil-rig on the surface of earth using a rotating drilling bit. The drilling bit is driven using a continuous flow of compressed drilling fluid (also known as “drilling mud”) supplied through a conduit, known as a drill string.
When driven, the drilling bits cut through the earth and move deeper in, leaving a tubular well-bore. The inflowing compressed drilling fluid which drives the drill bits gets released at the bottom of the bore, and due to continuous pressurized drilling fluid inflow, released drilling fluid is pushed back to surface of the earth through free space available between the well-bore and the drill string.
On its way back to the surface of the earth, the released drilling fluid carries away with it:
loose dirt and rock from the bore (most of which is generated during cutting action of the drill bits); gases (both trapped gases which were released while drilling the bore and gases which seeped into the bore from gaseous zones/formations surrounding the bore); and water and other fluids (including both trapped water and fluids which were released while drilling the bore and others which seeped into the bore from regions/formations surrounding the bore).
After reaching the surface of the earth, the used drilling fluid is collected, filtered and processed for reuse.
Apart from driving the drill bits, the drilling fluid also:
serves as a lubricant for the drilling bit; removes the debris produced by the drill bits while cutting the bore and aids in further deepening it; helps cool the drill bits under friction from cutting of the earth bed; and provides hydrostatic pressure in the bore which reduces inflow, seeping in and unwanted escape of oil, gases and fluids from regions surrounding the bore.
For a drilling fluid to be able to perform its desired functions, the correct composition and viscosity of drilling fluid must be maintained throughout the cycle. As drilling fluid is recycled, foreign material (such as rock debris and trapped gases) must be filtered out, and it must otherwise be processed to maintain the correct composition and viscosity. If trapped gases are not removed, the drilling fluid cannot provide the desired hydrostatic pressure. Additionally, as trapped gases may be flammable (such as methane or natural gas), there can be a risk of fire or explosion if they are not removed. Some trapped gases, including especially nitrogen and sulfur gas, can react with and corrode the drilling equipment, including the pumps. Trapped gases in the drilling fluid can also cause cavitation or even ‘gas-lock’ in the pumping equipment.
Over the years, various gas separators have been proposed for removal of trapped gases in the drilling fluid. Currently known gas-separators suffer from drawbacks including inefficiency in gas separation or otherwise; from lack of commercial viability; difficulty in installation in the limited available space of the bore; and inability to protect the pumping equipment. Hence, there's an acute need for a gas-separation equipment that overcomes the deficiencies of the prior art separators.
SUMMARY
The invention is a gas separator for separating trapped gases, including corrosive gases such as sulfur and nitrogen, from drilling fluid (or “mud”), including such fluid recycled from a well-bore which is being drilled.
The gas separator includes a cylindrical separator which is capable of rotating on its longitudinal axis. The cylindrical separator includes a hollow bore and multiple gas ejection ports communicating with the hollow bore. The ports include channels having a narrower cross-section towards the hollow bore and a wider cross-section towards exit of the fluid ejection port, to permit gas expansion on exit. Further, each of said hollow channels is aligned transverse to the axis of the cylindrical separator and substantially tangentially with the periphery of the hollow space such that an outflow of fluid (including gases) contained in said hollow bore through fluid ejection port induces a rotational torque onto the cylindrical separator.
When drilling fluid (having trapped gases) is pumped into the gas separator under pressure, it's delivered to the hollow bore. Continuous inflow forces the drilling fluid (and gases) to exit the bore through the hollow channels and the wider part of the ejection ports. Due to the alignment and configuration of hollow channels and ejection ports, while the gas in the fluid is exiting the ports, it expands and provides the rotational torque (or spinning force) to the cylindrical separator, which in turn generates momentum (sometimes called “centrifugal force”) on the drilling fluid in the hollow bore, and forces more gas trapped in the drilling fluid towards the fluid ejection ports—thereby enhancing the gas separation effect.
After the drilling fluid and gases exit the hollow bore through the ejection ports, the separated gases and the drilling fluid follow different paths. While the gases may travel towards one or more gas exit ports on an outer barrel surrounding the first chamber and into the casing space, the gas cleansed drilling fluid travels through the separator and towards drilling fluid pumps which pump the cleansed fluid towards the drill bits.
The gas-separator may be placed in the well-bore, attached in the drilling tool string, during drilling. Several can be used in a series, perhaps even some at the surface and some in the well-bore. It is preferably placed upstream of pumping equipment to remove damaging gases from the drilling fluid prior to pump intake.
Embodiments of the present invention will be discussed in greater details with reference to the accompanying figures in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exploded view of parts of a gas separator in accordance with a first embodiment of the present invention.
FIG. 2 illustrates a cross-sectional view of the gas separator in accordance with the first embodiment of the present invention.
FIG. 3 illustrates a cross-sectional view of the portion of the gas separator of FIGS. 1 and 2 featuring the fluid ejection ports.
FIG. 4 illustrates positioning of the gas-separator in accordance with the first embodiment of the present invention and the overall process of drilling fluid recycling and gas separation during drilling.
FIG. 5 is a cross-sectional view of a portion the of gas separator illustrating the gas separation therein.
FIG. 6 is a cross-sectional view of a portion the of gas separator illustrating the fluid flow therein. It should be understood that the drawings and the associated descriptions below are intended and provided to illustrate one or more embodiments of the present invention, and not to limit the scope of the invention. Also, it should be noted that the since the drawings are intended to describe the invention with better clarity, they may not be necessarily drawn to scale.
DETAILED DESCRIPTION
Reference will now be made in detail to a first embodiment of a gas separator of the invention. As illustrated in FIG. 1 , gas-separator 100 includes a hollow cylindrical barrel 102 , first fixture 104 , first bearing 106 , a cylindrical separator 108 , second bearing 110 and a second fixture 112 . The distal ends of fixtures 104 and 112 ( 126 and 158 , respectively) screw into mating portions of a drilling tool string, as shown schematically in FIG. 4 , but not otherwise.
The hollow cylindrical barrel 102 further includes multiple gas exit ports 114 (though more or fewer may be used). In a well-bore, gas exit ports 114 permit gases to pass into the space between the barrel 102 and the casing of the well-bore. Portions of inner surface of the barrel 102 proximal to each of the two ends 116 and 118 are threaded so as to allow, respectively, portions 122 of fixture 104 and 160 of fixture 112 to be screwed into the barrel 102 . Threaded portion 120 mates with portion 160 (note that the threaded portion corresponding to end 116 which mates with portion 122 remains hidden in FIG. 1 , but is shown in FIG. 2 ).
Fixture 104 includes dual-sided (inner and outer side) threading on connector 122 , a mid-portion 124 , a tapered threaded extension 126 to connect to the drilling fluid line and a bore 128 running through all portions of fixture 104 (bore 128 is illustrated in FIG. 2 ).
In gas-separator 100 , portion 134 of first bearing 106 is screwed into the interior of portion 122 of fixture 104 , and the outer threaded side of connector 122 is screwed into end 116 of barrel 102 . First bearing 106 includes, in addition to threaded portion 134 , a first cylindrical receiver 130 and an apertured rim 132 . The apertured rim 132 further includes several hollow delivery channels 138 . Once first bearing 106 is affixed to first fixture 104 , bore 128 becomes accessible to hollow delivery channels 138 through hollow region 136 included within threaded portion 134 .
Threads 148 of second bearing 110 are screwed into threads 156 of cylindrical separator 108 . Cylindrical separator 108 includes first chamber 140 , support stub 142 and pivot stub 144 . The support stub 142 and pivot stub 144 fittingly mate with corresponding portions in bearing 106 . Lower side of stub 142 and the lower side of portion of fluid channel cylinder 162 rests on Bearing 106 and bearing 110 respectively, such that separator 108 can rotate freely on its axis. Bearing 110 includes cylindrical receiver 146 which accommodates fluid channel cylinder 162 and fluid injecting cylinder 164 of fixture 112 .
In the cylindrical separator 108 , first chamber 140 includes a hollow bore 150 (hollow bore 150 is illustrated in FIG. 2 ) and includes several fluid ejection ports 152 near the end at which support stub 142 is positioned. Other locations or additional locations of ports 152 are within the scope of the invention.
Each of the fluid ejection ports 152 extend through outer wall of the first chamber 140 , and access hollow bore 150 , through a hollow channel 154 (two hollow channels 154 are illustrated in FIG. 2 ). Hollow channels 154 are narrower towards the hollow bore 150 and have a widened section towards outer periphery of the first chamber 140 . Further, hollow channels 154 are oriented substantially tangentially with periphery of longitudinal hollow bore 150 , though other orientations which provide rotational force to separator 108 when fluid and gases flow out through ports 152 are also within the scope of the invention. An enhanced view of the preferred orientation of ports 152 (along with their corresponding hollow channels 154 ) is shown in FIG. 3 .
The second fixture 112 comprises a cylinder 158 , a threaded cylinder 160 , a fluid channel cylinder 162 , a fluid injecting cylinder 164 and a longitudinal bore 168 running through each of the cylinder 158 , cylinder 160 , cylinder 162 and cylinder 164 (longitudinal bore 168 is more clearly illustrated in FIG. 2 ). As illustrated in FIG. 2 , the longitudinal bore 168 varies in shape and dimensions throughout its length. Starting from cylinder 158 , the longitudinal bore 168 becomes narrower towards the fluid injecting cylinder 164 . Further, the inner surface of cylinder 158 (which surrounds a portion of the longitudinal bore 168 ) is threaded to connect with threads on the drill string, and the outer surface of cylinder 160 is threaded to mate with threads 156 of separator 108 .
Fluid injecting cylinder 164 also includes one or more ports 166 to allow fluid venting and avoid excessive pressure build up inside fixture 112 .
Once portion 160 of fixture 112 is screwed into the threaded portion 120 of barrel 102 , the end 118 is sealed against the lower edge of cylinder 158 .
In the assembled gas-separator 100 , longitudinal bore 168 of fixture 112 extends through the second bearing 110 into the hollow bore 150 of the separator 108 . Further since longitudinal bore 168 extends into the hollow bore 150 , fluids vented by ports 166 are delivered into the hollow bore 150 (See FIGS. 2 and 5 ). Gas-separator 100 also has an additional chamber 170 formed between the cylindrical barrel 102 and the cylindrical separator 108 (illustrated in FIG. 2 ).
Implementation of gas-separator 100 in a well-bore for separating gases from drilling fluid will now be explained with reference to FIGS. 2, 3, 4, 5 and 6 . The drilling fluid to be recycled (retrieved form a well-bore being drilled) includes trapped gases. FIG. 4 illustrates positioning of the gas-separator 100 and an overall process of gas-separation within a well-bore 400 (having a casing 402 ). In FIGS. 4, 5 and 6 , while the drilling fluid and its direction of flow is depicted by arrows 404 , the trapped gases in a drilling fluid are depicted as bubbles 406 .
As illustrated in FIG. 4 , in the well-bore 400 , the gas-separator 100 is placed upstream of the PDM motors and pumps (together depicted as 408 ) in a drilling tool string 410 . Removal of the trapped gases, especially nitrogen and sulfur, from the drilling fluid protects the motors and pumps 408 (especially the rubber components of these motors and pumps 408 ). The motors and pumps 408 receive gas-cleansed drilling fluid 404 from the gas-separator 100 , and pass on compressed/pressurized gas-cleansed drilling fluid to drilling bits 412 lying beneath (downstream). When driven by compressed gas-cleansed drilling fluid 404 , the drilling bits 412 continue to dig the well-bore 400 further. After driving the drilling bits 412 , the drilling fluid 404 is pushed upwards towards the surface of the well-bore 400 . On its way to the surface, the drilling fluid 404 carries away material (loose soil, rock chips) and fluids in the well-bore (such as gases 406 and water) along with itself. On reaching the surface, retrieved drilling fluid 404 (including foreign materials such as soil, rock chips, gases and liquids) is collected at recycling units 414 for removal of non-gaseous foreign material. Thereafter, the drilling fluid 404 (along with trapped gases 406 ) is pumped into the drilling tool string 410 . In the string 410 , the drilling fluid 404 (along with trapped gases 406 ) is delivered to the gas-separator 100 for removal of gases 406 . After separation, while the gases 406 exit the gas-separator 100 through gas exit ports 114 and are delivered into space between string 410 and casing 402 , gas-cleansed drilling fluid 404 is delivered to PDM motors and pumps 408 . Finally, motors and pumps 408 deliver compressed gas-cleansed drilling fluid 404 to drilling bits 412 , and the process repeats as described. A cover 416 is useful to maintain desired drilling fluid pressure within the well-bore 400 . It is noted that since the illustration provided in FIG. 4 is intended to provide a simplified understanding of gas-separation, and other arrangements of components are within the scope of the invention.
FIGS. 5 and 6 , illustrate the process of gas separation within the gas-separator 100 . The process of gas-separation from drilling fluid 404 (having trapped gases 406 ) starts with pumping a continuous flow of the compressed/pressurized drilling fluid 404 (having trapped gases 406 ) into the gas-separator 100 through the longitudinal bore 168 . After being fed into the longitudinal bore 168 , the compressed drilling fluid 404 (along with trapped gases 406 ) travels through it and gets delivered into the hollow bore 150 . As bore 150 fills with the drilling fluid 404 (and gases 406 ), due to continuous pressurized inflow, the drilling fluid 404 (and gases 406 ) contained within bore 150 are forced into channels 154 and ultimately ejected from corresponding fluid ejection ports 152 . Due to the alignment and configuration of hollow channels 154 (and their corresponding fluid ejection ports 152 ) as described above, while the drilling fluid 404 (and gases 406 ) exit the fluid ejection ports 152 , they provide a rotational torque (or spinning force) to the cylindrical separator 108 . As a result of continuous ejection of drilling fluid 404 (and gases 406 ) through fluid ejection ports 152 (and corresponding continuous generation of rotational torque), the cylindrical separator 108 starts spinning about its longitudinal axis. Spinning of cylindrical separator 108 leads to application of centrifugal force on the drilling fluid contained within bore 150 which moves it towards the ports 152 and increases the gas separation from the drilling fluid 404 .
After exiting through ejection ports 152 , drilling fluid 404 (and gases 406 ) enter the second chamber 170 . In the second chamber 170 , buoyant gas bubbles 404 travel towards gas exit ports 114 on barrel 102 . While the gases which pass through gas exit ports 114 on the barrel 102 escape up to the surface, gas-cleansed drilling fluid 404 flows into the hollow delivery channels 138 and then to bore 128 . From bore 128 , the gas cleansed drilling fluid travels to motors and pumps 408 , and from there, to drilling bits 412 . So, from the second chamber 170 , separated gases and the cleansed drilling fluid follow different paths.
Embodiments of gas-separators provided by the present invention are readily deployed in the limited available space within a well-bore. As a result of efficient gas-separation, gas-separators of the invention effectively protect pumping equipment against corrosion, and also against problems such as cavitation (or ‘gas-locking’) of pumping equipment, and accumulation of inflammable gases (such as methane or natural gas). Additionally, due to efficient gas-separation, gas-separators of the invention also effectively contribute in maintenance of necessary hydrostatic pressure in the well-bore, because they help maintain the requisite composition and viscosity of the recycled drilling fluid.
It is to be understood that the foregoing description and embodiments are intended to merely illustrate and not limit the scope of the invention. Other embodiments, modifications, variations and equivalents of the invention are apparent to those skilled in the art and are also within the scope of the invention, which is only described and limited in the claims which follow, and not elsewhere. | A gas-separator for separating trapped gases from drilling fluids retrieved from a well-bore being drilled is disclosed. The gas-separator includes a cylindrical separator which is capable of rotating on its longitudinal axis when fluid and gases flow out through fluid ejection ports, which access the center bore of the cylindrical separator. The fluid ejection ports have a narrower cross-section towards the center bore and a wider cross-section at the opposite end, and are preferably aligned substantially tangentially with periphery of center bore, such that outflow of drilling fluid (and gases) from the center bore through the ejection ports induces a rotational torque on the cylindrical separator. Spinning of cylindrical separator enhances the gas-separation effect. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Application No. 10 2004 048 107.5, filed in the Federal Republic of Germany on Oct. 2, 2004, which is expressly incorporated herein in its entirety by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for compensating for a rotor angle deviation of a motor and to a steering system.
BACKGROUND INFORMATION
[0003] Steering systems such as electronic power steering systems, for example, exhibit deviations between the specified torque determined by the driver of the vehicle and the rotor angle actually set by the steering system. The torque, also called manual torque, is introduced into the steering system via a steering handle such as a steering wheel or a joystick and the like. A desired rotor angle (desired RW) is derivable from the manual torque. In an idealized manner, a linear relationship is assumed between the manual torque and the desired rotor angle. In conventional steering systems, the manual torque is transmitted via a torsion element known as a torsion bar (TB). The driver of the vehicle is supported by an electrical or hydraulic motor or actuator such that the manual torque to be introduced may be lower. The actuator transmits a rotor angle (RW) onto an actuator shaft. In the process, however, the steering system does not follow the specified manual torque completely. The deviations are attributed to numerous causes. Generally, the deviations are attributed to static deviations and dynamic deviations, which, being system-related, are sought in static frictions, in a hysteresis behavior of the steering system, in liquid friction losses, in velocity losses and many other causes.
[0004] German Published Patent Application No. 199 56 713 describes an electric power steering device, the control unit of which calculates a current control value for the motor of the power assisted steering device. Deviations of the specified current control value from the actual power steering device control are attributed to additional loads, which are caused by feedback effects of the roadway surface on the rack-and-pinion steering gear. The feedback effects are to be absorbed with the aid of an additional element, an elastic body.
[0005] U.S. Patent Application Publication No. 2003/006088 describes a compensation table for the kinetic friction being stored in the engine control unit.
[0006] A similar approach is described in German Published Patent Application No. 102 21 678, which attributes the friction in the steering system to a hysteresis torque, which is to be taken into account in the desired torque input. The hysteresis characteristic curve is ascertained as a function of the non-compensated desired torque.
[0007] German Published Patent Application No. 199 20 975 subdivides the causes for the friction losses in a more differentiated manner. Five different kinds of friction are distinguished and calculated in terms of control engineering. For this purpose an estimated value is assumed for the static friction. The control provided thus estimates the system deviation of the steering, which has a separately energized DC motor as an actuator.
[0008] On the whole, the foregoing steering systems represent an attempt to improve the feel of the steering for a driver of the vehicle. Conventional friction compensations partly have the tendency to overcompensate in the case of steering systems that have little friction.
SUMMARY
[0009] An example embodiment of the present invention may provide optimized friction compensation for steering systems.
[0010] Since the rotor angle deviation of the motor used in a steering system is controlled in a compensating manner via a piecewise linearized control on the basis of a desired rotor angle and the measured rotor angle, whereby at least of the control factors of the controls is changed as a function a the control range, the control of the steering system may be optimized in the operation of a steering system according to the method of an example embodiment of the present invention. The term “control range” refers to the deviation to be controlled. The control, which operates with actual measured values of the steering system, determines the required compensation. An overcompensation may be clearly reduced if not avoided.
[0011] One of the control factors of the control may be changed by a gradient change as a function of the control range. The gradient change may always provide an optimum control factor for the current rotor angle position. It changes continuously within an admissible range of values. If only slight adjustments remain to be made, then the control factor is changed such that a manipulated variable of the control is adjusted only minimally.
[0012] According to a design of the control loop of the steering system, the control may be designed such that, when the compensation exceeds the desired rotor angle, the control breaks off the compensation for the rotor angle deviation. This may prevent overcompensation, the so-called overswinging of the control. Steering systems that are only slightly affected by friction are therefore not overcompensated.
[0013] In contrast to conventional, very complex control systems, which may make all sorts of estimates using many input variables, the steering system makes do with one single control, which compensates for all friction-related deviations of the rotor angle when a manual torque is applied. The degree of complexity may be reduced, which may have advantageous effects on the stability and the mutual, reinforcing influence.
[0014] The controller deliberately has ranges of values in which it no longer operates in a linear manner. It is linearized in a piecewise manner. The linear share of the control may include a controller, which includes at least one controller either of a P-type or of an I-type, e.g., a PI-controller. Using a P-controller, the rotor angle deviation may be quickly eliminated. A PI-controller is used to reduce the system deviation. If the control factor of the I-controller is adjustable, then this may reduce the variability, the overswinging or overcompensating tendency. The variability of the I-controller may be designed such that the control factor of the I-controller in quantitative terms is provided with a maximum control factor in the case of input variables that are in quantitative terms far from zero, and that the controlled system may be provided with variable, that is to say, quantitatively decreasing control factors in an input variable range that is quantitatively near zero. With the quantitative delimitation of the control factor, the control fundamentally may move within a technically meaningful range of values and may not drift into an extreme position.
[0015] As a further measure for maintaining the controller within a range of values utilizable by the actuator, the values of the manipulated variable of the control may be limited. The compensation for the rotor angle deviation is limited within an admissible maximum range of values by influencing the manipulated variable via a value limiter. The value limiter has at least three sections or ranges. Within a first range, it operates in a linear manner, and within a second and a third range, the manipulated variable is quantitatively limited to the maximum manipulated variable.
[0016] As particular stabilizing measures may be taken on the output side of the controller, the method may also be stabilized by measures for the input variables. Thus in an exemplary embodiment, the manual torque may be quantitatively limited to a maximum value. The control may set in with any change of the manual torque. It may be provided, however, for the control to operate only once a limiting value of the manual torque has been exceeded and to set in only afterwards. Minimal changes may thus be absorbed and the control may not correct itself permanently.
[0017] The method may be based on the assumption that a desired rotor angle deviation is determined from the difference of the manual torque with respect to a previously stored manual torque, multiplied by a gear ratio and divided by a factor for the system stiffness.
[0018] A first control, the positive compensation control, may be selected if the manual torque is above a threshold value, and a second control, the negative compensation control, may be selected if the magnitude of the manual torque having a negative sign is above a threshold value. For this purpose, the threshold values of the manual torque may be quantitatively identical for the positive and negative compensation.
[0019] The foregoing may be used in a steering system, e.g., for motor vehicles such as passenger cars. Their friction-dependent rotor angle deviation may operate according to a method according to an example embodiment of the present invention.
[0020] According to an example embodiment of the present invention, a method for compensating for a rotor angle deviation of a motor includes: piecewise linearized controlling of a difference between a desired rotor angle and a measured rotor angle, the desired rotor angle being based on a manual torque on a steering handle and a stored rotor angle, a control factor of the controlling being variable as a function of a control range.
[0021] The motor may include an actuator in a steering system.
[0022] The control factor may be variable by a gradient change as a function of the control range.
[0023] The controlling may include breaking off the compensation for the rotor angle deviation in the event that the compensation exceeds the desired rotor angle.
[0024] The controlling may include compensating for all friction-related deviations of the rotor angle under influences of the manual torque.
[0025] The controlling may be performed by a controller that includes at least one of (a) a P-controller, (b) an I-controller and (c) a PI-controller.
[0026] A controlled system of the I-controller may be provided with a maximum control factor for input variables that are quantitatively far from zero and may be provided with variable, quantitatively decreasing control factors in an input variable range that is quantitatively near zero.
[0027] The method may include influencing a manipulated variable by a value limiter within an admissible maximum range of values.
[0028] The value limiter may be linear within a first range and limited to the maximum manipulated variable within a second range and a third range.
[0029] The method may include quantitatively limiting the manual torque to a maximum value.
[0030] The controlling may set in in accordance with a change in the manual torque.
[0031] The controlling may set in only when the manual torque exceeds a limiting value.
[0032] The method may include determining a desired rotor angle deviation from a difference of the manual torque with respect to a previously stored manual torque, multiplied by a gear ratio and divided by a factor for a system stiffness.
[0033] The method may include selecting a first control if the manual torque is above a first threshold value and selecting a second control if a magnitude of the manual torque having a negative sign is above a second threshold value.
[0034] The first control may include a positive compensation control.
[0035] The second control may include a negative compensation control.
[0036] The first threshold value and the second threshold value may be quantitatively identical.
[0037] According to an example embodiment of the present invention, a steering system includes: a device adapted to perform piecewise linearized controlling of a difference between a desired rotor angle and a measured rotor angle, the desired rotor angle being based on a manual torque on a steering handle and a stored rotor angle, a control factor of the controlling being variable as a function of a control range.
[0038] The steering system may be arranged as a steering system for a motor vehicle.
[0039] Example embodiments of the present invention are described in more detail with reference to the appended Figures
BRIEF DESCRIPTION OF THE DRAWINGS.
[0040] FIG. 1 is a state diagram of a control according to an example embodiment of the present invention.
[0041] FIG. 2 illustrates a method for compensating for a rotor angle deviation for positive rotor angle deviations.
[0042] FIG. 3 illustrates a method for compensating for a rotor angle deviation for negative rotor angle deviations.
DETAILED DESCRIPTION
[0043] FIG. 1 illustrates the sequence of a control for steering systems according to an example embodiment of the present invention in the form of a state diagram. In state 1 , the current variables are first saved by a recopying process 10 in a recopying and initialization step. Afterwards, a check is performed by a comparison of values as to whether the manual torque introduced, that is, the torque that a driver of the vehicle intends to transmit to the steering system as the selected torque, is to initiate a further processing step in a new state, the control state 3 and the control state 5 , so as to result in a control 38 , 58 , the actual compensation control. Within the scope of the recopying process 10 , the values of the rotor angle (RW), of the manual torque (TBT) and of the desired rotor angle (Desired RW or DeRW) are described. The rotor angle (RW) and the manual torque (TBT) are described using the current measured values. The desired rotor angle (DeRW) is set to 0 so that within the context of control 38 , 58 it is then able to receive the calculated value. If the manual torque is greater than a limiting manual torque value 12 (ZeroTBT), the system branches into the positive control state 3 . If the magnitude of the manual torque is greater than a limiting manual torque value 14 , the system branches into the negative control state 5 . If the limiting manual torque values (ZeroTBT) are undershot, then the control system remains in state 1 , which may also be referred to as an archiving and initialization state for the control.
[0044] The continuing specification considers a controller according to FIG. 2 and FIG. 3 , which includes an integrator in the form of an I-controller 124 , 224 and a proportional controller (P-controller) 136 , 236 , and which by an addition in adder 144 , 244 forms a PI-controller. It should be understood that example embodiments of the present invention are not limited only to PI-controllers, but that in their place PID-controllers or any other kind of control factor-adaptive controller type such as a pure P-controller or a controller of a higher order may be provided. For simplicity, the further remarks are presented for a PI-controller, including an I-controller 124 , a P-controller 136 and an adder 144 , having positive integration and compensation, or for a PI-controller, including an I-controller 224 , a P-controller 236 and an adder 244 , having negative integration and compensation.
[0045] The two states 2 , 5 illustrated in FIG. 1 , which yield the positive control state for compensating for a positive friction value, the friction compensation manipulated variable (FrictionComp) 150 , and the negative control state for compensating for a negative friction value, the friction compensation manipulated value (FrictionComp) 250 , are similar in structure. The different sign in the manual torque (TBT), however, is taken into account by sign multiplication by (−1) or by a reversal of the comparison operators. In states 3 , 5 , an ascertainment is made in a first comparison 30 , 50 as to whether the I-share of the position controller (IPart) is quantitatively higher than a specified I-share for a zero limit (ZeroPart). If the I-share (IPart) is quantitatively above an I-share limit value (ZeroIPart), then the respective compensation control 38 , 58 is activated. If the compensation limit for the compensation (TBTReady) exceeds 32 or undershoots 52 the manual torque (TBT) and the limit for the lower manual torque 34 , 54 is undershot, then the positive 38 or negative compensation control 58 may be started in states 3 , 5 . Otherwise a limiting value persistence 70 is checked in safety state 7 or a transition is made from control state 3 to control state 5 or vice versa following a storage step of variables 36 , 56 .
[0046] Favorable limits for a stable state change are limits of approximately 0.1 Nm for example. Below a manual torque (TBT) of approximately 0.1 Nm, the control assumes that the driver of the vehicle did not intend to perform a driving maneuver. As a result, the vehicle becomes more stable overall when there are smaller manual torque fluctuations in straightforward driving. The two control according to FIG. 2 and FIG. 3 are similar. Due to the different signs of the variable of the measured rotor angle (wrsRotrangle) 110 , 210 , of the manual torque (mstTorsionBarTorque) 102 , 202 and of the stored rotor angle (StoredRW) 100 , 200 , the I-controller 124 , 126 illustrated in FIG. 2 or the I-controller 224 , 226 illustrated in FIG. 3 and the P-controller 136 illustrated in FIG. 2 or the P-controller 236 illustrated in FIG. 3 are established using positive and negative values. The value of I-controllers 124 , 126 , 224 , 226 is limited in its maximum I-value (IPart) to a maximum value by the limiting value 128 , 228 in the limiter of I-controller 126 , 226 . From the difference between the subtracter 112 , 212 of the manual torque (TorsionBarTorque) 102 , 202 and the stored manual torque (StoredTBT) 104 , 204 , a rotor angle, which may be added to the stored rotor angle (StoredRW) 100 , 200 by an adder 118 , 218 , is determined using a position factor (TBTToPos) 106 , 206 and an optional value limiter 116 , 216 having a limiting value (maxOffsetangle) 100 , 200 .
[0047] Following the addition, controller 38 , 58 has the desired rotor angle (DesiredRW) 120 , 210 available, from which the measured rotor angle (Rotorangle) 110 , 210 is subtracted by a subtracter 122 , 222 . The signal of subtracter 122 , 222 is applied parallel to an I-controller including the elements 124 , 126 , 224 , 226 and to a P-controller 136 , 236 . The individual signals after the I-controller, including the elements 124 , 126 , 224 , 226 , and after the P-controller 136 , 236 are added to form a signal of a PI-controller via an adder 144 , 244 . Multipliers 130 , 140 , 230 , 240 , 132 , 134 , 232 , 234 are provided for value adjustment. At the same time, value limiters 146 , 148 , 246 , 248 may stabilize the control and may eliminate its tendency to oscillate.
[0048] The measures of stabilization by splitting signals and limiting signals may be optional and may not need to be present for a simple implementation of a control according to an example embodiment of the present invention. Behind adder 144 , 244 , the friction compensation manipulated value 150 , 250 may be read off, which is then applied to an actuator of the steering system. REFERENCE NUMERAL LIST
I state 3 control state 5 control state 7 safety state 10 recopying and initialization step 12 limiting manual torque value comparison 14 limiting manual torque value comparison 30 first comparison 32 compensation limit comparison 34 lower manual torque comparison 36 variables storage step 38 compensation control 50 first comparison 52 compensation limit comparison 54 lower manual torque 56 variables storage step 58 compensation control 70 limiting value persistence 100 stored rotor angle 102 manual torque 104 stored manual torque 106 position factor 108 limiting value 110 rotor angle 112 substracter 114 multiplier 116 value limiter 118 adder 120 rotor angle 122 substracter 124 I-controller 126 I-controller 128 limiting value 130 multiplier 132 multiplier 134 multiplier 136 proportional controller 140 multiplier 144 adder 144 value limiter 148 value limiter 150 friction compensation manipulated value 200 stored rotor angle 202 manual torque 204 stored manual torque 206 position factor 208 limiting value 210 rotor angle 212 substracter 214 multiplier 216 value limiter 218 adder 220 rotor angle 222 substracter 224 I-controller 226 I-controller 228 limiting value 230 multiplier 232 multiplier 234 multiplier 236 proportional controller 240 multipliers 244 adder 246 value limiter 248 value limiter 250 friction compensation manipulated value | A method is for compensating for a rotor angle deviation of a motor, which may be used as an actuator, e.g., as a servo actuator, in a steering system. The rotor angle deviation is compensated for by a piecewise linearized control of the difference between a desired rotor angle, which is based on a manual torque and a stored rotor angle, and a measured rotor angle, a control factor of the control being variable as a function of the control range. | 1 |
RELATED APPLICATIONS
[0001] The present application claims the benefit of Provisional Application Ser. No. 60/409,382 filed on Sep. 11, 2002 and entitled “System of and method for improving searching the world wide web for products and services by automatically categorizing web pages,” the disclosure of which is incorporated by reference as if set forth fully herein except to the extent of any inconsistency with the express disclosure hereof.
FIELD OF THE INVENTION
[0002] The present invention relates to systems and methods for searching sources of data such as the World Wide Web (“the Web”). In particular, one preferred embodiment of the present invention relates to an improved system and method of searching that utilizes automatic categorization of web pages and sites based on their type, such as whether or not they offer products and/or services.
BACKGROUND OF THE INVENTION
[0003] One way to search the Web for products and services is to employ a general purpose web search engine such as Google®, Yahoo®, Overture®, Alltheweb®, Inktomi®, AltaVista®, or the like. Such search engines may be able to reach an extremely vast array of e-commerce sites, but along with sites and pages actually offering products or services, they generally also return many sites and pages that merely describe, review, discuss, or otherwise mention the product or service being searched.
[0004] “Comparison shopping engines” such as BizRate®, DealTime®, PriceGrabber® and the like permit more focused searching of the Web for specific products or services that are desired to be obtained. The traditional comparison shopping engines search through only a limited number of e-commerce sites that are pre-selected by human editors, however, and also tend to focus on highly popular, mass-marketed products, to the exclusion of other items such as industrial products.
SUMMARY OF THE INVENTION
[0005] A system for searching a data source utilizing automatic categorization, according to the present invention, comprises a means for categorizing a plurality of documents in the data source, a category index that contains categorization information received from the automatic categorization means, means for receiving a user query, searching means for executing the user query on the data source and returning a list of documents satisfying the user query, means for checking the returned list of documents against the category index and manipulating the list of documents based thereon, and means for returning to the user the manipulated list of documents. A method of searching a data source utilizing automatic categorization, according to the present invention, comprises the steps of applying an automatic categorization algorithm to documents in the data source, storing resulting categorization information in a category index, receiving a user query, causing searching means to execute the user query on the data source and return a list of documents satisfying the query, checking the returned list of documents against the category index and manipulating the list of documents based thereon, and returning the user a manipulated list of documents. Thus, for example, an embodiment of the present invention can be made that permits extremely broad searching of the Web, but returns results limited to web sites and/or pages at which one can obtain a desired product or service, while excluding other sites and pages that only contain other content.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0006] In one preferred embodiment, the present invention may comprise a standalone categorization search site that operates in conjunction with one or more conventional search engines, and is hosted on computing means that are separately maintained and physically remote from the computing means hosting the search engine(s). Such an embodiment may operate as follows:
[0007] 1. Automatically (e.g., periodically) and/or at the direction of an administrator, a computer program of the categorization search site known as an information retrieval “robot” or “bot” crawls the Web to retrieve copies of web pages maintained on remote web servers (the number of which may optionally be limited to less than all accessible pages). The retrieved pages are (preferably automatically) then processed by a categorization program of the categorization search site that determines automatically (i.e., without human intervention) if they belong to one or more predefined categories, and then stores the corresponding Universal Resource Locators (“URLs”) and categorization data in a “category index” database maintained by the categorization search site. Optionally, the number of records to be stored may be limited, and/or records optionally may be automatically deleted after a certain period of time, and/or the URLs optionally may be abridged so that only domain names are stored.
[0008] 2. A user accesses (e.g., remotely over the internet) an interface of the categorization search site and enters a search request (“query”), which is automatically conveyed to one or more conventional search engine sites. Optionally, the user may be offered the choice to obtain only search results that belong to one or more categories specified by the user, and/or optionally may be offered the choice to limit the number of search results, and/or a preset limit may optionally be imposed, and/or meta-search techniques and the like optionally may automatically be applied to the outgoing query.
[0009] 3. The search engine(s) return(s) to the categorization search site a results list deemed to satisfy the query, along with other information such as brief summaries. Optionally, the categorization search site may truncate the list to any limit specified in step 2, and/or optionally may modify the list to prune out non-unique pages and/or abridge URLs to just domain names.
[0010] 4. Preferably, the categorization search site automatically checks the URLs of the list against the category index, utilizes the information retrieval bot to retrieve copies of pages having URLs not found in the category index, and causes those pages to be processed and added to the category index as described above.
[0011] 5. Category information is obtained and a limited (by number of results and/or category type per step 2) and/or categorized results list is displayed to the user. Category information may be obtained either at once by retrieval from the updated category index produced by step 4, or in parts, e.g., by retrieving information for all web pages found in the index existing prior to step 4 and then directly adding to that retrieved information the further category information produced in step 4. Optionally, the results list may include corresponding category information and/or any other desired information commonly displayed by conventional search engines, and the user optionally may also be offered a choice to further manipulate the displayed results. For example, if more than one category is displayed, means to (re-)sort them by category and/or block specified categories from view may be provided. The user's search results optionally may also be logged as is well-known in the art.
[0012] By employing multi-threading and load distribution among multiple computers, certain of these steps could be started without waiting for completion of all the preceding steps, as is commonly practiced in the field; for example, the automatic categorization program could begin analyzing the web pages already retrieved while the bots continue retrieving more pages from the Web, and/or categorization information could be retrieved from the category index while web pages are being retrieved from the Web, et cetera.
[0013] It is noted that in a variation of the embodiment described above, some or all of the information retrieval bots, categorization program, category index, interface, et cetera could be hosted by computer means located at the end-user's premises rather than at a categorization search site. In yet another embodiment, the information retrieval bot(s), categorization program, category index, interface, et cetera could be hosted by the same server means that hosts an otherwise conventional search engine, in which case they could be seamlessly integrated with the global index(es), information retrieval bots, user interfaces, and other components of the search engine. In this case, step 1 could be performed concurrently with the general indexing of web pages.
[0014] It is also noted that a system according to the present invention is preferably capable of receiving input from and/or delivering output to user(s) that are human or otherwise. A suitable human user interface may preferably include a graphical user interface provided by a client software application running on the user's computer, as well as a web browser interface, as is commonly practiced in the field. A suitable machine input/output interface may preferably comprise or include SOAP, XML Web Services, CORBA, Microsoft.Net, proprietary local and remote interfaces, et cetera.
[0015] The automatic categorization program can be a software implementation of any suitable categorization algorithm such as the well-known Support Vector Machines, k th Nearest Neighbor, Rocchio, Regression Trees, Neural Networks, Sleeping Experts, inductive rule learning, Naive Bayesian classifiers and the like. (See “The elements of statistical learning—data mining, inference and prediction” by Hastie, Tibshirani and Friedman (Springer Verlag, 2001, ISBN: 0387952845), and “Classification and Regression Trees” by Leo Breiman (Kluwer Academic Publishers, 1984; ISBN: 0412048418), the disclosures of which are incorporated herein by reference). Most such algorithms include, as their initial step, an automatic variable selection based on the manual selection and categorization of, e.g., a few thousand documents called a “training corpus.” The algorithm finds the variables (words, characters, and combinations thereof) most common among the documents in the training corpus, and then uses those variables in categorizing subsequent documents.
[0016] A preferred implementation of a categorization algorithm for use in the present invention, however, may preferably include one or both of two salient modifications. First, although all HTML tags, JavaScript source code symbols, and other markups are generally removed from web pages (leaving only ASCII text) before feeding them into a categorization algorithm, it may be preferable in the present invention to feed the entire HTML document including all of its source code, metatags, markup symbols, and the like into the algorithm (although HTML tags are preferably selectively removed from the variable list as noted below). For instance, using an example in the context of categorizing pages into shopping versus non-shopping, the string “<b> Price <font size=+2> $99.00 </font> </b>” may be more advantageous than the mere string “Price $99.00”.
[0017] Second, it may be preferred to modify a categorization algorithm for use in the present invention by manually editing—removing from and/or adding to—the variable list it automatically produces. This may be advantageous because more sophisticated logic can be utilized and a broader context can be taken into account when deciding which variables should be included in the list. In adding variables to the list, an editor examines the training corpus for variables that are common among documents in the training corpus but missed by the algorithm. For example, algorithms may tend to miss long word combinations (e.g., “Add to your shopping cart”) that can be readily manually identified. Conversely, in removing variables from the list, an editor examines the training corpus for variables that are common among documents in the training corpus but less indicative of the desired category. (For example, the common string “Designed and hosted by XYZ company” is not likely a strong determinant for a shopping category). The number of variables manually removed from and added to the list is discretionary, but the number of originally automatically selected variables remaining after manual removal may preferably be comparable with or smaller than the number of manually added variables, so as to balance the relative weight given to variables selected by the algorithm and human editors. A preferable process for selecting and modifying an algorithm for use in a categorization program of the present invention may thus proceed as follows:
[0018] 1) Manually select and classify into desired categories a few thousand web pages so as to create a training corpus (preferably with at least two people classifying each page so as to minimize human judgment errors).
[0019] 2) Similarly select and classify another set of web pages as a “test corpus.”
[0020] 3) Train several text categorization algorithms on the training corpus as is well-known in the art.
[0021] 4) Have humans review the lists of variables automatically selected by each algorithm, and modify each algorithm by selectively removing any desired variables and selectively adding any desirable variables to each of the algorithms' lists.
[0022] 5) Apply the modified algorithms to the test corpus, calculate their respective error rates, and select the modified algorithm that demonstrates the lowest error rate.
[0023] Preferably, one or more of the steps in this process (particularly steps 3-5) may be iteratively repeated to seek a modified algorithm with a further lowered error rate. It may also be preferable to repeat the process occasionally over time to accommodate the ongoing evolution the Web's content, as well as any potentially more accurate text categorization algorithms that are developed later.
[0024] In a preferred embodiment of the present invention, the predefined categorization of web pages and web sites preferably includes a basic categorization between a “shopping” category and a “non-shopping” category, wherein the “shopping” category is limited to web pages and sites offering products (and/or services). The “non-shopping” category may include all other pages and sites, or it may be limited to “non-shopping” pages and sites that relate to but do not offer products (which typically includes, e.g., online magazine and newspaper articles, reviews, descriptions, discussions, opinions, bulletin boards, newsgroups, personal web pages, and the like). By way of example, the following is a list of manually selected variables for addition (as part of step 4 above) that has been found to be advantageous for selecting a category limited to shopping for products:
my cart add to cart shopping cart add to basket view cart items in cart add to your shopping cart view all carts add cart add to order shopping basket view shop cart view your cart add to cart add to basket add to your shopping cart add items to your order add cart add one to basket add to shopping cart buy now buy it now buy one now buy this item now buy on line order now buy online click here to purchase click here to order order this item show order view order secure online order order tracking online ordering secure online shopping ordering info Show my order track your order click here to order click to order ordering instructions ordering<BR>instructions how to order have a salesperson contact me contact a salesperson contact a sales person have a sales person contact me
[0025] It is noted that even for the selection of a product shopping category, however, this or any other list cannot be considered perfect, because different list and algorithm combinations will exhibit different performance characteristics under different conditions, and the comparison of performance inherently involves a degree of subjective and/or offsetting factors.
[0026] In other embodiments of the invention, different main categories, and/or further divisions of the main categories into sub-categories, may also be defined and implemented in similar fashion to the foregoing example of “shopping” and “nonshopping” categories, with the selection of manually added and removed variables (if any) and the like depending upon the respective categories to be implemented in the particular embodiment. As one of many possible examples, the “shopping” category described above might be divided into online stores, “brick-and-mortar” (physical) stores, comparison shopping sites, online classifieds, auctions, real estate agencies, travel agencies, and/or other such subcategories, while the “non-shopping” category might be divided into magazine and newspaper articles, reviews, descriptions, discussions, opinions, bulletin boards, newsgroups, personal web pages and/or other such subcategories. Such subcategories could also optionally be hierarchically structured; for example, sub-subcategories of “online stores” and “brick-and-mortar” (physical) stores could comprise a single “stores” subcategory. In any case, the scope and nature of the particular predefined categories (and any subdivisions within them) of an embodiment of the present invention are preferably communicated to the prospective users.
[0027] It will be understood that each of the elements and/or steps of the method described above, or two or more together, may also find a useful application in other types of constructions and/or methods differing from the types described above. While preferred embodiments have been described in the context of searching the internet with internet search engines, the present invention can likewise be applied to other sources of data than the internet, such as intranets, databases, etc., in which case the web search engine could be replaced with any searching means (e.g., site search engines, intranet search engines, and software applications that find and retrieve information from single or multiple databases, including ones utilizing SQL and/or ODBC) suitable to the data source such as is well-known in the art. Moreover, while a preferred embodiment has been described in the context of a shopping/non-shopping categorization, the invention is not limited to such categorizations. Instead, the invention is limited only as set forth in the following claims and their legal equivalents. | A system and method for searching sources of data such as the World Wide Web for things such as available products and services, utilizing indexing of documents therein such as web pages and sites through automatic categorization based on their type, such as whether or not they offer products and/or services. | 6 |
FIELD OF THE INVENTION
The present invention relates to the field of window coverings and more particularly for improvements in bearing structures for adequately supporting and enabling the rotational movement of load bearing structures used to actuate vertical blinds and roller shades and which may be used to actuate any horizontal or other rotatable member.
BACKGROUND OF THE INVENTION
Conventional support and track systems for vertical blinds and roller shades have concentrated on two problems with two different structures.
First, for vertical blinds, the main objective has been to eliminate friction in actuating the rotation of the control rod which extends along the drapery track and which turns the individual vertical blind units simultaneously to admit or shut off light from entering the room. The control rod engages a gear associated with each support structure for each vertical blind panel, known as a carrier. The carrier has the ability to freely translate and roll within a raceway within the track, the system then having an ability to rotate the control rod to change the angle of the vertical blind panels regardless of where the carriers are located along the track.
Thus, the rod's contact with several carriers adds significant mechanical resistance to turning, especially when the turning is accomplished from the end of the vertical blind track. A significant turning force complicates the actuation with a pull chain, as the pull chain sprocket will normally experience additional friction from being actuated by being pulled downward, at a right angle from its axis of rotation.
One method and technique which has been applied to this problem is the use of the concentric reducing gear. This normally cuts the pull chain force in half by doubling the length of travel of the pull chain, but because of the lateral force friction, probably reduces the force by about 1/3. This can make the operation of the vertical blind set fussy and time consuming. Moreover, the gear mechanism significantly increases the cost of the mechanism, both from a number of parts standpoint, assembly standpoint, and even more importantly from a tolerance standpoint.
The cost for injection molded parts increases significantly once the tolerance specifications are made more exacting. Where several parts have to fit together and work properly, the tolerances have to be controlled within strict limits. Stricter limits translate to longer cycle times in the injection mold process and greater waste, both of which drive up the cost.
The size factor multiplies and exacerbates the above factors. Keeping tolerance on a small part is difficult. Having a series of smaller parts perform a load bearing function doesn't leave much room for wear. The use of a metal ball bearing set is out of the question as the added cost would be unbearable by the market.
Roller shades present the problem of controlled friction, coupled with bearing lateral force resistance and wear. One popular design uses a two ended coil spring which is activated by pushing the spring in an unwind direction to cause it to lose its grip and move. The spring, however, produces a good deal of friction upon the cylindrical tube upon which it is mounted. So, where the spring is made strong enough to strongly resist pulling on the window shade, it adds significant friction to the tube upon which it is mounted. Since the ends of the springs are all that hold the window shade in place, making a smaller spring would cause the force from the shade to bend the spring ends. As a result, the window covering industry has had to settle for a device which produces significant resistance to operation in order to provide window roller shade control. In reality, the force moment on a roller shade is small due to a general balance of material when rolled up, and a relatively short turning moment when fully unrolled.
In both the window shade and vertical blind configurations, the necessity to place greater force on the actuating member, particularly in the downward direction, means that greater time and effort must be expended in making certain that the mounting of the track or bracket is sufficient to withstand the pulling force of the actuation member, usually a looping suspended chain. So even in instances where dry wall would be sufficient to hold the roller shade or vertical blinds and more, additional labor and structure will be needed to further anchor the window covering device to a stud or beam. Of course, all installations should be secure, but where additional anchoring is needed simply because of the unreasonable forces needed to operate the window covering mechanism, the added money for much higher installation costs are not justified.
What is therefore needed is a mechanism for a window covering device which can be inexpensively injection molded and which makes up for relaxed tolerance in manufacture. The device should have load bearing capability and for roller shades, the resistive force to prevent the unwinding of the window shade should be adjustable.
SUMMARY OF THE INVENTION
An improved bearing mechanism works in conjunction with the control rod of a vertical blind system or a roller shade system to provide superior bearing and load handling capability. A conical bore has a plurality of grooves into the surface of the conical bore. A series of cylindrical rollers may be supported within the grooves, and against a central rotational member having a conical surface for bearing against the rollers. A set screw is used to control the seating of the central rotational member within the conical bore, is used to make up any tolerance created through the manufacturing process, and can be used to increase the tension necessary to hold a roller shade in place.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective partially exploded view of the system used with a vertical blind configuration and in which the end unit is open illustrating the main rotational member;
FIG. 2 is an end view of the housing shown in FIG. 1 and showing the angled nature of the bearings, which are shown in phantom, as well as cord pulleys for operating the carriers across a track;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2 and illustrate the end edge contact of the roller bearings on the face end of the central bearing member and on the opposite edge of the roller bearing at the end of a groove in the cylindrical bore of the bearing housing;
FIG. 4 is a section taken along line 4--4 of FIG. 3 and which illustrates the confines of the roller bearing grooves and the bearing contact with the conical surface of the main bearing, and also illustrates a hollow cylindrical version of the roller bearing;
FIG. 5 is an exploded view of a roller shade configuration utilizing the roller bearings of the invention in a different configuration;
FIG. 6 is a configuration of the roller shade as shown in FIG. 5, but with two actuation and friction units, one at each end of the roller shade;
FIG. 7 is a sectional view taken along line 6--6 of FIG. 5 and illustrating the internal bearing areas;
FIG. 8 is an expanded plan and side view of the lock washer seen in FIG. 7;
FIG. 9 is a closeup plan view looking into the space surrounding the roller bearing with an identification of its terminal radius, and side radius and blending from one to the other;
FIG. 10 is a closeup view, taken along line 10--10 and illustrating the details of the roller bearing and adjacent structures;
FIG. 11 is a sectional view taken along line 11--11 of FIG. 7, and illustrating the placement of the roller bearings at angular positions in between the balls of the chain for better distribution of force;
FIG. 12 is a closeup, exploded view of the non frictional fitting, and illustrating how it fits inside a window shade roller tube having an internal indent, or key, as well as the use of the indent as a key to hold the roller shade material;
FIG. 13 is an end view, taken along line 11--11 and illustrating how the roller shade material fits within the slot and that it is held in by a pin or other structure within the slot;
FIG. 14 illustrates an end view taken along line 14--14 of FIG. 12;
FIG. 15 illustrates a cross sectional view, similar to that seen in FIG. 7 where a pair of conical bearing surfaces carry no roller bearings; and
FIG. 16 illustrates a cross sectional view, similar to that seen in FIGS. 7 and 15 where a pair of cylindrical and radial bearing surfaces are used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The description and operation of the invention will be best initiated with reference to a vertical blind configuration which shown in FIG. 1. FIG. 1 is perspective partially exploded, distributed view illustrating a vertical blind system 21 made up of structures which are shown outside of their supporting rail or track which provides vertical support and enables horizontal translation of the vertical blind panels (also not shown) which are typically drawn to cover a window or sliding door. Beginning at the left, an outer housing member 23 has an outer shape which matches the outer shape of track 25. A series of two upper screws 27 are used for attachment of the outer housing member 23, while a set screw 29 is threadably supported by the outer housing member 23 and is used for adjustment by being urged into the outer housing member 23, as will be shown.
To the right of the outer housing member 23, a series of three solid cylindrical roller bearings 31 are shown surrounding a central bearing member 33. Hollow cylindrical roller bearings 31 can be used, or in extreme cases no roller bearings 31 need be used. However, if no roller bearings are used, the tolerances between the components making up the system of 21 must be much closer and exacting than normal; but it is remembered that compensating for non-perfect manufacturing tolerances is one objective which the inventive configuration is meant to compensate. Each of the roller bearings 31 is preferably a solid cylindrical tube, although it is possible to use a series of spherical ball bearings if chosen based upon the correct size and number to fit within a holding space. A hollow cylindrical tube could provide for lighter weight, but one which is formed from sheet stock might not have a sufficient closure weld, and one formed from tubing might not be strong enough to hold.
The central bearing member 33 has a cylindrical portion 35 having an end 37 into which a key fit, or in this case, what is shown as a cross shaped cavity 39 is formed. The cross shaped cavity will interfit with and rotate a control bar 41, which enables the central bearing member to transmit rotational force to the control rod 41. Central bearing member 33 has a conical bearing surface 43 which directly impinges upon and rolls against the roller bearings 31. However, as will be seen, some amounts of the contact force with respect to the roller bearings 31 will occur along their end edges, and this in turn depends on the tolerance and size.
Opposite the end at which the cross shaped cavity 39 is located, the central bearing member 33 has a disc shaped chain sprocket portion 45, having a series of apertures 46. The apertures 46 accommodate the spheres of a chain or ball rope 47 and provide traction between the sprocket portion 45 and ball rope 47. The ball rope 47 shown passing over the sprocket portion 45 and which extends downward. The apertures 46 are optional and appear where the sprocket portion 45 is thin and such structures enable the ball rope 47 to gain traction. Typically the ball rope 47 will form a closed loop at the bottom of its lower extent so that the chain may be continuously operated to turn the central bearing member 33.
To the right of the central bearing member 33 is an inner housing 49. Inner housing 49 carries a pair of rope pulleys 51 in the event that the carriers used in the vertical blind are to be displaced by pull ropes. Another alternative is the use of a wand mounted to a pull carrier. Adjacent the rope pulleys 51 is a central frusto-conical bore 53, which is complementary to the conical bearing surface 43. Evenly spaced within the central frusto-conical bore is a series of rounded slots 55. The slots 55 are rounded such that width is wider than the roller bearings 31, but the depth is sufficiently shallow that the roller bearings always have contact with the conical bearing surface portion 43. As will be seen, the slots 55 are formed with a larger radius circle r2 such that the radial center point is displaced slightly more toward the entrance of the slot 55. Put another way, circle r2 is more shallowly formed into the surface of the central frusto-conical bore 53, than the diameter r1 of the roller bearing 31 to cause the roller bearing 31 to protrude into the central frusto conical bore to contact the conical bearing surface 43. At the top of the inner housing 49 is a pair of engagement bosses 57 which provide the material into which the screws 27 are engaged to hold the outer housing member 23 onto the inner housing 49. The inner housing 49 is so named since its exterior shape is made to fit within the end of the track 25.
The control bar 41 is oriented to fit through a series of carriers 61, 63 & 65. A lead carrier, and its connection to ropes which would be supported by the pulleys 51 are omitted for clarity. Each of the carriers 61, 63 & 65 are designed to spread apart to a defined spacing when the vertical blind system 21 is closed and the window or door covered, and to compress to a close spacing when the vertical blind system 21 is opened and the window or door is exposed. The carriers 61, 63 & 65 have a series of slidably displaceable spacer tabs 67 each having a head end portion 69 with a horizontally enlarged portion and a tail end portion 71 with a vertically extending portion 73, to enable carriers 61, 63 & 65 to become automatically spaced and collapsed, but with no interference of the spacer tabs 67. The head end portions 69 can fit through an upper "U" shaped space 75 in each succeeding one of the carriers 61, 63 & 65 enabling the head end portions 69 to "stack" within the "U" shaped space 75. Each of the carriers 61, 63 & 65 has a vertically downwardly extending vane support 77.
The control rod 41 extends through a series of worm gear sleeves 79 within each of the carriers 61, 63 & 65 to rotate the series of vertically downwardly extending vane supports 77 to cause vertical blind panels (not shown) to rotate between a closed, light blocking position and a light admitting open position. When the system 21 is assembled, actuation of the ball rope 47 will cause the control rod 41 to actuate the vertically downwardly extending vane supports 77.
Referring to FIG. 2, a view taken along line 2--2 of the assembled housing, including the outer housing member 23 and the inner housing member 49 illustrates the end of the chan sprocket portion 45 of the central bearing member 33. The central frusto-conical bore 53 and its series of rounded slots 55 are shown in what appears to be double phantom, but it must be remembered that the series of rounded slots 55 are angled with respect to the straight-on view of FIG. 2 and thus have a nearer, circumferentially greater located end and a farther away, circumferentially smaller located other end, with respect to the center of the central bearing member 33.
The rope pulleys 51 are shown in greater detail and may be press-fit within the inner housing 49. The end view of the bosses 57 show their thickness to accommodate the screws 27, and which may also be formed to interfit with the outer housing member 23.
Referring to FIG. 3, a section taken along line 3--3 if FIG. 2 and which also illustrates portions of the outer housing member 23 are shown, since it is shown in assembled form. In this view, set screw 29 is shown within a pair of bosses 81 formed in outer housing member 23. As an alternative, an optional sleeve could be used having a metal internal thread for reinforced support by the outer housing member 23 and to prevent stripping of the set screw 29 with respect to the outer housing 23. As can be seen, the inside tip of the set screw 29 contacts the disc shaped chain sprocket portion 45 at a shallow bore 83, and which contains a thin metal plate 84 to prevent a wearing away of the center of the disc shaped chain sprocket portion 45. With the shallow bore 83, the set screw can act both to urge the central bearing member 33 forward, and also impart some centering assistance. Downward lateral force on the central bearing member 33 will be resisted both by the central bearing member 33 being surrounded by the inner housing 49, and by support from the set screw 29 engagement with the shallow bore 83.
Also seen are a series of round depressions 85 in the disc shaped chain sprocket portion 45. Each of the depressions 85 accommodates one sphere shaped member of the ball rope 47. At the upper side of FIG. 3, the roller bearing 31 can be seen as a hollow cylinder. Here can be seen two important areas of engagement of the roller bearing 31. The end of the roller bearing 31 facing the disc shaped chain sprocket portion 45 has a circumferentially innermost (measured with respect to the axis of the central bearing member 33) edge 87 which may roll against a radial surface 89. A gap is shown between the edge 87 and the radial surface 89, as would be expected to be present, particularly if the tolerances in the materials were not as exact.
At the other end of the roller bearing 31, an edge 91 rolls against an inner corner surface 93 of the series of rounded slots 55. Where the clearance adjacent the edge 87 exists, the roller bearing 31 may axially displace itself within the slot 55 as it rotates.
In this configuration, the roller bearing 31 has a dual mode of turning. First, the roller bearing 31 turns between the rounded slot 55 of the inner housing 49 and the conical bearing surface 43 of the central bearing member 33. Second, the circumferentially innermost edge 87 of the end of the roller bearing 31 closest to the disc shaped chain sprocket portion 45 rolls against the radial surface 89, as the circumferentially outermost edge 91 of the other end of the roller bearing 31 farthest from the disc shaped chain sprocket portion 45 rolls against the corner surface 93 of the end of the rounded slot 55. The angle of the roller bearings 31 with respect to the axis of the central bearing member 33 may vary between 5 and 15 degrees, and preferably is at 10 degrees.
Referring to FIG. 4, a view taken along line 4--4 of FIG. 3 illustrates the overall shape of the rounded slot 55. The dimensions of the slot are important, and some of the preferred dimensions follow. The roller bearing is preferably about 0.382 inches long. The outer radius is about 5/32 (five-thirty seconds) of an inch in diameter.
The rounded slot has two radius measurements, which are essentially two superimposed radii. The radius r1 is 5/64 of an inch and is taken from the center of a cylindrical roller bearing 95 to the middle surface of the slot 55. A second circle having a radius r2 of about 11/128 of an inch the taken from a radial point displaced slightly out of the slot 55, to create a 0.017 inch gap between the inner housing 49 and central bearing member 33, and which may approximate the differences in the radial centers for the two radii.
The widest point of the central frusto-conical bore 53 is preferably about 0.45 inches in radius, while the narrowest point is about 0.225 inches in radius. The conical tilt is about 10° from the axis of the central bearing member 33. Other angles of tilt are permissible, but it is remembered that a greater angle of tilt will require more pressure from the set screw 29 to hold the central bearing member 33 in place.
Referring to FIG. 5, a roller shade system 101 is illustrated. The roller shade system 101 utilizes many of the same principles as set forth for the vertical blind system 21, but utilizes a different structure. Beginning at the left, a cover plate 103 covers the end of a first bracket 105. The bracket 105 is angled and has the capability to be mounted against the mounting with screws or nails through both the bracket 105 and walls. At the other side of the drawing a bracket 107 is also seen. Brackets 105 and 107 have apertures 108 at its shallow end to accommodate a set of screws 109 for mounting on a wall in the other direction. Either or both of these mounting methods may be used.
Referring to the upper portion of the Figure for clarity, a roller shade control unit 111 is either attached to or formed integrally with a second bracket 107. The control unit 111 has a ball rope 113 which may be of the metal ball and link type, or may be of a rope and ball type. The control unit 111 has a plate shaped housing portion 115, including a cover plate portion 116, and a cylindrical insertion member 117 extending therefrom. The cylindrical insertion member 117 has a beveled tip portion 119 to facilitate its insertion into a roller shade tube assembly 121. The roller shade tube assembly 121 is in the shape of a hollow tube 123 and, in this case has a radially extending land 125 which can be helpful to help the shade material 127 roll onto the hollow tube 123 without binding or interfering with the ends. At the bottom of the shade material, a hem, or doubling over of the material 129 carries a stick 131 of wood or plastic to provide some greater weight at the bottom.
At the end of the roller shade tube assembly 121, a turning support 133 is located. A pure turning support 133 will have a matching plate shaped housing portion 115, and a cylindrical insertion member 117, and will merely provide rotational support for the other end of the roller shade tube assembly 121. However, with the present system, a second roller shade control unit 111 can be mounted on the first bracket 105 while the second bracket has an identical roller shade control unit 111, and will be shown in FIG. 6.
Since the roller shade control units 111 operate based upon friction, a window shade system 101 with two control units 111 can split the force necessary to operate the roller shade tube assembly 121. The use of two control units 111 are especially helpful where the window shade system 101 is used with an especially long roller shade tube assembly 121 and the user can operate it from either end. This is not possible with the two ended spring system discussed in the background section, since the two ended spring, which already has a heavy friction burden on actuation, has a lock out from any turning operation conducted from an opposite end of its roller shade tube assembly, such dual end operation is not possible.
Referring to FIG. 6, a system 135 illustrates two brackets 107. Note a hexagonal recess 137 at the back of the bracket 107, which will be for accommodating and rotationally locking a bolt head, which is shown in FIG. 7.
Referring to FIG. 7, a section taken along line 7--7 of FIG. 5 illustrates the internals of a roller shade control unit 111 which is integral with the second bracket 107. As can be seen, the cylindrical insertion member 117 continues inside the control unit 111 and is integral with a sprocket portion 141. Sprocket portion 141 carries a slot 143 having a series of accommodation spaces 145 to interfit wit the balls of the ball rope 113 to enable the ball rope 113 to have positive traction with respect to the sprocket portion 141.
As can be seen, the outer curved portion of the control unit 111 is formed integrally with the second bracket 107. The internal features thereof include a circular outer bore 147, an angled roller bearing accommodation slot 149, a central conical bearing surface 151, and a central bore 153. At the side of the second bracket 106 facing the cover plate 103 is the hexagonal shaped bore recess 137 which extends throughout the length of such bore. The hexagonal shaped bore 137 is a straight bore, but it may have a hexagonal radial surface closest to the bore 153 and some other larger smooth or rounded surface leading back to the cover plate 103. Hexagonal shaped bore 137 can be of any shape which will captures a hexagonal head 159 of a bolt 161.
The other end of bolt 161 engages a nut 163 which engages threads on the bolt 161. Note that there is more than adequate clearance within the cylindrical insertion member 117 to reach the nut 164 with a socket wrench or a hex driver. The nut 163 and bolt 161 are used to compress the cylindrical insertion member 117 and its sprocket portion 145 against the second bracket 107.
The compression members which apply force from the nut 163 to the cylindrical insertion member 117 are carefully chosen. Nut 163 bears against a punched bore washer 165, which has the inner most portions of its material, nearest its aperture 167 through which the bolt 161 extends, turned downward to make an external groove 169 into which a smooth conical surface of a lock washer 171 interfits. The lock washer 171 is a toothed lock washer having an outer diameter of about 16 millimeters and an internal diameter of about 8.4 millimeters.
The teeth of the toothed lock washer 171 bear against an oversized flat washer 173, which in turn bears against a flat radial surface 175 of the inside of the cylindrical insertion member 117. In this configuration the turning of the cylindrical insertion member 117 is isolated from the ability to turn the nut 163. In order for the nut 163 to turn, the turning of the cylindrical insertion member 117 must transmit its turning force to the flat washer 173, and from the flat washer 173 to the lock washer 171 through its widely dispersed and low surface contact area teeth, and from the lock washer 171 through its conical upper neck to the smooth external groove 168 of the punched bore washer 165, and then from the punched bore washer 165 to it tangential contact about the lower rim of the nut 163 which is preferably a lock nut, having some polymeric engagement with the bolt 161 to further prevent its unintended movement. At each bearing junction just mentioned, much slippage is expected to occur. It is expected that the chain of slippage will be such that the turning force applied to the nut 163, when and if it occurs, will not be sufficient to move the nut 163.
The internal features of the cylindrical insertion member 117 include a brief conical spacing surface 181 which rides over and should ideally have no contact with the central conical bearing surface 151. Adjacent the conical spacing surface 181 is a slot 183 which has an upper angled end surface 185 to provide clearance for the roller bearing 187, which may be identical to or sized differently from the roller bearings 31 seen in FIGS. 1-4. The internal dimensions of the slot 183 will be the same as those previously discussed for FIG. 4, in that the roller bearing 31 is given a wider space for lateral movement, than the spacing it is given for its depth. Again, the size of the roller bearing 31 is such that it will always protrude from its slot 183 to extend across a gap 189 between the conical bearing surface 151 and the conical spacing surface 181, to engage the conical bearing surface 151 and be primarily structurally responsible for keeping the gap 189 during the turning process. Note that the accommodation slot 149 is angled away from the roller bearing 31 such that the inner edge of the roller bearing 31 contacts the apex of an angle formed between the accommodation slot and the central conical bearing surface 151 at a corner 190A. Likewise, at the other end of the roller bearing 31, the upper angled end surface 185 and the slot 183 form an angle, the apex of this angle is contacted by the outer edge of the roller bearing 31, at a corner 190B.
The roller bearings 187 are angled with respect to the axis of the bolt 161 and may vary between 35 degrees and 55 degrees with respect to the axis of the bolt 161 and is preferably at 45 degrees.
Referring to FIG. 8, an expanded plan and side view of the lock washer 169 is shown, including its teeth 191 and central aperture 195.
Referring to FIG. 9, a closeup view of the structures immediately surrounding the roller bearing 187 are illustrated. For clarity and understanding. As the sprocket portion 141 and cylindrical insertion member 117 turn together, the roller bearing 187 turns within its slot 183 as it rolls against the central conical bearing surface 151. The force of turning of the sprocket portion 141 and cylindrical insertion member 117 with respect to the bracket 106 will depend upon the axial tension exerted by the nut 163 and bolt 161. This tension can be pre-set when the bracket 106 is assembled. For custom installations, the tension can be re-set during installation to exactly match the needed tension for adequately supporting the roller shade tube assembly 121, typically in a position when the roller shade tube assembly has its shade material 127 maximally extended or near the expected maximal extension to be encountered for a given window or door. Also seen are the corners 190A and 190B which bear force from the rolling edges of the roller bearings 187.
The roller bearings 187, slots 183 and conical bearing surface 151 are all parallel and inclined preferably about 45° from the axis of the bolt 161. The roller bearing 187 is preferably about 10.14 millimeters long and has an exterior diameter of about 4.0 millimeters. The slot 147 is again formed of two superimposed radii having different center points of sweep. FIG. 10 shows a radius r1 having a radius of about 2.0 millimeters. A radius r2 has its center point displaced slightly toward the central conical bearing surface 151, and has a radius r2 of about 2.25 millimeters. Again, the radius r1 and the radius r2 each have a sweep which is superimposed over each other and define the resulting shape of the slot 183.
Referring to FIG. 11, an end view taken along line 9--9 of FIG. 7 illustrates the use of eight roller bearings 187. It is clear that 3, 4, 5, 6, 7, and 8 roller bearings can be used and the number will depend upon the degree of balance and smoothness desired. The orientation of FIG. 11 is such that the roller bearings 187 are positioned between the points of support for the spheres of the balls of a ball rope 113. Also shown is the bolt 161 hexagonal head 159, and in detail the series of accommodation spaces 145 which accommodate each of the balls of the chain 113. A pair of side mounting apertures or bores 197 are seen, in addition to the apertures 108. A pair of curved guides 199 can be used to urge the bottom portion of the ball rope 114 together to give greater traction and to help prevent slippage of the ball rope 113 in the slot 143.
Referring to FIG. 12, a metal tube 201 is used as an alternative to traditional roller shade tubes. The tube 201 has a slot 203 extending along the side of the tube. The slot 203 supports an elongate rod 205. The elongate rod holds a length of thin roller shade material 207 inside the slot 203. In the alternative, a series of shortened rods 205 can be used to hold the material 207 inside the slot 203 at various intervals along the tube 201. The material 207 forms a roller shade 209 and has many of the same structures as shown for roller shade 121. The turning support 133 is seen to have a short length axle 211 about which it is rotatably supported by the bracket 105 seen in FIG. 5.
Referring to FIG. 13, an end view shows with greater detail the holding of the material 207 within the slot 203, and the position of the rod 205. Referring to FIG. 14, the turning support 133 can be seen to have a pair of side slots 215 which accommodate the internal extend of the slot 203 and not only permit cylindrical insertion member 117 to be inserted into the end of the tube 201, but rotationally lock the tube 201 with respect to the turning support 133. This feature is not as important for the free rotating end of the roller shade system 101 or 135, but this feature is used with the cylindrical insertion member 117 of control unit 111. One, two, three, four or more of the side slots 215 may be provided.
As stated previously, the roller bearings 187 help control the friction in the control unit 111. Referring to FIG. 15, a control unit 251 is provided having the conical bearing surface as was seen in FIG. 7, but where a sprocket portion 253 carries an inwardly disposed conical surface 255 which is complementary to and opposes the central conical bearing surface 151. Note that a gap 257 may be provided in any configuration leading up to the mating faces of the surfaces 151 and 255. As such other surfaces may be formed to a lesser tolerance since a non-touching relationship is expected to occur, and may include circular outer bore 147. Except for the replacement of the slots 183, and the provision of the inwardly disposed conical surface 255, the structure and operation of the control unit 251 is the same as was the case for control unit 111.
Referring to FIG. 16, a different embodiment, as a variation of the embodiment of FIG. 15 shows a bearing relationship of a sprocket portion 261 which uses a longer internal bore 263 with which to provide a longitudinal bearing surface against the bolt 161. Sprocket portion 261 has an expanded radial surface 265 which may operate against an expanded radial surface 267 located within the a differently shaped bracket 269. The operation of the control unit 251 is the same as was the case for control unit 111.
While the present invention has been described in terms of a bearing system which can be utilized in both vertical blind and roller shade configurations, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many similar appliances. The present invention may be applied in any situation where controlled bearing support is desired, as well as bearing support having the capability to make up for differences in tolerance of component parts.
Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art. | An improved bearing mechanism works in conjunction with the control rod of a vertical blind system or a roller shade system to provide superior bearing and load handling capability. A conical bore has a plurality of grooves into the surface of the conical bore. A series of cylindrical rollers are supported within the grooves, and against a central rotational member having a conical surface for bearing against the rollers. A set screw is used to control the seating of the central rotational member within the conical bore, is used to make up any tolerance created through the manufacturing process, and can be used to increase the tension necessary to hold a roller shade in place. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a housing for electrotechnical equipment comprising two side walls, a top wall and a bottom wall which form a box-like framework having two openings which are sealable by means of a back wall, door, or inspection window, and wherein at least the corner areas of the top and bottom walls are provided with pivotally mounted support legs which are adjustable from a retracted position in which they are flush with the housing to an extended position in which they are generally perpendicular to the plane of the top wall or the bottom wall.
2. Description of the Prior Art
A housing of this general type is taught by German Registered Utility Model No. 85 11 254. In this prior art housing, the support legs are designed as flaps which serve as support legs on the bottom of the housing, while on the top wall, they serve only to cover fastening screws which attach the top wall to the side walls of the housing. Additionally, the pivot axes of the flaps are oriented generally perpendicular to the side walls of the housing.
If several of the prior art types of housings are stacked on top of one another, they are not stabilized against shifting. There is the risk that if a stack in which they are arranged one on top of another in this manner is accidentally bumped, the uppermost housing may be displaced and fall. In addition, the stability of the prior art housing with four support legs provided on the bottom wall with the prescribed orientation of the pivot axes is not particularly good unless the support legs are lockable in the extended position. However, locking mechanisms require a considerable outlay.
As is taught in German Registered Utility Model No. 80 25 774, orienting the pivot axes of the support legs parallel to the side walls of the housing is also known.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide a housing for electrotechnical equipment of the type described above which is stackable with housings of the same type, whereby multiple, stacked housings are secured against lateral shifting in a simple manner.
This objective is achieved according to the present invention in that at least the support legs provided on the bottom wall of the housing are designed as stacking legs, and at least support legs provided on the top wall have stacking seats when they are in the retracted position for retaining the stacking legs on adjacent housings when the stacking legs are in the extended position.
Only by means of the present design of the support legs, can this type of interlocking connection between housings stacked one on top of another be attained. The positioning of housings in a stack of housings such that they are secured against lateral shifting is achieved by the engagement of the extended stacking legs of an upper housing in stacking seats of stacking legs in the retracted position in a lower housing.
The structure of the housing itself plays no role in this. The design may be such that side walls, top wall and bottom wall form a one-piece framework, or the side walls may be separate from and fastenable to the top wall and bottom wall, with the stacking legs covering the fastening screws.
To prevent the stacking legs from having too great an impact on the configuration of the housing, one embodiment provides that the stacking legs are pivotally mounted in recesses in the housing in the vicinity of the edges where the side walls join the top wall and the bottom wall.
When the stacking legs are mounted with pivot axes which are oriented parallel to these edges, the stability of an individual stacked housing is improved without the necessity of providing a locking mechanism to retain the stacking legs in the extended position, because when components are being inserted into the housing, no force which would displace the stacking legs to the retracted position may be exerted on the extended stacking legs.
According to another embodiment, additional stacking seats may be uniformly distributed between two stacking legs provided at the corners, and spaced at intervals (b) corresponding to the length of the stacking legs in the longitudinal direction plus the distance between adjacent stacking seats. Similar housings with shorter structural depths may then also be included in the stack. It is preferably provided that stacking legs are arranged at an interval (a) from the opening of the housing which corresponds to the intervals between adjacent stacking seats.
A definite positive locking of terminal ends of the stacking legs in the stacking seats is achieved according to one embodiment wherein the stacking seats are formed along the edges of the housing as grooves originating at the edges in the retracted position, and the groove bases, which are at an angle of about 135° to the outer surfaces of the adjacent side wall and the adjacent top wall or the adjacent bottom wall and which make the transition to the stacking seats by means of a perpendicular ledge, and that the end of the extended stacking leg has a contour corresponding to the contour of the groove base with its transitional sections.
Mounting of the stacking legs on the housing is facilitated in that each stacking leg is pivotally mounted in a base member which is mounted in a recess of the housing. The stacking leg may thus be manufactured separately as a unit together with the base member and then may simply be screw fastened into the recess in the housing. Where applicable, the top wall or bottom wall may be attached to the side walls with fastening screws.
One embodiment for pivotally mounting the stacking legs is characterized in that the base member is essentially U-shaped and has a base plate and two side arms; the base plate at one edge of the base member adjoins a bearing seat for a bearing block of the stacking leg; side arms of the base element are provided with bores for a bearing shaft in the vicinity of the bearing seat, and the bearing shaft is mounted in the bore of the bearing block of the stacking leg; and the base plate of the stacking leg, when in its retracted position, covers the side arms of the base member.
A defined extended position for the stacking legs may be simply provided when the bearing seat of the base member is provided with stops, against which counterstops of the bearing block of a stacking leg which is in the extended position come to rest. The stacking leg in its extended position is preferably perpendicular to the outer surface of the top wall or the bottom wall. According to one embodiment, the stacking leg is U-shaped and comprises a support plate and two side arms which extend from the bearing block; the outside of the base plate is flush with the outside of the top wall or the bottom wall and the side arms abut the base plate of the base member in the retracted position; the surfaces of the support plate and the side arms which face away from the bearing block form the end of the stacking leg; and the surface of the support plate which faces toward the bearing block and serves as a counterstop, in combination with the stop on the bearing seat of the base element which is exposed when the stacking leg is retracted, form a stacking seat.
If a tilted orientation of the housing is also desired, a further embodiment provides that along with the stacking leg, and on the same pivot axis, a support leg is pivotally mounted, the support leg being longer than the stacking leg and adjustable from a flush retracted position to an extended position in which it is at an angle of greater than 90° with respect to the outer surface of the top wall or the bottom wall.
Pivotable mounting of the support leg and stacking leg in the base member may be provided in that the support leg is mounted on the bearing shaft with its two side arms between the side arms of the base member and the side arms of the stacking leg; the side arms of the support leg in its retracted position abut the base plate of the base member and are connected in the region outside the support plate of the stacking leg by means of a connecting plate; the support plate of the stacking leg covers the side arms of the support leg and the side arms of the base member; the connecting plate of the support leg covers the side arms of the base member; and the front edges of the side arms of the stacking leg which face the support plate of the stacking leg in the retracted positions of stacking leg and support leg are at an acute angle to the support plate of the stacking leg, which angle opens toward the terminal end of the stacking leg and support leg.
If the top and bottom walls of the housing are precisely defined, then the cost can be further reduced. Stacking seats are only provided according to a prescribed distribution in the top wall of the housing and the bottom wall of the housing has four stacking units, each comprising a stacking leg and a support leg. The stacking legs and support legs are provided on the bottom wall and may be extended into stacking seats provided in the housing positioned below, the top wall of which has only the required stacking seats. By providing the same distribution of stacking seats, it is also possible to stack housings of varying depths.
If, on the other hand, the top wall of the housing is provided with four stacking units, each comprising a stacking leg, and stacking seats are arranged in that distribution, and the bottom wall of the housing is provided with four stacking units, each comprising a stacking leg or a stacking leg and a support leg, then the stacking legs on the top wall may be used to cover the fastening screws. If adjacent housings are arranged in a stack, the stacking legs may then be pivoted to an extended position from an upper or from a lower adjacent housing in the stack, and thus may be brought into mutual engagement.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will be described in greater detail below with reference to the drawings, in which:
FIG. 1 shows a perspective view of a schematic representation of a housing with stacking legs and stacking seats;
FIG. 2 shows a side view of a stack of a plurality of housings having varying depths;
FIG. 3 shows a longitudinal cross-sectional view of a stacking unit comprising a base member with a stacking leg and a support leg; and
FIG. 4 shows a top view, partially in cross section, of the unit shown in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
Box-like housing 10 shown in FIG. 1 comprises top wall 11, bottom wall 12 and side walls 13 and 14. Although the walls are shown as separate components, they may also be joined to form a one-piece unit. Stacking seats 15 and 16 are provided in the area of intersecting walls of the box-like housing framework. Stacking seats 15 and 16, which project toward the interior of the housing framework, are provided by pivotable stacking legs 18, 20, 22, 24, 26, and 28 when the stacking legs are adjusted to the flush, retracted position. These stacking legs are retractable into recesses 17, 19, 21, 23, 25 and 27 of top wall 11 and bottom wall 12. The structural design of the stacking legs and their retraction into the recesses will be discussed in greater detail below.
As shown in FIG. 2, the stacking legs are preferably arranged at an interval (a) from the edge of the housing framework. Interval (a) also preferably corresponds to the interval between stacking seats 15 and 16. Width (b) of the stacking legs and the width of the stacking seats 15 and 16 are preferably equal, and thus a uniform interval (T) corresponding to the sum of interval (a) and width (b) is provided between the stacking legs and stacking seats. If the distribution and dimensions of stacking legs and stacking seats are constant in the case of a plurality of housings 10.0, 10.1 and 10.2, which have varying depths, then these housings are stackable on top of one another as shown in FIG. 2 so that they will not shift laterally. The lowermost housing 10.0 has six additional stacking seats 16.0 between extended stacking legs 26.0 and 28.0 on the bottom wall and six corresponding additional stacking seats 15.0 between retracted stacking legs 22.0 and 24.0 on the top wall. If a similar housing 10.0 is stacked on top of it, then the extended stacking legs 26.0 and 28.0 of the second housing 10.0 will rest in stacking seats 15.0 of the stacking legs 22.0 and 24.0 of the first housing 10.0.
Housing 10.1 has only four additional stacking seats 16.1 between stacking legs 26.1 and 28.1 at the bottom wall and four additional stacking seats 15.1 between stacking legs 22.1 and 24.1 at the top part. Extended stacking leg 26.1 of housing 10.1 is inserted into stacking seats 15.0 of retracted stacking leg 22.0 of housing 10.0, while tended stacking leg 28.1 of housing 10.1 is inserted into stacking seat 15.0 in housing 10.0. Finally, housing 10.2 has only two additional stacking seats 16.2 between stacking legs 26.2 and 28.2 at the bottom wall and only two additional stacking seats 15.2 between stacking legs 22.2 and 24.2. The extended stacking leg 26.2 of housing 10.2 is inserted into stacking seat 16.2 of retracted stacking leg 22.1 of housing 10.1, while extended stacking leg 28.2 of housing 10.2 is inserted into stacking seat 15.1 of housing 10.1.
FIG. 2 also shows the stacking leg on the bottom of one housing extended and inserted into the stacking seat of a retracted stacking leg on the top of an adjacent housing positioned below it. One would, however, also achieve the same result if, for example, stacking leg 26.2 remained retracted at the bottom wall of housing 10.2 and instead stacking leg 22.1 of housing 10.1 positioned below it were extended and inserted into stacking seat 16.2 of stacking leg 26.2.
If the top and bottom walls of the housing are both provided in the same way with stacking legs and stacking seats, then the housing may be used in two positions which are rotated by 180°. This has undeniable advantages with respect to the outlay. However, if the top and bottom walls of the housing are clearly defined, then it is sufficient to provide only the bottom wall of the housing with the stacking legs and stacking seats and to design only the top wall with stacking seats. According to this embodiment, stacking seats may then be omitted between the stacking legs at the bottom wall without sacrificing the ability to stack housings of various depths.
The design of stacking legs and stacking seats will be explained in more detail with reference to the embodiment shown in FIGS. 3 and 4. The stacking leg may be manufactured separately as a unit comprising U-shaped base housing 30 installed in a correspondingly shaped and dimensioned recess 17, 19, 21, 23, 25, or 27 of the housing. This arrangement is provided in the vicinity of the outer edges of the top and/or bottom wall and extends inwardly from the edges of the housing, as shown in FIG. 1. Base housing 30 comprises base plate 35 and two side arms 36. Bearing seat 31 is provided at one end of base housing 30, and is provided with two stops 32 and 34. In the vicinity of bearing seat 31, side arms 36 have bores 37 for bearing shaft 38, which may be inserted into bore 41 of bearing block 40 of the stacking leg. Base plate 35 has bores for fastening screws 39, which may serve not only for connecting base housing 30 to the stackable housing, but also for connecting top wall 11 or bottom wall 12 to side wall 13 or side wall 14.
Two side arms 44 of the stacking leg are mounted on bearing block 40 which are supported in the retracted position on base plate 35 of base housing 30. Support plate 42 connects the two side arms 44 of the stacking leg and in the retracted position is flush with the outside of top wall 11 or bottom wall 12. Support plate 42 with its face which is turned toward bearing block 40 forms counterstop 43, while bearing block 40 itself forms counterstop 46 for stops 32 and 34 of bearing seat 31. In this manner, it is assured that the extended stacking leg is vertical to the outside of top wall 11 or bottom wall 12 facing it, as reference number 42' of the support plate which is shown as a dashed line indicates. Thereby support plate 42 with counterstop 43 is supported on stop 32 of bearing seat 31 and counterstop 46 of bearing block 40 is supported on stop 34 of bearing seat
Support plate 42 with its width covers side arm 36 of base housing 30, so that in the retracted position it completely closes the associated recess of the housing.
An additional support leg may also be supported next to the stacking leg on the same bearing shaft 38. This support leg has two side arms 48, which are supported on bearing shaft 38 at bore 49 between side arms 36 of base housing 30 and side arms 44 of the stacking leg. The support leg is longer than the stacking leg and the two side arms 48 are only connected with one another outside support plate 42 of the stacking leg by means of connecting plate 47. Side arms 48 of the support leg are supported in the retracted position on base plate 35 of base housing 30, whereby the outside of connecting plate 47 terminates flush with the outside of top wall 11 or bottom wall 12 and the outside of support plate 42 of the retracted stacking leg, as shown in FIG. 3. Connecting plate 47 thereby also covers side arms 36 of base housing 30, to completely cover the correspondingly enlarged recess in the housing.
Faces 52 of side arms 48 of the support legs which are turned toward support plate 42 of the stacking leg when the stacking leg and support leg are in the retracted position form, together with bottom 51 of support plate 42 of the stacking leg, an acute angle which opens toward the free ends of the stacking leg and support leg. This achieves the effect that when the support leg is extended, not only is the stacking leg necessarily extended with it, but also the stacking leg in the extended position provides a limit for the outward pivotal movement of the support leg. Thus faces 52 of side arms 48 of the support leg strike against bottom 51 of support plate 42 of the stacking leg, as is indicated with reference numbers 51', 52' in the positions of the stacking leg and support leg which are shown as a dashed line. The pivot angle of the stacking leg is 90°, while the support leg is extendable additionally by the acute angle formed by faces 52 of side arms 48 of the support leg and bottom 51 of support plate 42 of the stacking leg when these are in their retracted positions, and the housing may thus be arranged at a tilt.
In the universally applicable design, these types of units comprising a base housing, stacking leg and support leg are attached on the top and bottom of the housing, and stacking seats which are designed correspondingly are provided at uniform intervals. However, the simplified design, whereby only the bottom wall has such units while the top wall has only the stacking seats or units comprising a base housing and stacking leg, may also be utilized. In this case, the stacking legs serve only as stacking seats and cover flaps for necessary fastening screws.
The configuration of the stacking seats is also visible in FIG. 3. Stop 32 of bearing seat 31 and counterstop 43 of support plate 42 together with flat surface 33 of bearing block 40, which is inclined toward this at an angle of about 135°, form the boundaries of the stacking seat with a contour which corresponds to the contour of the face which is turned away from bearing block 40 of support plate 42 with the canted side arms 44 of the stacking leg and forms the stacking end of the stacking leg. Stacking seats 15 and 16 of the housing are provided in the form of grooves in the edges, whereby the groove base is at an angle of about 135° to the outsides of the adjacent side wall 13 or 14 and of top wall 11 or bottom wall 12, and merge into these via perpendicular shoulders. The perpendicular shoulders are thereby dimensioned in a manner which is determined by the thickness of support plate 42 of the stacking leg.
As mentioned previously, it is possible to provide stacking legs or stacking legs and support legs only on bottom wall 12 of the housing. Top wall 11 and bottom wall 12 of the housing are designed identically and are provided in the same way with recesses for the stacking legs or the stacking legs and support legs. However, recesses 17, 19, 21 and 23 of top wall 11 may be closed off by means of attachable cover plates which have stacking seats 15 in their edge regions. | Housing for electrotechnical equipment comprising two side walls, a top wall and a bottom wall which form a box-like framework with two openings which are sealable by means of a back wall, door, or inspection window, whereby in at least corner areas of the top and bottom walls support legs are pivotally mounted which are adjustable from a retracted position in which they are flush with the housing walls to an extended position in which they are perpendicular to the top wall and the bottom wall. Stacking of a plurality of housings such that they are prevented from shifting is attained in a simple manner in that at least the legs of the bottom wall are designed as stacking legs, and at least the legs on the top wall when they are in the retracted position form stacking seats for retaining the terminal ends of stacking legs of the adjacent housing which have been adjusted to the extended position. | 7 |
[0001] This application claims priority to U.S. Provisional Application serial No. 60/252,713 filed Nov. 22, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a bracket pressed over the screw housing of the worm drive clamp for attaching a worm drive clamp to a hose.
[0003] A worm drive clamp is attached to a hose to facilitate the installation of the hose on a vehicle. The clamps are made of stainless steel to provide for maximum corrosion protection. However, as quick setting glues do not bond well to stainless steel, glues are not a desirable method of attachment.
[0004] Worm drive clamps can be attached to the hose by a metal clip spot-welded to the band of the clamp. The clip is attached to the end of the hose and clinched into the interior wall. However, as the clip may damage the interior wall, this method of attachment is also undesirable.
[0005] An elastomeric patch or a woven patch of synthetic fabric have also been used as a method of attachment. The elastomeric patch is positioned over the band and vulcanized to the outer surface of the hose. A drawback to the elastomeric patch is that it is time consuming to prepare the surface of the hose and to vulcanize the elastomeric patch. The woven patch is glued over the clamp band, but is difficult to handle, making installation slow. Additionally, both types of patches are unattractive as they protrude over the exterior of the band.
[0006] In all of the above-mentioned methods of attachments, the worm drive clamp is attached to the hose at the band. A drawback associated with attaching the worm drive clamp at the band is that the worm drive clamp can twist around the outer surface of the hose as the screw is tightened, causing the screw to travel. If the screw travels into a tight space, problems can result in reaching the screw.
SUMMARY OF THE INVENTION
[0007] A bracket pressed over the screw housing of a worm drive clamp secures the worm drive clamp to a hose. The bracket is preferably made of plastic and includes a screw housing cover having a large portion and a small portion and a pair of opposing tabs. The tabs extend outside of the screw housing and have an appropriate curvature which approximately equals the curvature of the outer surface of the hose. A protrusion on each of the opposing interior surfaces of the screw housing cover secures the bracket onto the screw housing. The screw housing cover further includes a first end cap located on the front side of the large portion and a second end cap located on the opposing rear side of the small portion to maintain the position of the screw housing cover over the screw housing during assembly. Alternatively, the tabs extend inside the screw housing cover.
[0008] During assembly, the bracket is pressed onto the screw housing. After the hose is inserted into the gluing machine, glue is applied on the hose at the location where the tabs will be positioned. A gluing machine clamp block orients the worm drive clamp and brings the bracket into contact with the hose, providing pressure until the glue hardens.
[0009] The hose is then removed from the gluing machine with the bracket attached. The worm drive clamp is then tightened around the outer surface of the hose by turning the screw.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0011] [0011]FIG. 1 illustrates perspective view of the molded bracket of the present invention pressed over a screw housing of a worm drive clamp;
[0012] [0012]FIG. 2 illustrates a perspective view of the molded bracket;
[0013] [0013]FIG. 3 illustrates a front view of the molded bracket;
[0014] [0014]FIG. 4 illustrates a top view of the molded bracket;
[0015] [0015]FIG. 5 illustrates a perspective view of an alternative embodiment of the molded bracket; and
[0016] [0016]FIG. 6 illustrates a front view of the alternative embodiment of the molded bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] [0017]FIG. 1 illustrates the bracket 10 of the present invention pressed over a screw housing 12 of a worm drive clamp 14 . As a screw 16 is turned by a screw driver, the threads of the screw 16 engage threads 18 embossed on the band 20 of the worm drive clamp 14 , tightening the worm drive clamp 14 around the outer surface 22 of a hose 24 .
[0018] As illustrated in FIG. 2, the bracket 10 includes a substantially U-shaped screw housing cover 26 and a pair of opposing outwardly extending tabs 28 . Preferably, the bracket 10 is made of plastic and is injection molded. However, the bracket 10 can also be made of metal or a thermal plastic elastomer. The tabs 28 have a width W and a length L and are an integral part of the screw housing cover 26 . The tabs 28 each have a curvature 30 which approximately equals the curvature 58 of the outer surface 22 of the hose 24 (shown in FIG. 1). The length L of the tabs 28 can provide a visual gage such that when the end 32 of a tab 28 is aligned with the end of the hose 24 , the bracket 10 is positioned at the proper location.
[0019] As illustrated in FIGS. 3 and 4, the screw housing cover 26 includes a large portion 34 which receives the screw housing 12 and an adjacent small portion 36 which covers the screw housing offset 38 (shown in FIG. 1). A first end cap 40 on the front side 42 of the large portion 34 and a second end cap 44 on the opposing rear side 46 of the small portion 36 prevent the sliding of the screw housing 12 within the bracket 10 during assembly of the bracket 10 onto the hose 24 .
[0020] The bracket 10 further includes a pair of protrusions 48 on the opposing interior surfaces 50 of the screw housing cover 26 . After the bracket 10 is pressed over the screw housing 12 , the protrusions 48 retain the bracket 10 over the screw housing 12 . Preferably, each protrusion 48 is approximately {fraction (3/16)} of an inch long and approximately 0.010 of an inch in height.
[0021] When assembling the worm drive clamp 14 to the hose 24 , the bracket 10 is pressed onto the screw housing 12 , the protrusions 48 retaining the bracket 10 over the screw housing 12 . The worm drive clamp 14 is placed into a clamp gluing machine clamp block. After inserting the hose 24 into a gluing machine, a drop of glue 52 is applied on the outer surface 22 of the hose 24 at the locations where the tabs 28 will be positioned. Preferably, the glue is cyanoacrylate glue. However, it is to be understood that other types of glue can be employed. The clamp block orients the worm drive clamp 14 over the hose 24 and brings the bracket 10 into contact with the hose 24 , providing pressure until the glue 52 hardens. After the clamp block is removed, the hose 24 is removed from the gluing machine with the bracket 10 attached. The band 20 is tightened around the outer surface 22 of the hose 24 by turning the screw 16 with a screw driver. The end caps 40 and 44 prevent sliding of the screw housing 12 as the worm drive clamp 14 is tightened, insuring later alignment of the screw driver within the screw 16 .
[0022] [0022]FIGS. 5 and 6 illustrate an alternative embodiment of the bracket 110 of the present invention. The bracket 110 includes a screw housing cover 126 and a pair of opposing inwardly extending tabs 128 having a curvature 130 which approximately equals the curvature 58 of the outer surface 22 of the hose 24 (shown in FIG. 1). The tabs 128 preferably are approximately 0.015 of an inch thick. The tabs 128 are separated by a gap 132 having a curvature 148 which approximately equals the curvature 54 of the band 20 . Preferably, the gap 132 is approximately 0.125 of an inch wide.
[0023] The screw housing cover 126 further includes a large portion 134 which receives the screw housing 12 and an adjacent small portion 136 which receives the screw housing cover offset 38 . A first end cap 140 on the front side 142 of the large portion 134 and a second end cap 144 on the opposing rear side 146 on the small portion 136 prevent the sliding of the screw housing 12 within the bracket 110 .
[0024] When assembling the bracket 110 on the worm drive clamp 14 , the thickness 60 of the band 20 is inserted through the gap 132 of the bracket 110 having the curvature 148 . The bracket 110 is then rotated approximately 90° such that the inner surface 56 of the band 20 overlays the inward tabs 128 . The bracket 110 is then slid over the screw housing 12 . The bracket 110 slightly flexes and opens as the bracket 110 is slid over the screw housing 12 to prevent the end caps 140 and 144 from interfering with the sliding. The worm drive clamp 14 is then attached to the tube 24 in the same manner as the bracket 10 .
[0025] An advantage of the bracket 110 is that that as the tabs 128 extend inwardly, the tabs 128 can be made larger without affecting the size of the bracket 110 . Additionally, it is easier to apply the glue 52 as there is a greater surface area for attachment. Finally, as the tabs 128 are located on the inside of the screw housing cover 126 , the bracket 110 can be positioned closer to the end of the tube 24 as the bracket 110 can be made narrower.
[0026] The bracket 10 can also be pressed over the band 20 of the worm drive clamp 14 rather than over the screw housing 12 . The bracket 10 can be over-molded around the worm drive clamp 14 or formed from strip metal. Preferably, the hose 24 is a low-permeation hose. However, other types of hoses can be employed. The bracket 10 can also be utilized with other types of clamps, such as spring steel constant tension clamps, wire band clamps, and pipe boot clamps. The bracket 10 of the present invention is low in cost and has an attractive appearance.
[0027] The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specially described. For that reason the following claims should be studied to determine the true scope and content of this invention. | A plastic bracket ( 10 ) including a screw housing cover ( 26 ) and a pair of opposing tabs ( 28 ) is pressed over a screw housing ( 12 ) of a worm drive clamp ( 14 ) to secure the worm drive clamp ( 14 ) to a hose ( 24 ). The tabs ( 28 ) can extend either be inside or outside of the screw housing cover ( 26 ). A protrusion ( 46 ) located on each of the opposing inner surfaces ( 48 ) of the screw housing cover ( 26 ) retain the bracket ( 10 ) over the screw housing ( 12 ). End caps ( 40 ) and ( 44 ) molded across opposing sides of the screw housing cover ( 26 ) maintain the position of the screw housing ( 12 ) in the screw housing cover ( 26 ) during assembly and prevent the sliding of the worm drive clamp ( 14 ). | 8 |
RELATED APPLICATION
This is a continuation-in-part application of U.S. Ser. No. 09/943,725, filed on Aug. 30, 2001 now U.S. Pat. No. 6,541,241 which is a continuation of U.S. Ser. No. 09/197,079, filed Nov. 20, 1998 (U.S. Pat. No. 6,306,641), which is a continuation-in-part application of U.S. Ser. No. 08/782,410, filed Jan. 14, 1997 (U.S. Pat. No. 5,854,061), which is a continuation-in-part application of U.S. Ser. No. 08/685,116, filed Jul. 23, 1996 (U.S. Pat. No. 5,824,541), which is a continuation-in-part application of U.S. Ser. No. 08/223,523, filed Apr. 5, 1994 (U.S. Pat. No. 5,593,888), which is a continuation-in-part application of U.S. Ser. No. 08/043,666, filed Apr. 6, 1993 (abandoned), which is a divisional application of U.S. Ser. No. 07/918,528, filed Jul. 21, 1992 (abandoned).
BACKGROUND OF THE INVENTION
The present invention relates to a method for the remediation of manure-contaminated material, and more particularly to a method for the remediation of manure-contaminated material treated with chemical amendments. It also relates to producing an enriched fertilizer from the remediated manure-contaminated material.
There are known processes for treating manure-containing soil. U.S. Pat. No. 3,939,280, for example, is directed to a process for treating poultry manure with acid, formaldehyde and urea to obtain a pathogen-free product suitable as feedstuff for ruminant animals.
As stated in U.S. '208, poultry manure has been utilized for centuries as a soil enriching material because it contains an advantageous mixture of organic protein, inorganic nitrogen, fiber and minerals. The disposal of this material, which is collected in large quantities, poses a serious problem to the poultry industry. It is customary to remove the accumulated poultry manure periodically from under the cages and transport it to a disposal area some distance away. After drying and composting the poultry manure for a period of days or weeks, it is then used as a landfill, or it is sold as a soil builder. A major use of poultry manure at the present time is as a soil enriching agent, based on its inherent phosphorus content.
According to the U.S. '280 invention, there is provided a process which comprises four critical steps. In step 1, to the poultry manure as collected in the poultry raising operation, there is added an amount of acid capable of adjusting the pH of the poultry manure to be less than 7.0, preferably about 5.5 to 6.0. Formaldehyde, or a substance that releases formaldehyde, such as paraformaldehyde, is added in step 2 and is mixed in the poultry manure, before or after step 1, to kill the bacteria present therein. As the third critical step in the process, there is added from about 1 to about 20 weight percent of urea, preferably about 2 to 10 weight percent, based on the weight of poultry manure, calculated as having zero percent moisture. The final critical step of the process is drying the product of step C to a condition suitable for storage, packaging and use, generally to a moisture content of less than 15 weight percent, preferably about 10.+−.5 weight percent. This final drying is conducted at a temperature below the melting point of urea, i.e., 132.degree.C.
U.S. Pat. No. 5,928,403 relates to treating poultry manure in the growing location with alum in an amount of from about 0.15 to about 9.25 pounds per bird raised. The alum-treated manure may also be used as an agricultural fertilizer.
The invention of U.S. '403 is predicated on the discovery that treatment of poultry litter with the aluminum sulfate compound, alum, dramatically reduces ammonia volatilization from the litter. Results also indicate that alum, ferrous sulfate and calcium hydroxide effectively precipitate soluble phosphorus when added to litter, thereby reducing soluble phosphorus levels. Poultry litter is composed of a mixture of bedding material, manure, spilled food and feathers.
A need therefore exists for a method of remediation which will overcome problems associated with the above described prior art methods.
SUMMARY OF THE INVENTION
Applicants have met the above-described existing needs and have overcome the above-described prior art problems through the invention set forth herein.
Accordingly, a method is hereby provided for remediating manure-contaminated material. The method of the present invention comprises providing a mass of manure-contaminated material including in situ-formed bacteria and nitrogen-containing materials. The mass of manure-contaminated material is acidified to a pH of not more than about 7.0 without (a) destroying a substantial portion of said active bacteria, and/or (b) without liberating a substantial portion of said nitrogen-containing materials. Then, the acidified manure-contaminated material is particularized, preferably microenfractionated, as hereinafter described. The particularized, acidified manure-contaminated material is treated with at least one chemical amendment to form a treated particularized manure-contaminated material. Preferably, the microenfractionated, acidified manure-contaminated material is treated with at least one nutrient.
Preferably, acidifying of the mass of manure-contaminated material comprises neutralization. The mass of manure-contaminated material is preferably acidified with sulfuric acid and/or phosphoric acid and/or citric acid.
In a preferred form of this invention, the average size of the particularized, acidified manure-contaminated material is substantially reduced. Moreover, when the mass of manure-contaminated material undergoes microenfractionation, the average size of the particularized, acidified manure-contaminated material is substantially reduced as hereinafter described. Furthermore, the average surface area of the particularized, acidified manure-contaminated material is substantially increased. And, when the mass of manure-contaminated material undergoes microenfractionation, the surface area of the particularized, acidified manure-contaminated material is substantially increased as hereinafter described.
The amount of active bacteria, which is present in the mass of acidified manure-contaminated material, is substantially increased as compared to the amount of active bacteria which is present in said mass of manure-contaminated material. And, the amount of nitrogen-containing materials which are present in said mass of acidified manure-contaminated material as compared to the amount of nitrogen-containing materials which are present in said mass of manure-contaminated material.
Preferably, the chemical amendment comprises at least one nutrient. Additionally, the chemical amendment can be configured to activate the active bacteria so that subject method will proceed more expeditiously. Thus, in a preferred embodiment of this invention, the treated particularized manure-contaminated material comprises a fertilizer.
In one form of the invention, a method of using an apparatus is provided for the accelerated remediation of treated contaminated material. Treating of the contaminated material with at least one chemical amendment, with or without at least one biological amendment, can occur prior to, and/or during, and/or subsequent to, microenfractionating of the contaminated material. The chemical amendment can be at least one chemical reducing agent with or without at least one chemical oxidizing agent. For example, a contaminated material can be treated with at least one chemical amendment comprising a chemical reducing and/or oxidizing agent to form a treated contaminated material prior to microenfractionation of thereof. Then, an air stream is generated at a velocity sufficient for entraining the treated contaminated material therein, and the treated contaminated material is entrained in the air stream, and the treated contaminated material is microenfractionated under conditions sufficient to form a microenfractionated treated contaminated material such that subsequent accelerated remediation is provided under conditions sufficient for conducting said accelerated remediation. Alternatively, the chemical amendment(s) can be added during, or subsequent to, microenfractionating of the contaminated material. In any of the above-described methods, the accelerated remediation of the treated contaminated material can be facilitated.
The chemical amendment can also comprise at least one chemical reducing agent which is in the form of a liquid or a solid, preferably an aqueous solution, which is capable of acting as a chemical reducing agent for remediation or bioremediation purposes, particularly in the microenfractionation of contaminated materials of the present invention. These types of chemical amendments are particularly useful in the dehalogenation of halogenated hydrocarbons such as the difficult to remediate chlorinated hydrocarbons.
The chemical amendment of this invention can comprise a chemical reducing agent. Preferably, the chemical reducing agent comprises a metallic reducing agent. Preferably, the metallic reducing agent comprises a zero valent metallic compound. More preferably, the metallic reducing agent is a zero valent metallic compound comprising iron, zinc, tin, aluminum, manganese or other similar zero valent metallic compounds. Most preferably, the chemical reducing agent comprises a zero valent iron compound.
An activating agent can also be added to the chemical reducing agent to make the remediation with the chemical reducing agent more effective and/or efficient. Such activating agents are typically acidic activating agents, preferably organic acid acidic activating agents such as acetic acid, or inorganic acidic materials such as hydrochloric acid, phosphoric acid, or nitric acid. Other acidic activating agents may include aliphatic alpha-hydroxycarboxylic acids of the type RCHOHCOOH and the corresponding beta-hydroxycarboxylic acids RCHOHCH 2 COOH, complexing agents such as ethylenediaminetetraacetic acid (EDTA), nitrolotriacetic acid (NTA) and diethylenediamine-pentaacetic acid (DPTA) and amines, hydroxyl containing amines such as mono-, di- and triethanolamine and diamines, triamines, polyamines having complexing properties. Exemplary alpha- and beta-hydroxy carboxylic acids are glycolic acid, lactic acid, glyceric acid, α,β-dihydroxybutyric acid, α-hydroxy-butyric acid, α-hydroxy-isobutyric acid, α-hydroxy-n-valeric acid, α-hydroxy-isovaleric acid, β-hydroxy butyric acid, α-hydroxy-isobutyric acid, β-hydroxy-n-valeric acid, β-hydroxy isovaleric acid, erythronic acid, threonic acid, trihydroxy-isobutyric acid and saccharinic acids and aldonic acids, such as gluconic acid, galactoni acid, talonic acid, mannonic acid, arabonic acid, ribonic acid, xylonic acid, lyxonic acid, gulonic acid, idonic acid, altronic acid, allonic acid, ethenyl glycolic acid, and β-hydroxy-isocrotonic acid. Also useful are organic acids having two or more carboxylic groups, and no or from one to ten hydroxyle groups, such as oxalic acid, malonic acid, tartaric acid, malonic acid, tartaric acid, malic acid, and citric acid, ethyl malonic acid, succinic acid, isosuccinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, maleic acid, fumaric acid, glutaconic acid, citramalic acid, trihydroxy glutaric acid, tetrahydroxy adipic acid, dihydroxy maleic acid, mucie acud, mannosaccharic acid, idosaccharic acid, talomucie acid, tricarballylic acid, aconitic acid, and dihydroxy tartaric acid.
The chemical amendment can also comprise at least one chemical oxidizing agent which is in the form of a liquid or a solid, preferably an aqueous solution. Preferably, the chemical oxidizing agent can comprise a peroxide, a permanganate, a nitrate, a nitrite, a peroxydisulfate, a perchlorate, a sulfate, chlorate, a hypochlorite, an iodate, a trioxide, a peroxybenzoic acid, an oxide, an iodic acid, a nitric acid, a periodic acid, a peracetic acid, a hydantoin, a triazinetrione, a hydroxide, a percarbonate, a superoxide, an isocyanate, an isocyanic acid, a bromanate, a biiodate, a bromate, a bromate-bromide, a molybdic acid, a dichromate, a chromate, a periodate, a chlorite, an iodate, or a perborate. More preferably, the chemical amendment can comprise any one of the following: aluminum nitrate, ammonium dichromate, ammonium nitrate, ammonium peroxydisulfate, ammonium permanganate, aquaquant sulfate, ammonium perchlorate, microquant sulfate, ammonium peroxydisulfate, spectroquant nitrate, barium bromate, barium chlorate, barium nitrate, barium perchlorate, barium permanganate, barium peroxide, cadmium nitrate, 1-bromo-3chloro-5,5 dimenthylhydantoin, bismuth nitrate, calcium hypochlorite, calcium iodate, calcium nitrate, ceric ammonium nitrate, ceric sulfate, calcium chlorate, calcium chlorite, calcium hypochlorite, calcium perchlorate, calcium permanganate, calcium peroxide, cerous nitrate, chloric acid, chromium trioxide, chromium nitrate, cobalt nitrate, copper chlorate, cupric nitrate, halane (1,3, dichloro-5,5dimenthylhydandoin),3-chloroperoxybenzoic acid, cobalt nitrate, ferric nitrate, hydrogen peroxide, guanidine nitrate, iodic acid, lanthanum nitrate, lead dioxide, lead nitrate, lead oxide, lead perchlorate, lithium nitrate, lithium perchlorate, lithium hypochlorite, lithium chlorate, lithium peroxide lithium, perchlorate, magnesium bromate, magnesium chlorate, magnesium peroxide, magnesium nitrate, mercuric nitrate, mercurous nitrate, mercurous chlorate, manganese dioxide, mono-(trichloro)-tetra-(monopotassium dichloro)-penta-α-triazinetrione, magnesium perchlorate, nitric acid, nickel nitrate, mercurous nitrate, periodic acid, peracetic acid, perchloric acid solutions, Class II and III (depending upon centration), potassium peroxide, potassium superoxide, potassium biiodate, potassium bromate, potassium bromate-bromide, phosphomolybdic acid, phenylmercuric nitrate, potassium hydroxide, potassium iodate, potassium dichromate, potassium nitrate, potassium nitrite, potassium chromate, potassium dichloro-β-triazinetrione (potassium dichloroisocyanate), potassium dichromate, potassium chlorate, potassium percarbonate, potassium nitrate, potassium perchlorate, potassium periodate, potassium permanganate, potassium persulfate, silver peroxide, sodium bromate, sodium carbonate peroxide, sodium dichloro-β-triazinetrione (sodium dichloroisocyanate) silver nitrate, silver oxide, silver perchlorate, sodium chlorite, sodium chlorate, sodium nitrate, sodium iodate, sodium dichromate, sodium nitrate, sodium perborate, sodium perborate (anhydrous) sodium perchlorate, sodium percarbonate, sodium perchlorate monohydrate, sodium periodate, sodium nitrite, sodium persulfate, sodium permanganate, sodium peroxide, strontium nitrate, strontium perchlorate, strontium peroxide, thorium nitrate, trichloroisocyanic acid, zinc nitrate, thallic nitrate, uranyl nitrate, urea peroxide, yttrium nitrate, zinc bromanate, zinc chlorate, zinc permanganate, and zinc peroxide.
The contaminated material can comprise nitrated and/or chlorinated hydrocarbons including nitrated and/or chlorinated polycyclic materials, nitrated and/or chlorinated heterocyclic materials, and nitrated and/or chlorinated aliphatic materials. Exemplary contaminated compounds include chlorinated pesticides, TNT, and RDX.
Preferably, the accelerated remediation reaction is conducted aerobically or abiotically, and more preferably by an in situ abiotic process. The reaction can also be conducted methanogenically.
Generally, the means for generating a treated contaminated material entraining air stream at a predetermined velocity comprises an elongate drum having a longitudinal axis, first and second end portions, and a center portion. The drum is rotatable about its longitudinal axis at a predetermined rotational speed, and means extending outwardly from the drum are provided for generating the treated contaminated material entraining air stream. Preferably, the treated contaminated material entraining air stream comprises a plurality of air currents, and the air current generating means comprises a plurality of paddles extending outwardly from the cylindrical outer surface of the drum. Typically, each paddle comprises a base portion connected to the drum, and a blade portion. Each blade portion has a major surface oriented for generating at least one the air current having a sufficient velocity for entraining and transporting treated contaminated material upwardly of the rotating drum when the drum is rotated at the predetermined rotational velocity.
The treated contaminated material entraining air stream preferably comprises a plurality of intersecting air currents. Each of the intersecting air currents has a sufficient velocity for entraining and transporting a portion of the treated contaminated material upwardly of the air stream generating means. More specifically, the means for generating a plurality of intersecting air currents comprises a plurality of end paddles extending radially outwardly from the first and second end portions of the drum. Each end paddle can comprise a base portion connected to the drum and a blade portion. In this instance, the blade portion has a major surface oriented relative to the drum for generating an air current directed upwardly of the drum and transversely toward the center portion of the drum when the drum is rotated at the predetermined rotational speed. It also has a plurality of center paddles extending radially outwardly from the center portion of the cylindrical outer surface. Each center paddle comprises a base portion connected to the drum, and a blade portion having first and second major surfaces. The first and second major surfaces are oriented relative to the drum for generating an air current directed upwardly and rearwardly of, and transversely toward the first and second end portions of the drum respectively when the drum is rotated at the predetermined rotational speed. In use, the air currents generated by the end and center paddles intersect and combine to form the treated contaminated material entraining air stream for microenfractionating the treated contaminated material.
In a preferred embodiment, the treated contaminated material entraining air stream comprises a vortex-type air stream which transports the entrained treated contaminated material in a generally circular path. In this case, the end and center paddles can extend radially outwardly from the drum so that they are arranged in a plurality of helical longitudinal row. Also, the drum can further comprise first and second transition portions disposed between the center portion and the first and second end portions respectively. The first and second transition portions of the drums having a plurality of end paddles and a plurality of center paddles extending radially outwardly therefrom.
In another form of the invention, a method of accelerated remediation of treated contaminated material is provided. This method comprises the steps of (a) treating the treated contaminated material with chemical biological amendments for facilitating accelerated remediation thereof, (b) providing an entraining air stream having a sufficient velocity for entraining the treated contaminated material therein, (c) entraining the treated contaminated material in the air stream, (d) microenfractionating the treated contaminated material, and (e) discharging the microenfractionated treated contaminated material from the air stream so that the treated contaminated material will be acceleratedly remediated. The microenfractionating step preferably comprises homogenization and aeration of the treated contaminated material. The entraining air stream preferably comprises providing an entraining air stream including a plurality of upwardly and transversely flowing, intersecting air currents, and more preferably comprises a vortex-like entraining air stream. Typically, the step of providing an entraining air stream includes the step of rotating a drum assembly at a rotational speed sufficient for generating the entraining air stream. The drum assembly can include means for generating this plurality of intersecting air currents when the drum assembly is rotated.
In one preferred method, the treated contaminated material is contaminated with a hydrocarbon material, and the accelerated remediation of the treated contaminated material comprises accelerated chain scission of the hydrocarbon material. In another case, when the treated contaminated material is contaminated with hydrocarbon material, the accelerated remediation, typically employing chemical reduction. If the hydrocarbon contaminant is halogenated, a halogen will also be produced. A further instance is where the treated contaminated material is contaminated with hydrocarbon material, and the accelerated remediation comprises reduction of the total hydrocarbon material in the treated contaminated material.
In general, at least about 70%, preferably at least about 80%, more preferably at least about 90%, and most preferably at least about 95% of the accelerated remediation of the treated contaminated material is completed within 150 days, preferably within 120 days, more preferably within 90 days, and most preferably within 60 days. Moreover, the volume of treated contaminated material which is acceleratedly remediately treated by the method of the present invention is generally at least about 1500 cubic yards, preferably at least about 2000 cubic yards more preferably at least about 2500 cubic yards, most preferably at least about 3000 cubic yards, per day per apparatus. This is particularly significant in the case of chlorinated contaminates since most prior art systems cannot remediate these compounds even after years of trying to treat same.
The method of the subject invention produces high surface area treated contaminated microenfractionated material. The surface area of the treated contaminated non-microenfractionated material can be increased, after the microenfractionating step, as compared to the surface area of the treated contaminated non-microenfractionated material, by a factor of at least about 1×10 6 , preferably at least about 2×10 6 , more preferably at least about 3.5×10 6 , and most preferably at least about 5×10 6 . More specifically, the subject method can further include the step of discharging the microenfractionated treated contaminated material from the air stream and redistributing it throughout a soil matrix. In this manner, the surface area of the microenfractionated treated contaminated material is substantially increased. This is especially important when dealing with clay type soils.
Most prior art remediation processes cannot be conducted at ambient temperatures below 10 degrees C. However, when the method of the subject invention is employed, the aforementioned high degree of accelerated remediation can be maintained at an average ambient temperature which is not more than about 10 degrees C., preferably not more than about 7 degrees C., more preferably not more than about 3 degrees C., and most preferably not more than about 1 degree C.
One reason why the accelerated remediation of this invention can be conducted at the low ambient temperature conditions described in the preceding paragraph herein, is that the subject reaction is generates a more substantial amount of exothermic heat than known prior art remediation processes. Thus, the accelerated remediation is preferably conducted at an exothermic temperature measured within the contaminated material of at least about 5 degrees, and more preferably at least about 10 degrees, higher than an average ambient air temperatures of from about zero up to about 10 degrees C.
As for the treatment of the contaminated material with the chemical amendments, it is preferred that they are dispersed throughout the redistributed microenfractionated treated contaminated material thereby facilitating accelerated remediation.
Other preferred embodiments of the subject method include (a) locating an impervious undercover below the treated contaminated material prior to the microenfractionating step thereby preventing the chemical amendments from leaching into soil underlying the treated contaminated material, and (b) a cover over the microenfractionated treated contaminated material, the cover allowing substantial solar radiation to pass therethrough and into the microenfractionated treated contaminated material, thereby facilitating the accelerated remediation and preventing moisture from soaking the microenfractionated treated contaminated material and to prevent moisture evaporation from the microenfractionated treated contaminated material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the preferred apparatus for use in the present invention.
FIG. 1A shows a front view of an alternative embodiment of the present invention.
FIG. 1B schematically depicts an exemplary flow tank system 225 .
FIG. 2 is a rear view of the apparatus of FIG. 1 .
FIG. 2A shows a rear view of an alternative embodiment of the present invention.
FIG. 3 is a left side view of the apparatus of FIG. 1 .
FIG. 3A is a left side view of another embodiment of the apparatus according to the present invention.
FIG. 4 is a right side view of the apparatus of FIG. 1 .
FIG. 4A is a left side view of the apparatus according to the present invention as shown in FIGS. 1A and 2A.
FIG. 4B is an enlarged view of the pivoting rear wheel assembly in its extended position.
FIG. 5 is a top view of the apparatus of FIG. 1 .
FIG. 5A is a top view of an alternative embodiment of an apparatus according to the present invention.
FIG. 6 is a top view of the apparatus of FIG. 1 configured for being driven sideways.
FIG. 7 is a front view of the apparatus of FIG. 1 configured for being towed sideways.
FIG. 7A is a front view of an apparatus shown in FIGS. 1A and 2A configured for being transported by towing.
FIG. 7B is an enlarged view of the drum shaft bearing assembly.
FIG. 8 is a right side cross-sectional view of the drum and paddle assembly according to the first embodiment of the present invention.
FIG. 8A is a right side cross-sectional view of the drum and paddle assembly according to a second embodiment of the present invention.
FIG. 9 is an enlarged sectional view of the center portion of the drum and paddle assembly, showing the counter-rotating vortex-like airstreams generated when the assembly is rotated.
FIG. 9A is bottom view of an alternate drum and paddle assembly.
FIG. 10 is a top view of a right side paddle according to the first embodiment of the present invention.
FIG. 10A is a top view of a right side paddle according to the second embodiment of the present invention.
FIG. 11 is a top view of a center paddle according to the first embodiment of the present invention.
FIG. 11A is a top view of a center paddle according to the first embodiment of the second invention.
FIG. 12 is a top view of a left side paddle according to the first embodiment of the present invention.
FIG. 12A is a top view of a left side paddle according to the first embodiment of the second invention.
FIG. 13 is a side view of a right side paddle showing the shear pin feature, and showing the released paddle in phantom according to the first embodiment of the present invention.
FIG. 13A is a side view of a right side paddle showing the shear pin feature, and showing the released paddle in phantom according to the first embodiment of the second invention.
FIG. 13B is a enlarged fragmentary view of a paddle showing a cutting edge 72 formed on the leading edge of a paddle body 74 .
FIG. 14 is a front perspective view of a contaminated material according to the present invention, having the drapes removed to expose the chamber and drum assembly.
FIG. 15 is a top view of windrows formed in the treated contaminated material prior to microenfractionation.
FIG. 16 is a side view of windrows formed in the treated contaminated material prior to microenfractionation.
FIG. 17 is a perspective view of an alternative embodiment of the invention.
FIG. 18 is a front elevational view of a drum showing an alternative paddle arrangement wherein paddles in adjacent rows are offset.
FIG. 19 is a partial side view of an apparatus showing the drum drive motor mounted on a torque plate.
FIG. 20 is a sectional view along line A—A in FIG. 19 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the ex-situ method of this invention, the soil should be removed from the contaminated site and placed in windrows on top of durable liner which acts as an underliner in the subject accelerated remediation process. This underliner substantially prevents undesirable materials present in the ex-situ soil from leaching into the surrounding uncontaminated soil prior to the completion of the remediation process. It has been determined that a woven polyolefin fabric of the type exemplified by NOVA-THENE® RB616-6HD, manufactured by Polymer International (N.S.) Inc., of Truco Nova Scotia, Canada, is one of the most durable liners available for this purpose. One reason is that it will remain intact during the microenfractionation of the treated contaminated material by the hereinafter-described subject apparatus.
After the liner has been laid down in a pile (on as smooth a surface as possible), a layer of sand is applied over the liner. Windrows are typically spaced 6-8 feet apart. The windrows should be no wider than 14 feet and no higher than 6 feet. The above-described liner is extended out 4 feet past edge of pile with a berm of about eight inches to allow the microenfractionating equipment to straddle the pile. All rocks, chunks of concrete larger than two inches and other debris should be removed from contaminated soil prior to microenfractionation. Once the contaminated dirt has been windrowed, treatment with the chemical amendments can commence.
Soil Analysis Prior to Starting Treatment
First, the soil is analyzed for contaminant, and a full agricultural analysis is done. The testing for total petroleum hydrocarbons is not in itself an easy task. The type and quantity of contaminant must be accurately revealed. The contaminant reduction requirements must also be known. In addition, a series of soil tests must be undertaken. These tests include, but are not limited to, the following:
1. Total Petroleum Hydrocarbon Levels: The amount and nature of the hydrocarbon contaminants in the soil must be first determined. These include BTEX, PCP, PAH, PCB and the like.(EPA Test Nos. 418.1, 8015, 8020, 8270, etc.)
2. Standard ⅓ Bar Moisture Retention: The test will ascertain the quantity of water this soil will retain when placed under ⅓ bar vacuum. This is a standardized test to determine the saturation point of the soil with water. Knowing this will assist in determining the quantity of moisture that can be reasonably utilized during soil treatment.
3. pH: This test will determine if the soil is acidic, basic or neutral. Acidic pH is best for chemical oxidation degradation. If the soil is too basic (i.e. pH 8.0 or above), soil amendments will be necessary to make the soil pH more acidic.
4. Standard Buffer Capacity: This test will determine how much acid or base can be introduced into the soil before a pH change occurs. This information is useful because soil amendments can alter pH as can biological metabolyte materials produced during the biological treatment of petroleum hydrocarbon contaminated soil.
5. Standard Electrical Conductivity: Bacteria require a certain amount of electrical conductivity to survive and metabolize nutrients. If there is too little electrical conductivity or too much, the biological system can be inhibited or destroyed. Again, soil amendments can alter electrical conductivity if it becomes necessary.
6. Standard Sodium Absorption Ratio (SAR): This test determines an estimate of the exchangeable sodium percentage of what a soil is, or what it is likely to become if the water that comprises the sample water is in that soil for long periods of time. The SAR has a good correlation to the exchangeable sodium percentage and is easier to calculate exactly (or to estimate from a few simple analysis) than is exchangeable sodium.
percentage. If the SAR exceeds 13, the biological system will be greatly impaired.
The purpose for the test is to determine if too much salt in the soil will inhibit biological activity by having sodium ions occupy a high proportion of exchange sites in the soil causing high pH and low water permeability. If this situation occurs, biological activity will slow or cease. Note that the use of inorganic nutrients can promote high salt content in soil due to the salt nature of inorganic nutrients. Organic based nutrients do not cause this to happen because they are not salt based.
7. Standard Organic Matter: Organic matter is required for any biological system to function properly. The organic matter can be a media of bacteria, it can supply nutrients in some cases, and it can be an indicator of biological activity. Knowing the organic matter level can help determine if additional organic matter is needed for soils treatment.
8. Standard Micro-Nutrient Profile of the Soil: In addition to macro-nutrients, a micro-nutrient profile of the soil is very useful. Macro-nutrients are elements such as sulfur, copper, iron, zinc, boron, manganese, sodium, magnesium and calcium. All of these elements are necessary for microbial growth in very small quantities. If one or more of these nutrients are absent or unavailable, bacterial activity is inhibited. Conversely, if one or more micro-nutrients is excessive, this can also be inhibitory on bacterial growth. This must be known. The soil type of the contaminated soil must be ascertained, i.e. percentage of sand, silt, or clay. Each soil type must be treated differently. For instance, straight sand may not be capable of retaining moisture; clay or fine silt may require the addition of sand to assist in breaking the soil platelets apart, so that oxygen is not excluded from the system.
9. Redox Potential: This is a measure of the potential for a soil to oxidize or reduce introduced materials. More specifically, in soils, the redox potential determines the oxidation-reduction equilibrium as measured analytically using an electrode (usually a platinum electrode). This electrode potential will yield the oxidation states of iron and manganese in the soil as well as the sulfate/sulfide ratio, the nitrate activity, and other elements or compounds actively receiving or releasing electrons. The redox potential value is useful in estimating the quantities of oxidative and/or reductive chemicals required for remedial activity.
10. Contaminants: This includes the contaminant materials which typically pollute the soil including pesticides, insecticides, herbicides, dioxins, PAH compounds, and chlorinated hydrocarbons.
Ex-Situ Soil Treatment
Ex-situ treatment is the removal of contaminated material to a second site, and the remediation of thereof at that second site. In providing the second site, a berm is made typically from soil, straw or concrete ecology blocks. The width and length is dependent on the area available for use in remediation. First, the area contained by the berm is smoothed. It is then covered with the above-described underliner in order to create an impermeable barrier between the contaminated soil and the uncontaminated soil. Next, the underliner is covered with 2-4 inches of fine sand or pea gravel. Then, the windrows of contaminated soil 14 ft. wide and 6 ft. tall are laid out. Space must be left at sides and ends of berm for maneuvering the microenfractionating equipment. Finally, the entire windrow layout is covered with a translucent outdoor material which permits solar radiation to pass therethrough. The preferred material for this purpose is Loretex 1212 UV (clear), manufactured by Chave & Earley, Inc. of New York City, N.Y., a woven polyethylene substrate coated with polyethylene which is manufactured by The Loretex Corporation.
Treatment of Contaminated Materials
The soil is prepared by first adjusting the pH. In general, the soil pH is maintained in an acidic to neutral environment. Therefore, the pH of soil is preferably adjusted to between about 4.0 and 7.0, more preferably between about 4.5 and 6.5, and most preferably about 5.0, and is then treated with the chemical amendments.
Treatment Cell Construction
The treatment cell design of choice is a windrow configuration with the soil pile dimensions. For example, a windrow configuration conforming to 14 feet wide at the base, 5 feet wide at the top and a height of no more than 6.5 feet. Windrow length is limited only to available space at a given job site. The windrow should be placed on a level, smooth, firm surface. An underliner must be used and must be a continuous piece for surrounding environment protection. The edges of the underliner must be bermed 8″ to 10″ to prevent any leachate that may be produced during treatment form escaping. The berm material may vary, but a ridge of sand under the underliner and completely surrounding the contaminated soil works very well. Typically, when using this treatment method, no leachate collection basin has been necessary. By using sand or a similar textured material, the underliner covering the bermed section can be driven on by the microenfracting apparatus without damage to the underliner.
After the underliner structure and windows are set up, the soil amendments—pH modifiers and chemical reductants—may be added. The method for dispersion of soil amendment is via broadcast spraying by the H&H Eco Systems spray unit or equivalent, or it is injected directly into microenfractionating chamber of the Microenfractionator™ during the course of its operation.
A one piece top cover made from Loretex 1212 UV material is very resistant to damage from solar radiation. This material also transmits the maximum amount of solar radiation to the contaminated soil, thus assisting with elevated soil temperatures to assist the chemical reductive reaction. This property is very useful in promoting chemical activity during periods of low ambient air temperature.
Microenfractionation
Soil microenfractionation is one of the most critical aspects of soil remediation, such as chemical oxidative and/or reductive treatment of contaminated materials in general, and more particularly petroleum hydrocarbon contaminated soils. In the case of most petroleum hydrocarbon contaminated soil, for example, it is very unevenly contaminated or fractious in nature. The hydrocarbons will frequently form “globs” of contamination of high concentration in the soil. These “globs” repel water as well as maintaining a high enough concentration of petroleum hydrocarbon to inhibit complete chemical oxidation and/or reduction except at the contamination interface. The contamination interface will generally provide conditions favorable for chemical reaction with both available oxidants and/or reductants and relatively low hydrocarbon concentrations. The oxidative and/or reductive degradation rate is thus controlled by the active surface area of the hydrocarbon contaminant.
One conclusion that could be discerned from this is that, if the surface area of the hydrocarbon contaminant was increased, the rate of chemical oxidative and/or reductive reactivity would also increase. The apparatus used for that purpose in the subject invention very actively disperses the hydrocarbon contaminant throughout the soil matrix. The apparatus, known as the H & H Microenfractionator, is manufactured by Frontier Manufacturing Company and is capable of increasing surface area by a factor of at least about 1×10 6 with one two-way mixing pass. This same mixing action can disperse all of the soil amendments in the same manner. No other soil mixing machine currently in use is capable of this type of mixing. The H & H Microenfractionator does not just “mix” the soil; it literally homogenizes and aerates it. With this corresponding increase in surface area, the remediation degradation rate, in this case oxidative and/or reductive remediation degradation rate, will increase by several thousand times. This process is defined, for purposes of this invention, as “microenfractionation”.
After all additions are added, then the microenfractionation step can take place. For example, after application of pH modifiers and chemicals using a spray system such as the HH System 1000 sprayer, then an apparatus, such as the H & H Microenfractionator, can start its work. In order to achieve the maximum effect, the microenfractionating apparatus preferably must be passed through the soil matrix at least twice. The most efficient method is for the machine to pass through the soil in one direction, then, turn on its axis and pass through the soil in the opposite direction. This way the soil displacement (longitudinally) is essentially negated.
Stirring intervals for the contaminated soil will depend on the rate of remediation activity. If all of the treatment specifications are adhered to, a very rapid remediation rate will ensue. Additional/more frequent chemical requirements may be necessary depending on the soil analysis/testing done as the project progresses.
In the past, machines such rototillers, trackhoes, discs, and the like were used in remediation to “stir” contaminated soil. In the case of trackhoes, for example, this procedure was extremely time consuming, frequently taking all day to stir 500 cu. yards of soil. This factor alone greatly limited the economics of attempting a large remediation site. The soil handling would probably be cost prohibitive. While this method did a much better job of stirring than rototillers, it still did not address the stirring problem completely. Ideally the soil should be very thoroughly mixed with the soil amendments. The track hoe did not totally address this. It was also too costly as well as inadequate in aerating the soil. Extensive research was done to find soil mixing equipment that would adequately address all of the requirements for efficient biodegradation of hydrocarbons. A variety of rototillers, track hoe attachments, pug mills, batch mixers and shakers were researched. While some of the machines identified had merit, daily mixing volumes were limited. Also, all of the machines were inadequate in aeration.
The H & H Microenfractionator can mix remediation chemicals such as pH modifiers, chemical oxidants and/or reductants, other amendments with contaminated soil to form a treated microenfractionated material. Hydrocarbons will rarely contaminate soils in a uniform manner due to causes ranging from varying soil permeability to the water insoluble nature of hydrocarbons. Reducing the normally fractious nature of hydrocarbon contamination in soils is a task that this apparatus can accomplish very effectively. The mixing action simultaneously mixes the remediation chemicals and any other soil amendments with the hydrocarbon contaminated soil. This action brings the remediation chemicals and any soil amendments into direct contact with the contaminated soil to allow the most efficient remediation system. The HH System 614 also aerates the soil very thoroughly to keep the soil in an oxidated rather than a reduced state. It is also much faster—it can “microenfractionate” 500 cubic yards of soil per hour rather than “stir” the 1000 cubic yards per day that the track hoe is capable of doing.
Referring now to FIGS. 1 and 2, a microenfractionating apparatus for use in the present invention is shown generally at 10 . A second embodiment is shown in FIGS. 1A and 2A which differs in detail as described below.
The apparatus 10 includes frame 12 which is assembled from ladder-type left, right, and top subframes, 12 a , 12 b and 12 c respectively. Frame 12 is supported at its front end by left and right drive wheels 14 and 16 , and at the rear by left and right caster wheels 18 and 19 . Each wheel mounted on an axle which is journaled into a supporting frame assembly 40 . Each rear caster wheel is mounted into its respective frame assembly 40 by a vertical shaft journaled into frame assembly 40 as shown in FIG. 3 . Each rear caster wheel may be locked into a transverse position by locking pin assembly 19 when desired as described below. Each frame assembly 40 includes an upright member 42 slidably received within a complementary vertical sleeve 44 of a mounting assembly 46 . Frame assembly 40 may thereby be raised or lowered relative to the ground on upright member 42 by actuation of hydraulic cylinder 43 , allowing the ground clearance of apparatus 10 to be raised or lowered during operation as more fully described below. Mounting bracket 46 is in turn pivotally mounted on frame 12 at brackets 48 , allowing each frame assembly 40 and wheel to be pivoted by actuation of hydraulic cylinder 45 for different modes of operation as described below.
A spray system 200 , as depicted in FIGS. 1 and 3A, is provided for discharging chemical amendments and/or biological amendments into the air stream generated by the apparatus 10 which contains the microenfractionated contaminated material. In this way, the contaminated material can be treated with the chemical amendments and/or biological amendments thereby facilitating said accelerated remediation. The spray system 200 comprises a transversely-extending flow pipe 214 , which extends across the front of the apparatus 10 , beyond the transverse extent of the apparatus 10 . Vented ball valves 220 , including quick-connect fittings, are connected at each end of pipe 214 . A hose 275 (not shown) from a tank 240 (shown in FIG. 1B) containing chemical and/or biological amendments can be attached to either or both of the valves 220 for introducing the amendment(s) into the pipe 214 , and then into the flow pipe 212 and nozzle 210 (see FIG. 3 A).
Connected to the midpoint of flow pipe 214 is one end of a shorter flow pipe 212 . Flow pipe 212 extends rearwardly at a right angle to the flow pipe 214 . The other end of the flow pipe 214 is joined to a spray nozzle 210 which discharges a spray 250 of chemical amendments and/or biological amendments into the air stream generated by the apparatus 10 .
One or more trailers (not shown) can be attached to the rear of apparatus 10 . Each trailer has a flow tank system 225 mounted thereon for transferring the chemical amendment and/or biological amendment to the flow pipes 214 and 212 , and in turn to the spray nozzle 210 . An exemplary flow tank system 225 , shown schematically in FIG. 1B, comprises a holding tank 240 for storing the chemical amendment and/or biological amendment. In order to transfer the chemical amendment and/or biological amendment to the spray nozzle 210 from holding tank 240 , a pump 230 moves the amendment(s) from tank 240 (see arrows A), through flow pipes 245 , 255 , and 265 , and then through hose 275 to valve 220 , and onto spray nozzle 210 . Hose 275 is connected to valve 220 by a quick connect fitting. Pump 230 can also transfer chemical amendment and/or biological amendment from pump 230 back to holding tank 240 (see arrows B). The path of chemical amendment and/or biological amendment from pipe 245 to pipe 255 is limited by vented check valve 260 . The path of chemical amendment and/or biological amendment from pipe 265 to hose 275 is limited by vented check valve 265 . Finally, the path of chemical amendment and/or biological amendment from pipe 265 to pipe 285 is limited by vented check valve 280 .
In certain cases the chemical amendments and/or biological amendments have detrimental effect on the materials of construction of the apparatus 10 . In these instances it is advisable to use a material of construction for the apparatus 10 such as stainless steel and thereby avoid these detrimental effects.
An alternative design for the wheel frame assemblies 40 is shown in FIGS. 4A and 4B. Note that in the alternative frame assembly design for drive wheels 14 and 16 , frame assembly 40 does not pivot, but rather is moved rearward by hydraulic cylinder 45 and raised up by hydraulic cylinder 43 to its stowed position.
As best seen by reference to FIG. 5, frame 12 includes upper deck 32 on which are mounted fuel tank 34 , operator's cab 36 , hydraulic oil tank 37 , engine 38 , and hydraulic pumps 40 , 42 and 44 . As readily appreciated by those skilled in the art, suitable auxiliary equipment for operation of the engine and drive components in dusty environments is also provided, such as rotating self-cleaning screen 41 of the cooling system of engine 38 . Power for the operation of apparatus 10 is provided by hydraulic pumps 40 , 42 and 44 , which are driven by engine 38 , preferably a 460 hp diesel engine such as Model 3406, manufactured by Caterpillar. Each hydraulic pump 40 a and 40 b delivers pressurized hydraulic fluid to each of drum assembly drive motors 48 a and 48 b to reversibly drive rotating drum and paddle assembly 22 from each end. Hydraulic pumps 42 a and 42 b deliver pressurized hydraulic fluid to left and right drive motors 50 and 52 respectively. Pump 44 a delivers pressurized fluid to hydraulic cylinders 43 for raising and lowering frame 12 , while pump 44 b provides pressurized fluid for operating hydraulic cylinders 45 , and hydraulic cylinder 54 for raising and lowering tail section 31 . Left and right drive motors 50 and 52 are separately controllable by the operator for steering and for driving left and right drive wheels 14 and 16 respectively through an appropriate drive assembly of a suitable design as could be readily determined by one skilled in the art.
In the preferred embodiment, a planetary gear assembly, Model No. W-2 as manufactured by Fairfield is used on each the left side and right side drive wheel and motor assembly. The left side planetary drive assembly differs from that of the right side only in that it is rendered free wheeling for reasons described below by operation of an external T-handle. Apparatus 10 is steerable and driveable forwardly, rearwardly, and sideways as described below by virtue of the fact that each drive wheel is driveable forwardly and rearwardly independently of the other by appropriate hydraulic controls of standard design and well-known to those skilled in the art. Each hydraulic pump 40 a and 40 b delivers pressurized hydraulic fluid to each of drum assembly drive motors 48 a and 48 b to reversibly drive rotating drum and paddle assembly 22 from each end.
In an alternative four-wheel drive embodiment (FIG. 5 A), left and right castor wheels 18 and 20 are replaced by left and right rear drive wheels 15 a and 15 b and respective hydraulic drive motors 51 and 53 . Corresponding controls as described above with reference to the two-wheel drive embodiment are provided to allow the operator to control the speed and direction of each of the four driven wheels.
While the present invention is not intended to be defined or limited by reference to any specific dimensions, in both prior art apparatus and the present invention there is an efficiency of operation resulting from incorporation of a relatively long drum assembly, 17 feet or more for example. Accordingly, the overall width of the apparatus will be even greater than the drum length, while the overall length of the frame of the apparatus is preferably no greater than 8′ 6″. The overall width of the prior art apparatus prevents them from being driven through standard fence gates between adjacent fields, and requires that they be transported over public roads by truck and trailers designed for transporting heavy equipment. The present invention overcomes these limitations and cost disadvantages of the prior art apparatus by providing an apparatus which may be driven sideways under its own power through standard fence gates or over public roads for short distances, and which may be towed for longer distances over public roads when necessary. The means of configuring the present invention for so doing will now be described by reference to FIG. 5 where it can be seen that each wheel is mounted on a frame assembly 40 which is movable between a first position for accommodating forward and rearward travel of apparatus 10 during normal operation, and a second transverse position for accommodating towing or sideways travel of the apparatus. Each frame assembly 40 is moved between the first and second positions by a dedicated hydraulic cylinder 45 , which is controlled by means of appropriate controls (not shown) from operator's cab 36 .
Referring now to FIGS. 1 through 14, drum assembly 22 is mounted transversely within chamber 24 . Chamber 24 is an open-ended housing consisting of a top wall 26 , left and right side walls 28 and 30 , and tail section 31 (FIG. 5 ). Front opening 25 is partially shrouded as shown in FIG. 1 by front drapes 33 a-c . In the preferred embodiment, screened openings 23 are provided in left and right side walls 28 and 30 ahead of drum 56 to permit additional air to be drawn into chamber 24 during operation. (FIG. 3 A). Tail section 31 , essentially a rearwardly extending projection of chamber 24 , extends rearwardly from rear opening 27 . Tail section 31 may be described as a generally planar frame having rearwardly and inwardly extending side members pivotally attached to frame 12 at one end, and to lateral member at their outer ends. Drapes 39 are hung from each side member and the lateral member as best seen in FIG. 2 . The drapes may be made from any suitable material.
In the present embodiment, they are fabricated from grade 2 SBR in the form of ½″ thick conveyor belt material. Tail section 31 is pivotable by hydraulic cylinder 54 between a lowered operational position and a raised stowed position for use during transport of the apparatus. Rear drapes 35 are hung from each side and the rear of tail section 31 and from angled frame members defining rear opening 27 as shown. Chamber 24 serves to contain direct the air streams and contaminated material during operation of apparatus 10 , and to reform the contaminated material into a windrow after mixing and aerating as more fully described below.
Drum assembly 22 is journaled at opposite ends in left and right subframes 12 a and 12 b . Hydraulic motors 48 a and 48 b are mounted on left and right subframes 12 a and 12 b , and reversibly drive drum assembly 22 by means of shafts 49 a and 49 b when supplied with pressurized hydraulic fluid from hydraulic pumps 40 a and 40 b as described above.
Alternatively, motors 48 a and 49 b are each mounted on a torque plate 120 (FIGS. 19, 20 ), which has notched corners as best seen in FIG. 19 . Torque plate is fitted into a corresponding opening 121 in frame 12 . Rubber plates 122 are fitted into the notched corners between the torque plate and frame 12 to provide cushioning. As the motor is activated, torque plate 120 rotates in response to the reaction torque generated thereby. In addition, this mounting arrangement accommodates a certain amount of radial and axial movement of the drum relative to the frame.
Drum assembly 22 includes drum 56 , a hollow cylinder having closed ends, onto which are welded shafts 57 a and 57 b (not shown). Shafts 57 a and 57 b are journaled into frame 12 , and driveably connected with drum assembly drive motors 48 as described above. Each of shafts 57 a and 57 b are journaled into its respective subframe by means of a four bolt flange-type tapered roller bearing 91 such as Model FB 900 manufactured by Browning Company. Each bearing 91 is fitted into a corresponding hole in left and right subframes 12 a and 12 b . A split ring collar 92 is fitted into circumferential recesses 96 on each of shafts 57 a and 57 b , and bears against the protruding rotating race 94 of the tapered roller bearing to counteract spreading forces exerted on subframes 12 a and 12 b . Drum 56 thereby functions as a tension member in frame 12 counteracting spreading forces represented in FIG. 7A by force arrows 102 a and 102 b . This novel use of drum 56 as a tension member saves the weight of additional structural members which would otherwise be required to counteract spreading forces on subframes 12 a and 12 b , and allows a lower overall height which further accommodates towing the apparatus 10 on public highways.
Turning now to FIGS. 8-12, a plurality of left and right paddles 58 and 60 respectively, and center paddles 62 are mounted on the outer cylindrical surface of drum 56 as shown. In one embodiment, the paddles are arranged in four evenly spaced helical rows along the length of the drum, each row traversing 90° about the drum from one end to the other. In a second embodiment shown in FIG. 9A, the paddles are arranged in four “V-shaped” rows. The V-shaped rows of paddles serve to eliminate transverse steering torque on the apparatus which may be experienced with the use of helical rows where one end of the paddle row engages the contaminated material prior to the other. The V-shaped rows are oriented so that the paddles at each end of a row engage the contaminated material simultaneously, eliminating any steering effect resulting from paddles on one end of the drum engaging the contaminated material before the other. Additionally, the paddles of each V-shaped row are offset from those of adjacent rows to minimize bypassing of contaminated material past the drum. In one embodiment, the paddles in each row are spaced at 12″ intervals. The corresponding paddles of adjacent rows are offset 3″ from one another. Offsetting of the paddles in this manner promotes complete mixing and aeration since the contaminated material at every point along the entire length of drum 56 is directly in the path of at least one paddle.
It should be readily understood that more or less rows of paddles and different arrangements of paddles may be used. It is preferred however that left and right paddles 58 and 60 are mounted generally to the left and right of the center point of the drum respectively, while center paddles 62 are mounted along a central portion of the drum. Center paddles 62 may also be interspersed with the left and right paddles along transition portions of the drum as shown in FIG. 9 . Minor variations in the number and arrangement of center paddles interspersed with left and right paddles are possible in accordance to the present invention.
Each paddle has a base section 64 by which it is pivotally attached to bracket 66 , which in turn is welded to drum 56 as shown in detail in FIG. 13 . Each paddle is additionally secured in position by a shear pin 68 inserted into hole 70 . Shear pin 68 serves to release the paddle to pivot rearwardly if impacted by a solid object during rotation of drum assembly 22 . A deflector plate 71 is attached at a rearward angle to a forward edge of bracket 66 .
In a further embodiment of the present invention, each paddle has a base section 64 by which it is attached to bracket 66 , which in turn is welded to drum 56 (see FIGS. 8A, 10 A- 13 A and 13 B). Each paddle is attached by two bolts 68 inserted into holes 70 . Bolts 68 are designed to shear and release the paddle base section 64 if the paddle encounters an obstruction that would cause damage to the drum assembly 22 during drum rotation. Bracket 66 includes a deflector section extending forward of the paddle base attachment point as a rearward angle therefrom.
Each paddle includes a cutting edge 72 formed on the leading edge of paddle body 74 . Extending transversely from the trailing edge of left and right paddles 58 and 60 is a single paddle portion 76 extending inwardly toward the longitudinal center of drum 56 . Center paddles 62 each have a pair of opposed paddle portions 78 extending outwardly toward opposite ends of drum 56 . The paddle portions are preferably disposed at an angle slightly less than perpendicular relative to the paddle body. In a second embodiment (FIGS. 17, 18 ), one or more of the paddles include first and second slots 110 , 111 in place of bolt holes. Slots 110 and 111 are preferably oriented perpendicular to one another, although other orientations are possible. The mounting assembly for paddle 56 includes bracket 112 , plates 114 and nut and bolt assemblies 116 and 118 . Bracket 112 is welded onto drum 56 . Plate 114 is bolted to bracket 112 by bolts 116 . Paddle 56 is mounted by sliding slot 110 onto bolt 116 , sliding slot 112 onto bolt 118 , then tightening bolts 116 and 118 to clamp paddle 56 into the assembly. Use of this mounting assembly permits paddles 56 to be quickly and easily replaced by merely loosening bolts 116 and 118 , then tipping the paddle forward and sliding it out of the bracket assembly. A new paddle is then fitted in reverse order.
Each paddle portion 76 serves to generate an air stream directed upwardly of the drum and in the direction of the free end of the paddle when the drum is rotated in a direction such that the paddle travels upwardly and then rearwardly in its circular path around the drum. Stated slightly differently, the normal direction of rotation of the drum assembly is in the opposite direction of wheel rotation when the apparatus is being driven forward.
Having described the construction of the preferred embodiment, its operation will now be explained. The primary function of apparatus 10 is to shred, mix and aerate solid contaminated material. While a wide range of materials can be accommodated, the preferred embodiment is particularly suited to the contaminant of relatively light agricultural wastes such as straw and grass. Referring now to FIGS. 4 and 6, to configure the apparatus for being driven sideways, each hydraulic cylinder 43 is activated to lower frame 12 onto the ground and to raise each wheel several inches above the ground. Tail section 31 is retracted to its raised stowed position by hydraulic cylinder 54 . Each frame assembly 40 is pivoted to its transverse position as shown in FIG. 6; left and right drive wheels 14 and 16 are thereby aligned transversely, as are left and right rear caster wheels. Left drive wheel 14 is then drivably disengaged from left drive motor 50 by pushing T-handle 78 inward to disengage the planetary gear drive as discussed above. Each hydraulic cylinder 43 is then activated to lower each wheel and raise frame 12 above the ground.
Apparatus 10 is now configured for being driven sideways. It is propelled in this configuration by right drive wheel 16 , now facing in the direction of “forward travel”, which by virtue of being fitted with flexible hydraulic supply and return lines is operable in the transverse position. Steering is accomplished by operation of hydraulic cylinder 45 to “swing” right drive wheel 16 slightly as required to adjust the direction of travel. After arriving at the desired location, the apparatus 10 is reconfigured to its contaminated mode by reversing the foregoing procedure.
If it is necessary to transport the apparatus a greater distance, other transporting configurations are provided which allow the apparatus to be flat-towed by a truck. Referring to FIGS. 3 and 4, each wheel is raised above the ground, pivoted to its transverse position, and the wheels lowered, raising frame 12 above the ground. Left drive wheel 14 is driveably disengaged as before, and left rear castor is locked against castoring action by pin assembly 19 . As best seen in FIG. 7, a pair of auxiliary towing wheel assemblies' 80 a and 80 b are then mounted on the right side of frame 12 by being inserted into channels 82 a and 82 b , and yokes 84 a and 84 b respectively, and secured therein by locking pins 86 . Auxiliary towing wheel assemblies 80 a and 80 b are additionally secured by lateral link 86 , which is pinned into bracket 88 and frame 12 as shown. Right side drive wheel 16 and right rear castor 20 are then raised to lower the right side of frame 12 onto towing wheel assemblies 80 a and 80 b . As shown in FIG. 2, fifth-wheel assembly 90 is an articulated, hinged frame assembly which is normally stored in a retracted position, and which is extended and locked into position as shown in FIG. 7 for being hooked to a truck (not shown) for towing apparatus 10 . Fifth-wheel assembly 90 may be raised and lowered by any suitable winch assembly 92 (FIG. 6 ). An alternative fifth-wheel design is shown in FIG. 7A where rather than a separate towing wheel assemblies, an integral rear towing wheel assembly 81 is provided which can be raised into and lowered from its retracted position (FIG. 7A) by operation of hydraulic cylinder 83 without being detached from frame 12 . Apparatus 10 thus configured may be conveniently towed over public roads with considerably less expenditure of time, effort and expense when compared to prior art apparatus. Towing the apparatus is further accommodated by the novel frame design of the present invention as shown in the figures. Drum 56 serves as a tension member interconnecting vertical subframes 12 a and 12 b as discussed above. The use of drum 56 as a tension member in frame 12 eliminates the need for additional structural members to resist spreading forces exerted on subframes 12 a and 12 b during operation and towing. Frame 12 can therefore be designed with a lower overall height to accommodate passage beneath lower bridges and overpasses. Upon arriving at its destination, towing wheel assemblies 80 a and 80 b are removed and apparatus is reconfigured for operation by reversing the above procedure. In the alternative embodiment, wheel assembly 81 is retracted by operation of hydraulic cylinder 83 .
Prior art apparatus have proven generally unsatisfactory for processing such contaminated material due to their inability to effect adequate aeration of the materials to ensure aerobic conditions throughout the material, and due to their inability to effect adequate removal of excess moisture from the material when required. To this end, the present invention provides a novel drum and paddle assembly 22 , which is, rotated at high speed in a direction opposite to that of prior art apparatus. In addition to directly impacting the contaminated material for shredding it, the rotating drum assembly 22 also draws air from ahead of the apparatus into chamber 24 and generates a high-speed stream of air in chamber 24 . The high-speed air stream entrains the relatively light materials and circulates them in overlapping, counter-rotating circular patterns within chamber 24 for thoroughly aerating and mixing them. The entrained materials are suspended and circulated in the air streams, and then redeposited in a windrow to the rear of the rotating drum. As a further advantage, after mixing and aerating the contaminated materials as described, the present invention redeposits the materials in a relatively tall, more squared-off windrow having a higher volume of materials per unit of surface area than known apparatus.
To begin a contaminated operation, engine 38 is started, and drum drive motors 48 a and 48 b are engaged to counter-rotate drum assembly 22 , preferably at approximately 550 RPMs. apparatus 10 is now raised or lowered to a desired ground clearance by activation of hydraulic cylinders 43 . By so doing, apparatus 10 can be adjusted to process more or less material. This unique ability of the present invention allows for a more efficient operation by permitting greater volumes of material to be formed into a single windrow and processed in a single pass, resulting in more efficient use of the available ground area, and less processing time for a given amount of material. The height adjusting ability is additionally useful in that as the process partially decomposes the windrow of material, the volume of material decreases. The present invention allows the operator to readily adjust for the volume decrease without any decrease in the effective-ness of mixing and aeration.
Having selected the appropriate height, the operator now drives apparatus 10 forward to engage the contaminated material. As the apparatus engages and proceeds along the windrow, the contaminated material is mixed and aerated by the action of the counter-rotating drum assembly. We define counter-rotation to mean rotation in a counterclockwise direction when viewed from the right end of the drum assembly, or stated slightly differently, in the opposite direction of rotation of forward rolling drive wheels 14 and 16 . Counter-rotating drum assembly draws air into chamber 24 from ahead of the apparatus in the form of an upwardly and rearwardly directed air stream ahead of the drum assembly, providing significant advantages as will be further explained. As apparatus 10 approaches, the upwardly flowing air stream first engages the windrow ahead of the drum assembly and entrains a portion of the material which travels in the air stream and which does not directly engage the counter-rotating drum assembly. Counter-rotating drum assembly 22 then engages the remaining material which is deflected by deflector plate 71 toward cutting edge 72 , where the material is shredded, and then entrained in the air stream. While the precise amounts of material shredded in each pass of the apparatus are not known with certainty, in the processing of grass straw, for example, 3 - 4 passes through the contaminated material will normally produce a thoroughly shredded contaminated material.
Under certain operating conditions, particularly when processing heavier materials, drum 30 can be slowed and even stalled. Owing to the hydraulic coupling between the drum and engine, stalling of the drum can stall the engine as well. In the preferred embodiment, this problem is addressed by monitoring the engine speed to detect slowing of the drum, and reducing power to the drive wheels when slowing of the drum is detected. Reducing power to the drive wheels slows the forward progress of the apparatus through the windrow, thereby reducing the load on the drum and allowing it to resume its normal operating speed. In the preferred embodiment, the power to the drive wheels is first reduced by to 50% or normal, and if after no more than a few seconds the drum has not resumed its normal operating speed, further reducing power to the drive wheels to 30% of normal. Once the drum has resumed normal operating speed, the power to the drive wheels is increased to its normal level. In order to avoid lurching and resultant damage to the drive mechanism, applicants have found that the power to the drive wheels must be resumed gradually rather than all at once.
Reducing and increasing the power to the drive wheels in response to changes in the drum speed is achieved by means of electrical control of the hydraulic pumps which provide pressurized hydraulic fluid to the left and right drive wheel hydraulic motors 42 a and 42 b respectively. A schematic diagram of the control system is shown in FIG. 16. A manually operated speed controller is provided for each of the two drive wheels. During normal operation, speed controllers 104 a and 104 b electrically control the output of hydraulic pumps 40 a and 40 b responsive to movement of the speed controllers by the operator. When drum 30 (not shown in FIG. 16) slows, a corresponding slowing of alternator 102 triggers a signal to controller 100 , a Sundstrand Model MCH22BL1844. In response, controller 100 reduces the voltage applied to speed controllers 104 a and 104 b by 50%, which reduces the power to left and right drive wheel hydraulic motors 50 a and 50 b respectively by a corresponding amount. If within two seconds drum 30 has not resumed its normal operating speed, controller 100 further reduces the voltage to speed controllers 104 a and 104 b to 30% of normal. Typically, reduction of power to the drive wheels to 30% of normal has been sufficient to overcome all but the most severe stalling conditions.
Once drum 30 has resumed its normal operating speed, controller 100 restores normal voltage to speed controllers 104 a and 104 b and normal operation is resumed. Generally, the control system as described is so responsive that it is necessary to resume normal power to the drive wheels gradually in order to avoid lurching of the apparatus and damage to the drive train. To that end, once the drum has resumed normal operating speed controller 100 increases the voltage to speed controllers 104 a and 104 b gradually over several seconds.
The entrained contaminated material is propelled upwardly and rearwardly in a pair of generally rotating vortex-like airstreams. The end paddles generate air currents directed upwardly of the drum and transversely toward the center portion of the drum, while the center paddles generate an air current directed upwardly and rearwardly of, and transversely toward the ends of the drum when the drum is rotated.
The air currents generated by the end and center paddles intersect and combine to form the vortex-like, compost entraining air stream for mixing and aerating the windrow of contaminated material.
The airstreams overlap at their inner portions, providing repeated exchange of entrained material therebetween. As the air streams begin to lose their velocity, the contaminated material begins to drop out of the air stream and is redeposited into a windrow.
The airstreams are generated according to the preferred embodiment by the left, right and center paddles previously described. As best seen in FIGS. 9 and 14, each row of paddles according to the present invention includes a group of paddles having paddle portions 76 facing toward opposite ends of the drum. As the drum is rotated, each paddle portion 76 draws air into chamber 24 and generates a series of airstreams flowing in the direction of the drum rotation and laterally outwardly toward the end of the drum. The series of airstreams generated by the two group of similarly oriented paddle portions 76 combine to form oppositely rotating airstreams spiraling rearwardly within chamber 24 and intersect. The interspersing of paddles having opposite facing paddle portions 76 near the center of the drum creates a region in which the oppositely rotating airstreams overlap. In the overlapping region, contaminated material is continuously exchanged between the airstreams, providing more thorough mixing of the contaminated materials than has heretofore been possible. The relatively light materials remain entrained in the airstreams for a relatively long time, until the air stream slows sufficiently to cause the material to fall from the airstream. In this way, the contaminated material is afforded an extended contact time for aeration and drying. As the airstreams spiral rearward, they exit chamber 24 through rear opening 27 and rear tail portion 31 . Rear drapes 35 serve to limit the rearward travel of the airstreams and any entrained or thrown contaminated materials. Applicants have discovered that the mixing and aerating effectiveness of the present invention is significantly enhanced by the use of tail section 31 , which apparently serves to promote the formation and rearward extension of the rotating airstreams, extending the contact time between the air and contaminated materials. The ability of the present invention to provide extended, interstitial aeration of relatively light contaminated materials has not been possible with prior art apparatus, and represents a significant advance in the art.
A further benefit of the present invention over prior art apparatus is related to the large volume of fresh air, which is continually drawn into chamber 24 and into intimate contact with the contaminated material. This feature is also of significant benefit when contaminated heavier materials which may not be readily entrained in the airstream, and which are mixed primarily by being thrown upwardly and rearwardly due to contact with paddle portions 76 . Even so, with the large amount of air drawn into chamber 24 in the form of high-speed air streams, these heavier materials are contacted with significantly more air under more effective aerating conditions than is possible with known apparatus.
Having illustrated and described the principles of my invention in a preferred embodiment thereof, it should be readily apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles. I claim all modifications coming within the spirit and scope of the accompanying claims. | A method of accelerated remediation or bioremediation of contaminated material such as manure-contaminated material is provided comprising generating a treated contaminated material entraining air stream at a velocity sufficient for entraining the contaminated material therein. The contaminated material is entrained in the air stream and is then microenfractionated to form a microenfractionated contaminated material. Finally, the microenfractionated contaminated material is treated with a least one chemical amendment and/or one biological amendment thereby facilitating the accelerated remediation or bioremediation. The chemical amendment can comprise either a chemical oxidizing agent, a chelating agent, or a metallic reducing agent. The preferred metallic reducing agents are zero valent iron, zero valent zinc, zero valent tin, zero valent manganese and zero valent aluminum. | 8 |
This patent application is a continuation of U.S. patent application Ser. No. 10/858,457, filed on Jun. 1, 2004, now U.S. Pat. No. 7,222,798, which is a continuation of PCT/EP01/014453, filed Dec. 10, 2001. U.S. patent application Ser. No. 10/858,457 and International Patent Application PCT/EP01/014453 are incorporated herein by reference.
OBJECT OF THE INVENTION
The invention relates, in general, to a contact-less identification device comprising a flat conducting structure as an electromagnetic sensor or transducer, and more particularly the invention relates to contactless cards, hybrid cards and radio operated electronic labels and tags. The electromagnetic sensor architecture according to the invention is suitable for all the applications where contactless or hybrid cards are of advantage: high volume paying and toll applications (public transportation, public sport events, person and good identification, access to controlled areas, control of shipment of goods, handling of luggage, product control in chain production environments), etc.
The contact-less identification device has had its performance enhanced by the use of space-filling techniques in the design of its electromagnetic sensor and by the use of a planar capacitor in conjunction with said flat conducting structure.
BACKGROUND OF THE INVENTION
The use of Integrated Circuit (IC) cards has been going on for several years in multiple applications. These applications range, in terms of complexity, from simple token-wise payment applications in private environments to complex and intrinsically secure electronic banking applications including powerful encryption and decryption mechanisms. The interaction of the IC in the card with the reader is made through a set of metallic contacts on the surface of the card.
The public interest in many of today's applications of IC cards is greatly increased if the operation of the card does not require a mechanical interaction of the user with the reading device, thus allowing a much faster operation and an increased roughness of the reader that reflects in an increase in the reliability of the system. This is one of the main reasons for the development, which continues today with new standards being defined and tested, of the contactless operation of IC cards and electronic labels or tags.
There has been some effort put in the development of the electromagnetic sensor to be used in the contactless operation of the cards, but the outcome of this development has been the design of the electromagnetic sensor architectures that are not optimally using the available space within the card or tag.
In low frequency applications, where the coupling of the IC chip to the contactless reader is made via an inductive coupling, the most common solution has been the use of multiple-turn coils (see ( 2 ) in FIG. 10 ), which imply quite a complicated manufacturing process because of the fact that the two ends of the coils are located in different sides with respect to the coil windings (see bridge ( 3 ) in FIG. 10 ). Other simpler solutions such as ( 1 ) are convenient in terms of manufacturing simplicity, but feature a poor in performance.
In applications at higher frequencies, the minimum size of the electromagnetic sensor is determined by the wavelength at the operation frequency, and this fact implies that there is a clear compromise between the performance of the electromagnetic sensor and its size. This compromise has been solved with a limitation of the electromagnetic sensor size to values that are suitable for the final product, at the expense of obtaining electromagnetic sensor performances that are far from optimal.
The set of geometries named Space-Filling Curves (hereinafter SFC) were described in the patent publication WO 01/54225 wherein said space-filling curve was defined as a curve composed by at least ten connected straight segments, wherein said segments are smaller than a tenth of the operating free-space wave length and they are spatially arranged in such a way that none of said adjacent and connected segments form another longer straight segment, wherein none of said segments intersect to each other except optionally at the tips of the curve, wherein the corners formed by each pair of said adjacent segments can be optionally rounded or smoothed otherwise, and wherein the curve can be optionally periodic along a fixed straight direction of space if and only if the period is defined by a non-periodic curve composed by at least ten connected segments and no pair of said adjacent and connected segments define a straight longer segment.
In said document the space-filling curve features a box-counting dimension larger than one, being said box-counting dimension computed as the slope of the straight portion of a log-log graph, wherein such a straight portion is substantially defined as a straight segment over at least an octave of scales on the horizontal axes of the log-log graph.
SUMMARY OF THE INVENTION
The present invention optimizes the performance of the electromagnetic sensor or inductive element used in the contactless cards, hybrid cards and radio frequency operated labels and tags by incorporating a capacitive element connected in parallel to the electromagnetic sensor and by including in the design of the electromagnetic sensor geometry, in the capacitive element geometry, or in both cases the use of space-filling curves (SFC). This allows an optimal utilization of the limited area and volume within the card or label.
This invention is aimed at two main goals: on one hand, it presents a new procedure to improve the performance of electromagnetic sensors designed for inductive coupling, and on the other hand this invention portrays the advantages of using space-filling curves in order to optimize the solution to the performance-size compromise in applications for radiation coupling.
In applications where the radio frequency operation of the device implies an inductive coupling of the sensor to the electromagnetic field generated by the coupling device (the card/label reader), this method allows the optimization the electromagnetic sensor inductance (the main characteristic of the electromagnetic sensor for this type of coupling) in several ways:
First: By the use of SFC, the length of the electromagnetic sensor or inductive element can be substantially increased without exceeding the area allowed in the card or label for the deployment of the electromagnetic sensor, thus increasing the inductance of the electromagnetic sensor or inductive element. Second: By the inclusion of a suitably designed capacitive element connected in parallel to the electromagnetic sensor, the effective inductance that the pair capacitance/inductance presents to the card integrated circuit can be increased without affecting other operation parameters. Third: By the optimization of the inductance value of the electromagnetic sensor it is possible to achieve values of this parameter that are suitable for the operation of the contactless or hybrid card or the radio operated electronic label without having to use multiple-turn loops. This possibility is very interesting because it makes it possible to locate the two connection terminals of the electromagnetic sensor or inductive element in the internal region of the loop without the need to have a conductive path crossing over the loops, thus greatly simplifying the manufacturing techniques. Fourth: because of the above-mentioned features, contactless cards, hybrid cards and radio frequency operated labels and tags can be reduced in size with respect to prior art. Fifth: because of the above-mentioned features, contactless cards, hybrid cards and radio frequency operated labels and tags can be operated from a longer distance to the card detection device compared to those in the prior art.
In applications working at higher frequencies, where the operation of the device implies a radiation coupling (more that an inductive coupling) to the electromagnetic field generated by the coupling device (the card/label reader), this method allows an optimization of the electromagnetic sensor performance by allowing a reduction in the electromagnetic sensor size required for it to operate at the working frequency.
By the use of SFC's in this method, the use of the area where the electromagnetic sensor is being deployed is optimized, as the space-filling curves are able to pack a longer length in a smaller space than conventional curves (as meander-like curves or spiral curves).
In terms of manufacturing suitability, the fact that the electromagnetic sensor or inductive element can be manufactured without the need to cross over conductive paths allows the manufacturing of the electromagnetic sensor with a single layer construction method.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows some particular cases of SFC curves. From an initial curve 2 , other curves 1 , 3 and 4 with more than 10 connected segments are formed. This particular family of curves are named hereafter SZ curves.
FIG. 2 shows a comparison between two prior art meandering lines ( 5 and 6 ) and two SFC periodic curves 7 and 8 , constructed from the SZ curve of drawing 1 . Periodic Curves 5 and 6 are not SFC because their periods are defined with less than ten segments.
FIG. 3 shows a set of SFC curves ( 1 , 2 , 3 , 4 , 5 ) inspired on the Hilbert curve and hereafter named as Hilbert curves.
FIG. 4 shows a particular configuration of an electromagnetic sensor for contactless or hybrid cards. It consists on a flat single-turn rounded-corner rectangular loop with part of the straight segments that form the loop shaped as a SFC curve ( 2 ), and a coplanar flat capacitor connected in parallel to the loop with its gap shaped as a SFC curve ( 4 ). The electromagnetic sensor is connected to the contactless or hybrid card chip at the connection points ( 5 ).
FIG. 5 shows a particular configuration of an electromagnetic sensor for electronic label or tag. It consists on a single turn square flat loop with the straight lines that form the loop shaped as a SFC curve ( 1 ), and a coplanar flat capacitor ( 3 ) connected in parallel to the loop with its gap ( 4 ) shaped as a SFC curve. The electromagnetic sensor is connected to the electronic label chip or electronic tag chip at the connection points ( 2 ).
FIG. 6 shows an example of a dipole electromagnetic sensor for an electronic label of radio frequency operated electronic tag, wherein each of the dipole arms ( 2 ) is shaped as an SFC curve. The electronic label chip or the electronic tag chip is connected at the terminals of the electromagnetic sensor ( 3 ).
FIG. 7 shows a particular configuration of an electromagnetic sensor for contactless or hybrid cards. It consists on a flat single-turn rounded-corner rectangular loop whit part of the straight segments that form the loop shaped as a SFC curve ( 2 ). The electromagnetic sensor is connected to the contactless or hybrid card chip at the connection points ( 3 ).
FIG. 8 shows an example of a loop antenna for an electronic label of radio frequency operated electronic tag, wherein a flat single-turn circular loop has been modified by including radially-oriented SFC curves ( 2 ). The electronic label chip or the electronic tag chip is connected at the terminals of the electromagnetic sensor ( 3 ).
FIG. 9 shows an example of a lop electromagnetic sensor for an electronic label or radio frequency operated electronic tag, where in a flat single-turn square loop has been modified by including a SFC curve ( 3 ). The electronic label chip or the electronic tag chip is connected at the terminals of the electromagnetic sensor ( 4 ).
FIG. 10 shows two examples of current art in the design of electromagnetic sensor for contactless or hybrid cards. A single-turn flat loop ( 1 ) and a multiple-turn flat loop ( 2 ) are presented. The most important detail is the use of a wire running at a higher ( 3 ) level to overcome the need to cross over the loop windings and locate the two electromagnetic sensor contacts in the same side of the loop.
FIG. 11 shows two examples of capacitive elements with space filling curves applied to their shapes. In a parallel plate capacitor ( 1 ), the conductive surfaces ( 3 ) have been shaped a space-filling curve. In a coplanar capacitor ( 2 ), the shape of the gap between the conductive surfaces ( 5 ) has been shaped following a space-filling curve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 4 describes, without any limiting purpose, a preferred embodiment of a contactless identification device in particular a contactless or hybrid card comprising a pace-filling enhanced electromagnetic sensor. It is composed of a single-turn loop connected in parallel to a capacitor. A single-turn flat loop electromagnetic sensor in the shape of a round-cornered rectangle has been modified by replacing some of the straight lines that form the sides of the loop by a space-filling curve (SFC) ( 2 ). In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. A flat coplanar capacitor is connected in parallel to the ends of the loop electromagnetic sensor. The gap of the flat capacitor has been modified by shaping it as a space-filling curve (SFC) ( 4 ). In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The two ends of the loop and the capacitor form the connecting terminals of the electromagnetic sensor ( 5 ).
This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, by electrolytic etching of part of the metal layer of a metal-dielectric sandwich sheet, etc. The electromagnetic sensor is later on integrated in the manufacturing of contactless or hybrid cards ( 6 ). For reasons of external appearance, the electromagnetic sensor is usually integrated in some of the inner layers of the card body. The connecting points of the contactless card chip would be connected to the electromagnetic sensor connecting terminals by means of any of the available procedures, such as for instance using conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals. In a hybrid card application, the connecting points of the hybrid card chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste of some other method to overcome the thickness of the card body between the card surface, where the chip is attached to allow regular contact operation of the card, and the inner layer where the electromagnetic sensor is located.
As it can be appreciated from FIG. 4 , the whole electromagnetic sensor structure is located in one single level, without the need of conducting wires or stripes crossing over other parts of the electromagnetic sensor. This quality allows a very simple manufacturing of the electromagnetic sensor, as only one single layer of printed board, or one single dielectric sheet printed with conductive ink, for instance, need to be used. The fact of having all the electromagnetic sensor connection points at the same level as the rest of the electromagnetic sensor structure allows a simpler industrialization of the mechanical tasks required to connect the contactless chip or implant and connect the hybrid card chip (as drilling, depositing of conductive pastes, soldering, etc.).
This electromagnetic sensor architecture is suitable for all the applications where contactless or hybrid cards are of advantage: high volume paying and toll applications (public transportation, public sport events, etc.), person and good identification (access to controlled areas, control of shipment of goods, handling of luggage, product control in chain production environments, etc.), etc.
FIG. 5 describes another preferred embodiment of a space-filling enhanced electromagnetic sensor for a electronic label or radio frequency operated tag. A square flat loop has been modified by substituting the straight parts of the loop wire by SFC structures ( 1 ). In this particular example, a particular case of a SFC (the SZ curve) has been chosen, but other SFC could be used instead. The two ends of the arms form the connecting terminals of the electromagnetic sensor ( 2 ). At the same time, a flat coplanar capacitor ( 3 ) is shown connected in parallel to the electromagnetic sensor connection terminals. The shape of the gap of the capacitor ( 4 ) has been modified with a SFC curve. In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The capacitance of the capacitor and the inductance of the loop form a parallel resonant circuit. This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc. The antenna is later on incorporated into the manufacturing of the electronic label or radio frequency operated tag. The connecting points of the contactless electronic label chip or radio frequency operated tag chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals. As it can be appreciated from FIG. 5 , the whole electromagnetic sensor structure is located in one single level, without the need of conducting wires or stripes crossing over other parts of the electromagnetic sensor. This quality allows a very simple manufacturing of the electromagnetic sensor, as only one single layer of printed board, or one single dielectric sheet printed with conductive ink, for instance, need to be used. The fact of having all the electromagnetic sensor connection points at the same level as the rest of the electromagnetic sensor structure allows a simpler industrialization of mechanical tasks as drilling, depositing of conductive pastes, soldering, etc. This electromagnetic sensor architecture is suitable for all the applications where radio operated electronic label or electronic tags are of advantage: shopping antitheft applications, contactless intelligent shopping karts, identification of goods and control of stocks in real time, etc.
Another preferred embodiment for a space-filling enhanced electromagnetic sensor for a electronic label or radio frequency operated tag is shown in FIG. 6 . A wire dipole electromagnetic sensor has been modified by substituting the dipole arms ( 2 ) by SFC curves. In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The two ends of the arms form the connecting terminals of the electromagnetic sensor ( 3 ). This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc. The electromagnetic sensor is later on incorporated into the manufacturing of the electronic label or radio frequency operated tag. The connecting points of the contactless electronic label chip or radio frequency operated tag chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals.
FIG. 7 describes another preferred embodiment of a space-filling enhanced electromagnetic sensor for a contactless or hybrid card. A single-turn flat loop in the shape of a round-cornered rectangle ( 2 ) has been modified by replacing some of the straight lines that form the sides of the loop by a space-filling curve (SFC). In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The two ends of the loop form the connecting terminals of the electromagnetic sensor ( 3 ). This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, by electrolytic etching of part of the metal layer of a metal-dielectric sandwich sheet, etc. The electromagnetic sensor is later on integrated in the manufacturing of contactless or hybrid cards. For reasons of external appearance, the electromagnetic sensor is usually integrated in some of the inner layers of the card body. The connecting points of the contactless card chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals. In a hybrid card application, the connecting points of the hybrid card chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste of some other method to overcome the thickness of the card body between the card surface, where the chip is attached to allow regular contact operation of the card, and the inner layer where the electromagnetic sensor is located. With this new single-turn loop electromagnetic sensor architecture the need of wires crossing over other parts of the electromagnetic sensor is eliminated, and therefore the manufacturability of the system is greatly simplified as it is not necessary to include extra layers in the card body to allow the positioning of both electromagnetic sensor connecting terminals at the side of the electromagnetic sensor loop.
FIG. 8 describes another preferred embodiment of a space-filling enhanced electromagnetic sensor for a electronic label or radio frequency operated tag. A single-turn flat circular loop has been modified by including radially-oriented SFC structures ( 2 ) that optimize the distribution of the electromagnetic sensor wire over the surface of the tag in order to maximize the performance of the electromagnetic sensor. In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The two ends of the loop form the connecting terminals of the electromagnetic sensor ( 3 ). This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc. The electromagnetic sensor is later on incorporated into the manufacturing of the electronic label or radio frequency operated tag. The connecting points of the contactless electronic label chip or radio frequency operated tag chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals.
FIG. 9 describes another preferred embodiment of a space-filling enhanced electromagnetic sensor for a electronic label or radio frequency operated tag. A single-turn flat squared loop has been modified by including SFC curves ( 3 ) that optimize the distribution of the electromagnetic sensor wire over the surface of the tag in order to maximize the performance of the electromagnetic sensor. In this particular example, a particular case of a SFC (the Hilbert curve) has been chosen, but other SFC could be used instead. The two, ends of the loop form the connecting terminals of the electromagnetic sensor ( 4 ). This electromagnetic sensor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc. The electromagnetic sensor is later on incorporated into the manufacturing of the electronic label or radio frequency operated tag. The connecting points of the contactless electronic label chip or radio frequency operated tag chip would be connected to the electromagnetic sensor connecting terminals by means of conductive paste, or by direct soldering of the chip connecting points to the electromagnetic sensor terminals.
FIG. 11 describes, without any limiting purpose, two examples of preferred embodiments of capacitors with the application of space-filling curves to their shape. In a parallel plate capacitor ( 1 ) the two parallel conducting surfaces have been shaped following a space-filling curve. The capacitance of the element depends on the thickness of the insulating layer between the parallel plates, the kind of dielectric between the plates, and the effective area of the plates. Each of the two connecting terminals of the element ( 4 ) is connected to one of the plates. This capacitor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc., taking always into account that two conductive layers, separated by an insulating layer of a determined thickness, are required. The final element would be encapsulated with some dielectric material in order to prevent damaging of the parallel plates, while leaving the connection terminals out of the encapsulation. In a coplanar capacitor ( 2 ), and taking into account that the capacitance value is determined mainly by the length and the width of the gap between the coplanar conductive surfaces ( 5 ), the gap has been shaped following a space-filling curve, thus maximizing the length of the gap without increasing the total area of the component. This capacitor can be manufactured, among other techniques, by means of any of the current printed circuit fabrication techniques, by means of conductive ink printed on a dielectric sheet-shaped substrate, etc. In this type of capacitors, only one layer of conductive surface is required, making it especially suitable for mass production. After the shaping of the two coplanar conductive surfaces, the whole structure would be encapsulated with some dielectric material in order to prevent damaging of the conductive surfaces, while leaving the connection terminals ( 4 ) out of the encapsulation. | The invention relates to a contact-less identification device comprising a flat conducting structure as an electromagnetic sensor or transducer, and more particularly the invention relates to contactless cards, hybrid cards and radio operated electronic labels and tags. The electromagnetic sensor architecture according to the invention is suitable for all the applications where contactless or hybrid cards are of advantage: high volume paying and toll applications (public transportation, public sport events, person and good identification, access to controlled areas, control of shipment of goods, handling of luggage, product control in chain production environments), etc. The contact-less identification device according to the invention has had its performance enhanced by the use of space-filling techniques in the design of its electromagnetic sensor and by the use of a planar capacitor in conjunction with said flat conducting structure. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to improvements in a system for cleaning weaving machines, and at the same time, conditioning both the weft and warp yarns to improve both the quality of the fabric and the production of the weaving machines. The invention relates to equipment which is strategically located in those areas of the weaving machine where a significant part of lint, fly, dust, oil, etc. are generated from the warp and weft yarns. Drawing air from the ambient atmosphere in the weave room across the warp yarns just before they are subjected to the violent stresses of forming the warp shed and beating-up the weft makes it possible to reduce the overall humidity in the ambient atmosphere of the weave room and still provide adequate humidity for the conditioning of the warp and weft yarns just prior to their weaving.
Lint, fly and dust (hereinafter referred to as lint) are minute textile fibers, size and other particles which have become separated from the warp yarn or from the weft yarn at a number of different locations, especially where the warp yarns pass through the eyes of the drop wires, the eyes of the heddles, and between the blades of the reed. Lint is also generated from handling of the weft yarn. Such lint tends to collect on the surfaces of the weaving machine and is often incorporated into the fabric inadvertently when a large chunk of such lint falls off the surface of the weaving machine into the warp shed, or is entwined about individual warp or weft yarns and passes into the fabric past the beat-up point, resulting in defective fabric.
Lint is also objectionable because thick layers of the lint forming on the weaving machine surfaces may clog the weaving machine by falling into the weaving machine mechanisms and also collect oil used to lubricate the weaving machine. Furthermore, such large accumulations of this highly flammable material constitutes a fire hazard.
The general cleaning approach in most mills today is to permit the lint to accumulate on the surfaces of the weaving machine and periodically to manually blow such lint off of the weaving machine surfaces onto the floor where it is manually swept up by brooms. This removes a large amount of the lint; however, much of the lint is suspended in the air and lands back on the weaving machines, accumulates on the walls or ceilings, or into the fabric. With the high speed weaving machines used in today's textile plants, much production is lost due to the cleaning of the machines, therefore, it has become necessary to provide means for cleaning the weaving machines continuously to remove the bulk of the lint from the surfaces of the weaving machine while such machines are in operation.
Many attempts have been made to provide for a cleaning mechanism on weaving machines. One such attempt is shown in U.S. Pat. No. 3,627,201. This patent teaches a system which requires that each weaving machine be provided with a downwardly opening hood which fits snugly around the weaving machine and which has an annular rim around the downwardly directed opening thereof. The hood is supported by a mechanism which moves the hood upwardly and away from the operative position. The atmosphere within the hood is said to be maintained at a temperature of 15° to 50° C. by a source of air at that temperature which is supplied through the floor under the weaving machine. An exhaust conduit is also provided for leading the air injected into the hood outwardly after it has circulated around the weaving machine.
There are many problems connected with the device in U.S. Pat. No. 3,627,201. The main problem is that the mechanism is very cumbersome and it is very difficult for the weavers to have access to the weaving machines when broken warp yarns or the like must be repaired. Furthermore, the system disclosed in this patent does little or no cleaning of the surfaces of the weaving machine.
Another attempt was made in U.S. Pat. No. 3,378,998. In this patent, an attempt is made to provide an enclosure for the yarn manipulating mechanism of a weaving machine. A hood is provided for enclosing the upper portion of the weaving machine. This hood has an opening for receiving air. An air input means is connected to the opening in the hood. A central chamber is attached to the hood which encloses the working instrumentalities of the weaving machine at points where the lint is normally discharged and collects. A base enclosure is connected to the central chamber for receiving accumulated lint from the central chamber. A suction and collecting unit is provided for the base enclosure for creating a negative pressure within the hood. The flow of air through the enclosure is said to pass through the machinery and to maintain it substantially free from lint and fly.
The enclosure of U.S. Pat. No. 3,378,998 makes it very difficult for the weaver to get at the weaving mechanism to repair broken warp ends or broken weft ends, as was pointed out above, with regard to the device in U.S. Pat. No. 3,627,201. It should also be pointed out, however, that the air flow provided by both of these patents is generalized and is not concentrated upon the surfaces where the lint is most likely to accumulate. The general flow of air through these all encompassing housings does not remove the lint from the machine surfaces unless the flow is so strong as to cause false stops of the warp motion. While the device in U.S. Pat. No. 3,378,998 might be adequate for conditioning the yarn, it is not adequate for cleaning the surfaces of the weaving machine, and is so burdensome upon the weavers as to preclude its commercial usage.
An early attempt to clean a weaving machine was suggested in U.S. Pat. No. 1,850,502. In this patent, a pan-like device is located below the warp threads between the harnesses and the whip roll for collecting dust, fly and lint by a downdraft of air induced by a suction device, which is connected to the bottom of the pan or receptacle. While this device may collect some fly or lint from the warp yarns there is no suggestion that this device could clean adjacent surfaces of the weaving machine or condition the warp yarn by drawing the ambient atmosphere over and through the warp yarns.
A more recent attempt, which is similar to that of U.S. Pat. No. 1,850,502 is found in U.S. Pat. No. 2,984,263. In the system shown in this patent, a collection system is mounted directly on the weaving machine under the stop motion where it is said that the major fly and lint accumulation takes place. The system of this patent primarily utilizes a directed high velocity stream of air to cause a low pressure area in its surrounding environment, which draws the lint and fly to it and then transmits the lint and fly to a desired collection point. The use of such an air stream is said to be much more efficient than the use of a vacuum, and thus enables the device to collect large portions of lint and fly without the use of large, powerful or expensive equipment. While the device shown in this patent may be an efficient collector of lint which falls onto the surfaces of its baffles, there is nothing in this patent to indicate that the ambient atmosphere of the weave room is drawn across the surfaces of the warp yarn to condition such yarn prior to weaving. Furthermore, no provision is made for cleaning the surfaces of the heddles or harnesses or weft insertion device where large amounts of fly and lint are also generated.
In U.S. Pat. No. 3,451,435 a nozzle body with the shape of a prism is positioned across the warp directly above the reed and adjacent to the heddles of the weaving machine so that air currents containing dust are fanned by the oscillating reed into the inlet of a suction nozzle. While this device may be adequate to remove lightweight dust, fly or lint set into motion already by the reed, it is not adequate for conditioning the warp yarn or the weft yarn, nor does this mechanism suggest or teach any way in which the stop motion can be cleaned and the warp yarn conditioned at the same time.
Another more elaborate attempt to provide a cleaning mechanism for a weaving machine is found in U.S. Pat. No. 3,311,135. In this system, the patentees suggest the provision of one enclosure for the sley and reed and another enclosure for the warp stop motion, and still a third enclosure for the harness mechanism. The patentees suggest that the air within the various enclosures is conditioned and that such housings or enclosures, prevent the escape of lint or fly into the weave room at large. While the enclosures shown and suggested in this patent will enable the maintenance of the desired atmospheric conditions within the chambers and will provide some cleaning of adjacent weaving machine surfaces, it still suffers from the adverse drawback of being very difficult for the weaver to operate the weaving machines with this mechanism in place.
Still another attempt to provide a cleaning mechanism is found in U.S. Pat. No. 3,678,965. In this patent, lint and fly is said to be effectively and efficiently removed by suction box 34 located in the path of the warp yarns between the warp stop motion and the harnesses, with a first suction opening directed towards the warp stop motion, and a second suction opening directed towards the harnesses. Suction means is connected to the suction box for drawing the atmosphere across the warp stop motion and across the harnesses. However, this device is in a position which will necessarily interfere with the weaving operations by the weavers. For example, one merely has to observe FIG. 1 to determine how difficult it would be for the weaver to repair broken warp yarns which requires him to thread-up a new yarn through the stop motion, the hood and the warp heddles. Thus, such handicaps to the weaver makes it very unlikely that this device can function successfully on a commercial basis.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide an improved system for removing lint, size, oil, fly or other contaminating substances from selected surfaces of the weaving machine, while at the same time drawing air from the ambient atmosphere across both the warp and the weft to condition the warp and the weft.
It is another more specific object of the invention to provide a vacuum chamber located beneath and partially surrounding the warp stop motion, in a position where air from the ambient atmosphere is drawn across the warp yarns to condition the same at the warp stop motion, and where such air is also drawn across the surfaces of the drop wires and the supporting bars for the drop wires so that any lint, fly, dust or oil accumulations will be drawn into the vacuum chamber.
It is another object of the invention to provide a vacuum chamber located beneath and partially surrounding the harnesses for drawing air from the ambient atmosphere across the warp at the point where the greatest stress is applied to the warp to condition the warp and to remove therefrom and from the adjacent harness surfaces any accumulations of lint, fly, oil or starch which may interfere with the production of high quality cloth.
Still another object of the invention is to provide means for drawing air from the ambient atmosphere across the weft loading station and the weft yarn to condition the weft yarn and to provide an air flow across the adjacent weaving machine surfaces.
It is a still further object of the invention to provide means for conditioning the warp and the weft yarn simultaneously and for cleaning the surfaces of the weaving machine at the stop motion, at the harnesses, and at the weft loading and picking station of the weaving machine.
These and other objects and advantages of the invention will appear from a description taken hereinafter in connection with the accompanying drawings, illustrating a preferred embodiment of the form of the invention to accomplish these objectives. The invention provides a first vacuum chamber for conditioning the warp yarn at the stop motion and for cleaning the adjacent surfaces of the weaving machine thereat, a second vacuum chamber adjacent to the harnesses for again conditioning the warp yarn at the point it receives its greatest stress and for cleaning the adjacent surfaces of the weaving machine, that is the surfaces of the heddles, the harness frames and the frame members of the weaving machine which supports the harness motion; and a third vacuum chamber that comprises at least one elongated tubular (i.e. hollow) vacuum chamber which extends adjacent to the weft insertion mechanism so as to draw air from the ambient atmosphere across the weft yarn and for drawing air across the weft yarn handling mechanism for cleaning or removing lint, fly, starch, oil, or other materials from the surface of the weft handling mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood when considering the following detailed description in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view of the loading and picking station of a weaving machine showing the rectangular vacuum chamber for conditioning the weft yarn and for cleaning the surfaces of the adjacent picking and loading mechanism;
FIG. 2 is a perspective view of the picking and loading station of a weaving machine showing the tubular vacuum chamber for conditioning the weft yarn and for cleaning the adjacent surfaces of the weaving machine;
FIG. 3 is a perspective view of a vacuum chamber device for cleaning the picking station and for conditioning the weft yarn;
FIG. 4 is a perspective view similar to that of FIG. 3 but showing the other side of the vacuum chamber device;
FIG. 5 is an enlarged end view of the vacuum chamber device for cleaning the loading station and for conditioning the weft yarn taken along line 5--5 of FIG. 2 with some parts broken away for clarity;
FIG. 6 is a top plan view of the warp stop motion and the harnesses on a weaving machine;
FIG. 7 is a rear view of a weaving machine taken along line 7--7 of FIG. 8 with some parts shown in phantom for clarity;
FIG. 8 is a side sectional view of the weaving machine taken along line 8--8 of FIG. 6 and enlarged for clarity; and
FIG. 9 is a rear cross-sectional view of the vacuum chamber at the warp stop motion taken along line 9--9 of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-5 of the drawings, FIGS. 1 and 2 show the loading and picking station of a weaving machine such as those manufactured by Sulzer of Winterthur, Switzerland. Picking station 20 comprises weft yarn guides 23 and 23' for presenting the weft yarn 22 to a gripper shuttle 24. Gripper shuttle 24 fits within a slot 28 formed by upper and lower shuttle guide rails 26.
A closed rectangular vacuum chamber 30 is disposed beneath the picking station and comprises two tubular vacuum chambers 32 and 34 which extend horizontally from the rectangular vacuum chamber 30. Tubular vacuum chambers 32 and 34 are pneumatically sealed at 33 and 35, respectively. Tubular vacuum chambers 32 and 34 are provided with elongated slots 38 and 40, respectively. Slots 38 and 40 are located so as to draw air from the ambient atmosphere of the weave room whenever a partial vacuum is created within tubular vacuum chambers 32 and 34 or rectangular vacuum chamber 30. Thus, as shown more clearly in FIG. 5, slots 38 and 40 are disposed so as to draw air from the ambient atmosphere across different surfaces of the upper and lower guide rails and the projectile, as well as across the weft yarn itself.
Rectangular vacuum chamber 30 also acts as a baffle in that it fits snugly within the available space on the weaving machine beneath the loading station and prevents air from the ambient atmosphere from being drawn along the longitudinal axes of tubular vacuum chambers 32 and 34. This assures that air drawn into said tubular chambers will pass over the weft yarn and the surfaces of said loading station.
The ambient atmosphere in the weave room is one in which the relative humidity is raised to a level which is conducive to proper weaving conditions. Inasmuch as the vacuum chambers of the invention have a partial vacuum created within the vacuum chambers, this causes air from the ambient atmosphere to rush across the weft yarn and the adjacent surfaces of the weaving machine, thereby removing accumulated lint, fly, oil or dust as well as drawing the humidified air across the weft yarn to thereby condition the yarn by increasing the water content thereof at precisely the point at which such yarn is under its greatest strain or stress, i.e. during the weft insertion stage of the weaving process.
The vacuum within the tubular vacuum chamber and rectangular vacuum chamber 30 is created by a suitable pump or vacuum source within the weave room through exhaust pipe 36. Exhaust pipe 36 also directs any lint, fly, size, oil or the like which may be cleaned from the adjacent weaving machine surfaces to a waste recovery station (not shown). This waste recovery station may be provided for each individual weaving machine in the case of an individual drive or individual suction device, or to a central collection station where a central system is used within the weave room.
Referring now to FIGS. 6, 7, 8 and 9, wherein the vacuum chambers for cleaning the warp stop motion and the harnesses and for conditioning the warp yarn are shown in detail. As best seen in FIG. 8, the warp yarns 46 are drawn from a beam (not shown) through a series of drop wires 43 at warp stop motion 42. As is common in such warp stop motions, each warp end is provided with its own drop wire in either a mechanical or electrical warp stop motion. Surrounding the lower portion of the drop wires is a vacuum chamber 50, having four walls, disposed to draw air from the ambient atmosphere of the weave room across the drop wires 43 and the warp yarns 46 for removing all lint, fly, dust, size, oil or the like from the surfaces of the drop wires and for conditioning the warp yarn by concentrating the air from the ambient atmosphere onto such yarn just prior to its being subjected to its greatest stress during the weaving process, i.e. the formation of the warp sheds and the beat-up process. The concentration of the air drawn from the ambient atmosphere on the warp yarn increases the moisture content of the warp yarn over that naturally absorbed by its passage through the unconcentrated ambient atmosphere. This permits a lower relative humidity to be utilized in the ambient atmosphere for a given moisture content in the warp yarn. Vacuum chamber 50 extends the length of the warp stop motion and has walls which partially surround the drop wires. At one end of the vacuum chamber 50 is an exhaust pipe or duct 52. Exhaust duct 52 extends down the side of the weaving machine and extends to a central duct 56 which is connected to a central collection point either on the weaving machine itself or to a central collection system for the entire weave room.
Disposed beneath the harnesses 44 is a generally rectangular vacuum chamber 53. Vacuum chamber 53 is connected to central exhaust duct 56 through exhaust duct 54, as best seen in FIGS. 7 and 9. Where the weaving machines are very wide, vacuum chambers 53 and 50 may be compartmentalized as shown in FIG. 7. That is, different sections of the vacuum chambers may be separately exhausted so as to provide more uniform movement of air from the ambient atmosphere across the warp yarns and the adjacent surfaces of the weaving machine for cleaning the same.
Disposed within vacuum chamber 53 are two baffles 60 and 62. The surfaces of baffles 60 and 62 1ie in planes that extend at an angle to each other and intersect beneath the harnesses. Baffle 60 extends beyond the intersection point, whereas baffle 62 terminates short of baffle 60 so as to provide an exhaust slot or port for exhausting the dust, lint, fly, oil or other foreign material which may be removed from the surfaces of the heddles and harnesses by passage of air from the ambient atmosphere across the surfaces when a partial vacuum is created within the vacuum chamber.
Clearances 64 and 66 are also provided between the upper portions of baffles 60 and 62 and the adjacent surfaces of the walls of the vacuum chamber. The use of baffles 60 and 62 permit a greater velocity movement of air currents across the surfaces of the weaving machine and through the warp yarn for a given energy consumption in the vacuum creating mechanism.
As will be seen in FIG. 8, the positions of baffles 60 and 62 may be adjustable so as to vary the size of slot 68 and clearances 64 and 66. By varying the size of slot 68 and clearances 64 and 66, the velocity of the air drawn from the ambient atmosphere may be varied for a given vacuum within the vacuum chamber.
As illustrated herein, the hollow elongated vacuum chambers adjacent to the picking station may have a round cross-section, a rectangular cross-section, or other cross-section, as desired, and as space permits. For example, the cross-section of any of chambers 30, 32, 34, 50, and 53 may be so varied, as desired. It will also be understood that the means for creating a partial vacuum within the vacuum chambers may be provided for each individual weaving machine with its own individual vacuum pump and motor, or the vacuum creating mechanism may be provided at a central station within the weaving room with suitable connections to each of the weaving machines. The use of a central collection point makes recovery of the waste material more efficient.
In any event, whether the pneumatic source is provided for individually on the weaving machines or by a central location, means are contemplated for turning the vacuum producing means off for individual weaving machines. Means are provided for closing a suitable damper in the exhaust system when the weaving machine ceases operation; for example, in exhaust duct 56, when a central collection system is utilized.
While there is shown and described a preferred embodiment of the invention using specific terms, it is to be understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the appended claims. | In a weaving machine having a warp supply, a harness motion, a reed and filling insertion mechanism, vacuum chambers are provided adjacent to the weft insertion station for drawing air from the ambient atmosphere of the weave room across the weft yarn to concentrate the ambient air from the atmosphere onto such yarn and to condition the same and also to move the air drawn from the ambient atmosphere across the adjacent surfaces of the weaving machine for removing fly, lint, dust, oil or the like from such surfaces, and for preventing such material from becoming incorporated into the fabric. | 3 |
BACKGROUND OF THE INVENTION
This invention relates generally to an integrated circuit package. More particularly, it relates to a method of removing heat in a Ball Lead Integrated Package.
As technology advances, the complexity, functionality and speed of integrated circuit (IC) chips is steadily increasing. Increasingly complex, high speed IC chips often leads to higher power consumption which means more heat is generated that may affect the performance and reliability of these devices. Therefore, separate heat dissipating devices may be subsequently required that are both expensive and time consuming to attach during manufacturing. Further, complex IC chips require correspondingly increasing numbers of electrical interconnections due to their increased functionality. Consequently, high density interconnect package assemblies and the trend toward miniaturization have been principal objectives of semiconductor manufacturers. To this end, there have been semiconductor packages that have been developed with these objectives in mind.
One such example is a Ball Lead Integrated Package (BLIP) that combines ball and lead technologies to achieve high interconnect density (connectability) with a relatively small footprint. Such a device is fully described in the inventors' co-pending application Ser. No. 08/307,270, entitled: "High Density Integrated Circuit Assembly Combining Leadframe Leads With Conductive Traces" filed Sep. 16, 1994 which is incorporated herein by reference in its entirety.
FIG. 1 shows a cross section of a high density BLIP package, generally referred to by reference number 10. The package includes an IC die 12 mounted on a dielectric substrate 14 having a top surface 16 and a bottom surface 18. The package 10 attains high electrical interconnect density through the use of leads 20 and a multiplicity of solder balls 22 attached to the bottom surface 18 of the substrate 14 in the pattern of a grid array. The leads 20 are supported by the top surface of the substrate 14 and attached by way of insulative tape or non-conductive epoxy 24. Both the leads 20 and solder balls 22 serve to provide electrical interconnectivity to the outside world. This is accomplished by coupling die 12 to leads 20 and to conductive traces 28 simultaneously with bonding wires 26. Conductive traces 20 are routed on and through the substrate 14 by way of vias 29, or around the edges for connection with the solder balls 22. A plastic material is molded, in cooperation with the substrate 14, to encapsulate the device and to protect it from the outside environment.
One major disadvantage of the BLIP package is that it is inherently ineffective in removing heat generated internally by the die. The limited thermal performance of the BLIP package therefore may preclude its use for relatively high power/high speed devices. Since the BLIP was proposed as a high density package, the ability to package high heat generating devices without increasing the package size would be very useful. As will be described hereinafter, the present invention provides for a packaging arrangement for the BLIP having high interconnection density with heat extraction capabilities.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objectives and in accordance with purpose of the present invention, an integrated circuit assembly is disclosed herein. In a first embodiment of the present invention, the integrated circuit assembly includes a dielectric substrate with top and bottom surfaces and a group of conductive traces that are disposed at least on the top surface. A group of leads are supported and attached to the top surface of the substrate and are themselves electrically isolated from the conductive traces. An integrated circuit die having a plurality of bond pads is affixed to the substrate. A first group of bonding wires electrically couple associated bond pads on the die to the conductive traces and a second group of bonding wires couple other associated bond pads to the leads. A molding material cooperates with the substrate to seal the die, conductive traces, and inner portions of the leads from the outside environment. A heat sink is engaged with the top surface of the die and integrated into the molding material. The heat sink may be exposed to the ambient environment to facilitate the removal of heat generated by the die. A plurality of solder balls, which are in electrical communication with the conductive traces, are attached to the bottom surface of the substrate.
A method of dissipating heat from an integrated circuit package in accordance to a first embodiment is also described. A heat sink is attached to the top surface of an integrated circuit die in a Ball Lead Integrated Package (BLIP). The BLIP includes a substrate having a top surface with a die is affixed thereon. The substrate has a plurality of conductive traces integrated therein and a plurality of solder balls attached to the bottom surface. An encapsulating material is molded over the heat sink and the substrate assembly such that the heat sink extends through the molding and may be exposed to the ambient environment, thereby conducting heat away from the die.
These and other advantages of the present invention will become apparent upon reading the following detailed descriptions and studying the various figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a diagrammatic cross sectional view of a Ball Lead Integrated Package.
FIG. 2 is a diagrammatic cross sectional view of a Thermal Ball Lead Integrated Package in accordance with a first embodiment of the present invention.
FIG. 3 is a diagrammatic cross sectional view of a dielectric substrate conductive traces of that shown in FIG. 2.
FIG. 4 is a diagrammatic cross sectional view of the substrate in FIG. 3 with leads attached.
FIG. 5 is a diagrammatic cross sectional view of the structure in FIG. 4 with a die attached and wire bonded to the leads and conductive traces.
FIG. 6 is a diagrammatic cross sectional view of the structure in FIG. 5 encapsulated with a molding material and showing a heat sink integrated into the molding and exposed to the environment
FIG. 7 is a diagrammatic cross sectional view of the structure in FIG. 6 with solder balls attached to the substrate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A discussion of FIG. 1 directed towards an IC package was provided in the preceding sections. Attention is now directed to a Thermal BLIP which will address the thermal aspects of the BLIP package. Referring now to FIG. 2, there is shown a Thermal Ball Lead Integrated Package (Thermal BLIP) which is generally designated by reference numeral 32, in accordance with an embodiment of the present invention is shown and described. The Thermal BLIP includes an IC die 34 mounted on a dielectric substrate 36 having a top surface 38 and a bottom surface 40. A multiplicity of leads 42 are attached to and supported by the top surface 38, in conjunction with a series of conductive traces 44, and serve to provide the die 34 with a myriad of electrical interconnects for connection with external components. A first group of bonding wires 46 is used to couple associated bond pads on die 34 to the conductive traces 44, while simultaneously, a second group of bonding wires 48 couple other associated bond pads to the leads 42. This two-tiered wiring arrangement is the basis for the high interconnect density of the BLIP package. A plurality of solder balls 50 are attached to the bottom surface 40 of substrate 36 and are electrically connected to associated conductive traces 44. A molding material 52, in cooperation with the top surface of substrate 38, encapsulates die 34, inner portion of leads 42, and conductive traces 44 for protection from external environment. In accordance with the present invention, a heat sink 54 integrated in molding material 52 is attached to the top surface of the die and extends through the molding 52 where it is exposed to the ambient environment for removing internally generated heat.
FIG. 3 illustrates a dielectric substrate 36 used in the embodiment of FIG. 2 for the present invention. The substrate 36 has two substantially parallel opposing surfaces 38 and 40 that correspond to top and bottom surfaces respectively. The substrate may be made of any dielectric material such as silicon, aluminum oxide or FR4. The substrate itself is non-conducting but has conductive traces 44 integrated into its structure which are designed provide electrical connections between the top and bottom surfaces. This is often accomplished by way of vias (not shown) that run through, or by the traces extending around the edges of the substrate 36.
Referring now to FIG. 4, a set of lead frame leads 42 have been attached to the substrate 36 of FIG. 3. The leads 42 are similar to those leads of a lead frame for a Quad Flat Pack, for example, without a die attach pad and are arranged to provide the die with a additional routing interconnects for communication with the outside world. This increases the interconnect density for coupling one or more integrated circuit die with numerous input/output terminals, as described in the above incorporated BLIP reference. The bottom surface of leads 42 are secured to the top surface 38 of substrate 36 with an adhesive material 41 such as non-conductive epoxy or double-sided insulative tape.
FIG. 5 illustrates the structure in FIG. 4 with a die 34 attached to the substrate 36 and bonded to interconnects which comprise leads 42 and conductive traces 44. A conventional adhesive, used in the semiconductor industry, is used to attach die 34 to substrate 36. A first set of bonding wires 46 are bonded from associated bond pads on the die to conductive traces 44 which complete the first tier of interconnections. A second set of bonding wires simultaneously bond associated bond pads to the leads 42 to complete the second tier. Both sets of bonding wires, which bond the leads 42 and conductive traces 44, are electrically isolated from each other to provide individual paths to the external environment.
Referring next to FIG. 6, the structure of FIG. 5 has been encapsulated with molding material 52. A heat sink 54 has been integrated into the molding material and attached at one end to the top surface of die 34. Attachment to the die is made through the use of a non-conductive epoxy 56 that is not electrically but is thermally conductive, although attachment is not necessary as long as the heat sink 54 is sufficiently engaged with the die surface such that heat transfer can occur. The epoxy, in addition to adhesion, possesses high thermal conductivity which serves to enhance the transfer of heat from die 34 to the heat sink 54. The heat sink 54 may be constructed from a variety of thermally conductive materials such as copper or aluminum. In the preferred embodiment, copper is used because of its relatively high thermal conductivity and low cost. The heat sink used in the Thermal BLIP of FIG. 6, may be of any suitable shape as long as the design sufficiently clears the bonding wires when attached.
In general, the larger the heat sink the more heat it is capable of removing since the surface area of the heat sink is proportional to the heat transfer rate. Therefore its configuration should be taken into account for a particular application. The next step is to mold over the structure with a molding material 52 such that the die, inner portions of the leads 42, conductive traces 44 are sealed from the outside environment. The molding material may be of any suitable encapsulating material used in the semiconductor industry such as ceramics, epoxies, and polymides. Plastic works well as an encapsulant and is used in the present invention since it can be cost effectively applied by injection molding. In the preferred embodiment, the heat sink 54 is exposed through molding 52 to the ambient environment to expedite heat removal but it should be understood that an exposed heat sink is not an absolute requirement.
FIG. 7 shows solder balls 50 attached to the bottom surface 40 of the structure of FIG. 6. As mentioned earlier, the solder balls 50 are electrically connected to the conductive traces 44 by way of vias (not shown) that go through the substrate or by traces extending around the edge of substrate 36. Therefore each conductive trace 44 is electrically isolated from each other and the leads 42 and are connected by a via or substrate edge to an associated solder ball 50. The solder balls 50 are formed in a dense pattern of a grid array along the bottom surface 40 which are arranged to be received on a circuit board having corresponding electrical contacts, for example. This enables the BLIP package to achieve a relatively small footprint. Finally the outer portion of leads 42 are formed into the desired form configuration such as a gull wing, as best seen in FIG. 2, for surface mount applications.
The Thermal BLIP adds effective heat sinking capability to the BLIP package thus providing a package with increased interconnect density with improved thermal performance. That is, the package density is not altered due to the presence of the heat sink, since the heat sink is integrated into the molding. Therefore, the cumbersome, space intensive heat sinks used in the past are no longer needed. Further, Thermal BLIPs permit the use of high power/speed devices to be incorporated without increasing the package size, and therefore, making them well suited for high density circuit board applications.
While the invention has been described primarily in terms of a Ball Lead Integrated package, it should be understood that the invention may be applied to other types of packages as well, such as, Quad Flat Packs, Ball Grid Arrays (BGAs), and assemblies containing substrates. Further while only one embodiment of the present invention has been described in detail, it should be understood that the present invention may be embodied in other specific forms without departing from the spirit or scope of the invention. Particularly, heat sinks that may engaged but not attached to the die or heat sinks that are not externally exposed. The integrated heat sink concept may have applications other than for use in single die packages, for example, in applications where the multiple die are supported in a single package, as described in the Ser. No. 08/307,270 co-pending application mentioned earlier. Therefore, the present examples 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 of the appended claims. | A Thermal Ball Lead Integrated Package (Thermal BLIP) having improved thermal performance over prior art BLIPs is described. The BLIP combines ball and lead technologies to increase the interconnect density of the package but has relatively poor heat extraction capabilities. The Thermal BLIP is particularly well suited for high power and pin count integrated circuit devices. In an embodiment of the present invention, a heat sink is attached to the top surface of the die and extends through the package molding such that it is exposed to the ambient environment. Since the heat sink is integrated into the molding, the package size and footprint is not increased thereby limiting the cost increase of the package. This arrangement enables the use of high power devices in dense circuit board applications. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to cardiology, and more specifically to methods and apparatus for determining alternans data of an electrocardiogram (“ECG”) signal.
[0002] Alternans are a subtle beat-to-beat change in the repeating pattern of an ECG signal. Several studies have demonstrated a high correlation between an individual's susceptibility to ventricular arrhythmia and sudden cardiac death and the presence of a T-wave alternans (“TWA”) pattern of variation in the individual's ECG signal.
[0003] While an ECG signal typically has an amplitude measured in millivolts, an alternans pattern of variation with an amplitude on the order of a microvolt may be clinically significant. Accordingly, an alternans pattern of variation is typically too small to be detected by visual inspection of the ECG signal in its typical recorded resolution. Instead, digital signal processing and quantification of the alternans pattern of variation is necessary. Such signal processing and quantification of the alternans pattern of variation is complicated by the presence of noise and time shift of the alternans pattern of variation to the alignment points of each beat, which can be caused by limitation of alignment accuracy and/or physiological variations in the measured ECG signal. Current signal processing techniques utilized to detect TWA patterns of variation in an ECG signal include spectral domain methods and time domain methods.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In light of the above, a need exists for a technique for detecting TWA patterns of variation in an ECG signal that provides improved performance as a stand-alone technique and as an add-on to other techniques. Accordingly, one or more embodiments of the invention provide methods and apparatus for determining alternans data of an ECG signal. In some embodiments, the method can include determining at least one value representing at least one morphology feature of each beat of the ECG signal and generating a set of data points based on a total quantity of values and a total quantity of beats. The data points can each include a first value determined using a first mathematical function and a second value determined using a second mathematical function. The method can also include separating the data points into a first group of points and a second group of points and generating a feature map by plotting the first group of points and the second group of points in order to assess an alternans pattern of variation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic diagram illustrating a cardiac monitoring system according to the invention.
[0006] FIG. 2 illustrates an ECG signal.
[0007] FIG. 3 is a flow chart illustrating one embodiment of a method of the invention.
[0008] FIG. 4 illustrates a maximum morphology feature.
[0009] FIG. 5 illustrates a minimum morphology feature.
[0010] FIG. 6 illustrates an area morphology feature.
[0011] FIG. 7 illustrates another area morphology feature.
[0012] FIG. 8 illustrates a further area morphology feature.
[0013] FIG. 9 illustrates still another area morphology feature.
[0014] FIG. 10 illustrates a plurality of beats, each beat being divided into a plurality of portions.
[0015] FIG. 11 illustrates a window establishing a size of one of the plurality of portions of FIG. 10 .
[0016] FIG. 12 illustrates a feature matrix.
[0017] FIG. 13 illustrates a decomposition of the feature matrix of FIG. 12 as generated by a principal component analysis.
[0018] FIG. 14 illustrates a plot of values of data corresponding to values representative of a morphology feature.
[0019] FIG. 15 illustrates a determination of difference features using the values plotted in FIG. 14 .
[0020] FIG. 16 illustrates another determination of difference features using the values plotted in FIG. 14 .
[0021] FIG. 17 illustrates a further determination of a difference feature using the values plotted in FIG. 14 .
[0022] FIG. 18 illustrates a feature map of first and second groups of points generated using values of a vector of data.
[0023] FIG. 19 illustrates a feature map generated using values of a vector of data generated by performing a principal component analysis on a feature matrix including the vector of data utilized to generate the feature map of FIG. 18 .
[0024] FIG. 20 illustrates a feature map of first and second groups of points generated using a first mathematical function and a second mathematical function.
[0025] FIG. 21 illustrates a feature map of third and fourth groups of points generated using a third mathematical function and a fourth mathematical function.
[0026] FIG. 22 illustrates a feature map of fifth and sixth groups of points generated using a fifth mathematical function and the sixth mathematical function.
[0027] FIG. 23 illustrates a distance between a first center point of a first group of points and a second center point of a second group of points each plotted to form a feature map.
[0028] FIG. 24 illustrates a spectral graph generated using values of a vector of data.
[0029] FIG. 25 illustrates a spectral graph generated using values of a vector of data generated by performing a principal component analysis on a feature matrix including the vector of data utilized to generate the spectral graph of FIG. 24 .
DETAILED DESCRIPTION
[0030] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.
[0031] In addition, it should be understood that embodiments of the invention include both hardware and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic based aspects of the invention may be implemented in software. As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible.
[0032] FIG. 1 illustrates a cardiac monitoring system 10 according to some embodiments of the invention. The cardiac monitoring system 10 can acquire ECG data, can process the acquired ECG data to determine alternans data, and can output the alternans data to a suitable output device (e.g., a display, a printer, and the like). As used herein and in the appended claims, the term “alternans data” includes TWA data, or any other type of alternans data that is capable of being determined using one or more embodiments of the invention.
[0033] The cardiac monitoring system 10 can acquire ECG data using a data acquisition module. It should be understood that ECG data can be acquired from other sources (e.g., from storage in a memory device or a hospital information system). The data acquisition module can be coupled to a patient by an array of sensors or transducers which may include, for example, electrodes coupled to the patient for obtaining an ECG signal. In the illustrated embodiment, the electrodes can include a right arm electrode RA; a left arm electrode LA; chest electrodes V 1 , V 2 , V 3 , V 4 , V 5 and V 6 ; a night leg electrode RL; and a left electrode leg LL for acquiring a standard twelve-lead, ten-electrode ECG. In other embodiments, alternative configurations of sensors or transducers (e.g., less than ten electrodes) can be used to acquire a standard or non-standard ECG signal.
[0034] A representative ECG signal is schematically illustrated in FIG. 2 . The ECG signal can include [G] beats including beat-one B, through beat-[G] B G where [G] is a value greater than one. As used herein and in the appended claims, a capital letter in brackets represents a quantity, and a capital letter without brackets is a reference character (similar to a typical reference numeral).
[0035] The data acquisition module can include filtering and digitization components for producing digitized ECG data representing the ECG signal. In some embodiments, the ECG data can be filtered using low pass and baseline wander removal filters to remove high frequency noise and low frequency artifacts. The ECG data can, in some embodiments, be filtered by removing arrhythmic beats from the ECG data and by eliminating noisy beats from the ECG data.
[0036] The cardiac monitoring system 10 can include a processor and a memory associated with the processor. The processor can execute a software program stored in the memory to perform a method of the invention as illustrated in FIG. 3 . FIG. 3 is a flow chart of a method of the invention used to determine and display alternans data of an ECG signal. Although the cardiac monitoring system 10 is described herein as including a single processor that executes a single software-program, it should be understood that the system can include multiple processors, memories, and/or software programs. Further, the method of the invention illustrated in FIG. 3 can be performed manually or using other systems.
[0037] As shown in FIG. 3 , the processor can receive (at 100 ) ECG data representing an ECG signal. The acquired ECG data can be received (e.g., from a patient in real-time via the data acquisition module or from storage in a memory device) and can be processed as necessary. The ECG data can represent continuous and/or non-continuous beats of the ECG signal. In one embodiment, the ECG data, or a portion thereof, can be parsed into a plurality of data sets. Each data set can represent a portion of a respective beat B of the ECG signal (e.g., the T-wave portion of a respective beat B of the ECG signal), a portion of a respective odd or even median beat of the ECG signal, a portion of a respective odd or even mean beat of the ECG signal, and the like. The parsed data sets can be saved in an array (e.g., a waveform array). In other embodiments, the ECG data can be saved in a single data set, or alternatively, saved in multiple data sets.
[0038] The processor can determine (at 102 ) a quantity [C] of values W representing a quantity [D] of morphology features F of a beat B (e.g., beat-one B 1 ) of a quantity [G] beats, where [C] and [D] are each a quantity greater than or equal to one. In some embodiments, a single value W is determined for each morphology feature F (i.e., the quantity of [C] is equal to the quantity of [D]). However, in some embodiments, multiple values W are determined for a single morphology feature F and/or a single value W is determined for multiple morphology features F. Determining a quantity [C] of values W representing a quantity [D] of morphology features F can be repeated for a quantity [H- 1 ] of beats of the quantity [G] of beats represented in the collected ECG data where a quantity [H] is greater than or equal to one and less than or equal to the quantity [G].
[0039] In some embodiments, any morphology features F of the beats B can be determined. FIGS. 4-9 illustrate some examples of such morphology features F. FIG. 4 illustrates a maximum morphology feature (i.e., the maximum value of the data set representing the T-wave portion of a respective beat). FIG. 5 illustrates a minimum morphology feature (i.e., the minimum value of the data set representing the T-wave portion of a respective beat). FIG. 6 illustrates an area morphology feature (i.e., the area between a curve formed by the data set representing the T-wave portion of a respective beat and a baseline established by the minimum value of the data set). FIG. 7 illustrates another area morphology feature (i.e., the area between a curve formed by the data set representing the T-wave portion of a respective beat and a baseline established by the maximum value of the data set and a point of the data set representing the maximum up-slope of the curve). FIG. 8 illustrates still another area morphology feature (i.e., the area between a curve formed by the data set representing the T-wave portion of a respective beat and a baseline established by the minimum value of the data set and a point of the data set representing the maximum down-slope of the curve). FIG. 9 illustrates yet another area morphology feature (i.e., the area between a curve formed by the data set representing the T-wave portion of a respective beat and a baseline established by a point of the data set representing the maximum up-slope of the curve and a point of the data set representing the maximum down-slope of the curve). Other types of maximum, minimum, and area morphology features can also be used.
[0040] Other examples of morphology features that can be used include amplitude morphology features (e.g., an amplitude of a point representing the maximum down-slope of the curve formed by the data set representing the T-wave portion of a respective beat) and slope morphology features (e.g., a maximum positive slope of the curve formed by the data set representing the T-wave portion of a respective beat). Another example is mathematical model morphology features obtained by determining values representing a mathematical model of the curve formed by the data set representing the T-wave portion of a respective beat using, for example, a Gaussian function model, a power of Cosine function model, and/or a bell function model. A further example is time interval morphology features (e.g., a time interval between a maximum value and a minimum value of the data set representing a T-wave portion of a respective beat). Still another example is shape correlation morphology features obtained by determining a value representing a shape correlation of the curve formed by the data set representing the T-wave portion of a respective beat using, for example, a cross-correlation method and/or an absolute difference correlation method. An additional example is ratio morphology features (e.g., a ST:T ratio). Any other suitable morphology feature can be used in other embodiments of the invention. In some embodiments, as discussed above, the morphology feature can be determined using values of the data set(s) of the ECG data. In other embodiments, the morphology features can be determined using values representing the values of the data set(s) of the ECG data (e.g., a morphology feature of the first derivative of the curve formed by a respective data set).
[0041] Morphology features can be determined using an entire parsed data set as illustrated in FIGS. 4-9 , or alternatively, using a portion thereof as illustrated in FIGS. 10 and 11 . As shown in FIG. 10 , each of the beats B can be divided up in a plurality of portions. The center of each portion can be defined by a vertical divider line. As shown in FIG. 11 , a window can be established to define the size of the portion. The window can include a single value of the data set (e.g., a value representing the point where the divider line crosses the curve formed by the data set), or values of the data set representing any number of points adjacent the intersection of the curve and the divider line.
[0042] As shown in FIG. 3 , the processor can generate (at 104 ) a feature matrix. As used herein and in the appended claims, the term “matrix” includes any table of values. The generated feature matrix can include a quantity [C] of values W representing each of the quantity [D] of morphology features F for each of the quantity [H] of beats B (i.e., the feature matrix includes a quantity [C]×[H] of values W). Each value W can directly represent the determined morphology feature F (e.g., the actual value of the determined area morphology feature), or can indirectly represent the determined morphology feature (e.g., a normalized value of the determined area morphology feature).
[0043] A representative column-wise feature matrix A is illustrated in FIG. 12 . The feature matrix A can include [C] columns and [H] rows. The feature matrix A can use the columns to represent the quantity [D] of morphology features F (i.e., each column includes a quantity [H] of values W of the same morphology feature as determined for each of the quantity [H] of beats B), and the rows to represent the beats B (i.e., each row includes a quantity [C] of values representing the quantity [D] of morphology features for each of the quantity [H] of beats). The values W of the morphology features F can be represented in the illustrated feature matrix A using the notation W I B J and F I B J where I is a value between one and [C], the quantity of [C] being equal to the quantity of [D], and J is a value between one and [H]. In other embodiments, the feature matrix A can be arranged in other suitable manners. In yet other embodiments, the values W representing the morphology features F can be saved for later processing.
[0044] As shown in FIG. 3 , the processor can preprocess (at 106 ) the feature matrix A. In some embodiments, a principal component analysis (PCA) can be performed on the feature matrix A. PCA involves a multivariate mathematical procedure known as an eigen analysis which rotates the data to maximize the explained variance of the feature matrix A. In other words, a set of correlated variables are transformed into a set of uncorrelated variables which are ordered by reducing variability, the uncorrelated variables being linear combinations of the original variables. PCA is used to decompose the feature matrix A into three matrices, as illustrated in FIG. 13 . The three matrices can include a matrix U, a matrix S, and a matrix V.
[0045] The matrix U can include the principal component vectors (e.g., the first principal component vector u 1 , the second principal component vector u 2 . . . , the pth principal component vector u p ). The principal component vectors are also known as eigen vectors. The first principal component vector us can represent the most dominant variance vector (i.e., the first principal component vector u 1 represents the largest beat-to-beat variance), the second principal component vector u 2 can represent the second most dominant variance vector, and so on.
[0046] The S Matrix can include the principal components (e.g., the first principal component S 1 , the second principal component S 2 , . . . , the pth principal component S p ). The first principal component S 1 can account for as much of the variability in the data as possible, and each succeeding principal component S can account for as much of the remaining variability as possible. The first principal component S 1 can be used to determine alternans data (e.g., the square-root of the first PCA component S 1 can provide an estimation of the amplitude of the most dominant alternans pattern of variation). In some embodiments, the second principal component S 2 and the third principal component S 3 can also provide useful alternans data.
[0047] The matrix V is generally known as the parameter matrix. The matrix V can be raised to a power of T. In other embodiments, the preprocessing of the feature matrix A can include other types of mathematical analyses.
[0048] The robustness of the preprocessing of the feature matrix A can be enhanced by increasing the quantity of [H] as the quantity of [D] increases. In other words, an increase in the number of morphology features F represented in the feature matrix A generally requires a corresponding increase in the number of beats B for which the morphology features F are being determined. The correspondence between the quantities of [D] and [H] is often based on the dependency between each of the [D] morphology features F. In some embodiments, the quantity of [H] is greater than or equal to 32 and less than or equal to 128. In other embodiments, the quantity of [H] is less than 32 or greater than 128. In some embodiments, the value of [H] is adaptively changed in response to a corresponding change in the level of noise in the measured ECG signal.
[0049] As shown in FIG. 3 , the processor can determine (at 108 ) [E] points L using data corresponding to at least some of the values W, [E] being a quantity greater than or equal to one. The data corresponding to the values W can include at least one value W, at least one value of a principal component vector (e.g., the first principal component vector u 1 ), and/or at least one value of any other data that corresponds to the values W. Each point L can include a first value (e.g., one of an X-value and a Y-value) determined using a first mathematical function Feature(beat+[N]), and a second value (e.g., the other of the X-value and the Y-value) determined using a second mathematical function Feature(beat), [N] being a quantity greater than or equal to one. Each of the first and second values of the points L represents a feature of the data corresponding to the values W. In the illustrated embodiment, the feature is a difference feature Q (i.e., the difference in amplitude between two values of the data corresponding to the values W as specified by the respective mathematical function). In other embodiments, the first and second values of the points L can represent another difference features (e.g., an absolute difference feature, a normalized difference feature, a square-root difference feature, and the like), or any other mathematically-definable feature of the data corresponding to the values W. For example, the feature can include a value feature where the feature is equal to a specified value of the data corresponding to the determined values W.
[0050] Equations 1 and 2 shown below define an example of the mathematical functions Feature(beat+[N]) and Feature(beat), respectively. The first values of the points L determined using the mathematical function Feature(beat+[N]) can represent a difference feature Q K+[N] and the second values of the points L determined using the mathematical function Feature(beat) can represent the difference feature Q K , where K is a value equal to a beat (i.e., the beat for which the respective mathematical function is being used to determine either the first or second value of a point L).
Feature(beat+[ N ])= W (beat+2[N]) −W (beat+[N]) =Q K+[N] [e1]
Feature(beat)= W (beat+[N]) −W (beat) =Q K [e2]
[0051] Tables 1-3 shown below represent the determination of points L using the mathematical functions Feature(beat+[N]) and Feature(beat) as defined in Equations 1 and 2 for [N]=1, 2, and 3, respectively. Equations 3 and 4 shown below define the mathematical functions Feature(beat+[N]) and Feature(beat) for [N]=1.
Feature(beat+1)= W (beat+2) −W (beat+1) =Q K+1 [e3]
Feature(beat)= W (beat+1) −W (beat) =Q K [e4]
Equations 5 and 6 shown below define the mathematical functions Feature(beat+[N]) and Feature(beat) for [N]=2.
Feature(beat+2) =W (beat′4) −W (beat+2) =Q K+2 [e5]
Feature(beat)= W (beat+2) −W (beat) =Q K [e6]
Equations 7 and 8 shown below define the mathematical functions Feature(beat+[N]) and Feature(beat) for [N]=3.
Feature(beat+3)= W (beat+6) −W (beat+3) =Q K+3 [e7]
Feature(beat)= W (beat+3) −W (beat) =Q K [e8]
[0052] As shown by Equations 3-8, the offset between the difference feature Q K+[N] and the difference feature Q K is dependent on the value of [N]. For [N]=l, the first value of the point L is determined by finding the difference between the value W of the second next beat B I+2 and the value W of the next beat B I+1 , while the second value of the point L is determined by finding the difference between the value W of the next beat B I+1 and the value W of the current beat B I . For [N]=2, the first value of the point L is determined by finding the difference between the value W of the fourth next beat B I+4 and the value W of the second next beat B I+2 , while the second value of the point L is determined by finding the difference between the value W of the second next beat B I+2 and the value W of the current beat B I . For [N]=3, the first value of the point L is determined by finding the difference between the value W of the sixth next beat B I+6 and the value W of the third next beat B I+3 , while the second value of the point L is determined by finding the difference between the value W of the third next beat B I+3 and the value W of the current beat B I . Accordingly, the first values of the points L determined using the first mathematical function Feature(beat+[N]) are offset relative to the second values of the points L determined using the second mathematical function Feature(beat) by a factor of [N]. For example, for [N]=1, the first mathematical function Feature(beat+[N]) determines Feature(2) . . . Feature(Z+1) for beat-one B, through beat-(Z) B Z , while the second mathematical function Feature(beat) determines Feature(1) . . . Feature(Z) for beat-one B 1 through beat-(Z) B Z ; for [N]=2, the first mathematical function Feature(beat+[N]) determines Feature(3) . . . Feature(Z+2) for beat-one B 1 through beat-(Z) B Z , while the second mathematical function Feature(beat) determines Feature(1) . . . Feature(Z) for beat-one B 1 through beat-(Z) B Z ; for [N]=3, the first mathematical function Feature(beat+[N]) determines Feature(4) . . . Feature(Z+3) for beat-one B 1 through beat-(Z) B Z while the second mathematical function Feature(beat) determines Feature(1) . . . Feature(Z) for beat-one B 1 through beat-(Z) B Z . This offset relationship between the first values of the points L determined using the first mathematical function Feature(beat+[N]) and the second values of the points L determined using the second mathematical function Feature(beat) is further illustrated in Tables 1-3. In Tables 1-3 shown below, the “Beat” column can represent respective beats B of the ECG signal and the “Feature Value” column can represent a value W of a morphology feature F of the corresponding respective beat B (e.g., an area morphology feature). As discussed above, the points L can be generated using values of other data corresponding to the determined values W. Also in Tables 1-3, an asterisk (*) represents an undetermined value of the point L (i.e., a value of the point L for which feature values W corresponding to beats B subsequent to the listed beats B 1 -B 12 are required to determine the value of the point L), “f(b+N)” represents the mathematical function Feature(beat+[N]), and “f(b)” represent the mathematical function Feature(beat). Each point L shown in Tables 1-3 includes an X-value determined using the first mathematical function Feature(beat+[N]) and a Y-value determined using the second mathematical function Feature(beat).
TABLE 1 [N] = 1 Feature f(b + N) = W (b+2N) − W (b+N) f(b) = W (b+N) − W (b) Feature Map Beat Value f(b + 1) = W (b+2) − W (b+1) f(b) = W (b+1) − W (b) Point Group 1 2 f(2) = 3 − 5 = −2 f(1) = 5 − 2 = 3 (−2, 3) A 2 5 f(3) = 6 − 3 = 3 f(2) = 3 − 5 = −2 (3, −2) B 3 3 f(4) = 2 − 6 = −4 f(3) = 6 − 3 = 3 (−4, 3) A 4 6 f(5) = 4 − 2 = 2 f(4) = 2 − 6 = −4 (2, −4) B 5 2 f(6) = 3 − 4 = −1 f(5) = 4 − 2 = 2 (−1, 2) A 6 4 f(7) = 7 − 3 = 4 f(6) = 3 − 4 = −1 (4, −1) B 7 3 f(8) = 3 − 7 = −4 f(7) = 7 − 3 = 4 (−4, 4) A 8 7 f(9) = 5 − 3 = 2 f(8) = 3 − 7 = −4 (2, −4) B 9 3 f(10) = 3 − 5 = −2 f(9) = 5 − 3 = 2 (−2, 2) A 10 5 f(11) = 7 − 3 = 4 f(10) = 3 − 5 = −2 (4, −2) B 11 3 f(12) = W 13 − 7 = * f(11) = 7 − 3 = 4 (*, 4) A 12 7 f(13) = W 14 − W 13 = * f(12) = W 13 − 7 = * (*, *) B
[0053]
TABLE 2
[N] = 2
Feature
f(b + N) = W (b+2N) − W (b+N)
f(b) = W (b+N) − W (b)
Feature Map
Beat
Value
f(b + 2) = W (b+4) − W (b+2)
f(b) = W (b+2) − W (b)
Point
Group
1
2
f(3) = 2 − 3 = −1
f(1) = 3 − 2 = 1
(−1, 1)
A
2
5
f(4) = 4 − 6 = −2
f(2) = 6 − 5 = 1
(−2, 1)
B
3
3
f(5) = 3 − 2 = 1
f(3) = 2 − 3 = −1
(1, −1)
A
4
6
f(6) = 7 − 4 = 3
f(4) = 4 − 6 = −2
(3, −2)
B
5
2
f(7) = 3 − 3 = 0
f(5) = 3 − 2 = 1
(0, 1)
A
6
4
f(8) = 5 − 7 = −2
f(6) = 7 − 4 = 3
(−2, 3)
B
7
3
f(9) = 3 − 3 = 0
f(7) = 3 − 3 = 0
(0, 0)
A
8
7
f(10) = 7 − 5 = 2
f(8) = 5 − 7 = −2
(2, −2)
B
9
3
f(11) = W 13 − 3 = *
f(9) = 3 − 3 = 0
(*, *)
A
10
5
f(12) = W 14 − 7 = *
f(10) = 7 − 5 = 2
(*, *)
B
11
3
f(13) = W 15 − W 13 = *
f(11) = W 13 − 3 = *
(*, *)
A
12
7
f(14) = W 16 − W 14 = *
f(12) = W 14 − 7 = *
(*, *)
B
[0054]
TABLE 3
[N] = 3
Feature
f(b + N) = W (b+2N) − W (b+N)
f(b) = W (b+N) − W (b)
Feature Map
Beat
Value
f(b + 3) = W (b+6) − W (b+3)
f(b) = W (b+3) − W (b)
Point
Group
1
2
f(4) = 3 − 6 = −3
f(1) = 6 − 2 = 4
(−3, 4)
A
2
5
f(5) = 7 − 2 = 5
f(2) = 2 − 5 = −3
(5, −3)
B
3
3
f(6) = 3 − 4 = −1
f(3) = 4 − 3 = 1
(−1, 1)
A
4
6
f(7) = 5 − 3 = 2
f(4) = 3 − 6 = −3
(2, −3)
B
5
2
f(8) = 3 − 7 = −4
f(5) = 7 − 2 = 5
(−4, 5)
A
6
4
f(9) = 7 − 3 = 4
f(6) = 3 − 4 = −1
(4, −1)
B
7
3
f(10) = W 13 − 5 = *
f(7) = 5 − 3 = 2
(*, *)
A
8
7
f(11) = W 14 − 3 = *
f(8) = 3 − 7 = −4
(*, *)
B
9
3
f(12) = W 15 − 7 = *
f(9) = 7 − 3 = 4
(*, *)
A
10
5
f(13) = W 16 − W 13 = *
f(10) = W 13 − 5 = *
(*, *)
B
11
3
f(14) = W 17 − W 14 = *
f(11) = W 14 − 3 = *
(*, *)
A
12
7
f(15) = W 18 − W 15 = *
f(12) = W 15 − 7 = *
(*, *)
B
[0055] FIG. 14 illustrates a plot of the feature values from Tables 1-3 for beat-one B 1 through beat-seven B 7 where each peak and each valley of the plot can represent a respective feature value W (e.g., value-one WI which represents beat-one B 1 , value-two W 2 which represents beat-two B 2 , . . . , value-seven W 7 which represents beat-seven B 7 ).
[0056] FIG. 15 illustrates for [N]=1 how the mathematical functions Feature(beat+[N]) and Feature(beat) determine the first and second values of the points L which represent the difference features Q K and Q K+1 . For [N]=1, the seven values (i.e., value-one W 1 through value-seven W 7 ) generate six difference features (i.e., difference feature-one Q 1 through difference feature-six Q 6 ). Referring to Table 1, the first mathematical function generates difference feature-two Q 2 through difference feature-six Q 6 for beat-one B 1 through beat-five B 5 , respectively, using the seven values, and the second mathematical function generates difference feature-one Q 1 through difference feature-six Q 6 for beat-one B 1 through beat-six B 6 , respectively, using the seven values.
[0057] The difference feature Q is illustrated in FIG. 15 as dotted-line arrows extending between two specified values of the plot of FIG. 14 . As an example, to determine difference feature-three Q 3 (i.e., the first value of the point L as determined by the first mathematical function Feature(beat+[N]) for beat-two B 2 , the second value of the point L as determined by the second mathematical function Feature(beat) for beat-three B 3 ), the difference can be found between value-four W 4 which represents beat-four B 4 and value-three W 3 which represents beat-three B 3 . Similarly, to determine difference feature-six Q 6 (i.e., the first value of the point L as determined by the first mathematical function Feature(beat+[N]) for beat-two B 5 , the second value of the point L as determined by the second mathematical function Feature(beat) for beat-six B 6 ), the difference can be found between value-four W 7 which represents beat-seven B 7 and value-six W 6 which represents beat-six B 6 .
[0058] FIG. 16 illustrates for [N]=2 how the mathematical functions Feature(beat+[N]) and Feature(beat) determine the first and second values of the points L which represent the difference features Q K and Q K+2 . For [N]=2, the seven values (i.e., value-one W 1 through value-seven W 7 ) generate five difference features (i.e., difference feature-one Q 1 through difference feature-five Q 5 ). Referring to Table 2, the first mathematical function generates difference feature-three Q 3 through difference feature-five Q5 for beat-one B 1 through beat-three B 3 , respectively, using the seven values, and the second mathematical function generates difference feature-one Q 1 through difference feature-five Q 5 for beat-one B 1 through beat-five B 5 , respectively, using the seven values.
[0059] The difference feature Q is illustrated in FIG. 16 as dotted-line arrows extending between two specified values of the plot of FIG. 14 . As an example, to determine difference feature-three Q 3 (i.e., the first value of the point L as determined by the first mathematical function Feature(beat+[N]) for beat-one B 1 , the second value of the point L as determined by the second mathematical function Feature(beat) for beat-three B 3 ), the difference can be found between value-five W 5 which represents beat-five B 5 and value-three W 3 which represents beat-three B 3 . Similarly, to determine difference feature-five Q 5 (i.e., the first value of the point L as determined by the first mathematical function Feature(beat+[N]) for beat-three B 3 , the second value of the point L as determined by the second mathematical function Feature(beat) for beat-five B 5 ), the difference can be found between value-four W 7 which represents beat-seven B 7 and value-five W 5 which represents beat-five B 5 .
[0060] FIG. 17 illustrates for [N]=3 how the mathematical functions Feature(beat+[N]) and Feature(beat) determine the first and second values of the points L which represent the difference features Q K and Q K+3 . For [N]=3, the seven values (i.e., value-one W 1 through value-seven W 7 ) generate four difference features (i.e., difference feature-one Q 1 through difference feature-four Q 4 ). Referring to Table 3, the first mathematical function generates difference feature-four Q 4 for beat-four B 4 using the seven values, and the second mathematical function generates difference feature-one Q 1 through difference feature-four Q 4 for beat-one B 1 through beat-four B 4 , respectively, using the seven values.
[0061] The difference feature Q is illustrated in FIG. 17 as dotted-line arrows extending between two specified values of the plot of FIG. 14 . As an example, to determine difference feature-three Q 4 (i.e., the first value of the point L as determined by the first mathematical function Feature(beat+[N]) for beat-one B 1 , the second value of the point L as determined by the second mathematical function Feature(beat) for beat-three B 3 ), the difference can be found between value-seven W 7 which represents beat-seven B 7 and value-four W 4 which represents beat-four B 4 .
[0062] As shown by the “Group” column of Tables 1-3, each point L can be assigned to a respective group (e.g., group A or group B). The points L representing each odd beat (e.g., beat-one B 1 , beat-three B 3 , . . . , beat-eleven B 11 ) can be assigned to a first group (i.e., group A), and the points representing each even beat (e.g., beat-two B 2 , beat-four B 4 , . . . , beat-twelve B 12 ) can be assigned to a second group (i.e., group B). The points L can be assigned to group A and group B in this manner to represent a proposed odd-even alternans pattern of variation (i.e., ABAB . . .). In other embodiments, the points L can be alternatively assigned to groups to represent other proposed alternans patterns of variation (e.g., AABBAABB . . . , AABAAB . . . , and the like).
[0063] As shown in FIG. 3 , the processor can plot (at 110 ) a feature map [e.g., a feature map of Feature(beat+[N]) versus Feature(beat)]. Both groups of points L (e.g., group A and group B) can be plotted on the same axis to generate the feature map. The polarity of the differences of the group A points are inverted relative to the polarities of the differences of the group B points. As a result, plotting the points L determined using the mathematical functions Feature(beat) and Feature(beat+[N]) as defined by Equations I and 2 can accentuate any difference between the values specified by the mathematical functions Feature(beat) and Feature(beat+[N]). The inverted polarity of the differences between the first and second groups is illustrated in FIGS. 15-17 where the direction of the dotted-line arrows that represent the difference features Q alternates between adjacent difference features Q.
[0064] The feature map provides a visual indication of the divergence of the two groups of points, and thus the existence of a significant alternans pattern of variation. If there is a significant ABAB . . . alternans pattern of variation, the two groups of points will show separate clusters on the feature map (for example, as shown in FIGS. 20 and 22 ). If there is not a significant ABAB . . . alternans pattern of variation, the feature map will illustrate a more random pattern of points from the two groups (for example, as shown in FIG. 21 ).
[0065] FIGS. 18 and 19 illustrate two examples of feature maps. The [E] points plotted to generate the feature maps of FIGS. 18 and 19 were determined using ECG data representative of an ECG signal having a 5 microvolt TWA pattern of variation, 20 microvolts of noise, and 20 milliseconds of offset, where [H] is equal to 128. The first and second groups of points can be distinguished by the markers utilized to represent the points of the group (i.e., the first group of points, group A, can include asterisks shaped markers, and the second group of points, group B, can include round markers). Lines can be used to connect sequential markers of each group (e.g., for group A, point-two P 2A can be connected to each of point-one P 1A and point-three P 3A by lines).
[0066] The feature map of FIG. 18 illustrates a plot of points determined using values directly from the feature matrix A (i.e., the feature matrix A was not preprocessed using a principal component analysis or other mathematical analysis). As illustrated in FIG. 18 , the points of the first and second groups are intermixed (i.e., the feature map illustrates a random pattern of the points from the two groups). Accordingly, the feature map of FIG. 18 does not illustrate the presence of a significant divergence of the two groups of points, and thus, does not indicate the existence of a significant alternans pattern of variation.
[0067] The feature map of FIG. 19 illustrates a plot of points determined using values of a first principal vector u 1 . The first principal vector u 1 is a result of a principal component analysis performed on the same feature matrix A from which the values used to determine the points L plotted in FIG. 18 were obtained. As illustrated in FIG. 19 , although the first and second groups of points are partially overlapped, the first group of points is primarily positioned in the upper-left quadrant of the feature map and the second group of points is primarily positioned in the lower-right quadrant of the feature map. Accordingly, the feature map of FIG. 19 appears to illustrate the presence of a significant divergence of the two groups of points, and thus, a significant alternans pattern of variation may exist.
[0068] Although FIGS. 18 and 19 illustrate the same ECG data, the feature map of FIG. 19 indicates the existence of an alternans pattern of variation, while the feature map of FIG. 18 does not. The effect of noise and time shift in the measured ECG signal on the determined alternans data is clearly indicated by the feature maps of FIGS. 18 and 19 . Preprocessing the feature matrix A increases the robustness of the determination of alternans data by limiting the effect of noise and time shift in the measured ECG signal.
[0069] In some embodiments, multiple feature maps can be generated for various quantities of [N] using the same set of values (e.g., the feature maps for [N]=1, 2, and 3, respectively, can be generated using the points determined in Tables 1-3). The display of multiple feature maps can further verify the existence of a significant alternans pattern of variation for the proposed alternans pattern of variation (e.g., a ABAB . . . alternans pattern of variation).
[0070] FIGS. 20-22 illustrate feature maps for [N]=1, 2, and 3, respectively, where the points plotted in each of the feature maps were determined using the same set of values. The divergence of the first and second groups of points in the feature maps of FIGS. 20 and 22 in combination with the lack of divergence of the first and second groups of points in the feature map of FIG. 21 provides visual evidence that the proposed ABAB . . . alternans pattern of variation is correct.
[0071] The operator can change the proposed alternans pattern of variation (i.e., change the grouping of the points to a different alternans pattern of variation) if the feature maps for [N]=1, 2, and 3 do illustrate differing divergence patterns for [N]=1 and 3 and [N]=2, respectively. For example, if the two groups of points diverge in the feature map for [N]=1 and 2, but not for the feature maps of [N]=3, the ECG signal represented by the values used to determine the points for the feature maps does not represent the proposed ABAB . . . alternans pattern of variation. However, the ECG signal can include a different alternans pattern of variation. Reassignment of the [E] points to different groups can be used to test a different proposed alternans pattern of variation.
[0072] As shown in FIG. 3 , the processor (at 112 ) can statistically analyze the data plotted in the feature map. Although the feature map provides a visual indication of the existence of a significant alternans pattern of variation, the feature map does not provide a quantitative measure of the confidence level of the alternans pattern of variation. Accordingly, the data plotted in the feature map, or similar types of data that are not plotted in a feature map, can be statistically analyzed to provide such quantitative measures of the confidence level of the alternans pattern of variation.
[0073] In some embodiments, a paired T-test can be performed on the first and second groups of points. A paired T-test is a statistical test which is performed to determine if there is a statistically significant difference between two means. The paired T-test can provide a p-value (e.g., p=0.001). In one embodiment, the confidence level is increased (i.e., a significant alternans pattern of variation exists) when the p-value is less than 0.001. In other embodiments, other suitable threshold levels can be established.
[0074] In some embodiments, a cluster analysis (e.g., a fuzzy cluster analysis or a K-mean cluster analysis) can be performed on the [E] points to determine a first cluster of points and a second cluster of points. The cluster analysis can also generate a first center point for the first cluster and a second center point for the second cluster. The first and second clusters of points can be compared with the first and second groups of points, respectively. A determination can be made of the number of clustered points that match the corresponding grouped points. For example, if point-one L 1 and point-two L 2 are clustered in the first cluster, point-three L 3 and point-four L 4 are clustered in the second cluster, point-one L 1 , point-two L 2 , and point-three L 3 can be grouped in the first group, and point-four L 4 can be grouped in the second group. Clustered point-three L 3 does not correspond to grouped point-three L 3 , thereby resulting in a 75% confidence level. The confidence level can represent the percentage of clustered points that match the corresponding grouped points. In one embodiment, a confidence level about 90% can be a high confidence level, a confidence level between 60% and 90% can be a medium confidence level, and a confidence level below 60% can be a low confidence level. In other embodiments, the thresholds for the high, medium, and/or low confidence levels can be other suitable ranges of percentages or values.
[0075] As shown in FIG. 3 , the processor can determine (at I 14 ) an estimate of an amplitude of the alternans pattern of variation. As discussed above, in one embodiment, the square-root of a principal component (e.g., the first principal component SI) can be used to provide an estimate of the amplitude. In other embodiments, a distance can be determined between a first center point of a first group of points and a second center point of a second group of points. The center points can include the center points of the first and second groups of points A and B as determined using a mathematical analysis (e.g., by taking the mean or median of the values of the points for each respective group), the center points provided by the Paired T-test, the center points provided by the cluster analysis, or any other determined center points that represent the ECG data.
[0076] FIG. 23 illustrates a distance measurement between the first and second center points. The distance can be determined using Equation 9 shown below, where the first center point includes an X-value X 1 and a Y-value Y 1 and the second center point includes an X-value X 2 and a Y-value Y 2 .
Amplitude ESTIMATE =√{square root over (( X 1 −X 2 ) 2 +( Y 1 −Y 2 ) 2 )} [e9]
[0077] The amplitude of the alternans pattern of variation often depends on the [D] morphology features used to determine the values W. Accordingly, the estimated amplitude is generally not an absolute value that can be compared against standardized charts. However, comparisons can be generated for estimated amplitudes of alternans patterns of variation based on the morphology features F that are determined and the processing step that is used.
[0078] As shown in FIG. 3 , the processor can report (at 116 ) alternans data to a caregiver and/or the processor can store the alternans data. The alternans data (e.g., the feature maps, the estimated amplitudes of the alternans pattern of variation, the confidence level of the alternans pattern of variation, the uncertainty level of the alternans pattern of variation, the p-value of the alternans pattern of variation, and the like) can be reported using any suitable means (e.g., output to a suitable output device such as a display, a printer, and the like).
[0079] As shown in FIG. 3 , in some embodiments, the processor can plot (at 118 ) a spectral graph using values resulting from preprocessing the feature matrix (e.g., the values of the first principal component vector u 1 ). FIGS. 24 and 25 illustrate two examples of spectral graphs. The values used to generate the spectral graphs of both FIGS. 24 and 25 were determined using ECG data representative of an ECG signal having a 5 microvolt TWA pattern of variation, 20 microvolts of noise, and 20 milliseconds of offset, where [H] is equal to 128 .
[0080] FIG. 24 illustrates a spectral graph generated using values directly from the feature matrix A (i.e., the feature matrix A was not preprocessed using a principal component analysis or other mathematical analysis). As illustrated in FIG. 24 , the spectral graph does not include a dominant frequency at half of the beat sample frequency, but instead includes a number of frequency spikes having varying amplitudes. Accordingly, the spectral graph of FIG. 24 does not indicate the existence of a significant alternans pattern of variation. FIG. 25 illustrates a spectral graph generated using values of a first principal vector u 1 . The first principal vector u 1 is a result of a principal component analysis performed on the same feature matrix A from which the values used to generate the spectral graph of FIG. 24 were obtained. FIG. 25 illustrates a single frequency spike at half of the beat sample frequency. Accordingly, unlike the spectral graph of FIG. 24 , the spectral graph of FIG. 25 appears to illustrate the presence of a significant alternans pattern of variation. The effect of noise and time shift in the measured ECG signal on the determined alternans data is indicated by the spectral graphs of FIGS. 24 and 25 . Preprocessing the feature matrix A increases the robustness of the determination of alternans data when using spectral domain methods. | Method and apparatus for determining alternans data of an ECG signal. The method can include determining at least one value representing at least one morphology feature of each beat of the ECG signal and generating a set of data points based on a total quantity of values and a total quantity of beats. The data points can each include a first value determined using a first mathematical function and a second value determined using a second mathematical function. The method can also include several preprocessing algorithms to improve the signal to noise ratio. The method can also include separating the data points into a first group of points and a second group of points and generating a feature map by plotting the first group of points and the second group of points in order to assess an alternans pattern of variation. The feature map can be analyzed by statistical tests to determine the significance difference between groups and clusters. | 0 |
FIELD OF THE INVENTION
[0001] Short tandem repeat (STR) markers are sequence motifs that consist of repeatedly occurring short sequences in non-coding parts of the genome. They are polymorphous with regard to the number of repeats which led during evolution to a high number of variants for every STR loci. Therefore, there is a high probability that two human beings differ in the number of STR repeats and therefore STR5 have been discovered and developed as genetic markers. Such markers are frequently used by scientists in the field of forensic analysis, paternity determination, monitoring of bone marrow transplantation, linkage mapping as well as detection of genetic diseases and different types of cancers.
[0002] Forensic investigations in Europe and in the United States involve a core loci set analysis. In order to ensure that a match between two samples of tissue is statistically significant, multiple polymorphic loci need to be analyzed. The workflow scheme is such that the STR marker is amplified in a PCR reaction. However, this is often not a trivial task due to several complications.
[0003] In the case of SE33, amplification has been proven to be difficult. Upstream of the SE33 marker region, a repetitive element is found. Multiple copies of this repetitive element are found in the genome and this complicates the design of SE33-specific primers. In addition to the repetitive element, several single nucleotide polymorphisms (SNPs) and insertions/deletions (InDels) are located in close proximity to the marker region. Such sequence variations in the binding sites of the primers affect specificity and thereby decrease or even abolish efficient amplification of the marker region. The presence of a SNP prevented amplification when using the primers reported by Polymeropoulos et al (Polymeropoulos et al., Nucleic Acids Res., 1992, 20, 1432). Further, mistyping occurred due to the presence of SNPs which cause a change in hairpin structure of the amplicon.
[0004] A system for the amplification of SE33 and efficient genotyping would provide an important contribution to the field of forensic science.
BRIEF DESCRIPTION OF THE INVENTION
[0005] The invention addresses the technical problem with a set of primers for the efficient amplification of SE33 and also describes a method for the analysis of the presence and/or level of SE33 in combination with other STR markers.
[0006] The invention relates to a nucleic acid consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO: 1 and preferably 95% identical to SEQ ID NO: 1, wherein said nucleic acid that is preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO:1, preferably 95% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-prime nucleotides that are identical to SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter at its 5′ end. Terminal (identical) herein meaning the last nucleotides at the 3′ end.
[0010] The invention further relates to a nucleic acid consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least 70% identical to SEQ ID NO: 1, wherein said nucleic acid that is at least 70% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-nucleotides that are identical to the 5, 4, 3, 2 or 1 terminal 3′nucleotides of SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end. Terminal (identical) herein meaning the last nucleotides at the 3′ end.
[0014] The invention relates to the use of a nucleic acid as described above in a method for amplifying a fragment of SE33 of a preferred fragment size of 385-500 by (related to allele 42), more preferred 400-475 (related to allele 42), most preferred 425-445bp (related to allele 42).
[0015] The invention also relates to a method for the detection of the presence and/or level of the SE33 marker comprising the following steps:
i. mixing a sample with two nucleic acid oligonucleotides, wherein one nucleic acid is a forward primer consisting of a sequence selected from the group of
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO: 1 and preferably 95% identical to SEQ ID NO: 1, wherein said nucleic acid that is preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO:1, preferably 95% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-prime nucleotides that are identical to SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end and the other is a reverse primer suitable to form an amplification product when used with said forward primer in an amplification reaction,
ii. performing an amplification reaction and iii. detection of the presence and/or level of SE33.
[0023] The invention additionally relates to a method for the detection of the presence and/or level of the SE33 marker comprising the following steps:
i. mixing a sample with two nucleic acid oligonucleotides, wherein one nucleic acid is a forward primer consisting of a sequence selected from the group of
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least 70% identical to SEQ ID NO: 1 wherein said nucleic acid that is at least 70% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-nucleotides that are identical to the 5, 4, 3, 2 or 1 terminal 3′-nucleotides of SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end and the other is a reverse primer suitable to form an amplification product when used with said forward primer in an amplification reaction,
ii. performing an amplification reaction and iii. detection of the presence and/or level of SE33.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The term “SE33” as used herein refers to the β-actin related pseudo gene. It is located on chromosome 6 (band 6q14), whereby about 83 allelic variants are known for SE33 to date. The GenBank accession number is AJ746167. The predominant repeat motif is AAAG, however the locus is highly polymorphic.
[0031] The term “amplification products” as used herein are nucleic acids or oligonucleotides that are the product of an amplification reaction, e.g. of a polymerase chain reaction. They are for example defined by the primers used for amplification.
[0032] An “oligonucleotide” herein refers to a stretch of nucleic acid, e.g. RNA or DNA, that comprises a sequence of two or more nucleotides, e.g. between 2 and 250 nucleotides, more preferably between 2 and 200, even more preferably between 2 and 100, even more preferably between 2 and 30, even more preferably between 2 and 25, even more preferably between 2 and 20, even more preferably between 5 and 25, and most preferably between 10 and 25 nucleotides.
[0033] A “primer” herein refers to an oligonucleotide comprising a sequence that is complementary to a nucleic acid to be amplified or transcribed (“template”). During replication polymerases attach nucleotides to the 3′-OH end of the primer complementary to the respective nucleotides of the template.
[0034] A “probe” herein is an oligonucleotide, nucleic acid or a fragment thereof, which is substantially complementary to a specific nucleic acid sequence.
[0035] The invention relates to a nucleic acid consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO: 1 and preferably 95% identical to SEQ ID NO: 1, wherein said nucleic acid that is preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO:1, preferably 95% identical to SEQ ID NO: 1, has at least 5, 4, 3, 2 or 1 terminal 3′-prime nucleotides that are identical to SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end. Terminal, herein meaning the last nucleotides at the 3′ end. Hence, if 5 are identical, these are the last 5, if 4 are identical these are the last 4 and so on.
[0039] The invention additionally relates to a nucleic acid consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least 70% identical to SEQ ID NO: 1 wherein said nucleic acid that is at least 70% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-nucleotides that are identical to the 5, 4, 3, 2 or 1 terminal 3′-nucleotides of SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end. Terminal, herein meaning the last nucleotides at the 3′ end. Hence, if 5 are identical, these are the last 5, if 4 are identical these are the last 4 and so on.
[0043] In a preferred embodiment of the invention said nucleic acid is at least 75% identical to SEQ ID NO 1. In a more preferred embodiment of the invention said nucleic acid is at least 80% identical, more preferably 85% identical, even more preferably 90% identical and most preferably 95% identical to SEQ ID NO 1.
[0044] In a preferred embodiment the invention relates to a nucleic acid as described above, wherein the nucleic acid is a probe or primer.
[0045] In one embodiment of the invention the nucleic acid is a nucleic acid as describe above with a length of at the most 25 nucleotides. In a preferred embodiment the nucleic acid has a length of at the most 20 nucleotides. In another embodiment the nucleic acid has a length of 15 nucleotides or less.
[0046] In one embodiment the invention relates to a nucleic acid, wherein said nucleic acid may have a fluorescent dye attached and preferably, said dye is attached to the 5′-end of the nucleic acid.
[0047] The invention relates to the use of a nucleic acid as described above in a method for amplifying a fragment of SE33 of a preferred fragment size of 385-500 bp (related to allele 42), more preferred 400-475 (related to allele 42), most preferred 425-445 bp (related to allele 42).
[0048] The invention also relates to a method for the detection of the presence and/or level of the SE33 marker comprising the following steps:
i. mixing a sample with two nucleic acid oligonucleotides, wherein one nucleic acid is a forward primer consisting of a sequence selected from the group of
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO: 1 and preferably 95% identical to SEQ ID NO: 1, wherein said nucleic acid that is preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO:1, preferably 95% identical to SEQ ID NO: 1, has at least 5, 4, 3, 2 or 1 terminal 3′-prime nucleotides that are identical to SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end and the other is a reverse primer suitable to form an amplification product when used with said forward primer in an amplification reaction,
ii. performing an amplification reaction and iii. detection of the presence and/or level of SE33.
[0056] The invention also relates to a method for the detection of the presence and/or level of the SE33 marker comprising the following steps:
i. mixing a sample with two nucleic acid oligonucleotides, wherein one nucleic acid is a forward primer consisting of a sequence selected from the group of
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least 70% identical to SEQ ID NO: 1 wherein said nucleic acid that is at least 70% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2 or 1 terminal 3′-prime nucleotides that are identical to the 5, 4, 3, 2 or 1 3′-terminal nucleotides of SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end and the other is a reverse primer suitable to form an amplification product when used with said forward primer in an amplification reaction,
ii. performing an amplification reaction and iii. detection of the presence and/or level of SE33.
[0063] In a preferred embodiment of the invention said forward primer is at least 75% identical to SEQ ID NO 1. In a more preferred embodiment of the invention said nucleic acid is at least 80% identical, more preferably 85% identical, even more preferably 90% identical and most preferably 95% identical to SEQ ID NO 1.
[0064] In one embodiment of the invention the nucleic acid is a nucleic acid as describe above with a length of at the most 25 nucleotides. In a preferred embodiment the nucleic acid has a length of at the most 20 nucleotides. In another embodiment the nucleic acid has a length of 15 nucleotides or less.
[0065] In one embodiment the invention relates to a method for the detection of the presence and/or level of the SE33 marker, wherein the reverse primer has a sequence selected from the group of SEQ ID NO: 2, SEQ ID NO: 4, SEQ ID NO: 6 and SEQ ID NO: 7.
[0066] In one embodiment the invention relates to a method, wherein the amplification is performed by using a method selected from the group polymerase chain reaction, rolling circle amplification, strand displacement amplification, transcription-based amplification system, nucleic acid sequence based amplification (NASBA), rolling circle amplification (RCA), transcription-mediated amplification (TMA), self-sustaining sequence replication (3SR), Qβ amplification, ligase chain reaction and isothermal amplification.
[0067] In a preferred embodiment the invention relates to a method, wherein the detection of the presence and/or level of SE33 is performed by a method selected from the group comprising capillary electrophoresis, qPCR, digital PCR, agarose gel electrophoresis and next generation sequencing. Such analysis of the amplification reaction gives further insights into quality of the reaction by analysis of the presence and/or quantity of the target product and for the presence of non-specific side products. Detection can be performed by means of fluorescence in the case labelled primers are used. Other options include agarose gel electrophoresis and subsequent analysis of the pattern of bands.
[0068] The invention also relates to a method, wherein the sample is genomic DNA.
[0069] In particular, the invention relates to a method, wherein the sample is from one of the following sources but not limited to: saliva, urine, faeces, semen, blood, blood serum, hair, skin, teeth, humerus and femur.
[0070] The invention preferably relates to a method, wherein the analysis of the SE33 marker is in the context of forensic science. The polymorphic STR markers D1S1656, D2S441, D2S1338, D3S1358, D5S818, D7S820, D8S1179, D10S1248, D12S391, D13S317, D16S539, D18S51, D19S433, D21S11, D22S1045, CSF1PO, FGA [FIBRA], TH01 [TC11], TPDX, vWA, SE33 [ACTBP2], DYS391 and the gender-specific Amelogenin marker, recommended by the CODIS (Combined DNA Index System) Core Loci Working Group, the European Network of Forensic Science Institutes (ENFSI) and the European DNA Profiling Group (EDNAP), are preferably used in the context of forensic science.
[0071] The invention relates to a method, wherein the presence and/or level of SE33 is analyzed in combination with other STR markers. The analysis of multiple STR markers in a sample ensures that the results obtained are statistically significant. Such analysis reduces the likelihood of random matches within the general population.
[0072] The invention relates to a method, wherein the analysis is performed using multiplex PCR.
[0073] In a preferred embodiment invention relates to a method, wherein the multiplex PCR comprises other STR markers selected from the group of D1S1656, D2S441, D2S1338, D3S1358, D5S818, D7S820, D8S1179, D10S1248, D12S391, D13S317, D16S539, D18S51, D19S433, D21S11, D22S1045, CSF1PO, FGA [FIBRA], TH01 [TC11], TPDX, vWA, SE33 [ACTBP2], DYS391 and the gender-specific Amelogenin marker.
[0074] In a preferred embodiment the invention relates to a method, wherein the multiplex PCR comprises other STR markers selected from the group of D1S1656, D2S441, D2S1338, D3S1358, D5S818, D7S820, D8S1179, D10S1248, D12S391, D13S317, D16S539, D18S51, D19S433, D21S11, D22S1045, CSF1PO, FGA [FIBRA], TH01 [TC11], TPDX, vWA, DYS391 and the gender-specific Amelogenin marker.
[0075] The invention relates to a kit for the detection of the SE33 marker in a sample comprising at least a nucleic acid, consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO: 1 and preferably 95% identical to SEQ ID NO: 1, wherein said nucleic acid that is preferably 70% identical to SEQ ID NO: 1, 75% identical to SEQ ID NO: 1, 80% identical to SEQ ID NO: 1, 85% identical to SEQ ID NO: 1, preferably 90% identical to SEQ ID NO:1 and preferably 95% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2, 1 terminal 3′-prime nucleotides that are identical to SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter or longer at its 5′ end and reagents for amplification, detection and quantification of nucleic acids.
[0079] The invention further relates to a kit for the detection of the SE33 marker in a sample comprising at least a nucleic acid, consisting of a sequence selected from the group of,
a) SEQ ID NO: 1 and, b) a nucleic acid that is at least 70% identical to SEQ ID NO: 1
wherein said nucleic acid that is at least 70% identical to SEQ ID NO: 1 has at least 5, 4, 3, 2, 1 terminal 3′-nucleotides that are identical to the 5, 4, 3, 2 or 1 terminal 3′-nucleotides of SEQ ID NO: 1 and, wherein, said nucleic acid may also optionally be 1 to 5 nucleotides shorter at its 5′ end and reagents for amplification, detection and quantification of nucleic acids.
[0082] In a preferred embodiment of the invention said nucleic acid is at least 75% identical to SEQ ID NO 1. In a more preferred embodiment of the invention said nucleic acid is at least 80% identical, more preferably 85% identical, even more preferably 90% identical and most preferably 95% identical to SEQ ID NO 1.
[0083] In one embodiment of the invention the nucleic acid is a nucleic acid as describe above with a length of at the most 25 nucleotides. In a preferred embodiment the nucleic acid has a length of at the most 20 nucleotides. In another embodiment the nucleic acid has a length of 15 nucleotides or less.
[0084] In one embodiment the invention relates to a nucleic acid, wherein said nucleic acid may have a fluorescent dye attached and preferably, said dye is attached to the 5′-end of the nucleic acid.
EXAMPLES
[0085] Analysis of the SE33 Marker Region and Primer Design
[0086] SE33 is located in a region of the human genome that makes the design of reliably working PCR primers difficult ( FIG. 1 ).
[0087] A reliable and specific amplification of the SE33 marker was not possible with existing primers. Several reported mutations in the primer binding site lead to allelic dropouts or mistyping while determining the genotype of certain individuals. Specifically, the primers reported by Polymeropoulos et al. do not achieve the desired performance in the presence of SNP alleles as reported by Heinrich et al (Heinrich et al., International Journal of Legal Medicine, 2004, 118, 361-363). This leads to mistyping and misinterpretation of individual genotypes. Further, mistyping is observed in the presence of SNP alleles downstream of the SE33 marker, due to a change in a hairpin structure of the amplicon that leads to unwanted effects during the downstream analysis. For details, see Davis et al. (Davis et al., Forensic Science International: Genetics, 2012, 6, 494-497). In order to circumvent the mentioned issues, new PCR primers needed to be designed. However, the presence of a highly repetitive element upstream of the SE33 locus makes the design of specific primers difficult.
[0088] A set of primers was identified that is suited to amplify the SE33 locus with high specificity which are also robust to the presence of known mutations in a sample.
[0089] The size of the amplicon is compatible for a multiplex setup that allows the analysis of several other STR markers in a single reaction. These primers are listed in Table 1.
[0000]
TABLE 1
Primers for the amplification of SE33.
SEQ ID NO
Primer name
Sequence
1
SE33_1_44-F
GAGGCTACAGTGAGCCGAGG
2
SE33_1_44-R
CGCGGTGTAAGGAGGTTTATATATAT
3
SE33_1_22-F
TACAGTGAGCCGAGGTCATG
4
SE33_1_22-R
CGCGGTGTAAGGAGGTTTATATA
5
SE33_1_62-F
GTGAGCCGAGGTCATGCCAT
6
SE33_1_62-R
CTCCGCGGTGTAAGGAGGTTTA
7
SE33_1_P-R
ACATCTCCCCTACCGCTATA
[0090] Multiplex PCR Experiments
[0091] In order to test the specificity of the primers and to assess their suitability for analysis of the SE33 locus in combination of other STR5, Multiplex PCR experiments were performed.
[0092] A Multiplex-PCR using 23 primer pairs simultaneously, including beside others the primer “SE33_1_44-F” (SEQ ID NO: 1) to amplify a fragment of the SE33 marker region was performed and the results are shown in FIG. 2 . The amplified DNA fragments were analyzed with capillary electrophoresis (CE) on an ABI 3500 instrument. As seen in the electropherogram of the CE, all markers, in particular SE33, were amplified with a high and equal PCR yield. No unspecific products were detected. Therefore, this primer is suited for the simultaneous amplification of SE33 in parallel with 22 additional HuID markers.
[0093] A multiplex PCR using 23 primer pairs simultaneously, including the primer pair “SE33_1_62-F//SE33_1_62-R” to amplify a fragment of the SE33 marker region is shown in FIG. 3 . The amplified DNA fragments were analyzed with capillary electrophoresis (CE) on an ABI 3500 instrument. As seen in the electropherogram of the CE, the signal intensity of the SE33 PCR product is less than the signal intensities of the other markers. Furthermore, unspecific PCR products were detected in the blue, green and yellow channel. This highlights the complexity of designing an appropriate primer pair for SE33.
[0094] As shown in FIG. 1 , several mutations in the flanking region of the target STR region were reported, that might lead to allelic dropouts or mistyping while determining the genotype of certain individuals. The primer binding site of “SE33_1_44-F” does not include any known mutations so far. Therefore, using “SE33_1_44-F//SE33_1_44-R” the amplification of SE33 proceeds with a high yield and no mistyping is detected ( FIG. 4 ). In contrast, when using the QIAGEN “Investigator ESSplex SE Kit” (CatNo 381525) alleles are not typed correctly in all cases of DNA samples.
[0095] In addition, further DNAs were analyzed with reference to the concordance and correct genotyping of SE33. The results of the concordance analysis of “SE33_1_44-F” vs. “Investigator ESSplex SE Kit” are shown in Table 2. All DNAs were genotyped correctly with “SE33_1_44”, but all DNAs showed dropouts or dropdowns when using the “Investigator ESSplex SE Kit”.
[0000]
TABLE 2
Concordance analysis with 2 different SE33 primers.
Reference
Primer
DNA
Genotype
SE33_1_44
ESSplex SE
18414
17/20
17/20
—/20
PT83880
13/18
13/18
13dd/18
PT83882
15/17
15/17
15/17dd
Y5
15/19
15/19
15dd/19
PT84195
16/17
16/17
16dd/17
Annotations are as follows: dd = dropdown = very weak signal, “—” = dropout = no signal detected.
[0096] Comparision of SE33_1_44 with ACTBP2
[0097] In order to test the specificity of the primer “ACTBP2_f_seq” (Heinrich et al., International Journal of legal medicine, 2004 (118), p. 361-363) (SEQ ID NO 8) and to assess its suitability for analysis of the SE33 locus in combination of other STR5, Multiplex PCR experiments were performed. A Multiplex-PCR using 23 primer pairs simultaneously, including beside others the primer “ACTBP2_f_seq” to amplify a fragment of the SE33 marker region was performed, and the results are shown in Table 1 and 2. The amplified DNA fragments were analyzed with capillary electrophoresis (CE) on an ABI 3500 instrument. As shown in Table 3 and 4, unspecific PCR products were detected in the green, yellow and purple channel. This highlights the complexity of designing an appropriate primer pair for SE33 and shows that the primer “ACTBP2_f_seq” is not applicable for the analysis of the SE33 locus in combination with other STR5. In contrast, when performing a Multiplex-PCR using 23 primer pairs simultaneously, including beside others the primer “SE33_1_44-F” (SEQ ID NO: 1) to amplify a fragment of the SE33 marker region, no unspecific products were detected, as shown in Table 5 and 6.
[0000]
TABLE 3
Specific and unspecific Multiplex-PCR products using control DNA 9948 as template
and primer “ACTBP2_f_seq” (D5, SEQ ID NO: 8) for the analysis of the SE33 locus.
Dye
specific products [bp]
unspecific products [bp]
Blue
77
80
99
115
171
179
267
351
355
Green
97
101
142
172
184
220
244
346.1
358
187
206
300
301
354
449
Yellow
104
116
173
179
248
252
308
312
417
357
Red
96
100
175
187
333
340
Purple
74
113
179
183
248
311
320
371
435
91
[0000]
TABLE 4
Specific and unspecific Multiplex-PCR products using DNA 45 isolated of a blood sample as
template and primer “ACTBP2_f_seq” (D5, SEQ ID NO: 8) for the analysis of the SE33 locus.
Dye
specific products [bp]
unspecific products [bp]
Blue
77
107
179
183
254
274
351
355
Green
109
176
179
232
236
305
321
187
195
203
244
353
449
Yellow
108
159
248
252
299
312
401
405
357
Red
96
108
163
171
321
333
Purple
73
118
122
183
248
252
307
311
367
435
91
[0000]
TABLE 5
Specific and unspecific Multiplex-PCR products using control DNA 9948 as template
and primer “SE33_1_44-F” (SEQ ID NO: 1) for the analysis of the SE33 locus.
Dye
specific products [bp]
unspecific products [bp]
Blue
77
80
99
115
171
179
267
351
355
—
Green
97
101
142
172
184
220
244
359
371
—
Yellow
104
116
173
179
248
252
308
312
417
—
Red
96
100
175
187
333
340
—
Purple
74
113
179
183
248
311
320
371
435
—
[0000]
TABLE 6
Specific and unspecific Multiplex-PCR products using DNA 45 isolated of a blood sample
as template and primer “SE33_1_44-F” (SEQ ID NO: 1) for the analysis of the SE33 locus.
Dye
specific products [bp]
unspecific products [bp]
Blue
77
107
179
183
254
274
351
355
—
Green
109
176
179
232
236
316
332
—
Yellow
108
159
248
252
299
312
401
405
—
Red
96
108
163
171
321
333
—
Purple
73
118
122
183
248
252
307
311
367
435
—
FIGURE CAPTIONS
[0098]
FIG. 1
[0099] Overview on the genomic context of the SE33 marker on the human chromosome 6. Annotations are as follows: The chromosomal position is given on the top. The exact location of the SE33 marker is illustrated by the upper light grey bar. The position of previously used amplicon of published primers by Polymeropoulos et al. is shown thereunder in grey. The location of the amplicon formed by the herein reported primers “SE33_1_44-F//SE33_1_44-R” is shown in black. Below, all SNP and InDel loci known from the literature or public data repositories are listed with the wild type being written over the mutant allele. At the bottom the number of sequence copies found within the human genome is shown, indicating the location of a repetitive element.
[0100]
FIG. 2
[0101] Analysis of the PCR performance of 23 HuID markers. Amplification of SE33 using the primer “SE33_1_44-F//SE33_1_44-R”. All markers, in particular SE33 (second channel 4th system), were amplified with a high and equal PCR yield. No unspecific products were detected.
[0102]
FIG. 3
[0103] Analysis of the PCR performance of 23 markers. Amplification of SE33 using the primer pair “SE33_1_62-F//SE33_1_62-R”. The signal intensity of the SE33 PCR product is less than the signal intensity of the other markers. Unspecific PCR products were detected in the first, second and third channel (encircled and marked with an X).
[0104]
FIG. 4
[0105] Analysis of the PCR performance of 5 STR markers. Annotations are as follows: SE33 marker was amplified with “SE33_1_44” (A, 5 th STR marker) and with the primers contained in the ESSplex SE kit (B). Both SE33 alleles of reference DNA “PV 35-11_EV” were amplified with the new designed primer “SE33_1_44” in concordance to the known genotype (A, 5th STR marker). In contrast, the SE33 amplification with primers of the ESSplex SE kit leads to a mistyping of the DNA, as one allele is not amplified (B, dropout, encircled). | Short tandem repeat (STR) markers are genetic elements that are frequently used in the fields of forensic analysis, paternity determination and detection of genetic diseases and cancers. Such analysis involves the amplification of STR loci. Technically, this can be challenging due to sequence variations in the flanking regions of the locus. In the case of SE33, previous amplification efforts have failed. The present invention describes a set of primers for the amplification of SE33 and a method for the analysis of the presence and/or level of SE33, also in combination with other STRs. | 2 |
BACKGROUND OF THE INVENTION
[0001] In a wireless communication system, a radio communication channel extends between a sending station and a receiving station. A cellular communication system is a multi-user communication system in which several fixed-site base stations operate to communicate with radio telephones in a geographical area. The communication signals are transmitted with controlled power between a base station and a radio telephone. Each of the radio telephones, therefore, must be equipped with appropriate power control systems.
[0002] A power control system for a radio telephone is described in U.S. Pat. No. 6,178,313, which is commonly owned with the subject application. The disclosure of the '313 patent is incorporated herein by reference. Such a system is used to ensure that transmitted communication signals are strong enough to recover the informational content at the receiver, but also low enough to not reduce the communication capacity of the communication channel. The communications system of the '313 patent utilizes a closed-loop power control scheme in which power control signals are generated and transmitted by network infrastructure on the forward link channel to a radio telephone. These power control signals control the power levels for the reverse link communication signals transmitted by the radio telephone.
[0003] The transmitter portion of a radio telephone, therefore, typically includes a power amplifier. The power amplifier amplifies a reverse link signal prior to its transmission so that it will be received by a base station via a radio channel. A power amplifier requires relatively large amounts of energy for its operation. Conventionally, power amplifiers are powered or biased to optimize the the transmitter efficiency on the different power levels transmitted by the radio telephone. However, the typical power levels of reverse link signals are generally significantly less than the maximum power levels.
[0004] It is well known that the performance of a power amplifier within a mobile telephone may be effected by the ambient temperature of the integrated circuit chip in which the amplifier is imbedded. In addition the power amplifier itself will generate heat during its operation which will have a significant effect on its operating temperature of its components. It would be advantageous, therefore, to monitor the temperature in order to compensate by adjusting signal or power levels or by shutting down the mobile telephone. It is a feature of this invention to provide a simple system for sensing the operational temperature of a power amplifier.
[0005] A power amplifier requires a bias current to maintain the power amplifier within its operational range. There is normally a voltage drop over a biased transistor and this voltage drop varies with the operational temperature of the transistor.
[0006] Although in many instances the bias circuit is contained in an integrated circuit (IC) chip of the power amplifier, this is restrictive, if a more intelligent adjustment of the bias is desired. Since it is prevalent to use Gallium Arsenide transistors in power amplifier ICs, intelligent biasing is difficult to achieve within the power amplifier IC. An intelligent bias circuit allows the adjustment of the bias to accommodate, varying output levels, temperature compensation, or power control. In such instances an external bias circuit will be used to adjust the bias circuit according to a predetermined algorithm. It is a feature of this invention to use the external bias circuit to monitor the operational temperature of the power amplifier.
[0007] It is a feature of this invention to sense the voltage drop over a component or components in the bias circuit to obtain a signal relative to the operating temperature of the power amplifier. Another feature of this invention is to monitor the operational temperature of the power amplifier using the external bias pin of the power amplifier IC.
SUMMARY OF THE INVENTION
[0008] In accordance with the illustrated embodiment, the power amplifier of a mobile telephone transceiver circuitry is “intelligently” controlled via an external bias circuit. The external bias is provided to the power amplifier through a dedicated pin in the power amplifier IC. The biasing input is monitored to obtain a signal indicative of the voltage drop across the transistors of the amplifier. This signal is used directly to monitor the operating temperature of the power amplifier and generate signals for further use.
[0009] The RF signals processed by the radio telephone will have an effect on the bias current, in order to avoid inaccuracies that may be caused by this effect, it may be advantageous to time the temperature sensing sequence immediately after the transmission slot ends.
[0010] The monitoring circuit sequence is controlled by an algorithm. According to the monitoring sequence, the voltage at the bias input pin of the power amplifier integrated circuit (IC) is checked, indicating the voltage drop across the transistors within the power amplifier. In one embodiment of this invention, the checking is accomplished immediately following the end of an RF signal transmission. Since this voltage varies according to temperature, it is used to indicate the operating temperature of the IC. This information can be used within the control algorithm of a intelligent bias circuit to adjust the bias of the power amplifier as function of temperature, to adjust the gain control as a function of temperature, to shut down the power amplifier at excessive temperatures and other purposes.
DESCRIPTION OF THE DRAWING
[0011] The subject invention is described in more detail below with reference to the drawing in which:
[0012] [0012]FIG. 1 is a block diagram of a mobile telephone transceiver;
[0013] [0013]FIG. 2 is a circuit diagram of a sensing circuit of this invention;
[0014] [0014]FIG. 3 is a block diagram of the steps of the method of the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] A mobile station 10 in which the temperature monitoring system of this application is operable, is shown in FIG. 1. In a conventional manner, the mobile station 10 is selectively tuned to receive signals through antenna 11 transmitted upon a forward channel from a base station (not shown).
[0016] The mobile station 10 includes a transceiver 12 which, in a well know manner, consists of a receiver 13 and transmitter 16 . Transmitter 16 includes power amplifier 18 and modulator 15 . Receiver 13 includes front end 28 and demodulator 14 . The signal received at the receiver 13 is processed in the main control processor 17 . A transmission signal is amplified in power amplifier 18 which forms part of transmitter 16 .
[0017] Power amplifier 18 has an external bias current supplied by bias control 19 . A bias control system is shown, for example, in the '313 patent cited herein. Another, more simple, bias control is shown in FIG. 2. The power amplifier 18 is generally constructed of a set of transistors, for example transistors 20 , 21 , and 22 of the circuit of FIG. 2. Such power amplifiers are generally produced as an integrated circuit (IC) and provided with appropriate input pins for connection to associated modules. In circumstances, such as shown in the cited '313 patent, the bias circuit is controlled by an algorithm which varies the bias current according to predetermined parameters, such as data imbedded in the received signal. This so called “intelligent” bias is generally implemented in a circuit external to the power amplifier IC 18 . A pin 23 is, therefore, constructed in the IC 18 to receive the external bias.
[0018] Depending on the type of transistors used, the power amplifier 18 will have a characteristic response to variations in temperature. In particular the voltage occurring across the transistor will vary with temperature in a known manner. Since the operating temperature of the IC 18 , can significantly effect the performance of the mobile station 10 , it is advantageous to monitor this temperature. The operating temperature is monitored by sensing the voltage at the pin 23 . This voltage is representative of the voltage drop across the transistors and therefore may be used as a direct indication of the operating temperature of the IC.
[0019] In operation, as shown in FIG. 3, in the system of this invention, the signal at pin 23 is sensed and converted to a digital signal in converter 24 and directed to voltage/bias monitor 25 for processing. Bias monitor 25 is shown in FIG. 2 as a separate module, but could equally be implemented as a part of the main control processor 17 . In either instance the monitoring function is controlled by a temperature control algorithm 26 which can be stored in the memory 27 of the mobile station 10 . The temperature control algorithm 26 is constructed to cause the bias monitor 25 to generate a signal indicative of the operating temperature of IC 18 . The algorithm 26 may be further designed to cause the main processor to shut down when excessive temperatures are reached or to adjust the bias in response to predetermined fluctuations in the temperature.
[0020] The bias current will also be effected by the RF signal being processed in the power amplifier. This could cause inaccuracies in the sensing of the temperature in IC 18 . To avoid this problem, as indicated in FIG. 3, the algorithm 26 causes the bias monitor 25 to sense the voltage at pin 23 in a timed sequence immediately after the RF traffic slot.
[0021] In operation the power amplifier IC temperature is sensed by monitoring the voltage at the external bias pin 23 of the power amplifer IC 18 . The sensed bias pin voltage provides a signal that is directly usable to monitor the the operating temperature of the IC 18 . The temperature signal may be used to control the bias current, to provide warnings to the user, or to shut down the radio telephone. The sensing sequence is timed to avoid the effects of RF signals on the bias pin voltage.
[0022] By the use of the bias pin voltage as a temperature indicator, the use of an additional element, such as a temperature sensitive resistor, or the need for an additional connector pin on the IC is avoided. In addition the temperature that is sensed is at the critical location and not remote from the transistors as in the case of a separate element. The sensed temperature is therefore provided accurately in a cost effective manner without adding appreciably to the cost of the ASIC in which the power amplifier is imbedded.
[0023] The embodiments of FIGS. 1 - 3 are provided for illustration of possible implementations of the invention. It should be noted that the apparatus and method of this invention may be executed in a wide variety of power amplifiers, transistors and bias current sensing circuits which would be known to an artisan skilled in the art. | A method and apparatus for sensing the operational temperature of a power amplifier within a mobile telephone is disclosed. A sensor circuit is connected to sense the voltage at the input of the bias current supply to the power amplifier. This voltage being indicative of the voltage drop over the biased transistor of the power amplifier will also be indicative of the operating temperature of the power amplifier. | 7 |
This application is a continuation of application Ser. No. 09/070,612, filed Apr. 30, 1998, now U.S. Pat. No. 6,131,077 which is a continuation of application Ser. No. 08/714,193, filed Sep. 16, 1996, and issued on Sep. 15, 1998 as U.S. Pat. No. 5,808,905, which is a continuation of application Ser. No. 08/466,361, filed Jun. 6, 1995, and issued on Sep. 17, 1996 as U.S. Pat. No. 5,557,537, which is a file wrapper continuation of application Ser. No. 08/261,760, filed on Jun. 17, 1994, now abandoned, which is a file wrapper continuation of application Ser. No. 07/876,003, filed on Apr. 29, 1992, now abandoned, which is a continuation-in-part of application Ser. No. 07/551,919, filed Jul. 12, 1990, now abandoned.
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/551,919 filed on Jul. 12, 1990, now abandoned.
TECHNICAL FIELD
This invention relates to a method and apparatus for designing and editing a distribution system for a building and, in particular, to an automated system for designing and editing the distribution system.
BACKGROUND OF THE INVENTION
Distribution systems are found in every building. Such distribution systems provide for the movement and channelling of gases, liquids and electricity through a building. In any building, there are one or more distribution systems including a sprinkler system, duct work for heating, ventilation and air conditioning, plumbing and electrical systems.
One major type of distribution system is a sprinkler system for fire containment which is found in many buildings today. In today's society, any building where people congregate to live, work or play such as office buildings, factories, hotels, motels, apartment buildings, condominiums or shopping malls likely will include a sprinkler system to protect the public from a fire catastrophe.
Governmental bodies have recognized the need to protect against catastrophic fires by legislating standards for sprinkler systems into their building codes. Also, insurance companies, fearful of the potential liability of a catastrophic fire, have often demanded sprinkler systems in buildings as a condition for insurance coverage.
A building will have to comply with one or more standards for any distribution system. First, any building will need to comply with the standards set forth in relevant governmental codes. Often, insurance companies will require compliance with standards which may be tougher than the relevant governmental code. These standards can be set by the industry itself such as the National Fire Protection Association (NFPA) guidelines or the standards may be set by an insurance company directly.
A design for a sprinkler system must take into account many factors. The primary concern is ensuring adequate containment in the event of a fire. Thus, the spacing as well as the available water volume and water pressure at the sprinkler heads must be considered. Consideration must be given to the occupancy use to be made of a building. A chemical factory utilizing flammable solvents will require a different sprinkler system than a shopping mall.
In addition, there are many engineering or architectural constraints placed on sprinkler system design. For example, if interconnected sprinkler lines do not lie in a horizontal plane, drains must be inserted to allow water flow to prevent freezing. This is particularly true in the case of a dry sprinkler system which must not contain water except during actual use.
The sprinkler system must be designed with other building elements and adjuncts in mind. Locations must be found to hang the sprinkler system. Manually determining paths which avoid these obstructions, where to support the sprinkler system, how to allow each line to lie in a plane yet providing an adequate water supply which meets all requirements is difficult, tedious and very time consuming.
The concerns expressed above for a sprinkler system also relate to heating, ventilation and air conditioning (hereafter “HVAC”), plumbing and electrical systems. Standards also must be complied with when designing these systems for a building. The proper amount of light, ventilation and heat must be provided for each area.
The problem is compounded when, as usual, the various distribution system subcontractors must work out between themselves where to position the electrical conduits, the HVAC duct work, the plumbing piping and the sprinkler system. Generally, an architect or a general contractor designs the building elements such as beams, walls and joists. Left for the subcontractors is usually a space near the top of the steel. Into this space must go the various building adjuncts such as electrical conduit, overhead lighting fixtures, HVAC duct work and sprinklers. It is left to the subcontractors among themselves to specifically locate each such adjunct system.
Still another concern is keeping the cost of the system reasonable without sacrificing system performance. Designing a system which utilizes material in the most cost efficient manner is very difficult. For example, piping comes in standard lengths which are then cut to size as needed. Two sometimes conflicting concerns are (1) minimizing labor costs by minimizing the number of cuts and (2) reducing the left-over scrap material. Balancing these concerns is not a trivial exercise for an engineer.
In addition, the engineer must design a system which provides adequate HVAC to all parts, of a building given the varying conditions different portions of a building may encounter. For example, the HVAC requirements for the sunless north side of a building will differ from the full sun south side or the half day sun of the east and west sides. As is apparent, designing a distribution system manually is an onerous task. There is a need for a system which automatically performs these tasks.
What is needed is a system which coordinates the layouts of all the various distribution systems needed for a building. Such a system should provide for efficient design of the system, not only for its operation, but also its installation and cost.
The system should also provide hard copy or design for use in constructing the designed system. This hard copy can be used by people installing the electrical or sprinkler system at the construction site. It would also be useful if the system would provide a complete listing of the elements needed to install the distribution system.
The present invention meets these desires.
SUMMARY OF THE INVENTION
The invention is a method and apparatus for designing and editing a distribution system for a building. The distribution system can be any system used in a building including plumbing, electrical, sprinkling, ventilating and related systems or any combination of such systems. Information about the distribution system elements and various standard requirements is stored into a memory of a computer. Information about the building elements and adjuncts including location of walls and similar obstructions are entered into a computer. These building elements and adjuncts are then stored in the memory of the computer. The user can edit the building elements and adjuncts as desired. The user also selects the particular standard which is applicable to the building being constructed. For example, this may be a particular standard for lighting systems or a particular fire code used to design a sprinkler system.
A computer program then divides the building into suitable floors and then each floor into sections. Sections most often are either bays which are defined by the location of the beams of the building or individual rooms defined by the walls. This division breaks the problem down into manageable proportions.
The computer program then computes the layout needed for the distribution system based upon the selected standard. For example, how much light or ventilation is needed in a particular room. The layout is routed as economically as possible while avoiding the building elements and adjuncts. In addition, the quantity and location of hangers needed to support the distribution system as well as other special fittings needed are calculated. These computations are repeated for each section.
After the computations are complete, the program stores the information in memory and then can print out hard copy of the layout of the system. Also, an elements listing showing the number of components can be printed. For example, this will list how many and what type of light fixtures and wire are needed or, in the case of a sprinkler system, how many and what types of sprinkler heads and pipes are needed. Lastly, the most economical plan for cutting elements (e.g. pipes) to size is devised and printed.
An editing capability is provided to allow the user to edit either the layout or the building elements and adjuncts. In either case, the layout is reconfigured to include the proposed changes if still in compliance with the identified standard. otherwise, error messages are generated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which form a portion of this disclosure:
FIGS. 1 through 9 in combined form represent a flowchart of the computer program used in generating the present invention;
FIG. 10 is a diagram of a sprinkler system for combined warehouse and office space designed by the present invention;
FIG. 11 represents the editing menu used in the present invention;
FIG. 12 represents the editing pipes submenu of the preferred embodiment;
FIG. 13 represents the editing fittings submenu of the preferred embodiment;
FIG. 14 represents the editing sprinklers submenu of the preferred embodiment;
FIG. 15 represents the editing lines submenu of the preferred embodiment;
FIG. 16 represents the editing mains submenu of the preferred embodiment;
FIG. 17 represents the editing hangers submenu of the preferred embodiment;
FIG. 18 represents the editing headers submenu of the preferred embodiment;
FIG. 19 represents the editing structural elements (steel) submenu of the preferred embodiment;
FIG. 20 represents the editing walls submenu of the preferred embodiment; and
FIG. 21 represents the editing ceiling grid submenu of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A computer system for use in the design of distribution systems preferably consists of a CRT display and a keyboard-type input operatively connected to a computer. The computer is preferably operatively linked to a plotter, a printer and disk type storage units. For ease of description, the example of a sprinkler system is given, however, many of the same elements apply to other distribution systems. A sprinkler system is generally the most complicated and accordingly serves as a good example.
As described in detail later, elements of a distribution system are first stored on the disk type storage units. For a sprinkler system, the elements include information regarding all standard sprinkler heads, piping, fittings, hangers, drains including physical dimensions and fluid flow capacities.
Also stored on the disk type storage units are the requirements of relevant standards. The requirements can include the number, type, separation and water supply for sprinkler heads demanded by a particular governmental body or an insurance company.
A building designer or architect enters into the computer data regarding the building elements and adjuncts of buildings. The entry of the data may be accomplished though a number of methods. Examples include directly through the keyboard, floppy disk or modem. The building elements and adjuncts will include, among others, the dimensions and locations of the water stub-in, beams, columns, walls, ceilings, floors, girders, joists and electrical equipment. The building designer or architect also selects a standard to which the building must comply. Lastly, the designer chooses the elements to be optimized when constructing a building. For a sprinkler system, the designer generally will select either lines or sprinkler heads for optimization. For purposes of orientation, the lines will generally be parallel to the beams.
The computer program preferably treats each floor of a multistory structure as a separate building. The computer program provides two options for dividing the floors. In the first method, each floor is divided into sections which are oriented horizontally and are defined by the location of the beams. Generally, though not always, this method is utilized for large, open floor plan buildings such as warehouses. In the second option, the building is divided into individual rooms as per the floor plan. This method is generally used for office buildings and the like. Both methods may be used in one structure. As seen in FIG. 10, one example of mixed use is a warehouse wherein the main storage area may be divided by the first method, but the office area may be done by the second method. whatever the method, as hereinafter used, the term “section” refers to bays as in option one or rooms as in option two.
The computer program selects a section to begin its analysis. The first step is the determination of the number and location of the lines. The width of the selected section is divided by a maximum distance between lines permitted in the user selected standard.
The resulting number is rounded up to a next highest whole number, this whole number being the number of lines for this section. The number of lines is then also divided into the width of the section. The result of this division is the minimum distance between lines. Note that the minimum distance between lines may equal the maximum distance between lines if the width of the section divided by the maximum distance between lines is a whole number.
The placement of a first line from the first lengthwise wall is computed by dividing the minimum distance between lines by two. The first line is then located parallel to the first lengthwise wall at the placement distance.
The computer electronically checks the location by running an obstruction analysis which compares the location of the first line with the building elements and adjuncts input data to determine if there is a conflict. If there is a conflict, the first line will be relocated an incremental distance away from the first lengthwise wall and the computer reruns the obstruction analysis. The relocation-obstruction analysis cycle is repeated until either the separation between the first line and the first lengthwise wall exceeds one half the maximum distance between lines or an obstruction free path is found.
Preferably, the incremental distance chosen initially is one foot (30 cm.). If an obstruction free path is not found before one-half the maximum distance is reached, the program repeats the cycle using an incremental distance of one inch. If an obstruction: free path is still not found, the computer notifies the user and manual editing may be required to either relocate the elements of the section, the line or adding more lines to allow complete coverage.
If an obstruction free path is found, then the computer moves on to locating a subsequent line. The placement distance for subsequent lines is the minimum distance between lines. Any subsequent line is also located parallel to the beams.
Again, the computer repeats the obstruction analysis for the subsequent line. If a conflict is found, the subsequent line will be relocated the incremental distance from the first or preceding line until either the separation between the first or preceding line exceeds the maximum distance between-lines or else no obstruction is found.
Preferably, the incremental distance is initially one foot (30 cm.) with a second pass at one inch (2.5 cm.) if no obstruction free path is located on the first pass. Again, preferably the designer will be notified if neither pass finds an obstruction free path. The subsequent line locating procedure is repeated until the total number of located lines equals the calculated number of lines needed.
The next step is determining the number and location of sprinkler heads needed to comply with the selected standard. The length of the section is first multiplied by the minimum distance. between lines to yield the total area heads on a given line must cover. From the selected standard, the computer finds the maximum area a single head is to cover. The total area per line is divided by this maximum area. The result is rounded up to the next whole number which is the number of heads per line.
The minimum distance between heads is determined by selecting the lessor of:
a) dividing the length of the section by the number of heads;
b) dividing the maximum area a head is to cover by the minimum distance between lines; and
c) the maximum distance between heads allowed under the selected standard.
The placement distance from the first widthwise wall of a first head is determined by dividing the minimum distance between heads by two. The first head is positioned along the line at the placement distance from the wall.
The computer electronically checks the location of the first head by running an obstruction analysis. The analysis compares the location of the first head with the location input of building elements and adjuncts data to determine if a conflict exists. The obstruction analysis checks not only the head itself, but the projected spray from the head to ensure proper coverage.
If there is a conflict, the first head will be relocated at an incremental distance further from the first widthwise wall. The obstruction analysis is then rerun. The relocation-obstruction analysis cycle is repeated until either an obstruction free area is found or the separation between the first head and the first lengthwise wall exceeds one half the maximum distance between lines.
In this preferred embodiment, the incremental distance chosen initially is one foot (30 cm.). If an obstruction-free path is not found before the one half maximum distance is reached, the program will repeat the cycle using a one inch incremental distance. If an obstruction free path is still not found, the computer notifies the user and manual editing will be required to either relocate building elements and adjuncts or customize a head location.
If an obstruction free path is found, then the computer moves to locating a subsequent head. The procedure is the same as detailed above except for using the minimum and maximum distances between heads instead of one half the minimum and maximum distances between heads. The cycle is repeated until the number of located heads equals the number heads calculated for the line. If that is the case, the computer then moves to a subsequent line and locates the heads on the subsequent line. The cycles continue until all the heads are located for a given section.
The preferred embodiment is as described above. Alternatively, the computer can be programmed to calculate the number and location of heads first and then connect the heads via lines.
The computer program now determines the number of mains needed in a section. Preferably, one main is used if the number of heads per line is seven or less. Two mains are used if the number of heads per lines is greater than seven.
The mains are oriented perpendicular to the lines and in the same plane just below the beams. The main will overlap all the lines preferably by at least six inches on either side.
If only one rain is used, the computer divides the number of heads per line by two and truncates, the result to an integer. The main is placed between the head corresponding to the integer value and the head corresponding to the integer value plus one as counted from the first head.
If two mains are used and there are eight or nine heads per line, a first main is located between the first head and the first widthwise wall. A second main is located between the seventh and eighth heads as counted from the first head.
If two mains are used and there are ten or more heads per line, the first main is located between the second and third heads as counted from the first head. The second main is located between the second to last and the third to last main as counted from the first head.
The computer now searches through the stored sprinkler elements to determine the proper fittings to connect the heads to the lines and the lines to the mains. The mains are connected to the water stub-in where the water enters the building. Hangers will be added to support the pipes. An appropriate slope, preferably one half inch in ten feet will be computed. This completes the sprinkler system for the section.
The computer program stores the completed section into the disk storage means. Another section is selected and the process described above repeated until the sprinkler system layout for the entire building is finished and stored.
A hydraulic analysis is performed on the entire system which must be within the limits of the available water supply, including the static pressure, the residual pressure and the residual flow. The appropriate test for the selected standard is chosen. Various factors including the density per area, rules of NFPA 13 , Hazan-Williams coefficient and the K factors for the heads to be used in the tests. The largest head coverage area in the most physically remote section is initially selected.
The computer begins a Newton-Raphson analysis which sets up an N×M matrix wherein “N” equals the number of pipes with differing flows or pressures and “M” equals the number of parameters evaluated. Preferably, “M” equals fourteen. These parameters include the pipe length, pipe diameter and “K” factors for the heads or other outlets.
Using the Newton-Raphson matrix, the computer may evaluate:
1) Minimum water pressure needed for the system to function per the selected standard;
2) The flow at any given input pressure; or
3) The flow at the given input pressure.
As an alternative, a Hardy Cross analysis may be performed. In either case, the computer can supply the hydraulic data for any line, main or head in the building. If any problems are detected, manual editing with recalculation is possible. Preferably, at any step through this computer, a user may manually edit lines, mains, heads or the building elements and adjuncts of the building. For example, if an obstruction analysis shows a beam blocking a pipe, then the program will suggest an alternate path which avoids the beam.
Once the entire system is completed and checked, hard copy, including blueprints, can be generated to supply the user. Also, a full inventory of fittings, piping, hangers, heads and drains needed is available. As an additional benefit, the computer will optimize the cutting of standard 21, 24 or 25 foot piping lengths or combinations thereof to minimize the time and scrap generated. This alone can result in substantial savings.
Referring to FIGS. 1-9, an alternative embodiment is described. This alternative embodiment is very similar to the embodiment described above. However, there are differences which will be pointed out as they occur.
Referring to FIG. 1, blocks 1 and 2 , the user inputs data which includes the steel, walls, joists, columns and beams. Also included is the location of the water stub-in for this particular building. Again, as used herein the term building includes the individual floors of a multistory structure.
In block 3 , the computer next determines which way the pipes are run by determining the direction the beams run. As in the previous embodiment, the lines will run parallel to the beams.
In block 4 , the computer breaks the building into sections by looking at the beams, walls and systems as appropriate. The term “sections” as used herein includes both the bay sections which are the open spaces between beams or rooms which are determined by the location of walls. Again, these sections are determined by what use is to be made of the structure.
In block 5 , the computer determines which sections have not had a sprinkler system installed with the program. It then selects a section to electronically install the sprinkler system. In the next block, the program determines the location of this particular section within the entire structure.
In block 7 , the computer will get data from the user relating to the hazards which a particular section will encounter. This entails a knowledge of the activities which will occur in a particular section. The hazards within. a section will determine the maximum head and line spacing as determined by the building standards the user selected.
In block 8 , the computer will determine the number of lines in the particular section by dividing the maximum distance between the lines into the width of the section. The width of the section is the direction perpendicular to the beams.
In block 9 , the computer determines the distance between lines for this particular section. The computer, in blocks 10 and 11 , evaluates possible routes. to avoid joists and other obstructions. Block 10 does the evaluations to the nearest foot to avoid these obstructions. If a clear path is not found in block 10 , then block 11 evaluates possible paths every inch to seek to avoid the obstructions. If a clear path is not found, the computer simply finds the minimum distance between lines without looking at any possible obstructions or interference as shown in block 12 . The computer will give a message to the user that it is doing so.
Once a path is determined, the computer in block 13 will find the number of heads to be placed on the line by looking at the maximum spacing for heads, the distance between the lines and the maximum area a head may cover.
In block 14 , the user will input into the computer whether or not the user is minimizing the number of heads or the number of lines in this particular system. If the user is minimizing heads in block 14 , the computer will check in block 15 and see if adding an additional line will result in fewer heads.
If adding a line does result in fewer heads, the computer will add an additional line by determining that the number lines in the section is now the original determination plus one and repeat the cycle beginning with block 9 . If the user is not minimizing heads or if adding a line does not reduce the number of heads, the computer will calculate the distance between the heads necessary for each line as shown in block 17 .
Turning now to FIG. 2, in block 18 the computer determines the starting location of the first line. The method is as described in the earlier embodiment. Once the location is found, in block 19 the computer then determines the starting location of the first head on this line. Note that this contrasts with the earlier described embodiment wherein all the line locations were found before positioning any heads. The computer will store these locations into its memory in block 20 .
The computer will continue to add heads onto the line and connect the heads to the pipe as noted in the cycle denoted by blocks 20 through 24 until the number of heads calculated in block 13 are positioned.
The next determination, in block 25 , is whether the number of lines calculated in blocks 8 or 16 are located. If the answer is no, then it will add in another line as described above in block 18 and the sequence picks up from there. If the number of lines is complete, then the next step is to move on to determining the location for the mains as noted in block 26 . In blocks 27 and 28 , the computer determines the location and number of mains. The number of mains is determined by looking at the number of heads on a line as described in the earlier embodiment. It then determines in block 29 where to position the main relative to the heads. The computer finds a joist to support the mains in block 30 . Determining which joist to use involves checking that the main is located on the proper side of the selected joist in block 31 . If the main is located on the wrong side of the joist, it may have to be relocated as this can make connecting to the lines very difficult.
It also makes sure in block 32 that the main will not intersect a column. of course, inserting a line through a column which might involve some drilling could damage the structure of the building. The computer adds in the main by storing the location and size to the appropriate memory means in block 33 .
Turning now to FIG. 3, block 34 , the computer electronically connects the mains to the lines via riser nipples. Riser nipples are piping which is set at ninety degree angles and comes out of the top side of the mains.
The program in block 35 adjusts the pipe wall type of lines which involves determining the wall thickness of the pipe for the lines. The computer lastly connects the mains and the riser to the mains to the water stub-in which was input in block 1 .
The next step in the procedure is to elevate the lines. Prior discussion located the lines in a horizontal plane. This next analysis locates the lines in a vertical plane.
There are three alternative methods of elevating the lines. The first method is described. in blocks 39 - 41 and located in the mains in the joists. The elevation of the lines is determined by looking at the elevation of the joists that the line passes through and the deflector distance of the heads. With exposed construction, the lines can then be moved to place the deflectors an appropriate amount of distance from the structure such as four inches (10 cm). As another alternative, the computer may locate the lines at a constant elevation and in blocks 42 and 43 .
In the third and last methods, the computer may elevate the lines based on a center line. The center line is the distance from the top of the steel. The line is moved to place the deflector four inches (10 cm) from the top of the steel. This option is used in open warehouse environments without a drop ceiling.
In block 47 , the computer elevates the heads on the lines. This is done by analyzing where the location of the deflector is compared to the top of the steel. If the deflector is too close to the top of the steel, the computer will change the head to a pendant type which hangs beneath the lines as opposed to the normal which is mounted above the line as shown in block 48 . Alternatively, if the deflector is too far from the top of the steel, the computer will add sprigs to the head which mounts the head even further above the line than would be normal as shown in block 49 .
The computer as shown in block 50 adjusts the riser nipples to a ninety degree angle. In block 51 , the computer pitches the part of the lines which overhang the mains to up to one-half inch in approximately ten feet. Turning now to FIG. 4, the computer's next task in blocks 56 - 62 is to elevate the mains themselves. First, the computer determines the elevation of the lowest intersecting steel below the main. The computer checks the joists and beam elevations input in block 1 and takes the lowest elevation.
In block 58 , the computer finds the largest diameter of the pipe in the main and in block 59 simply elevates the main to two inches below the lowest steel found. The computer in block 60 moves the main to the new elevation. Again, the computer adjusts the riser nipple to get a ninety degree angle. The computer then adjusts the bulk elevation to match this main elevation.
In blocks 63 - 70 the computer performs a check of the system as located. The computer checks the heads and checks that the heads cover the areas they are designed to cover. These checks also include reviewing deflector distances to the top of the steel to see if it is located properly.
Next, the computer checks the distance to any walls in the vicinity and makes sure the distance from the head is correct. The computer checks the distance to nearby heads to be assured that the heads properly cover. Finally, the computer checks the distance to any nearby joists to be assured clearance is adequate. If a problem is discovered, a message is always given to the user.
In FIG. 5, the systems checks continue in blocks 71 through 80 . Now, the computer begins to look at the piping rather than the heads. The first check is to see whether the piping lengths are adequate. Then it begins to check whether the pipes avoid obstructions. First, the computer evaluates whether the piping intersects any beams, columns, joists or other obstructions found in the building. The computer also checks to see if the pipes are not intersecting with one another or impeded by any doors or walls which have been installed.
In FIG. 6, in blocks 81 - 88 , there is a second check of the sprinklers to make sure that they are adequate. This check is very similar to the one described in FIG. 4 . The only addition is in block 88 where the computer checks that the sprinkler head is not located in a light fixture.
In FIG. 7, blocks 89 through 101 , the computer evaluates the hydraulics of the system to be assured that the computer designed system will provide adequate coverage in the event of a fire. The user selects which type of flow test it is going to be using. Those two main analytical methods are the Hardy Cross and the Newton-Raphson methods. These have been described in the earlier embodiment.
Lastly, FIGS. 8 and 9, show where the computer will actually print out and list all of the elements needed to complete the job.
In blocks 102 - 119 , the computer now runs a check on the heads looking for unconnected piping or sprinklers. If it finds any unconnected heads, a message is given to the user. This can occur only if a user manually edited a system and ignored numerous messages.
In blocks 104 - 107 , the computer now checks the fittings to be sure that the fittings will connect all pipes together. The computer checks the piping types and, it also checks to makes sure the number of pipes going into a particular fitting is adequate. For example, in a tee-fitting, the computer. will check to be assured that three pipes are coming into a particular tee-fitting. The computer checks that the wall thickness in a fitting matches to the pipes and it also finally checks to make sure that the pipe angles match. If any of these tests show a problem, a message is given to the user.
The computer will check for drains in any trap pipes and will add them if needed. The computer will check the length of the pipes and the diameters of the pipes to be sure they are adequate and that the piping matches. Finally, it will check the type and number of hangers to be assured they are adequate to support the system. If necessary, the hangers will be added. Once all of these tests are done, the computer will list the job. It will first go on and list the pipe in block 120 with instructions as to how to make on the pipe fitting. In block 121 , it will list the riser nipples needed. In block 122 , it will list the sprigs needed for the system. It will list all the fittings and couplings necessary to put the system together. It will list all the nuts and bolts. It will list the heads and it will list the signs, bells and spare heads necessary for the system. Lastly, the number of hangers will be listed out.
The final step in block 130 is to draw the piping for the entire system. This drawing consists of a blueprint or other layout design to show all or selected elements for a stock list for a particular system.
The major difference between the more detailed description shown in FIGS. 1-9 and the earlier summary description is the method in which the location of heads and lines are computed in the earlier system, the lines are located first and then the heads are added on to that particular system. In the detailed description described in FIGS. 1-9, a line is added followed by the heads for that particular line and then a subsequent line is added followed by the heads for that subsequent line and so on until all lines and heads are cited. In still a third embodiment, not described, is to locate all heads first and then connect these heads with lines. In all of these cases, the mathematics is roughly similar and anyone skilled in the art would be able to interchange such systems at will.
FIG. 10 illustrates a combined warehouse and office space having a sprinkler system designed by the present invention. The building elements which must be avoided can be seen as the beams 126 , the columns 127 , the joists 128 , and the outside walls 130 . The building adjuncts which must be avoided are structures such as the lighting fixtures 131 , the interior walls 132 the HVAC duct work 133 and the warehouse lighting fixtures 134 . The designed sprinkler system begins at a water stub-in 135 .
The water stub-in is connected via mains 136 . The mains then connect to the individual lines 137 which, in turn, connect to the individual sprinklers 138 .
The sprinkler system is relatively simple to design in the large open spaces of a warehouse.
The computer essentially starts near wall 140 and locates a line 137 as described above. The next line 137 is positioned at twice the distance first line 137 is from the wall. The same. procedure of spacing is used to locate the sprinklers 138 positioned along each individual line 137 . The lines are connected to the mains at positions 141 . The lines 137 feed directly from the mains 136 which in turn feed directly from the water stub-in 135 . The major structural elements or adjuncts which the sprinkler must avoid are the overhead lights 134 , the joists 128 and the beams 126 . However, these spaced in a predictable fashion and are relatively easy to avoid.
Contrast this with the office space 142 . The interior walls 132 make positioning the sprinkler system much more difficult. There are other obstacles such as the HVAC system 133 . This makes the computations much more difficult. For example, each individual closet space 143 will need its individual sprinkler and the supporting lines and mains. Free standing walls 132 also cause problems because they interrupt the straight lines and easy flow found in the warehouse 139 . The sprinklers need to be interrupted and adjusted to fit into these particular areas. The present invention does these adjustments automatically.
An editing system can be included with the program. The editor will allow a user to alter the system as desired and will perform the checks described to prevent inadvertent standards violations. The user starts in the editing menu shown in FIG. 11 .
The user may elect to edit portions of either the distribution system (HVAC, Sprinkler System) or the structural elements and adjuncts of the building. Changes in both areas are common occurrences. For example, a user may be asked to amend the distribution system by adding sprinklers in a certain room because the building owner may desire protection in that room above and beyond that called for in the relevant code.
Another common occurrence is the rearrangement of an office layout when the tenants change. The rearrangement may require the redesign of the sprinkler system as walls and rooms are moved, added or deleted. The present invention allows a user to enter such changes to the structural elements and then amend the sprinkler system for code compliance quickly and efficiently.
In the preferred embodiment, the user selects the particular item for which change is desired from the edit menu seen in FIG. 11 . Each such item has a submenu as shown in FIGS. 12 through 21.
In general, the editing functions operate by first obtaining the element in the distribution system to change as well as the proposed change. Generally, this information is obtained from a user through a keyboard, a mouse or other standard. input devices. The process then finds or determines the dimensional requirements of the proposed change by reference to the first memory means.
Checks are then performed based upon the dimensional requirements of the proposed change, the designed layout as well as reference to the standards for the distribution system. The checks can be obstructions analyses relating to building elements and adjuncts as well as the other elements of the distribution system itself, hydraulic analyses, or requirements analyses, such determining that a given pipe can accommodate a proposed fitting.
If the checks are satisfactory, the proposed change is made and adjustments are made to accommodate the change. These adjustments are typically made to hangers, pipe lengths and wall types.
If, however, the checks indicate that the proposed change is not satisfactory, the editing function will generate an error message.
Once all the editing is complete, a hydraulics analysis as described earlier is run to be certain the distribution system will perform. If satisfactory, an elements listing and revised layout are generated.
FIG. 12 shows the menu for editing the pipes. As shown the preferred embodiment includes a multiplicity of choices for editing pipes. Selecting any of these choices brings you into actual operation of the program.
To add pipe 144 , the user selects this option from the editing pipes submenu. The user must select a fitting to add to the pipe. To add this fitting to a pipe 145 , a user must select where on the pipe the fitting is to be positioned. A check is made on this location to determine if the selected fitting can be added. If the fitting is so close to another fitting such that no piping can connect the two fittings, a message is generated and the subroutine terminates.
If the fitting can be added, it is. On the other hand, if a new fitting is added at the location of an old fitting 146 , the old fitting is simply replaced.
A check is made to determine what direction that pipe can be added to the selected fitting. For example, adding a T-shaped fitting to the middle of a length of pipe restricts the possible directions of an added pipe to a plane which is perpendicular to the pipe at the proposed fitting.
The program gets the direction, length and pipe type and diameter for the added piping. A new fitting is then located at the end of the added pipe opposite the existing piping. A check is made to determine if the added pipe and the new fitting will intersect any of the structural elements and adjuncts or the elements of the distribution system. If it does, the user can optionally terminate the addition.
The fittings and the pipe therebetween are then. added to the distribution system as well as any hangers and adjustments to fittings needed. The program can loop back and add pipe from the new location if desired.
The wall type 147 and diameter 148 of a pipe can be changed and all related changes are performed automatically. For example, new fittings, hangers and cut lengths are. determined. Such automatic changes are also made when any element of the distribution system is changed.
The length of a pipe can be changed 149 by selecting which pipe to change and which fitting to move. The desired change can be entered as either directly to the cut length of the pipe or as the distance from a center of one fitting to the center of the second fitting. The distance and direction of the proposed movement are obtained from the user.
A check is automatically performed to see if the selected fitting can be moved as desired. The checks are to be certain that the fitting is not moving through another fitting and that other pipes attached to the fitting are also movable. If the fitting cannot be moved, the user is informed and the subroutine terminates.
If the fitting can be moved, the hangers are deleted, the fitting is moved, the pipe length is adjusted and the hangers added back to the distribution system. The change is then complete.
Piping can be deleted 150 . A pipe is selected and then the hangers and the pipe itself are removed form the line and the database. The pipe is disconnected from the appropriate fittings which are then adjusted or deleted accordingly. If the pipe is the last pipe for a given line, the line itself is also removed.
A pipe can be moved 151 if desired. The directions that the pipe can be moved are determined and a specific direction and distance are selected. A check is made to determine if relevant fittings can be moved as described previously. If not, the user is informed and the subroutine terminates.
If the pipe is movable, the hangers are deleted, the pipe is disconnected from the fittings, the fittings are moved, the pipe is moved, the fittings are reconnected and the hangers are added back in.
Two pipes can be selected and joined together 152 . If the pipes are parallel, the X, Y location of either end of one of the pipes must by located between the ends of the other pipe to join. If not, a message is given and the subroutine terminates.
If the pipes do overlap, then the location to join the pipes is determined. If the pipes are at differing elevations and if the pipes we are joining are two mains, the one sloping pipe is used to join. Otherwise, one Z-axis pipe and one level pipe are used to join the two pipes.
If one sloping pipe is used, couplings are added to each pipe, the pipe type and diameter are selected and the pipe is added in between the couplings. If two pipes are used, couplings are positioned on each pipe and at the location in which the two new pipes will meet. The pipe diameter and types are related and the pipes added between the couplings. In both the one pipe and two pipe options, the fittings, hangers and cut lengths are adjusted accordingly.
If the pipes are not parallel, they are perpendicular and a check is made to see if they cross each other. The two ends of each pipe are checked to determine if they fall on opposing sides of the other pipe.
If the pipes do cross, fittings are added at the crossing points on both pipes. If the fittings are abutting, fittings are joined. If the fittings are not abutting, pipe is added therebetween to join the fittings.
If the pipes do not cross, the pipes with the least slope is extended until the pipes do cross. Then the procedure is as discussed above for crossing pipes.
In all cases, a final adjustment is to the fittings, hangers and pipe lengths before the subroutine ends.
A pipe can be selected for extension 153 . A fitting and a direction to extend are selected. A check is made to be certain that pipe can be added to the selected direction. If. a pipe already extends from the fitting in that direction, another cannot be added. Also, a proper fitting must exist to allow the desired extension. If not, a message is given to the user and the subroutine terminates.
The distance and final location at the extended pipe end is determined. If the fitting is a cap, then the hangers are removed, the cap is moved and the hangers are simply replaced. If the fitting is not a cap, a fitting is positioned at the extended pipe end, piping is added between the fittings, the fittings are adjusted and hangers are added.
A pipe can be selected for disconnection 154 from a fitting. A check is made to determine if one or two pipes are found at the particular fitting. If only one, the pipe cannot be disconnected as the fitting would be left with no piping. If two, a cap is added at the same location as the fitting. The selected pipe is disconnected from the old fitting and the cap in connected to the remaining pipe. The old fitting is adjusted as needed as well as the length of the remaining pipe.
A pipe can be offset around a beam 155 . The pipe to be offset is selected and the intersecting beam is formed. If no such beam is found, the subroutine automatically terminates. The location on the piping on either side of beam to be offset are found.
Couplings are added at both such locations. The distance that the pipe needs to be offset is also found. The line is then moved between the couplings this distance. A plug is added to one of the fittings and final adjustments are made to the fittings, the cut length of the pipes and the hangars.
Detail boxes can be inserted or highlighted in the drawings for various portions of the distribution system. Such portions can include an anti-freeze loop 156 , an auxiliary drain 157 and a fire hose rack 158 .
The anti-freeze loop and its detail box can be deleted 159 . The starting and ending fittings are first determined and all other lines connected to the loop are deleted. The line for the loop is determined and each pipe of the line is deleted until none remain. The starting and ending fittings are then connected and the standard adjustments to the fittings, the pipe length and the hangars are made.
Of course, an anti-freeze loop can also be added 160 to the system. The starting and ending locations for the loop are obtained. A check is made to certain that enough room exists for the loop. If not, the program terminates.
If there is enough room, couplings are added to both the starting and the ending location. The pipe between the starting and ending locations is deleted.
A location is found to position a control valve on the pipe connected to the starting location. A coupling which is later changed to a control valve is added. The hangers and the pipe lengths are adjusted.
At the starting location fitting, a pipe is added two inches (5.0 cm) up from the fitting and a globe valve is positioned on the end of this pipe. A pipe is extended two inches (5.0 cm) from the globe valve and a fill cup is positioned on the pipe.
At the starting location fitting, a pipe is added to extend one foot (30.5 cm) down from that fitting. A weld tee is added to the end of the one foot pipe. The fittings and cut lengths are adjusted.
A nipple, a three-inch (7.5 cm) pipe, comes out of the weld tee. A second globe valve is added at the nipple's end. A plug is added to the globe valve and the nipple's cut length is adjusted.
A pipe is added to be four feet (1.2 meters) down from the weld tee. A second weld tee is added at the end of the four foot pipe. Again, a nipple is added to the weld tee with a globe valve and plug. The nipple length is adjusted.
The bottom of the loop is determined. A pipe is added for the weld tee. to this location. An elbow is added to the end of this pipes and the pipe's length is adjusted. Also, a location is determined for a check valve. Piping is added to this location from the elbow and the check valve added to the end of the pipe.
Lastly, a location is determined to rise up to the ending location. Again, pipe is added to the rise up. location from the check valve. An elbow is positioned at the end of the piping and the standard adjustments made. A drain is positioned at the elbow. The end location fitting and this elbow are connected with a pipe. Again the standard adjustments are made.
A drain can be added 161 to the distribution system. If the distribution system is a dry system which will trap more than five gallons (19 liters) of water, a condensate valve will be added.
If the drain is to be added to a fitting, that fitting is simply selected. If the drain is to be added to a pipe, a location on the pipe must be selected and a coupling added to that location. A direction to add the drain is obtained.
At the selected fitting, a one-foot (30.5 cm) pipe is added in the chosen direction. A new fitting, a globe valve, is added to the end of the one-foot (30.5 cm) pipe. The length is then adjusted downward to three inches (7.5 cm).
If the system is a dry system with more than five gallons (19 liters) of trapped water, a one-foot (30.5 cm) pipe, one inch (2.5 cm) in diameter, is added to the globe valve. A coupling is added to the end of this pipe and the length adjusted to three inches (7.5 cm).
Another one-foot pipe (30.5 cm) with a two-inch (5.0 cm) diameter is added to the screwed coupling. Again, a screwed coupling is added to the end of the two-inch (5.0 cm) pipe and the cut length is adjusted to one foot (30.5 cm). A one-inch (2.5 cm) diameter pipe is added to the screwed coupling. A globe valve is added to this pipe and the length of the pipe adjusted to three inches (7.5 cm).
In all cases, a plug is added to the globe valve which is at the end of the piping. A note is added to the drawing relating to the added drain.
A drain can be deleted 162 . The desired drain is selected and a check is made to confirm that the-selected fitting is a globe valve with a plug and that it is therefore a drain. If it is, the drain is changed to a sprinkler and then deleted.
The drain in the distribution system can be highlighted or not highlighted 157 . A check is made of each fitting in the distribution system to determine if it is a drain and that it is connected with pipe to the distribution system. If it is a drain, it is highlighted or not highlighted as selected. The drains in the distribution system are also counted.
A fire hose rack can be added 163 by selecting a location which will then be adjusted to correspond to the nearest column. If the building has more than one distribution system, pipe is obtained to connect the location to the other systems. Otherwise, the closest main is selected for connection.
The direction, the elevation of the fire hose rack and the elevation at the top of the drop are obtained. A fitting is then added at the top of the drop. A tee is added at the elevation for the hose rack.
One inch (2.5 cm) pipes are added to both the drop fitting and the tee. A pipe is also added to the tee in the direction of the fire hose rack. A hose unit is added at the end of this pipe. The cut length is also adjusted to three inches (7.5 cm).
A six-inch (15.25 cm) downward extending pipe and a cap for the pipe are added from the tee. The top of the drop is then connected via a pipe to the tee. The elements of this pipe, the associated fittings, cut lengths and hangers are all adjusted. A detail box can be added to the drawings if desired.
The direction of the fire hose rack can be changed by simply selecting the new direction 164 . The piping and the hose unit at the old location are deleted while the new pipe and hose unit are added. A similar adjustment can be made for the elevation of the fire hose rack 165 . However, a check is made to be certain that the new elevation is not above the pipe at the top of the fire hose rack.
The fire hose rack and its associated detail box, if any, may be deleted 166 by simply by selecting it. The fire hose rack is changed to a sprinkler and simply deleted.
A fire hose rack may be joined 167 to a distribution system. The fire hose rack to be joined is first selected. If more than one system is in the distribution system, a pipe in another system is selected for joining, else a pipe in the current system is selected. The location on the pipe to join is chosen and the two pipes are joined.
Flushing connections are added 168 by selecting a fitting. A check is made to be certain that the selected fitting has a cap and is on a main. The cap is extended one-foot (30.5 cm) form the fitting where the appropriate coupling is substituted for the cap. A two-inch (5.0 cm) pipe is added from the coupling to the cap. The cut length of this pipe is adjusted to six inches (15.25 cm).
The deletion of a flushing connection 169 is the reverse of the above. In essence, the pipe and coupling are deleted while the cap replaces the coupling. Of course, appropriate checks are made to be certain that the desired deletion really is of a flushing connection.
An inspector's test connection can be added 170 to the distribution system. Again, either a fitting is or a location on a pipe is selected. If a pipe, the appropriate fitting is added at the chosen pipe location. A check is made to be certain a coupling can be added at the selected location.
A wall, preferably an outside wall, is selected for the test connection to extend through. A one-inch (2.5 cm) diameter pipe is added from the fitting to wall. A location for a globe valve is chosen and a one-inch (2.5 cm) pipe added from fitting to that location. A globe valve. is then added.
A location for an elbow at the end of a drop is chosen and a pipe is added from the globe valve to that location. An elbow is added to the end of the pipe.
A location for a smooth bore outlet is selected on the outside of the selected wall and a pipe added from the elbow to that location. The smooth bore outlet is added at the end of this pipe. The pipe through the wall will be denoted as being galvanized.
To delete the inspector's test connection 171 , the smooth bore outlet is found and deleted after being. converted to a sprinkler.
A mutual can be added 172 to the system. First, a pipe for the mutual rust be selected as well as two fittings for the mutual. One of the fittings must be an elbow with a drop. The location of the other fitting is saved while the pipe is disconnected from the fitting.
A new location is found for the pipe which determines the distance to move each fitting on that pipe. The fittings are then moved and a pipe is added to connect the moved pipe with the saved fitting. The deletion of a mutual 173 is the reverse of the above process.
A nipple end cap combination can be added 174 to an existing fitting if steel is found nearby. The direction to add is found and checks are. made to determine (1) if the fitting type is appropriate and (2) that no existing pipe prevents such an addition.
A location and distance are found to add the nipple and the cap. A pipe is added from the fitting in the found direction and to the found distance and a cap is added at that location. All standard adjustments are performed. Again, the deletion of a nipple and cap 175 is simply the reverse of the above procedure.
Standpipes can be added 176 to the distribution system. The location of the standpipe is obtained as well as the number of floors within the building. A floor, its elevation and the elevation for a hose valve are obtained.
If a first floor standpipe is to be added, an elbow is mounted at that location and elevation and a hose valve added to the elbow. If other than the first floor, a tee is added at the hose valve elevation and a pipe added from the tee to the previous fitting (tee or elbow). A hose valve is added to each such tee. The pipe length is adjusted and hangers added. This procedure is repeated until the top floor is reached.
On the top floor, a pipe is added up from the tee and a weld tee added to the top of this pipe. A pipe and a cap are added up from the welded tee. Also, a pressure gauge is added to the welded tee. All standard adjustments to fittings, pipe cut length, diameter and wall tape end hangers are performed.
The deletion for the standpipe 177 is simple. The standpipe line is selected and deleted in its entirety.
To move a standpipe 178 , the distance and direction are first obtained. Then each pipe and its associated fittings are moved the chosen distance and direction until all such pipes have been moved.
FIG. 13 shows the menu for editing the fittings. As shown therein, it is seen that the preferred. embodiment includes a multiplicity of choices for editing fittings. A user simply selects any of these choices as desired.
To add a coupling to a pipe 179 , the pipe and the proposed location on the pipe for the coupling are obtained 180 . At that point, the line the pipe is in is found as well as the fittings at either and of the pipe. All the hangers for the pipe are then deleted.
A new coupling is added at the chosen location. A pipe is disconnected from one of the end fittings and extended to the added coupling. A new pipe connects the other end fitting with the added fitting. The hangers are replaced and adjustments are made to the fittings and the length of the old and new pipes as needed. Reversing the above procedure will delete a coupling 181 .
Addition of a plug to a fitting 182 is simple. The fitting is chosen as well as the plug's direction. The plug is added and appropriate adjustments made. The reverse holds true for deleting a plug 183 .
A tee with a plug can be added to a pipe 184 . The pipe is selected as well as the location for the tee. The tee is added as any fitting would be (see above) and a plug added to the tee.
A valve can be added to a pipe 185 by adding a fitting to the pipe as described previously. The fitting is then changed to a valve and adjustments made to the pipe wall and the length of the pipe. The procedure for adding a union 186 is identical except the fitting is changed to a union.
A fill cup can be added 187 to a cap or a coupling by selecting the particular fitting and the direction to add. A globe valve is added to the fitting. A two-inch (5.0 cm), long pipe is added to the fitting in the selected direction. A fitting is added to this pipe and a fill cup added to the fitting. A check is made to be certain that the fill cup is added to the globe valve. To delete a fill cup 188 , the chosen fill cup is changed to a sprinkler and the sprinkler is then deleted.
A wall hydrant can be added 189 to a selected fitting or a main. An outside wall must be available which to add the wall hydrant to or else the subroutine terminates. A direction is chosen and is also checked to be certain that pipes can be added in that direction.
A location inside the chosen wall is obtained for a drop and for a control valve. A pipe is added from the chosen fitting to the drop location. An elbow is added to the end of the pipes and adjustments made to the fitting and the pipe length while hangers are added.
Pipe is added from the elbow to the control valve location. A control valve is added at that location and the pipe length is adjusted. Another elbow is added to the control valve.
Pipe is added from the second elbow to the wall hydrant location and a wall hydrant is added. A ball drip is added to the lowest elbow elevation. The pipe lengths are adjusted accordingly.
The wall hydrant is deleted 190 by determining the wall hydrant to delete and finding the point on the main to stop. The components are deleted one by one from the wall hydrant to the main.
A fitting can be selected and changed 191 to a new type of fitting. All pipes connected to the old fitting are adjusted to accommodate the new fitting.
A fitting can be moved 192 by either obtaining the direction and distance to move 193 or obtaining the fitting to move towards 194 . If the second option, the distance and direction are determined by the relative positions of the stationary fitting and the fitting to be moved.
All hangers are deleted and the new location of fitting determined. The fitting is moved along with any pipes in the fitting. All pipe lengths in the fitting are adjusted and the hangers are then replaced.
Two fittings can be chosen for merger or joining 195 . If the fittings are in the same location one is deleted. Pipes which connected to the deleted fitting are then connected to the remaining fitted and adjusted accordingly.
If the two fittings are separated, a pipe is added to join them. The two fittings, the wall type and length of the pipe are adjusted and hangers added.
FIG. 14 shows the menu for editing the sprinklers. As shown therein, it is seen that the preferred embodiment includes a number of such options. Selecting any such option bring forth the desired subroutine.
This submenu includes a subroutine which allows the automatic placement of sprinklers in an office 196 . This feature is useful when office space is redesigned to accommodate a tenant. The new office room is first selected together with the hazard type of the room. Information relating to the orientation and positioning of the room's walls is thereby obtained.
If the room is not a simple-shape which are defined as squares, rectangles or trapezoids, it is divided into a minimum number of sections which are simple-shaped. If such an automatic division is not possible, the division can be done manually. If the room itself is simple-shaped, then it is also divided into subsections. A simple-shaped section is selected to begin. The subroutine will repeat until no such sections are found.
The program will place the sprinklers in the center of a ceiling tile if available. The distances between extreme left and extreme right and extreme front and extreme back points are determined. These distances yield the area of the simple-shape section.
The distances determined above, the section area and the hazard type of the room are compared with the appropriate regulations to determine the: number of lines needed in the simple-shaped section, the distance between the lines and the distances between the sprinklers. The sprinklers are then positioned to be free of building adjuncts. The locations and distances are checked for compliance with regulations and adjusted if needed.
A sprinkler can be added 197 to the distribution system by three separate paths. First, a sprinkler can be added to fitting. A check is then made to determine whether a sidewall, upright or pendant sprinkler is appropriate. The selection is made from the acceptable types and the selected types are installed.
If a sidewall sprinkler, a further check is made of the possible directions to add and one possible direction is selected. If a pendent sprinkler, a further check is made to see if a suspended ceiling led to this choice. All fittings are adjusted as needed.
A sprinkler can be added directly to a pipe. As is normally the case, the location on the pipe is determined and a fitting added thereto. The sprinkler's type and elevation are determined in view of any suspended ceiling and the elevation of the pipe.
The sprinkler is then positioned of the desired location. A check is made to determine if the sprinkler location matches the pipe's location. If not, pipe is added and the standard adjustments are made. If the locations are the same, no pipe is added and only the fitting is adjusted.
A twist to these situations occurs when placing a sprinkler under an overhead door. The overhead door is selected as well as a location for a drop. A check is made to determine if another door is within a certain distance which is dependent on the relevant standards. If no such nearby door is found, the drop is six inches (15.25 cm) from the door. If a second door is nearby, the drop is placed midway between the two doors.
The closest pipe and the nearest point on this pipe to the drop are determined. A coupling is added to the pipe at this location. A first fitting is positioned at the X, Y location of the drop but at the elevation of the coupling on the pipe. The coupling and the first fitting are joined as described above in joining fittings.
A second fitting is added eight inches (19.3 cm) below the door. The first fitting is also corrected and adjusted with a pipe. If two doors are involved, two more fittings are positioned six inches (15.25 cm) from each door's edge and eight inches (19.3 cm) under it. If only one door, a third fitting is added six inches (15.25 cm) from the door edge and eight inches (19.3 cm) under it.
The new fitting(s) situated under the doors is connected to the second fitting with pipe. All the fittings are adjusted. A side wall sprinkler then is added to any under-door fittings.
Sprinklers can be deleted 198 from the system. If pipes exist solely to connect the sprinklers to the distribution system, they can also be deleted if so desired.
An unconnected sprinkler may be connected to a pipe 199 or an outlet 200 . First, a check is made to determine if the sprinkler is unconnected. If it is, it is then deleted from the distribution system. A sprinkler of the same type, diameter and direction is then added to either the pipe closest to the original location or to an outlet which is altered to be a regular fitting.
To disconnect a sprinkler 201 , a check is first made to be certain the sprinkler is indeed connected. The fitting the sprinkler is connected to is determined and the sprinkler is then disconnected therefrom. The fittings are adjusted as needed. Alternatively, the sprinkler can simply be changed to a plug.
A head guard can be added 202 to an existing sprinkler if one is not present. Of course, a head guard can also be deleted 203 if the sprinkler already has one. A sprinkler's temperature range 204 and diameter 205 can also be altered.
A sprinkler's outlet size can be changed 206 to a different valve if it is not connected to the line by a vertical pipe and is connected by either a bushing or a standard fitting.
If the sprinkler is connected to the line by a bushing, a check is made to determine if the new outlet size is the same as the sprinkler's diameter. If it is, the bushing and the old sprinkler are deleted and the new sprinkler substituted. If not, the bushings diameter is simply altered to fit the new sprinkler.
If the old sprinkler was connected to the line by a standard fitting, than a bushing of the appropriate diameter must be used to connect the new sprinkler.
A sprinkler's type can be changed 207 to a type different than the original. If the old sprinkler was attached via a vertical pipe, the location of the vertical pipe is obtained. If the new type is a sidewall sprinkler, the direction of the sidewall is also obtained.
If, however, the new type is not a sidewall but the old type was, then the pipe direction must also be obtained. Depending on the direction of the pipe, the sprinkler type is changed to either a pendant or an upright. The vertical pipe is also deleted.
On the other hand, if neither the new type nor the old type is sidewall, no other information is needed. The new location and type are obtained and assigned for the sprinkler.
If the sprinkler is not connected by a bushing or a standard fitting, then an error message is generated. If it is connected by a standard fitting, and the new type is a sidewall, the new location and type are obtained and assigned to the sprinkler.
If it is connected by a standard fitting and the new type is sidewall, the sidewall's direction must be obtained. If that direction is already occupied, another error message is generated. If it is not occupied, then a new location and type are assigned to the sprinkler.
A sprinkler can also be moved 208 . If the sprinkler is unconnected either the new position or a distance and direction are given to move. The distance and direction are later converted to a new position. The new position is the assigned to the sprinkler.
If the sprinkler is to be moved is the X, Y plane, the distance to move is obtained. The sprinkler, its fitting and all other fittings between the old and the new position are moved.
If the sprinkler is to move in the Z-direction, the sprinkler's type is obtained and it is determined whether a vertical pipe on the sprinkler exists. If such a pipe is found, the direction of the pipe is determined. If the direction to move the sprinkler is the same as this direction, then the sprinkler is simply moved. If it is not, then the length of the vertical pipe is determined. If the distance to move is greater then this length, no move is allowed. If it is not, the sprinkler is moved as desired.
If no vertical pipe is found, then the sprinkler direction must be the same as the proposed move direction or. a move is not permitted. If the directions are the same, any bushing is first deleted. The sprinkler type is saved and the sprinkler is then deleted and the. fitting added to the location of the deleted sprinkler. A cap is added to the new location and the fitting and cap are connected. The fitting is adjusted and the sprinkler substituted for the cap.
FIGS. 15 and 16 show the menus for editing the lines-and the mains respectively. As shown therein, it is seen that the preferred embodiment includes a number of options for editing the lines and the mains in the system. Due to the similarities between lines and mains, many of the functions performed in each submenu are the same for both.
To add a line 209 , the starting point and ending point for the line are obtained. Fittings are situated at both points and a pipe is added to connect the two fittings. This arrangement is a line.
A review of all piping is made to find a main that crosses the line. If no such main is found, the line can be completed but it will be unconnected. If such a main is found, the line will be connected to that main via a riser nipple which is adjusted appropriately. The program cycles until all mains which cross the line are found and connected with the line as described.
At this point, sprinklers can be added to the line if desired. The distance between sprinklers is obtained and the first sprinkler is positioned at the starting fitting. Subsequent sprinklers are spaced the obtained sprinkler separation distance until the end of the line is reached.
If the default for adding welds to the line is set, such welds are now added. Once the welds are added, or if the default is not set, the line is positioned at the proper elevation. A check is performed to determine if the line is hitting anything. It if is, a message to that effect is generated. Lastly, the hangers are added to the distribution system.
To delete a line 210 , the line is first selected. A pipe in the line is found and deleted along with all the fittings on the pipe. This process repeats until no further piping is found.
The diameter of a pipe can be changed 211 by the pipe schedule 212 which is provided by the data base. A starting fitting, a direction to change and the type of schedule to use are selected. Beginning with the starting fitting, the pipe to be changed is marked as well as the fitting on the end opposite the starting fitting. If the second fitting is a sprinkler, it is counted. This process cycles until all pipes are found.
The process returns to the starting position and finds the current pipe diameter. The diameter is changed and the next pipe found. This process repeats until all diameters are changed.
A line can be copied to another location 213 . The copying can be done to an empty space 214 or to replace an existing line 215 . The existing line to be replaced is first deleted when the location for the copied line is found. The differences to move are calculated.
A pipe on the line to be copied is obtained as well as the fittings at both ends of the pipe. A check is made to determine if these fittings have already been copied. If not, the same types of fittings are situated at the new location.
Piping is then positioned between the two new fittings and adjustments made to the wall type and the cut length. The process repeats until the entire line has been copied.
Once completely copied, the riser nipples and the hanger are added. A check is made to be certain that the new line does not hit anything. If it does, a message to that effect is generated. The subroutine then terminates.
The overhang pitch of a line may be altered 216 . The line and the fitting to change are obtained. The corresponding fitting on the main, the orientation and the amount to slope are then found.
The process then gets the line to slope. The two fittings to change are found and marked to the correct location for the chosen slope. The process iterates until no further pipes are found. The hangers and the pipe lengths are adjusted accordingly.
The sprinkler spacing on a line can be changed 217 . The line, the location of the first sprinkler and the new desired spacing distance between sprinklers is obtained. A pipe on the line is found as well as fittings on both ends. If either fitting is a sprinkler, it is deleted. This process repeats until all sprinklers or the like are deleted.
A sprinkler is then added at the starting location and subsequent sprinklers are positioned on the line with the new spacing until the end of the line is reached.
If no welds exist in a line, they may be added 218 . The line to add welds and the amount of welds allowed are obtained. Then, the first fitting is found and a determination made whether the fitting should be a weld fitting or not. If it is, it is changed to a weld fitting. The next fitting is found and counted and the process repeats until all the fittings are fully accounted for. Deletion of welds 219 is essentially the same process except all welded fittings which are found are now changed to non-welded fittings.
A riser nipple can be moved 220 . The particular riser nipple to be moved is obtained as well as the fitting on top of it. The pipe which goes into the top fitting is also found. A check is made to be certain that this pipe is an armover, otherwise the subroutine terminates.
A location on the main is found to which to move the riser nipple. A coupling is added at this location. The armover pipe and the riser nipple are then deleted. A riser nipple is then added from the top fitting to the main fitting and the riser nipple adjusted.
The editing of a fire hose rack to a line is identical to the procedures as described previously in connection with a pipe.
Turning now to some subroutines found only in the edit mains submenu of FIG. 16, one can add a main across a number of lines 221 . The first line and the last line are obtained which allows the orientation of the mains to be found. The location on each line where the main is to connect is checked to be certain that the main can be added. The main must also follow either an X-axis or Y-axis orientation only. If suitable locations are not found, the subroutine terminates.
If suitable locations are found, fittings are added to the first line and the last line. These fittings are connected with pipe. Each line pipe is found and evaluated to determine if it crosses the new main. If it does, the line is connected to the main by a riser nipple where they cross. The process repeats itself until no lines remain. At this point, the main is elevated and hangars are added.
Alternatively, a main can be added in space 222 . The proposed starting location, ending location and orientation are obtained. Fittings are added to both the starting and ending locations. A pipe is added which connects the two fittings. Lastly, the main is elevated and hangers added.
A main can be deleted 223 if desired. If the main has a sloped overhang, the slope is first set to zero. The pipes which make up the main along with corresponding fittings are deleted until no such pipe remains.
Quite a number of the subroutines found in both the edit line submenu of FIG. 15 and the edit main submenu of FIG. 16 are equivalent.
For example, the wall type 224 (e.g. thickness and composition) or the diameter of a line/main 211 / 215 can be changed on all lines/mains 228 , on one line/main 226 or on one part of a line/main 227 . The line/main to be changed is selected as well as the new wall type or diameter. Each pipe in the line/main is changed until all have been altered. If it is determined that the cut length of any altered pipe is too small, the wall type or diameter is changed back to the old type and a message to that effect is generated.
The slope of a line/main 229 can be changed by selecting the line/main, the fitting on the end of the line/main to move and the orientation to move. The slope can be changed by either obtaining a direction and amount to move or a direction, a slope and a fitting to move. If the latter, checks are made to be assured that the desired slope is greater than one inch (2.5 cm) in ten feet (3 meters). If less than that slope, the user is prompted to slope only part of the line/main.
A check is performed to see if any fitting will be bent past tolerance by the proposed slope. Also, a check is made to discover any other pipes which are attached to the line/main (not counting riser nipples). If either situation is found, the subroutine terminates.
A line/main pipe and its respective fittings are then found. The fittings are moved to the correct location for the desired slope which also moves the pipe. Another line/main pipe is found and its fittings moved and so on until all such pipes. and fittings have been moved. At that point, the pipe lengths and hangers are adjusted. If this is a main, lastly the riser nipples are adjusted.
A line/main can be moved 230 by selecting the pipes to move and the direction and distance to move. A check is made to determine if pipes connected to the line/main which are not in the line/main can also be moved. If not, the subroutine terminates.
A pipe in the line/main and a fitting at one end are moved. If other pipes are in fitting, these are also moved. The process repeats until all pipes and fittings both in the line/main and connected thereto are moved. The riser nipples and hanger are finally adjusted. Lastly, a check is made to be certain that the moved line/main is not hitting anything.
Couplings can be added to a line/main 231 . A line/main is selected as well as the fitting to start. The distance between couplings, the direction to add the couplings and a location for the new couplings are obtained. A pipe on the selected line/main is found.
If the pipe has a location to add a coupling, that location is found and the coupling added. The process cycles until all desired couplings are found. Hangers are then adjusted.
To delete couplings 232 , a search for all couplings on a line/main is made. Any such couplings are deleted. Once complete, the hangers are added.
Lines/mains are optionally labelled 233 . The editing function allows such labelling to be turned on and off as desired. The on and off labeling routine continues pipe by pipe until completed.
FIG. 17 shows the submenu for editing the hangers. This portion of the editing menu is less complex than those depicted in earlier submenus.
To change a hanger type 234 , the hanger to be changed is obtained as well as the desired hanger type. The new type is simply substituted and a new rod length calculated.
Hangers may be deleted 235 either individually, by pipe, by line or to the entire distribution system. To delete an individual hanger, it is simply selected and deleted.
To delete all hangers, a cycle begins where each hanger is found. The same cycle occurs with the process of deletion of hangers on a pipe or a line with the additional search criteria that a selected hanger must be on the pipe or line.
Hangers can be added 236 to a location to a pipe. If a location, the pipe at this location is found as well as its orientation and end points. A check is made to be certain no other hangers are too close. If a hanger is too close, the subroutine terminates.
Next, it is determined whether or not the hanger will be mounted on, in preferred order, concrete, a joist or a beam, or trapeze style from two steel parts. If none of the above are found, the subroutine will also terminate. The rod length is calculated, the hanger type determined and the hanger added.
Hangers are added to a pipe by first selecting the pipe. The orientation and distance to the nearest steel is determined as well as the distance to the feed main. The start and end fittings of the selected pipe are found as well as the location on the pipe to start.
The program determines whether the hanger will be mounted on a joist, a beam or trapeze-style from two such pieces of steel. If no mounting locations are found, the program terminates. Once a suitable mount is found, rod lengths are calculated and the position and type of hanger are added. A check is made to determine if the location of the hanger is too far from the pipe ends. If so, more hangers are added until the pipe is properly supported.
To change hanger type, the new type as well as the hanger to change are determined. The change is simply made at that point.
In FIG. 18, the submenu for editing the headers is shown. This submenu also. includes options for editing certain auxiliary portions of a distribution system. These auxiliaries include water flow switches, bells, alarms and the fire department connection.
Water flow switches can be added or deleted 237 as desired. To delete, the water flow switch to delete is simply selected and then automatically deleted. The total number of such switches is reduced by one. The addition of a water flow switch is simply the reverse except a check is also made to be certain a water flow switch is not already positioned there.
Bells can be added, deleted or changed 238 as desired. To add, it is necessary to determine whether the bell to be added is inside, outside or both as well as the wall to mount it upon. The bell is drawn and its location and number stored. Deletion is the reverse process. To change, a bell is selected with the desired change and it is simply made and stored.
A fire department connection can be added, deleted or changed 239 . If no such connection exists, it may be added if desired. A wall is selected for the connection as well is a riser to start building the connection. The riser elbow in replaced with a tee. A check valve, an elbow, a pipe and finally the connection itself are added in sequence.
To delete a connection is the reverse of adding. The process starts with the connection and deletes pipes and fittings one by one until the check valve is reached. It then goes one more fitting. In addition, an inside and outside bells can now be deleted if desired. Further, any detail box for the connection can be deleted as well. After both deletion and changing of the connection, a check is made to determine if a new connection should be added.
Turning now to the headers themselves, the details of header can be changed as desired 240 . Included among these options are the addition, deletion and. change of headers.
A header can be added as a new component or to replace an existing header. In replace an existing header, the line where the riser is found is obtained. That line together with the water flow switch, the pipe stands, dimension lines for the measurements the building and components, and the bells are all deleted. Thus the existing line is removed to allow for addition of its replacement. of course, deletion is available even if a replacement is not desired.
There are three options to build a header, (1) automatically, (2) by recall of a stored header and (3) by custom building. A header can be automatically built by obtaining the location of the water stub-in, the default header diameter and the header direction. A flange followed by a flanged tee are added to the underground pipe. One end of the flanged tee will go to domestic service. The other end will have a OS&Y valve.
As an option, a backflow preventor followed by a second OS&Y valve can be installed. In either case, the last OS&Y valve is followed by a secured flanged tee. One end of the second flanged tee can include a fire department connection if desired.
If more than one system exists in the building, an OS&Y valve is added at the other end of the tee. Whichever system is employed, a vertical pipe is now positioned on the previous fitting. A weld cross is added to the vertical pipe.
An angled main drain is added to one side of the weld cross with a gauge assembly on the other. A second vertical pipe with a cap is added to the top of the cross. Bells and a flow switch are the last additions to complete the header.
Once a header is built, it can be stored into memory. As such, it can be easily recalled for use where another header is desired.
A header can also be custom-built. The process is the same as an automatic build up to adding the flange to the underground pipe. After that point, the fittings submenu (FIG. 13) will come up and a header can be custom-designed.
Once the header is completed by the installation of a cap or a plug, or deciding that it is finished, the positions of the flow switch, the pipe stands and the dimensions are obtained. These items are added and the custom-built system is finished.
The header direction or location can be changed. For example, the direction can be changed by obtaining the new direction desired. The existing header is stored in memory and then deleted. A water stub-in is then added at the header's location. A loop is performed in which the direction of each fitting in the stored header is changed be accommodate the-new direction. The stored header is then recalled.
The header can also be moved a distance and a direction. Both the distance to move and the direction are obtained. A. check is made to be certain that the new location will not be outside the building. If it is, the subroutine terminates. If not, the amount is added to the X, Y coordinates of all end points of the header, thus moving the entire header the desired direction and distance. In essence, the same procedure is followed to move to a new location.
In addition, the fittings and the pipes in the header can be edited as discussed previously for pipes and fittings in general. In addition, spools and pipe stands can be added or deleted. The diameter of either the header or the underground pipe are also editable.
The steel or structural elements of a building can also be edited as shown in FIG. 19 . The user would select the desired option from the edit steel submenu as desired.
For example, a column can be added 241 on a wall, on a beam or at any X, Y location. The X, Y location or the location on the beam or the wall are obtained. The column angle, its depth and its width are also gathered.
A check is made to be certain that no other columns would contact a column at the desired location. If none is found, the column is added.
To delete a column 242 , it is simply selected and deleted. To move a column 243 , the desired column is selected along with a direction and distance to move. The column is simply moved to the new location.
The type, angle or size of a column may be changed 244 also. The type (I-beam, rectangular or circular) and the angle is obtained along with the desired column. The change in then made.
To alter the size, the column is first selected. If it is a circular column, the new diameter is obtained and the change is made. If it is a non-circular column, the new column depth and width are obtained. A check is made to be certain the new dimensions are less than 8 feet (3.25 meters) and then the change is made.
A beam can be added 245 as desired. The first and second end points on either a column, a beam or a wall are selected. A check is made to be certain the first and the second points are not in the same beam, column or wall. An error message is generated to that effect if they are.
The beam depth is obtained. A check is made to determine if the beam is to the deck which automatically sets the height of the beam. If it is not, then the beam height must be obtained.
A check is made to be certain that the new beam does not cross other beams. If it does, an error message is generated. If it does not, the beam is added and the two end points corrected for the-wall, column or beam elevation.
A beam can be deleted 246 if desired. A check is made to determine if joists on both sides will match up. If not, a warning message is generated though the deletion can still occur.
The matched joists on both sides are connected together while unconnected joists are deleted. All beams and joists which are left overhanging columns (stumps) are extended or deleted as needed. This process deletes the beam.
A beam can be changed 247 in a number of ways. For example, the beam elevation, depth and width can be changed by simply selecting the beam to change and the desired change. It is then made and adjustments to the elevation of the line and main are automatically made.
The bearing plate thickness of a beam can be changed as described above except a check is made to be certain that the new thickness is not greater than the joist depth. If it is, there will be a joist in space not bearing on anything. The hangers are adjusted and the line and main are elevated if needed. All beams or one beam can be changed.
A beam's elevation may be changed if desired. This can be done in a number of ways. For example, the end point elevation can be changed by selecting the end point on a given beam. Alternatively, a splice point may be added to a beam by selecting a location for the splice point on the beam. If the desired splice point is too close to the end point, the program will recycle to ask for a new splice point.
In either the end point change or the addition of a permitted splice point, there are four options for obtaining the new elevation. First, the current top of steel number may be used. Second, the beam on both sides of the splice may be found and the desired change can be to line up with the found beam. Third, the previous elevation can be used. Lastly, a new elevation may be obtained.
After the new elevation is found, the room height is changed if needed and the new splice point is added in.
A splice point can also be moved if desired. The splice point to move is obtained as well as the distance and direction to move. Again, a check is made to be certain that the new location is not too close to the end of the beam. In addition, a second check is made to be certain that new location is actually on the beam. If both checks are satisfactory, the old splice point is deleted and the new one added.
A splice point may simply be deleted by selection of the point to eliminate. A check is made to be certain that the point to delete is not intersecting a location on a perimeter bearing wall. If it is, the splice cannot be deleted as a beam cannot go through a perimeter bearing wall. If it is, then an error message is generated and the a new location may be selected. Otherwise, the splice point is simply deleted.
A beam or collinear beams can be moved 248 . First, the columns attached to the beam(s) are found. Any columns which also attach to beams which are not being moved are retained. The direction and distance to move are obtained. A check is made to be certain that another beam is not already at the new location. A second check is made to be certain that the new location for the beam will not cross an existing beam. If either check is affirmative, a message is generated and the subroutine terminates.
The beam to be moved is then deleted. Columns are then either added or moved if attached to the moving beam. A check is made to determine if the new location will hit any pipe. If so, a warning message is generated though the process can still proceed. The beam is added. at the new location and the steel is adjusted.
A joist may be replaced with a beam 249 . The joist to replace is obtained. The closest beam to the joist is then found. The joist is deleted while a beam is added to the location that the joist occupied. The hangers are then adjusted accordingly.
A joist can be added to the deck 250 . A point to add a joist to-is selected. Two joists on either side of the point are then found. A check is made to be certain that two joists have been found. If not, the end points of the new joist must be obtained. If two joists are found, then the same starting and ending location as these two joists will be used for the added joist.
The joist depth is obtained. Checks are made to be certain that the new joist is not too close to another joist or that the new joist does not cross another joist. If either event is found, then an error message is generated and the subroutine terminates. The panel width and offset are then obtained and a new joist is added.
A joist can be added below the deck 251 . A first and a second point are obtained on beams along with the joist depth. Three checks are made to determine that the first and the second point are on two separate beams, that the two beams are oriented in the same manner and that the new joist will not hit any walls. If all of these conditions hold, the new joist is added. If any one does not hold, an error message is generated and the program will hunt for a second point that does meet the proper criteria.
A joist can be moved 252 . The joist is selected and the direction and distance to move are obtained. A check is made that the new location for the joist will not hit any walls. If it does, the process will obtain a new distance to move. If it does not hit a wall, then the joist is moved to the new location. The joist's elevation at the new location is determined and the hangers adjusted if needed.
Joist panels, depths, off set or spacing may be changed 253 . To change the depth, the joist to change is selected and the new depth obtained. A check is made to compare the bearing plate thickness to the new joist depth to be certain that this depth is not less than that thickness. If it were, then there would be a joist in space not bearing on anything. If the new depth passes that check, the depth is changed to the new value, the lines elevated if needed and the hangers adjusted accordingly.
The joist offset is changed by selecting the joist to change and obtaining the new offset. A check is made to be certain that the offset is not greater than the length of the joist. If it were, there would be no panels for the joist and this is impossible. If it passes this check, the desired direction is obtained and the offset assigned. The lines are elevated and the hangers are adjusted if needed.
The joist panel change is done in several different ways. The number of “A” or “V” webbing can be altered. The joist to change is selected and the new number obtained. A check is made to be certain that the number of panels times the length of each panel does not exceed the total length of the joist. If it does not, the new number is assigned to the selected joist.
A vertical bar can be added or deleted to the “A” or the “V” webbing. The joist to add to or delete from is selected and the addition or the deletion is made. Center “A” or “V” webbing can be selected for all joists also.
The panel width can be changed. The new panel width is obtained and the new panel width is assigned to the joist(s).
The joist spacing can be changed. An area to change is selected and all joists entirely within this area are found. All of the found joists are then deleted from the distribution system. The beams and walls closest to the system are found along with the distance form one end of the area. The new spacing between joists is obtained as well and the joist depth. The new joists are added to the area. The elevations for these new-joists are assigned based on the elevation of the beams and walls which were found previously.
The steel can be rotated 90 degrees 254 if desired. A bay section is selected for rotation. All the joists in that bay section are then deleted. If no other joists are found on beams in the bay section, the beams are also deleted. A check is made to determine if beams exist in the location that is needed to rotate the steel. This location is at both ends of the rotated orientation. If no beams are found, such beams are added in.
The spacing, depth, panel width and offset of joists are obtained and the chosen joists added in the rotated orientation. Hangers are then added to pipes in the bay section.
The top of steel may be changed 255 by obtaining the highest and lowest points of all beams and joists which reach the deck. A check is made to be certain that the elevation (z-location) of all the steel in the building is the same. If it is, the building is level and the new top of steel value can simply be obtained. If not, then the amount to raise or lower the deck elevation must be obtained. If we are raising the top of the steel, then the deck elevation is changed as well as the pipe elevations.
If, however, we are lowering the top of steel, then a series of checks must be performed to be certain that (1) the new top of steel is above the lowest part of the building, (2) the. steel at the new location does not hit any walls below the deck, (3) the new elevation is above the ceilings and (4) the new elevation for the steel does not hit any steel below the deck. All of the above conditions must be met before the new elevation of top of steel is allowed.
A joist may be deleted 256 by simply selecting the joist and deleting it from the distribution system. Any hangers that need adjustment are corrected.
In FIG. 20, the edit walls submenu is shown. As with all previous submenus, the user simply selects the desired option and the process proceeds.
A wall can be added 257 to the building. A first point is obtained on an existing wall to start the new wall from. A second point for the other end of the new wall is obtained and an attempt is made to line up the new wall with an existing wall either in a perpendicular or a parallel orientation. A check is made to be certain that the new wall will not overlap an existing wall and that the attempt to line up has been successful. If either condition fails, an error message is generated and the program looks for a new second point.
If this is the first wall added, then the room number is found for the new wall. Then, the closest wall and the distance to it in the direction of the new wall is found. A check is made to determine if this new wall is too far away. If it is, the wall thickness is obtained and the second wall is used as the first point for the next new wall.
If the distance is not too far, then the new wall is connected to the found existing wall. The wall thickness is obtained and a check is made to determine if the added walls are inside any room. If they are, then a new inside room is added to the database. If they are not, then a new outside room is added to the database.
Walls can be moved 258 within the building by three differing procedures.
First, a corner can be slid. The corner and the wall to slide are obtained. Available walls to slide along are found and one of such walls is selected. The direction to move and the distance to move are obtained. This distance must be greater than the wall thickness. If the distance is greater, then the wall is slid along the selected available wall the chosen distance and direction.
Second, a part of a wall may be moved. A first and a second point on the wall are selected. A check is made to be certain that there is enough room between the two points to add a wall. A direction and a distance to move are obtained and another check made to be certain that the distance is adequate to allow a new wall to be added without hitting existing. walls. The wall part is then moved if it passes this check.
Third, a wall segment consisting of either a whole wall or a part of a wall can be moved. If a whole wall, that wall is simply selected. If part of a wall, the particular segment is selected. In either case, the distance and direction to move are then chosen. Another check is made to be certain that the distance to move is large enough. If it is, then the move is made.
A new inside room may also be added. The height of the new walls is obtained. Walls which form a closed area starting from the last added wall and continuing counter-clockwise until the starting point is reached again are found. This process is repeated from the same point but in the clockwise direction also. The smaller of the two rooms thus obtained is deleted and the larger retained.
Those walls which are in the new room but no longer belong to their original room are deleted from the original room's database. The ceiling grid information from the original room is copied to the new room. The room number of those components which are in the new room are changed to the new room's number. Any head which is not in any room (such as one which is on the edge of a new wall) is deleted. The ends of all mains are adjusted accordingly.
A new outside room may be added. The counter-clockwise rotation from the starting point as described for the inside room is also performed here. The height of the newly added walls above the deck are assigned as well as the default hazard for the new room. The walls thickness and locations can be changed if desired. After such changes, the steel is put in as well as the pipes for the room.
The walls can be changed 259 in a variety of ways. The thickness of a wall is changed by obtaining the wall segment of the whole wall to change. The new wall thickness is obtained and a check is made to be certain that the new wall thickness will not cause the wall to hit anything. If the wall is an outside wall, the thickness is changed by maintaining the outside surface of the wall while thickening the inside surface. If the wall is an inside wall, the center location is maintained while both surfaces are moved.
A wall height can be changed by selecting a wall segment, a whole wall or a corner. If a wall segment or a whole wall, the new height is obtained and assigned to the desired area. If a corner, the corner height is first changed. Then any bearing wall which are at the corner are found and joists and beams on the bearing walls must also be adjusted.
A wall can be split by selecting the point where the split is desired. Beams are found which are at the same orientation as the wall and which lie on the wall. The beams are split at this point (see process described above) as well as the walls.
A corner can also be changed by moving its location or by altering its radius. To move the corner, the desired corner is selected. If this is a round corner (radius does not equal zero) it is changed into a square corner for the move. The distance and the direction for the move are selected and a check made to be certain that the new location is not too close to another corner such that the walls of the respective corners will hit each other.
A further check is made to be certain that the walls that will be moved do not hit another wall. The new position is assigned to the chosen corner and heads which would be either outside the building or on the edge of a wall are deleted. The ends of the mains are adjusted as well as the steel.
The radius of a corner can also be adjusted. The corner to change and the new radius are selected. Checks are made to determine that (1) there are only two walls on the corner, (2) the angle between the two walls must be 90 degrees and (3) the radius must be greater than the wall thickness or zero and less than the shortest length of either wall.
The overhead doors on a round corner are deleted and the new radius is assigned to the corner. The steel is adjusted and any heads now outside the building or on the wall edge are deleted. The ceiling grid is also corrected.
A wall can be selected for deletion 260 . A check is made to see if the rooms on both sides of the wall are the same. If they are the same, then a check is made to determine if a joist is supported by the wall. If so, then there must be a beam at that location to support the joist. If no beam is located there, then such a beam must be added at the wall's location to support the joist. Columns will be added if needed to support the beam.
A further check is made to see if the wall is an outside wall. If it is, then the other walls in the room must be changed to reflect their new status as outside walls after this wall is deleted.
The room to delete is found and its components are deleted, the ceiling grid erased, the overhead doors erased, the wall deleted from the database and the rooms joined. If this is an outside wall, then heads which are now outside are deleted, the ends of mains and the steel adjusted.
The ceiling grid submenu is shown in FIG. 21 . As is standard procedure, the option desired is selected and the subroutine which performs the option executes.
To change the ceiling grid 261 in a room 262 , the room is selected in which the change is to occur. Then, the ceiling grid in the room can be changed by (1) adding a ceiling grid, (2) changing a ceiling grid line, (3) deleting a ceiling grid or (4) moving a ceiling grid.
To add a ceiling grid in a room, the ceiling panel size and the ceiling grid angle are obtained. Also, the far left, far right, far back and far forward points in the room's ceiling grid line coordinate system are obtained. The starting and ending grid line locations are obtained with respect to the ceiling grid coordinate system. These locations are then translated into the coordinate system for the building. The database is then updated including the other rooms.
A ceiling grid may be deleted by simply assigning zero to the variables about the ceiling grid line in the selected room. The database is then updated.
A ceiling grid can also be moved by obtaining the direction and distance to move. The default value for the panel widths is checked to be certain that it is larger than the distance the grid is to be moved. Otherwise, a new distance and direction must be entered before the grid can be moved.
A ceiling grid line may be changed by (1) changing the panel size, (2) changing the ceiling grid angle and (3) adding, deleting, moving or shifting a single grid line.
The panel size may be changed by obtaining the new panel size, deleting the old panels and adding a new grid which utilizes the new panel size. The process for altering the ceiling grid angle is essentially the same.
To add a single grid line, the location to add the line is obtained. A check is made to be certain that the new grid line will not be too close to an old line or lines. If it is, a new location must be entered to proceed. If the line is not too close, then the new line is added and the database updated.
A single grid line may be deleted by simply selecting it. The line is deleted and the database updated.
A single grid line may be moved by obtaining the direction and distance to move. A check is made to be certain that the new position will not interfere with existing grid lines as was done for adding a single grid line. If the location is acceptable, the move is made and the database updated.
A set of ceiling grid lines may be shifted in a process which is virtually identical to the process for moving a single grid line. The process is a little more complicated since one must check a number of lines instead of one. In addition, the lights and duct openings inside the moving set of grid lines must also be moved.
The height of a ceiling can also be changed 263 . The room to change is first selected. The old height is saved while the new height is obtained. Checks are made to be certain that this new height is (1) not above the height of the walls in the room and (2) the height is not above the lowest elevation of the steel in the room.
If the new height passes the two criteria cited above, the ceiling height for the room is changed. All sprinklers which were below the old ceiling height are moved to a new position which is six inches (15.25 cm) below the new height.
A ceiling may be added 264 to a room without one. The ceiling height is obtained and checked as described in the subroutine for changing the height of a ceiling. If it passes those criteria, the height is assigned to the room. The subroutine will allow the user to enter a ceiling grid at this point if desired.
A check is made to determine if the room has sprinklers in it already. If it does, these sprinklers can be changed to pendants six inches (15.25 cm) below the new ceiling if desired. Also, the hazard type for the room can be changed if needed.
A ceiling in a room can also be. deleted 265 . The room to delete is chosen and the ceiling height is saved. All the variables relating to the ceiling are set to zero. A check is made to determine first if there were any sprinklers in the room. If so, then a comparison is made to see if any of these sprinklers were lower than the saved height of the ceiling. If any of the sprinklers were lower than that height, then they are repositioned six inches (15.25 cm) under the roof.
A ceiling grid may be matched to the ceiling grid in another room. The room to match as well as the paradigm room are selected. The ceiling grid in the room to match is deleted along with the lights and duct openings. The ceiling grid information from the paradigm room is used in the now empty match room and a ceiling grid is added.
An entire distribution system may also be matched to an existing system in a multi-system building. The paradigm system is selected as well as the current system to be changed. The paradigm is substituted (and drawn if desired) for the current system. The appropriated editing functions as previously described are available for use to customize sections of the system is needed.
The hazards in a room or a section may be changed as desired. In both cases, the room or section is obtained along with the desired new hazard. The old hazard is deleted and the new one substituted.
Information can be obtained from the system at any time by simply selecting the type of item to get information on. The item is found and highlighted by the computer and the information is displayed.
Information may also be calculated for certain items. For example, the clearance information relating to a given pipe and any other element can be obtained by selecting the pipe and the element. The distance between the pipe and the element is calculated by allowing for the outside diameter of the pipe and the outside dimensions of the element. If the distance is negative, the pipe and the element are contacting each other and a warning message is generated. If the distance is very far, the clearance is irrelevant and will not even be displayed. Otherwise, that clearance is shown.
The above distances can be calculated for any two items in the database. A dimension line will be drawn between such chosen items and the distance is displayed.
The volume of piping which is located past a certain fitting is calculated in an alternative fashion. Each pipe past the selected fitting is found and its volume calculated and added to a running total. When the. iterations find no further pipe past the fitting, the total volume is converted to gallons and displayed. Essentially, the same alternative process is used to calculate the total volume in a given line.
The sprinkler coverage on a given line can be checked. The line is selected and the sprinklers on the line are found one by one. The coverage of the found sprinklers if obtained and compared to the required coverage to determine if it is adequate. If it is not, that particular sprinkler is highlighted in red.
Next, the deflector distance is obtained. If this deflector distance is the largest or the smallest found, the respective distance is saved. Otherwise, the iteration continues to the next sprinkler until no sprinklers remain. The largest and smallest deflector distances are displayed along with warning messages relating to any sprinklers found with inadequate coverage.
A sprinkler or pipe count can be obtained from the database. Again, an iterative process cycles through each sprinkler or pipe which is found in the system. The sprinkler is performed by type, temperature range, size and style. The pipe count is performed by length, diameter and wall type. Once all the sprinklers or pipes have been accounted for, the total number of each category as well as the total number in the system is displayed.
If desired, sprinklers or pipes of a given kind can be highlighted. Again, an iterative process goes through each sprinkler or pipe in the system. All those of the desired kind are found, highlighted and counted.
The pipe interference on a given. line may by checked. Each pipe in the line is separately checked to see if it is hitting any structural elements or elements of the distribution system. If it is, such elements are highlighted and a warning message is displayed.
The high and low point on the beams can be calculated in an iterative process. Each beam in the system is found and its elevation at splice points and each end point are found. If the highest or the lowest elevation of all the beams found, such numbers are saved. Once all the beams have been tested, the high and low points are highlighted.
Lastly, head spacing information can be obtained from the database. The area width across the lines and the area length in the direction of the lines is obtained. The area dimensions are displayed along with the maximum sprinkler spacing and coverage area for the hazard type in the area.
Optionally, the maximum spacing and coverage areas can be changed at this point. If such a change is made, then the method described above for calculating the sprinklers needed is performed and information displayed. Again, optionally, the number of lines, distance between lines, number of sprinklers or distance between sprinklers can then be edited if desired.
The foregoing is illustrative 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. Accordingly, all suitable modifications and equivalents may be resorted to while still falling within the scope of the invention. | A method and apparatus for designing and editing a distribution system for a building is disclosed. Elements of such distribution systems and requirements of relevant standard, are stored in a computer's memory. Building parameters are entered into a computer manually. The user identify the standard to be followed and the element to be optimized. The system divides the building into sections as appropriate to the user identified standard. The system then computes layout needed to comply with the selected standard. The layout is routed and sized to avoid building structural members, yet the elements of the layout are optimized for size and length. The apparatus prints out a hard copy of the design layout which can include an elements listing needed to complete the system. The design layout as well as the building parameters can be edited. The edited layout is checked for compliance with the identified standard as well as avoidance of building parameters. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a file creation method, a server, a computer terminal, a recording medium, an information processing apparatus and a program addition system, and more specifically to a file creation method, a server, a computer terminal, a recording medium, an information processing apparatus and a program addition system, which are configured to add a program to a program initiating recording medium.
2. Description of the Related Art
An information processing apparatus, such as a personal computer, carries out various kinds of information processing by performing one or more programs corresponding to respective information processing procedures.
Moreover, an image forming apparatus (for example, a multi-function peripheral system), which is an application example of the information processing apparatus, is provided with the display unit, the printing unit, the image pickup unit, etc., which are accommodated in a single housing, in addition to the four kinds of programs corresponding to the printer, the copier, the facsimile, and the scanner, respectively. By selecting one of the programs, the multi-function peripheral system is operated as the selected one of the printer, the copier, the facsimile, and the scanner.
Japanese Laid-Open Patent Application No. 2002-084383 discloses an example of the multi-function peripheral system mentioned above.
Upon power-up of the multi-function peripheral system or the like, the BIOS (basic input/output system) and the boot loader are started. The boot loader expands the operating system (OS) and the root file system on the RAM (random access memory), and initiates the OS. The OS mounts the root file system. The “mounting” herein means that a file system, a peripheral device, etc. are started so that the file system or peripheral device can be accessed by another system or device.
After the startup of the OS, the bootstrap which starts an application program (which is called the application) is started. The bootstrap is a process which is first started by the information processing apparatus or the multi-function peripheral system.
The bootstrap mounts the file system according to a predetermined configuration file. The bootstrap starts the program, which is required for operation of the information processing apparatus or the multi-function peripheral system and recorded in a program-initiation recording medium, such as a hard disk drive (HDD) or a SD (secure digital) card, according to the predetermined configuration file.
In recent years, there is an increasing demand for a program addition system that can easily add a new program for use in the information processing apparatus or the multi-function peripheral system to the program-initiation recording medium mentioned above.
The addition of a new program to the above-mentioned program-initiation recording medium may be carried out through the network, such as the Internet or a LAN. Moreover, the addition of a new program to the program-initiation recording medium may be carried out by using an SD card which is a detachable recording medium the insertion and removal of which is possible.
The user can make use of the program which is added to the program-initiation recording medium, in any information processing apparatus or multi-function peripheral system. Hence, there is a possibility that the program may be illegally added to a program-initiation recording medium which is provided in the information processing apparatus or the multi-function peripheral system which is not authorized to add the program thereto.
Moreover, when a program is added to a program-initiation recording medium using a detachable program-addition recording medium, such as an SD card, the insertion and removal of which is possible, the program recorded in the program-addition recording medium can be also used with any information processing apparatus or multi-function peripheral system. There is also a possibility that the program may be illegally added to a program-initiation recording medium which is provided in the information processing apparatus or the multi-function peripheral system which is not authorized to add the program thereto.
Therefore, when adding the program to the program-initiation recording medium of the information processing apparatus or the multi-function peripheral system, the provision of a mechanism for preventing the program added to the program-initiation recording medium from being illegally used is demanded, in order to establish the security of the program.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved file creation method in which the above-described problems are eliminated.
Another object of the present invention is to provide a file creation method which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
Another object of the present invention is to provide a server which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
Another object of the present invention is to provide a computer terminal which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
Another object of the present invention is to provide an information processing apparatus which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
Another object of the present invention is to provide a computer-readable recording medium which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
Another object of the present invention is to provide a program addition system which creates a program-addition file on a recording medium in response to identification information of a program-initiation recording medium, in order to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
The above-mentioned objects of the present invention are achieved by a file creation method which creates a program-addition file for adding a program to a program-initiation recording medium of an information processing apparatus, the method comprising the steps of: acquiring identification information of the program-initiation recording medium; and creating a program-addition file in response to the identification information so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium.
The above-mentioned objects of the present invention are achieved by a server which creates a program-addition file for adding a program to a program-initiation recording medium of an information processing apparatus, the server comprising: an identification-information acquisition unit acquiring identification information of the program-initiation recording medium; and a file creation unit creating a program-addition file in response to the identification information, so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium.
The above-mentioned objects of the present invention are achieved by a computer terminal which stores a program-addition file in a program-addition recording medium, the program-addition file being used to add a program to a program-initiation recording medium of an information processing apparatus, the computer terminal comprising: an information transmitting unit transmitting, to a server, information required to acquire identification information of the program-initiation recording medium; a file receiving unit receiving, from the server, a program-addition file which is created by the server in response to the identification information so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium; and a file storing unit storing the received program-addition file into the program-addition recording medium.
The above-mentioned objects of the present invention are achieved by a computer-readable recording medium storing a program embodied therein for causing a computer to execute a file creation method which creates a program-addition file for adding a program to a program-initiation recording medium of an information processing apparatus, the file creation method comprising: acquiring identification information of the program-initiation recording medium; and creating a program-addition file in response to the identification information so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium.
The above-mentioned objects of the present invention are achieved by an information processing apparatus which adds a program to a program-initiation recording medium by using a program-addition recording medium in which a program-addition file for adding the program to the program-initiation recording medium is stored, the information processing apparatus comprising: a recording-medium detection unit detecting the program-addition recording medium in which the program-addition file is recorded; and a program addition unit performing an authentication check of the program-addition file read from the program-addition recording medium, and adding the program to the program-initiation recording medium according to a result of the authentication check.
The above-mentioned objects of the present invention are achieved by a program addition system comprising: a server which creates a program-addition file for being stored in a program-addition recording medium; and an information processing apparatus which adds a program to a program-initiation recording medium by using the program-addition recording medium, wherein the server is configured to acquire identification information of the program-initiation recording medium, and to create a program-addition file in response to the identification information, so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium, wherein the information processing apparatus is configured to detect the program-addition recording medium in which the program-addition file is recorded, to perform an authentication check of the program-addition file read from the program-addition recording medium, and to add the program to the program-initiation recording medium according to a result of the authentication check.
The above-mentioned objects of the present invention are achieved by a program addition system comprising: a server which creates a program-addition file for being stored in a program-addition recording medium; and an information processing apparatus which adds a program to a program-initiation recording medium by using the program-addition recording medium, wherein the server is configured to acquire identification information of the program-initiation recording medium, and to create a program-addition file in response to the identification information, so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium, wherein the information processing apparatus is configured to receive the program-addition file from the server, to perform an authentication check of the received program-addition file, and to add the program to the program-initiation recording medium according to a result of the authentication check.
According to the present invention, the program-addition file is created in response to the medium identification information so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium. Starting of the program on the information processing apparatus is not allowed with a program stored in a different program-initiation recording medium. Therefore, it is possible to prevent the illegal use of a program added to the program-initiation recording medium and establish the security of the program added thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be apparent from the following detailed description when reading in conjunction with the accompanying drawings.
FIG. 1 is a block diagram of an embodiment of the information processing apparatus of the invention.
FIG. 2 is a block diagram of a hardware composition of the information processing apparatus of FIG. 1 .
FIG. 3 is a block diagram of an embodiment of the multi-function peripheral system of the invention.
FIG. 4 is a block diagram of a hardware composition of the multi-function peripheral system of FIG. 3 .
FIG. 5 is a block diagram of an embodiment of a MFP booting unit in the multi-function peripheral system of FIG. 3 .
FIG. 6 is a diagram for explaining the processing to add a program to a program-initiation SD card by using a program-addition file.
FIG. 7 is a diagram for explaining examples of processing of the multi-function peripheral system, the server, and the computer terminal.
FIG. 8A , FIG. 8B , FIG. 8C and FIG. 8D are diagrams of examples of the screen displayed on the display device of the computer terminal.
FIG. 9 is a block diagram of an example of the database provided in the server.
FIG. 10 is a flowchart for explaining an example of the processing to create a program-addition file.
FIG. 11 is a flowchart for explaining an example of processing of the authentication check of the requested application program.
FIG. 12 is a flowchart for explaining an example of processing of the authentication check of the configuration file.
FIG. 13 is a diagram of an example of the program-addition location selection screen.
FIG. 14 is a diagram of an example of the program-initiation SD card to which the program is added.
FIG. 15A and FIG. 15B are block diagrams for explaining an example of processing to add a program from the program-addition SD card to the program-initiation SD card.
FIG. 16 is a diagram for explaining other examples of the processing of the multi-function peripheral system, the server, and the computer terminal.
FIG. 17 is a diagram of an example of the program-addition file recorded in the program-addition SD card.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A description will now be given of the preferred embodiments of the invention with reference to the accompanying drawings.
FIG. 1 is a block diagram of an embodiment of the information processing apparatus of the present invention.
The information processing apparatus 1 is constituted so that the software group 2 , the boot unit 3 , and the hardware resources 4 may be included.
The boot unit 3 is first activated upon power-up of the information processing apparatus 1 , and starts the program initiating unit which is described later.
The program initiating unit starts the software group 2 of the information processing apparatus 1 .
Moreover, the program initiating unit reads the programs of the SD card control unit 11 , the program addition unit 12 , the applications 14 - 1 to 14 - n from the auxiliary memory device or the SD card, etc., and transmits each program to the memory device so that it starts the program. Hereinafter, the applications mean the application programs which are executed on the OS (operating system), and such programs or the application programs may also be called the applications.
The hardware resources 4 comprise the hardware resources, including the input device, the display device, the auxiliary memory device, the memory device, the interface device, and the SD-card slot.
Moreover, the software group 2 includes the programs of the SD card control unit 11 , the program addition unit 12 , and the applications 14 - 1 to 14 - n , which are started on the OS, such as UNIX (registered trademark).
The OS carries out parallel execution of the programs (or the applications) of the SD card control unit 11 , the program addition unit 12 and the applications 14 - 1 to 14 - n , as the processes on the OS.
The API (application program interface) 15 is used for the pre-defined function to receive the request from the applications 14 - 1 to 14 - n . The engine I/F 16 is used for the pre-defined function to transmit the request to the hardware resources 4 .
In addition, the SD card control unit 11 , the program addition unit 12 , and the program initiating unit will be described later.
Next, a description will be given of a hardware composition of the information processing apparatus 1 of FIG. 1 .
FIG. 2 shows a hardware composition of the information processing apparatus 1 of the present invention.
The information processing apparatus 1 of FIG. 2 is constituted so that the input device 21 , the display device 22 , the auxiliary memory device 23 , the memory device 24 , the arithmetic processing device 25 , the interface device 26 , and the SD card slot 27 , which are interconnected by the bus B, may be included.
The input device 21 includes the keyboard, the mouse, etc., and it is used by the operator to input various operational instructions. The display device 22 displays various operational data and windows which are required for the operations.
The interface device 26 provides the interfaces for connecting the information processing apparatus 1 to the network or the computer terminal, and includes the modem, the router, or the devices according to various interface specifications.
The insertion and removal of the SD card is possible with respect to the SD card slot 27 . An interrupt signal, which is generated in response to the insertion or removal of the SD card, is transmitted to the SD card control unit from the SD card slot 27 .
The auxiliary memory device 23 stores various files, data, etc. The SD card inserted in the SD card slot 27 and the auxiliary memory device 23 store the programs of the SD card control unit 11 , the program addition unit 12 , the applications 14 - 1 to 14 - n , which are related to the processing of the information processing apparatus 1 , and store various files, data, etc. required for the program processing.
The memory device 24 stores the programs, which are read from the SD card control unit 11 , the program addition unit 12 , and the applications 14 - 1 to 14 - n , from the SD card inserted in the SD card slot 27 , and the auxiliary memory device 23 , etc. at the time of starting of the information processing apparatus 1 .
The arithmetic processing unit 25 performs arithmetic processing according to the programs of the SD card control unit 11 , the program addition unit 12 and the applications 14 - 1 to 14 - n , which are stored in the memory device 24 .
Next, a description will be given of the composition of the multi-function-peripheral system 31 as an application example of the information processing apparatus 1 of the invention.
The following description will be focused on the composition of the multi-function peripheral system 31 . However, the same is applicable to the composition of the information processing apparatus 1 of the invention.
The image forming apparatus in the present embodiment is provided with the respective functions of image forming modules, such as the printer, the copier, the facsimile, and the scanner, which are contained in one housing of the apparatus, and the image forming apparatus will be called the multi-function peripheral system (MFP).
The multi-function peripheral system (MFP) includes the display unit, the printing unit, the image reading unit, etc. in a single housing, and is provided with the four kinds of software (application programs) corresponding to the printer, the copier, the facsimile, and the scanner, respectively. By selecting one of these applications, and the MFP is operated as the selected one of the printer, the copier, the facsimile, and the scanner.
FIG. 3 is a block diagram of an embodiment of the multi-function peripheral system of the invention.
As shown in FIG. 3 , the multi-function peripheral system (MFP) 31 is constituted so that the software group 32 , the MFP boot unit 33 , and the hardware resources 34 are included.
The MFP boot unit 33 is activated upon power-up of the multi-function peripheral system 31 , and starts execution of the application layer 35 and the platform 36 in the software group 32 .
For example, the MFP boot unit 33 reads the programs of the application layer 35 and the platform 36 from the hard disk drive (HDD) etc., transfers each read program to the memory storage, and starts the execution thereof.
The hardware resources 34 include the monochrome laser beam printer (B&W LP) 41 , the color laser printer (Color LP) 42 , and other hardware resources 43 , such as the scanner and the facsimile.
The software group 32 includes the application layer 35 and the platform 36 which are operated on the operating system (OS), such as UNIX (registered trademark).
The application layer 35 includes the programs which perform processing specific to the respective user services related to the image formation, such as the printer, the copier, the facsimile, and the scanner. Specifically, the application layer 35 includes the printer application 51 , the copier application 52 , the fax application 53 , the scanner application 54 , and the network file application 55 .
The platform 36 includes the control service layer 37 , the system resource manager (SRM) 69 , and the handler layer 38 . The control service layer 37 interprets the processing request from the application layer 35 , and generates the acquisition request to the hardware resources 34 . The SRM 69 manages one or more hardware resources 34 , and arbitrates the acquisition request from the control service layer 37 . The handler layer 38 manages the hardware resources 34 according to the acquisition request from SRM 69 .
The control service layer 37 is constituted to include one or more service modules therein. Specifically, the control service layer 37 includes the network control service (NCS) 61 , the delivery control service (DCS) 62 , the operation panel control service (OCS) 63 , the facsimile control service (FCS) 64 , the engine control service (ECS) 65 , the memory control service (MCS) 66 , the user information control service (UCS) 67 , and the system control service (SCS) 68 .
In addition, the platform 36 is constituted with the pre-defined functions so that the application program interface (API) 81 which receives a processing request from the application layer 35 is included. The operating system (OS) carries out parallel execution of the applications of the application layer 35 and the platform 36 as processes thereon.
The process of NCS 61 acts as the agent that distributes the data received from the network through the corresponding protocol over the applications, and transmits the data from the applications to the network through the corresponding protocol. For example, the process of NCS 61 controls data communications of HTTP (hypertext transfer protocol) between the MFP and the clients connected via the network, by using HTTPD (hypertext transfer protocol daemon).
The process of DCS 62 controls delivery of the accumulated documents etc. The process of OCS 63 controls operation of the operation panel. The process of FCS 64 provides the application program interface for performing the facsimile transmission and reception using the PSTN or ISDN network from the application layer 35 , the registration/retrieval of various facsimile data managed with the backup memory, the facsimile reading, the facsimile reception and printing, etc.
The process of ECS 65 controls the engine units, such as the monochrome laser beam printer 41 , the color laser printer 42 , and the other hardware resources 43 . The process of MCS 66 performs memory control of the memory acquisition and releasing, the use of HDD, the compression and expansion of image data, etc. The process of UCS 67 manages user information. The process of SCS 68 controls the application management, the operation panel control, the system monitor displaying, the LED monitor displaying, the hardware-resources management, the interrupted application control, etc.
The process of SRM 69 carries out the system control and the management of the hardware resources 34 associated with SCS 68 . For example, the process of SRM 69 arbitrates the acquisition requests from the upper layer to use the hardware resources 34 , such as the monochrome laser beam printer 31 and the color laser printer 32 , and controls the execution thereof.
Specifically, the process of SRM 69 determines whether the hardware resources 34 can be used according to the acquisition request (or whether they are currently used according to another acquisition request). If the use of the hardware resources 34 is possible, the process of SRM 69 notifies the upper layer that the hardware resources 34 can be used according to the acquisition request.
Moreover, the process of SRM 69 performs scheduling of the use of the hardware resources 34 according to the acquisition request from the upper layer, and carries out the contents of the request (for example, the paper conveyance and the imaging operation by means of the printer engine, the memory reservation, the file generation, etc.) directly.
Moreover, the handler layer 38 includes the facsimile control unit handler (FCUH) 70 which manages the facsimile control unit (FCU), and the image memory handler (IMH) 71 which carries out the memory assignment of the process and the management of the memory assigned to the process.
SRM 69 , FCUH 70 , and IMH 71 perform the processing request to the hardware resources 34 by using the engine interface 82 which transmits the processing request to the hardware resources 34 with the pre-defined functions.
With the above-described composition of FIG. 3 , the multi-function peripheral system 31 can carry out the intensive control of each processing commonly required by the respective applications on the platform 36 .
Next, a description will be given of the hardware configuration of the multi-function peripheral system 31 of the invention. FIG. 4 shows the hardware configuration of the multi-function peripheral system 31 of FIG. 3 .
As shown in FIG. 4 , the multi-function peripheral system 31 includes the controller 100 , the operation panel 120 , the facsimile control unit (FCU) 121 , and the engine unit 122 .
The controller 100 includes the CPU 101 , the system memory 102 , the north bridge (NB) 103 , the south bridge (SB) 104 , the application-specific integrated circuit (ASIC) 106 , the local memory (LM) 107 , the hard disk drive (HDD) 108 , the network interface controller (NIC) 109 , the SD card slot 110 , the USB device 111 , the IEEE1394 device 112 , and the Centronics interface 113 .
CPU 101 performs the control of the whole multi-function peripheral system 31 . CPU 101 starts execution of NCS 61 , DCS 62 , OCS 63 , FCS 64 , ECS 65 , MCS 66 , UCS 67 , SCS 68 , SRM 69 , FCUH 70 , and IMH 71 , and performs each process of the programs on the OS. Moreover, CPU 101 starts execution of the printer application 51 , the copier application 52 , the facsimile application 53 , the scanner application 54 , and the network file application, which constitute the application layer 35 , and performs each process of the programs on the OS.
NB 103 is the bridge which is provided for interconnection of CPU 101 , the system memory 102 , SB 104 , and ASIC 106 . The system memory 102 is the memory which is used for image drawing of the multi-function peripheral system 31 . SB 104 is the bridge which is provided for interconnection of NB 103 , ROM (not shown), the PCI bus 114 , and the peripheral devices.
The local memory 107 is the memory which is used as the image buffer for copying documents or the buffer for encoding images. ASIC 106 is the application-specific integrated circuit for image processing uses including the hardware for image processing. HDD 108 is the storage device for accumulating images, document data, programs, font data, forms, etc. The operation panel 120 is provided to display the operational messages to the operator and receive the input operational commands from the operator.
NIC 109 is the interface device for connecting the MFP 31 to the network. The SD card slot 110 is provided to allow the insertion and removable of the SD card, and the SC card slot 110 transmits an interrupt signal, generated in response to the insertion and removable of the SD card, to the SD card control unit. The USB device 111 , the IEEE1394 device 112 and the Centronics interface 113 are the interface devices according to the respective interface specifications.
FIG. 5 is a block diagram of an example of the multi-function-peripheral system (MFP) booting unit of FIG. 3 .
The multi-function-peripheral system (MFP) booting unit 33 comprises the ROM monitor 130 and the program initiating unit 131 . As described above, the MFP booting unit 33 is first activated upon power-up of the multi-function peripheral system 31 , and starts execution of the application layer 35 and the platform 36 in the software group 32 .
The ROM monitor 130 which is the BIOS and boot loader is activated upon power-up of the MFP 31 , and performs the initialization of the hardware, the diagnosis of the controller 100 , the initialization of the software, etc.
The ROM monitor 130 expands the OS and the root file system on the system memory 102 , and starts execution of the OS. The OS mounts the root file system.
Moreover, the program initiating unit 131 is called from the OS, and secures the memory areas on the system memory 102 and the LM 107 .
The program initiating unit 131 is the process which is first initiated by the multi-function peripheral system 1 , and mounts the file system according to a predetermined configuration file. Specifically, according to the predetermined configuration file, the program initiating unit 131 reads the programs of the application layer 35 and the platform 36 , required for operation of the MFP 31 , from the HDD 108 , the SD card, the ROM, etc., and expands each read program to the memory areas which are secured on the system memory 102 and the LM 107 , so that and the program initiating unit 131 starts the processes of the application layer 35 and the platform 36 .
Next, a description will be given of processing of the program initiating unit 131 .
The program initiating unit 131 reads a predetermined master configuration file at the time of starting, and performs mounting of the file system and starting of the processes according to the read master configuration file.
Moreover, the program initiating unit 131 performs mounting processing according to the description of the mounting, when the description of the mounting is included in the read master configuration file.
Furthermore, when the predetermined directory which includes the file of a predetermined extension in the root director of the file system mounted when the predetermined configuration file existed in the root of the mounted file system exists, the program initiating unit 131 reads the predetermined configuration file or the file of the predetermined extension, and performs mounting processing of the file system.
In addition, “gzromfs” is an example of the file system which can be mounted by the program initiating unit 131 . This file system “gzromfs” manages the files of the ROMFS format which are “gzip” compression encoded.
Next, a description will be given of the preferred embodiments of the invention in which the processing to add a program to a program-initiation SD card (which is a program-initiation recording medium) is carried out.
The first preferred embodiment of the present invention will be explained. FIG. 6 is a diagram for explaining an embodiment of the processing to add a program to a program-initiation SD card by using a program-addition file.
In the following, only the composition required for description among the composition of the multi-function peripheral system 31 is shown in the diagram of FIG. 6 , and the composition which is not required for description is omitted.
The multi-function peripheral system 31 is provided with the SD card slot 110 in which the program-initiation SD card 141 is inserted. The multi-function peripheral system 31 is connected to the computer terminal 160 through the network 210 . Moreover, the multi-function peripheral system 31 is connected to the server 150 through the network 200 . The multi-function peripheral system 31 carries out the processing to add the program to the program-initiation SD card 141 or the flash ROM 142 by using the program-addition file.
The server 150 is the device which creates the program-addition file used for adding the program to the program-initiation SD card 141 . The server 150 creates the program-addition file based on the acquired information. The server 150 transmits the created program-addition file to the MFP 31 via the network 200 , or to the computer terminal 160 via the network 210 .
The computer terminal 160 is connected to the server 150 via the network 200 . Moreover, the computer terminal 160 is connected to the multi-function peripheral system 31 via the network 210 . The computer terminal 160 transmits information to the server 150 via the network 200 , and transmits the program-addition file, received from the server 150 , to the multi-function peripheral system 31 via the network 210 .
Referring to FIG. 7 , a description will be given of the processing of the multi-function peripheral system 31 , the server 150 , and the computer terminal 160 , which are shown in FIG. 6 .
FIG. 7 is a diagram for explaining examples of the processing of the multi-function peripheral system, the server, and the computer terminal. The examples of the processing of FIG. 7 are directed to the transmission of the program-addition file from the server 150 to the MFP 31 through the computer terminal 160 .
In the processing of FIG. 7 ( a ), the information of the application program, which is desired by the operator who operates the computer terminal 160 to be added to the multi-function peripheral system 31 , is sent to the server 150 as the name of the requesting application program.
The operator can transmit the information of the application to be added to the multi-function peripheral system 31 , to the server 150 by using the screen shown in FIG. 8A to FIG. 8D displayed on the display device of the computer terminal 160 .
FIG. 8A to FIG. 8D show examples of the screen displayed on the display device of the computer terminal 160 .
The operator on the computer terminal 160 who desires to add the requesting application program to the multi-function peripheral system 31 starts the pre-installed application program in the computer terminal 160 , and displays the application starting screen of FIG. 8A to FIG. 8C on the display device of the computer terminal 160 .
In the screen of FIG. 8A , the user ID input item, the password input item, and the application selection column are included.
In the screen of FIG. 8B , the model name input item, the device purchase date input item, and the application selection column are included.
In the screen of FIG. 8C , the model ID input item and the application selection column are included.
If the operator operates the computer terminal 160 and inputs the information to any one screen of FIG. 8A to FIG. 8C , the input information will be transmitted to the server 150 from the computer terminal 160 .
However, in the case of the screen of FIG. 8A , the identification information (for example, the model name, the model ID, etc.) for identifying the multi-function peripheral system 31 is not transmitted to the server 150 .
Therefore, when there are two or more model IDs corresponding to the requesting application program, the computer terminal 160 displays the screen of FIG. 8D on the display device, so that the operator is requested to choose the desired model ID from among them.
Alternatively, the server 150 may display the screens of FIG. 8A to FIG. 8D on the display device of the server, which are displayed on the display device of the computer terminal 160 as in the above-described embodiment.
Referring back to FIG. 7 ( a ), the server 150 performs the user authentication based on both the information stored in the database 170 of FIG. 9 and the information received from the computer terminal 160 . When the user authentication is completed normally, the program-addition file used for adding the program to the program-initiation SD card 141 is created.
FIG. 9 is a block diagram of an example of the database 170 provided in the server 150 .
As shown in FIG. 9 , the information stored in the database 170 includes the user ID, the MFP-system list, the model ID related with the multi-function peripheral system contained in the MFP-system list, the model name, the loaded application list, the purchase date, the serial ID (the SD serial ID) of the program-initiation SD card 141 installed in the MFP system, the application name related with the application program contained in the application list, and the purchase date of the application program.
In addition, the database 170 may store the newest information because it is cooperated with the system which receives the update information from one or more multi-function peripheral systems 31 at respective intervals of a predetermined time.
The server 150 receives, from the database 170 , the SD serial ID of the program-initiation SD card 141 of the multi-function peripheral system 31 of concern.
Therefore, the acquisition of the SD serial ID can be easily carried out by the server 150 if each SD serial ID of one or more multi-function peripheral systems 31 is stored in the database 170 .
The server 150 creates a program-addition file, which is required to add the program to the program-initiation SD card 141 , as shown in FIG. 10 .
FIG. 10 is a flowchart for explaining an example of the processing to create the program-addition file.
As shown in FIG. 10 , the server 150 at step S 10 selects the application program, the electronic signature of the application program, and the configuration file based on the model ID and the requested application name which the server 150 received from the computer terminal 160 .
Progressing to step S 11 , the server 150 creates the MD (message digest) of the configuration file chosen at step S 10 and the SD serial ID acquired from the database 170 .
Progressing to step S 12 , the server 150 enciphers the MD created at step S 11 with the private key, and creates the electronic signature of the configuration file.
Progressing to step S 13 , the server 150 creates the program-addition file based on the application program, the electronic signature of the application program, and the configuration file, which are chosen at step S 10 , and based on the electronic signature of the configuration file created at step S 12 .
Referring to FIG. 7 ( b ), the server 150 transmits the program-addition file to the computer terminal 160 , the program-addition file including the application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file.
In the processing of FIG. 7 ( c ), the computer terminal 160 transmits the program-addition file, received from the server 150 , to the NCS 61 of the multi-function peripheral system 31 .
In the processing of FIG. 7 ( d ), the NCS 61 transmits the program-addition file to the program initiating unit 131 through the SCS 68 .
The program initiating unit 131 performs the electronic authentication check of the requesting application program and the configuration file using the authentication check library 134 , in order to check the justification of the received program-addition file. For example, the authentication check of the application program is performed as in the flowchart of FIG. 11 .
FIG. 11 is a flowchart from explaining an example of the processing of the authentication check of the requesting application program.
At step S 20 , the program initiating unit 131 acquires the model ID.
Progressing to step S 21 , the program initiating unit 131 creates the MD 1 (message digest) based on the model ID acquired at step S 20 and the application program included in the program-addition file.
Progressing to step S 22 , the program initiating unit 131 creates the MD 2 (message digest) by deciphering the electronic signature of the application, contained in the program-addition file, with the public key.
Progressing to step S 23 , the program initiating unit 131 determines whether the MD 1 and the MD 2 are equal to each other.
If it is determined at step S 23 that the MD 1 and the MD 2 are equal, the program initiating unit 131 at step S 24 determines that the authentication check of the requesting application program is set to OK.
If it is determined at step S 23 that the MD 1 and the MD 2 are not equal, the program initiating unit 131 at step S 25 determines that the authentication check of the requesting application program is set to NG. This is because, if the MD 1 and the MD 2 are not equal, the possibility that the requesting application program included in the program-addition file is altered is considered high.
Moreover, the authentication check of the configuration file is performed by the program initiating unit 131 as in the flowchart of FIG. 12 .
FIG. 12 shows an example of the processing of the authentication check of the configuration file.
At step S 30 , the program initiating unit 131 acquires the application SD serial ID from the program-initiation SD card 141 .
Progressing to step S 31 , the program initiating unit 131 creates the MD 1 based on the SD serial ID obtained at step S 30 and the configuration file contained in the program-addition file.
Progressing step S 32 , the program initiating unit 131 creates the MD 2 by deciphering the electronic signature of the configuration file, contained in the program-addition file, with the public key.
Progressing step S 33 , the program initiating unit 131 determines whether the MD 1 and the MD 2 are equal to each other.
If it is determined at step S 33 that the MD 1 and the MD 2 are equal, the program initiating unit 131 at step S 34 determines that the authentication check of the configuration file is set to OK.
If it is determined at step S 33 that the MD 1 and the MD 2 are not equal, the program initiating unit 131 at step S 35 that the authentication check of the configuration file is set to NG. This is because, if the MD 1 and the MD 2 are not equal, the possibility that the requesting application program included in the program-addition file is altered is considered high.
After the program initiating unit 131 checks the justification of the program-addition file, the control of the program initiating unit 131 is transferred to the processing of FIG. 7 ( e ).
In the processing of FIG. 7 ( e ), the program initiating unit 131 notifies the SCS 68 that the preparation to add the program is completed.
The SCS 68 writes a part or all of the program-addition file to the program-initiation SD card 141 or the flash ROM 142 . In the present embodiment, according to the description of the configuration file, the SCS 68 is requested to write the program-addition file to either of the program-initiation SD card 141 or the flash ROM 142 . Alternatively, the present embodiment may be modified so that the addition location selection screen as shown in FIG. 13 is displayed on the control panel 120 , and the operator is requested to choose desired one from among the addition locations.
The addition location selection screen of FIG. 13 contains the character string in which the selection of the addition location is requested, and the selection button for choosing the desired addition location.
When the program-initiation SD card 141 is chosen by the operator as the addition location, the SCS 68 is caused to write the requesting application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file to the program-initiation SD card 141 .
FIG. 14 shows an example of the program-initiation SD card in which the program is added.
In the example of FIG. 14 , “apl.cnf” under the directory “init.d” indicates the configuration file, and “apl.lic” indicates the electronic signature file which is used for the authentication check of the configuration file. Moreover, “apl.mod” under the directory “module” indicates the requesting application program, and “apl.mac” indicates the electronic signature of the application program.
On the other hand, when the flash ROM 142 is chosen by the operator as the addition location, the SCS 68 is caused to write the requesting application program and the configuration file to the flash ROM 142 . In starting of the program from the flash ROM 142 , the electronic signature check is not performed. Hence, the writing of the electronic signature of the application program and the electronic signature of the configuration file to the flash ROM 142 is omitted in this case.
In the above examples of the processing of FIG. 7 , the program-addition file is transmitted from the server 150 to the MFP 31 through the computer terminal 160 . Alternatively, the program-addition file may be transmitted from the server 150 directly to the MFP 31 without using the computer terminal 160 .
In such alternative embodiment, the processing of FIG. 7 ( a ) is carried out so that the operator who operates the MFP 31 or the server 150 inputs or transmits the information of the desired application program to be added to the MFP 31 , to the server 150 as the name of the requesting application program. The operator can input or transmit the information of the application program to be added to the MFP 31 , to the server 150 by using the screen shown in FIG. 8A to FIG. 8D displayed on the display device of the server 150 or the operation panel 120 of the MFP 31 .
Moreover, in such alternative embodiment, the processing of FIG. 7 ( b ) or FIG. 7 ( c ) is carried out so that the server 150 transmits the program-addition file to the NCS 61 of the MFP 31 via the network 200 , and the program-addition file including at least the application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file.
In any case, according to the processing of FIG. 7 , the requesting application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file are downloaded via the network, and the program-initiation SD card 141 of FIG. 14 can be created easily.
In the case in which the program is started using the program-initiation SD card 141 of FIG. 14 , the authentication checks of the application program and the configuration file are performed according to the processings of FIG. 11 and FIG. 12 , and only the program whose justification has been confirmed, among those currently recorded in the program-initiation SD card 141 , can be started safely.
A description will be given of the second preferred embodiment of the present invention.
FIG. 15A and FIG. 15B show an example of the processing to add the application program of the program-addition SD card to the program-initiation SD card.
In the composition of FIG. 15A and FIG. 15B , only the elements of the multi-function peripheral system 31 required for description are illustrated, and the elements which do not need description are omitted.
As shown in FIG. 15B , the multi-function peripheral system 31 is provided with the program-addition SD card 140 inserted in the SD card slot 110 . The multi-function peripheral system 31 is an information processing apparatus which adds the program to the program-initiation SD card 141 or the flash ROM 142 by using the program-addition SD card 140 .
As shown in FIG. 15A , the server 150 is a device which creates the program-addition file for adding the program to the program-initiation SD card 141 . The computer terminal 160 is connected to the server 150 through the network 200 , such as the Internet or LAN.
The computer terminal 160 is provided with the SD card slot. The computer terminal 160 reads the information from the program-addition SD card 140 inserted in the SD card slot, and transmits the read information to the server 150 via the network 200 . On the other hand, the computer terminal 160 receives the information from the server 150 via the network 200 , and writes the received information to the program-addition SD card 140 inserted in the SD card slot.
Referring to FIG. 16 , a description will be given of the processing of the multi-function peripheral system 31 , the server 150 , and the computer terminal 160 of FIG. 15A and FIG. 15B .
FIG. 16 shows another example of the processing of the multi-function peripheral system, the server, and the computer terminal.
In the processing of FIG. 16 ( a ), the operator who operates the computer terminal 160 transmits to the server 150 the information of the desired application program to be added to the multi-function peripheral system 31 , as the name of the requesting application program.
The operator looks at one of the screens of FIG. 8A to FIG. 8C displayed on the display device of the computer terminal 160 , and can transmit the information of the desired application program to be added to the multi-function peripheral system 31 , to the server 150 .
For example, the operator who desires to add the application program to the multi-function peripheral system 31 starts the dedicated application program pre-recorded in the computer terminal 160 , so that any one of the screens of FIG. 8A to FIG. 8C is displayed on the display device of the computer terminal 160 .
The computer terminal 160 automatically starts the dedicated application program when the program-addition SD card 140 is inserted in the SD card slot of the computer terminal 160 , and any one screen of FIG. 8A to FIG. 8C is displayed.
If the operator operates the computer terminal 160 and inputs the information into any one of the screens of FIG. 8A to FIG. 8 C, the input information will be transmitted to the server 150 from the computer terminal 160 .
In the case of the screen of FIG. 8A , the identification information (for example, the model name, the model ID, etc.) for identifying the multi-function peripheral system 31 is not transmitted to the server 150 . Therefore, when there are two or more model IDs corresponding to the requesting application program, the computer terminal 160 displays the screen of FIG. 8D on the display unit, so that the operator is requested to choose the desired model ID from among them. Alternatively, the server 150 may display one of the screens of FIG. 8A to FIG. 8D on the display device of the computer terminal 160 .
The server 150 performs the user authentication based on both the information stored in the database 170 of FIG. 9 and the information received from the computer terminal 160 . When the user authentication is completed normally, the program-addition file for adding the program to the program-initiation SD card 141 is created by the server 150 .
The server 150 receives from the database 170 the SD serial ID of the program-initiation SD card of the multi-function peripheral system 31 , and creates the program-addition file required for adding the program to the program-initiation SD card 141 as in the flowchart of FIG. 10 .
In the processing of FIG. 16 ( b ), the server 150 transmits the program-addition file to the computer terminal 160 , and the program-addition file including at least the requesting application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file.
In the processing of FIG. 16 ( c ), the computer terminal 160 receives from the server 150 the program-addition file, and writes the received program-addition file to the program-addition SD card 140 inserted in the SD card slot, as shown in FIG. 17 .
FIG. 17 shows an example of the program-addition SD card in which the program-addition file is recorded. In the example of the program-addition SD card 140 in FIG. 17 , “apl.cnf” indicates the configuration file, “apl.lic” indicates the electronic signature of the configuration file, “apl.mod” indicates the requesting application program, and “apl.mac” indicates the electronic signature of the application program.
In the processing of FIG. 16 ( d ), the program-addition SD card 140 as shown in FIG. 11 is inserted in the SD card slot 110 of the multi-function peripheral system 31 . The SD card control unit 133 detects the insertion of the program-addition SD card 140 in the SD card slot 110 , and notifies the detected insertion of the SD card to the program initiating unit 131 .
In the processing of FIG. 16 ( e ), the program initiating unit 131 reads the program-addition file from the program-addition SD card 140 , and performs the authentication checks of the requesting application program and the configuration file using the electronic authentication check library 134 , in order to check the justification of the program-addition file.
For example, the authentication check of the requesting application program is performed as in the flowchart of FIG. 12 . Moreover, the authentication check of the configuration file is performed by the program initiating unit 131 as in the flowchart of FIG. 13 .
If the program initiating unit 131 checks the justification of the program-addition file read from the program-addition SD card 140 , the program initiating unit 131 progresses to the processing of FIG. 16 ( f ). In the processing of FIG. 16 ( f ), the program initiating unit 131 mounts the program-addition SD card 140 .
In the processing of FIG. 16 ( g ), the program initiating unit 131 notifies to the SD card control unit 133 that the mounting of the program-addition SD card 140 is completed.
In the processing of FIG. 16 ( h ), the SD card control unit 133 notifies to the SCS 68 that the preparation to add the program of the program-addition SD card 140 to the program-initiation SD card is completed.
In the processing of FIG. 16 ( i ), the SCS 68 writes a part or all of the program-addition file read from the program-addition SD card 140 , to the program-initiation SD card 141 or the flash ROM 142 .
In addition, the SCS 68 determines the addition location of the program-addition file (either the program-initiation SD card 141 or the flash ROM 142 ) based on the description of the configuration file. Alternatively, the addition location selection screen as shown in FIG. 14 may be displayed on the control panel 120 , and the operator may be requested to choose one from among them.
When the program-initiation SD card 141 is chosen as the addition location, the SCS 68 writes the requesting application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file to the program-initiation SD card 141 , as shown in FIG. 15 .
On the other hand, when the flash ROM 142 is chosen as the addition location, the SCS 68 writes the requesting application program and the configuration file to the program-initiation SD card 141 .
According to the processing of FIG. 16 , the requesting application program, the electronic signature of the application program, the configuration file, and the electronic signature of the configuration file are acquired not only through the network but also through the application SD card, and the program-initiation SD card 141 of FIG. 14 can be created easily.
When the program of the program-initiation SD card 141 of FIG. 14 is started, the processings of the flowcharts of FIG. 11 and FIG. 12 are performed so that the authentication checks of the application program and the configuration file are performed, and the application program is initiated after the authentication checks are performed. Only the program whose justification has been checked, among the programs currently recorded in the program-initiation SD card 141 can be started safely.
In the above-described embodiments, the description is focused on the processing of the multi-function peripheral system 31 , and the same is easily applicable to the information processing apparatus 1 shown in FIG. 1 and FIG. 2 .
The present invention is not limited to the above-described embodiments, and variations and modifications may be made without departing from the scope of the present invention.
Further, the present application is based on Japanese priority application No. 2003-076605, filed on Mar. 19, 2003, and Japanese priority application No. 2004-057680, filed on Mar. 2, 2004, the entire contents of which are hereby incorporated by reference. | A file creation method creates a program-addition file for adding a program to a program-initiation recording medium of an information processing apparatus. The file creation method comprises the steps of acquiring identification information of the program-initiation recording medium, and creating a program-addition file in response to the identification information so that starting of the program on the information processing apparatus is allowed by the program-addition file with the program stored in the program-initiation recording medium. | 8 |
This application is a continuation of application Ser. No. 595,375, filed Mar. 30, 1984, now abandoned.
BACKGROUND OF THE INVENTION
This invention concerns tools used to remove a volume of material from a workpiece and is especially concerned with the use of center cutting end mills for forming contours in titanium materials.
Materials such as titanium have relatively light weight and great strength and, for that reason, are used in structural and operating parts for aircraft. Structural parts for aircraft, when made from titanium, must be thin in cross section while having flanges perpendicular to said cross sections. In order to manufacture such parts having thin cross sections from titanium, it is necessary to machine said parts out of solid blocks of stock. This usually requires that more titanium material be removed from the block than will remain in the workpiece.
To date, the method used in removing the titanium has been using a drill to make a cylindrical access hole with a predetermined depth in the pocket to be formed in the titanium. End mills are then lowered to a fraction of the depth of the access hole and traversed over an x and y axis until the entire surface of the pocket to be formed is traversed. The method is again repeated until each fraction of depth of cut totals the required part print depth.
The problem with the above procedure is that it is extremely time consuming, and the cutting edges of the end mills are easily and very often damaged. The cause of the damage usually is due to the cutting edge recutting an already machined chip.
When the cutting edge of the end mill encounters a previously machined chip, it can cause systems deflection and damage itself. When utilizing carbide instead of H.S.S. material in the drill or end mill, the carbide cutting edge can also be damaged when a previously machined chip is caught between the cutting edge and the uncut material.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, disclosed herein is a method of removing material from a workpiece, especially a titanium alloy workpiece, to form a rectangular or square configuration which includes the steps of forming individual cylindrical holes having a predetermined depth in a workpiece and positioning said holes along the length and width of the rectangle or square contour so that portions of their diameters are tangent with at least portions of the diameter of two other holes in the surface of the workpiece. Once these holes are placed within the boundaries of the rectangle or square, posts or cusps will be formed which are bounded by portions of the tangent diameters of said holes. The completed rectangle or square contour may then be finished by removing the posts and cusps from the workpiece by an end milling technique.
Further, the method specifically concerns the reciprocal movement of a center cutting end mill along its Z axis to form a single cylindrical hole, and when repositioned in its starting position, moving it along its x or y axis a distance equal to a multiple of its diameters, and then reciprocally machining another Z axis hole.
BRIEF DESCRIPTION OF THE DRAWINGS
The exact nature of the present invention will become more clearly apparent upon reference to the following detailed specification taken in connection with the accompanying drawings in which:
FIG. 1 is a sectional view of a typical structural part.
FIG. 2 is a side sectional view from a blovk of material necessary to create the part in FIG. 1.
FIG. 3 is the center cutting end mill used with the method of the present invention.
FIG. 4 is a plan view of the block shown in FIG. 2 and being prepared by the method of the present invention.
FIG. 5 shows typical continuous and discontinuous type chips.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings somewhat more in detail, what is shown in FIG. 1 is a typical titanium structural part found as part of an aircraft structural system.
The structural part 10 resembles a four-sided box with walls 12 and a thin cross sectional area 14. The thin cross sectional area 14, in some cases, may only be as much as 0.050 to 0.100 inches thick, with the thickness of walls 12 being approximately the same.
When the part 10 is made of titanium in order to achieve the configuration shown in FIG. 1, special procedures must be used. Specifically, shown in FIG. 2 is a piece of stock 16 from which the strucutral part 10 may be fabricated. Presently, part 10 is constructed by, first, sinking a hole 18 to the depth required to create an end mill access hole. Next, an end mill is lowered to depth 20 in the access hole 18, and the end mill is then transversed over its x and y coordinates until it covers the surface area necessary to create top half of part shown in FIG. 1. The end mill will then be lowered another fractional part of the depth of hole 18, and the entire surface area will be again transversed.
This procedure will be repeated continuously until the bottom 21 of the hole 18 is reached. The part will then be turned over and the same procedure applied to the lower side 22 so as to create part shown in FIG. 1.
As a part of the present invention, a special tool has been created, pictured in FIG. 3. The tool 24 has a shank 26 with a whistle notch type configuration, as shown at 28, for attachment to a rotary power source. The tool is similar to pre-existing center cut end mills, except that its forward section 29 has been elongated so as to be able to create the depth of hole necessary for the particular part to be machined.
The tool also has a center hole 30 which supplies the coolant through the shank 26 and out end faces 32 so as to cool and flush the chips as they are generated from the workpiece. The inserts 34 are mounted on the tool. The inserts used particularly have a sharp edge rather than any honed or preground edge. A relief 35 is provided behind the second mounted insert 34, not shown.
Since safety is of utmost concern to the metalcutting industry, this method produces cool, safe chips which are generated at conservative cutting feeds and speeds. The inherent fire hazard of titanium is significantly reduced because the chip is formed at low surface speed per minute (S.P.M.) and in a coolant induced environment.
While this invention has been used for the processing of titanium, it is thought that, if one were to advance to the machining of other materials, the cutting edge may be honed rather than sharp.
What is shown in FIG. 4 is a plan view of a piece of stock 36 from which will be made the typical part as shown in FIG. 1. It has now been proven that the center cutting end mill 24 is most preferably designed to have a diameter which is a multiple of the width and length of the cavity 37. When the end mill 24 is so designed, material from the part may be removed most efficiently by maneuvering the tool reciprocally in the Z axis direction. The Z axis direction, according to FIG. 4, would be facing into the paper.
The x and y axes are shown as indicated at 38 and 41. It is most desirable that the end mill 24 be positioned at the necessary x and y coordinates so as to start by drilling hole 40. Hole 40 necessarily has portions of its diameter tangent to the sides 43 and 44 of part 36.
Producing hole 40 may require the center cut end mill to instantaneously pause its feed at certain intervals during its engagement with the workpiece so as to break the chip being formed. This will be required when the chip type is continuous in formation, and it may not be required if the chip type is discontinuous during formation (see FIG. 5).
Once hole 40 is created by reciprocally moving the end mill 24 in the Z axis direction, it may then, when in the up position, be moved in the direction so that reciprocal motion in the Z axis will create hole 42. The end mill 24 may then again be raised, and by repositioning the tool in the x and y coordinate directions, multiple holes may be created that fit within the boundaries of the width and length of part 36.
When created, the holes 40, 42 and typical holes 46, will have portions of their diameters that are cotangent with portions of the diameters of adjacent holes.
When the entire plan view of part 36 has been machined with the necessary holes 40, 42 and 46, what will be left are the posts 47 which will be in the form of a star when viewed in a plan view and the cusps 48 formed along the peripheral boundary of the part 36.
Preferably, the next step according to the present invention is to position the end mill 24 along the x and y coordinates so that it rests along the Z axis immediately above the remaining posts 47. Reciprocal movement along the Z axis again does away with posts 47, and this step must be repeated for every post that remains as a star in the plan view of FIG. 4.
Cusps 48 are then removed by the normal techniques of lowering an end mill along the Z axis until it reaches the correct depth and then transversing the x and y coordinates so as to form the necessary boundaries and/or using the Z axis machining method to remove the cusps.
One of the reasons it is believed that tool life is enhanced immensely over the procedures of the prior art concerns the cotangency points shown in FIG. 4 of multiple holes 40, 42 and 46. When a tool is rotating in a hole, there is always the possibility that an already hardened and precut chip can get caught between the wall and the cutting edge of the tool. When this occurs, the cutting edge of the tool, whether it be high speed steel or carbide, is chipped, thereby diminishing the effective life of the tool. In the present case, when such an occurrence happens, the chip merely deflects the thin walls of the holes at the cotangency points, thereby lessening the damage to the cutting edge of the tool.
Two additional reasons it is believed that tool life is enhanced immensely over the procedures of the prior art concern the minimizing of systems deflection and elimination of the tangential impacts of end milling. The machine tool life should also be extended because the Z axis force does not impose the spindle bending forces of peripheral end milling, but imparts Z axis force in the direction of strength of the machine tool system.
Modifications may be made within the scope of the appended claims. | A method of efficiently removing material from a workpiece of difficult-to-machine materials. The Z axis machining includes the steps of using a center cutting end mill and forming multiple cylindrical holes having tangent diameters and predetermined depths. Said holes, when formed, leave posts that, when viewed in plan, form stars and cusps. Said stars are then removed by reciprocal movement of said end mill along its Z axis and cusps removed by Z axis machining and/or conventional end milling. | 8 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims an invention which was disclosed in Provisional Application No. 60/754,106, filed Dec. 27, 2005, entitled “OVERFLOW DOWNDRAW GLASS FORMING METHOD AND APPARATUS”. The benefit under 35 USC §119(e) of the U.S. provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to the manufacture of glass sheet and, more particularly, to glass sheet used for the production of TFT/LCD display devices that are widely used for computer displays and for flat panel television.
DESCRIPTION OF RELATED ART
[0003] The glass that is used for semiconductor powered display applications must have very high surface quality to allow the successful application of semiconductor type material. Sheet glass made using the apparatus of U.S. Pat. No. 3,338,696 assigned to Corning, Inc. makes the highest quality glass as formed and does not require post-processing. The Corning patent makes glass by a manufacturing process termed “The Overflow Process”. Glass made using other processes requires grinding and/or polishing and thus does not have as fine a surface finish. The glass sheet must also conform to stringent thickness variation and warp specifications.
[0004] FIGS. 1A through 1D illustrate the principle parts of a typical “Overflow Process” manufacturing system. The molten glass ( 2 ) from the melting furnace and forehearth, which must be of substantially uniform temperature and chemical composition, enters the forming apparatus from the downcomer pipe ( 7 ) at the downcomer pipe bottom end ( 17 ) into the inflow pipe ( 8 ) (also called an inlet pipe) and flows into the sheet forming structure ( 1 ). Examples of the glass sheet forming apparatus are found in U.S. Pat. Nos. 3,338,696 and 3,451,798. The glass sheet forming apparatus is also described in detail in U.S. Pat. Nos. 6,748,765, 6,889,526, 6,895,782, 6,990,834, and 6,997,017 and U.S. patent application Ser. Nos. 11/006,251, 11/060,139, 11/184,212, and 11/553,198 which are hereby incorporated herein by reference. The glass sheet forming apparatus includes a shallow trough on the top of a wedge shaped forming structure ( 1 ). Straight sloped weirs ( 4 ) substantially parallel with the pointed edge of the wedge, herein termed the root ( 5 ), form each side of the trough in the forming structure ( 1 ). The trough bottom ( 6 ) and the sides of the trough are contoured in a manner to provide even distribution of the glass ( 2 ) to the top of each side weir ( 4 ). The molten glass ( 2 ) then flows through the trough, over the top of each side weir ( 4 ), down each side of the wedge shaped sheet forming structure ( 1 ), and joins at the root ( 5 ) to form a sheet of molten glass. The molten glass is then cooled as it is pulled off the root ( 5 ) to form a solid glass sheet ( 10 ) of substantially uniform thickness.
[0005] The refractory materials from which the forming structure and its support structure are made have high strength in compression and low strength in tension. Like most structural materials they also change shape when stressed at high temperature by a phenomenon termed “thermal creep”.
[0006] FIGS. 2A through 2D illustrate the typical effects of thermal creep on the shape of the forming structure when the end support and compression blocks impart different compression stress in the bottom of the forming structure ( 1 ) near the root ( 5 ). FIG. 2A shows that with no compression loading, the forming structure ( 1 ) sags in the middle such that the top of the weirs ( 4 ) and the root ( 5 ) are now curved ( 21 ) and the trough bottom ( 6 ) has a change in curvature ( 21 ). This longitudinal curvature ( 21 ) causes the molten glass ( 2 ) to no longer flow with constant thickness ( 22 ) over the weirs ( 4 ). More specifically, the longitudinal curvature ( 21 ) allows more glass to flow over the middle of the weirs resulting in an uneven sheet thickness distribution. The forming structure ( 1 ) has an initial longitudinal length ( 20 ) as defined by the phantom lines ( 24 ) and ( 29 ). With no external loading the weirs ( 4 ) get shorter and the root ( 5 ) gets longer.
[0007] FIG. 2B shows that sagging of the forming structure is minimized under the optimum longitudinal compression loading ( 26 ) of the lower section of the forming structure ( 1 ) near the root ( 5 ). With optimal loading both the weirs ( 4 ) and the root ( 5 ) shorten equally to longitudinal length ( 27 ). FIG. 2C shows that if too great a longitudinal compression load ( 25 ) is applied to the lower section of the trough ( 1 ) near the root ( 5 ), the root ( 5 ) is compressed excessively, thus producing a convex longitudinal curvature ( 23 ) to the trough weirs ( 4 ), the trough bottom ( 6 ), and the root ( 5 ). The root ( 5 ) shortens considerably more than the weirs ( 4 ) as can be seen by the movement relative to the phantom lines ( 24 ) and ( 29 ). FIGS. 2A through 2C represent the effect of thermal creep over the same time period. FIG. 2D shows a forming structure ( 1 ), which has shortened a greater amount to longitudinal length ( 28 ). This increased shortening is caused by imparting the correct longitudinal load ( 26 ) for the increased time of a substantially longer production campaign. This increased shortening has an adverse effect on the width of the manufactured sheet.
[0008] U.S. Pat. No. 3,451,798 teaches that a sheet glass edge control device, termed “edge director” herein, must be installed at each end of the trough to prevent narrowing of the formed sheet as a result of surface tension. FIGS. 3A through 3D show the prior art edge director assemblies ( 41 ) and ( 42 ) shown in FIGS. 4A through 4F attached to the ends of the trough forming structure ( 1 ). The flanges ( 47 ) of the inflow edge director assembly ( 41 ) are compressed against the forming structure ( 1 ) by the inflow support and compression block ( 31 ). The inflow support and compression block ( 31 ) rests on the inflow end support structure ( 33 ) and is held in position by the adjustment bolt ( 34 ). The flanges ( 48 ) of the far end edge director assembly ( 42 ) are compressed against the forming structure ( 1 ) by the far end support and compression block ( 32 ). The far end support and compression block ( 32 ) rests on the far end structure ( 35 ) and is held in position by the force motor ( 38 ). A force motor ( 38 ) is a device that generates a substantially constant linear force ( 26 ), in a longitudinal direction ( 36 ). The energy required to maintain this force ( 26 ) may be supplied by gravitational, pneumatic, hydraulic, or mechanical means. Some examples of force motors include, but are not limited to, an adjustable spring assembly, a mechanical adjustment device that is constantly or periodically monitored and adjusted, an air cylinder, an air powered motor, a hydraulic cylinder, a hydraulic powered motor, a solenoid, an electric motor, or a weight and lever system.
[0009] FIGS. 4A through 4C are side, end, and top views of the inflow end edge director ( 41 ) as used in the prior art. The inflow end edge director ( 41 ) has a fence ( 43 ) to which the glass attaches such that the width is maintained. The edge director ( 41 ) also has symmetrical edge director surfaces ( 45 ) that provide for gravity to assist the flowing glass to attach to the fence, and flanges ( 47 ) that are used to secure the edge director to the inflow end of the forming structure ( 1 ).
[0010] FIGS. 4D through 4F are side, end, and top views of the far end edge director ( 42 ) as used in the prior art. The far end edge director ( 42 ) has a fence ( 44 ) to which the glass attaches such that the width is maintained. The edge director ( 42 ) also has symmetrical edge director surfaces ( 46 ) that provide for gravity to assist the flowing glass to attach to the fence, and flanges ( 48 ) that are used to secure the edge director to the far end of the forming structure ( 1 ). Attached to the outlet edge director ( 42 ) is a wedge shaped protrusion, herein termed a plow ( 49 ), which aids in the control of the glass flow over the weirs ( 4 ) near the far end edge director ( 42 ).
[0011] The edge directors are normally fabricated via welding from platinum sheet or platinum alloy sheet (platinum herein). In the prior art, the edge directors are fixed to each end of the forming structure. Thus, as the campaign progresses and the forming structure becomes shorter via thermal creep, the manufactured sheet becomes narrower. This results in fewer square feet of production, and required process changes.
[0012] The forming structure of the prior art is made from a single block of refractory material which is isostatically pressed. The size capability of presently available equipment for isostatic pressing limits the dimensions of the forming structure.
[0013] A major drawback of the apparatus of “The Overflow Process” is that the forming apparatus deforms during a manufacturing campaign in a manner such that the glass sheet no longer meets the thickness and width specifications. This is a primary cause for premature termination of the production run.
[0014] Another drawback is that the edge directors are required because the glass does not flow over the ends of the forming structure.
[0015] Another drawback of the apparatus is that the production rate is limited by the size forming structure.
SUMMARY OF THE INVENTION
[0016] The present invention is a significant modification of “The Overflow Process” that embodies design features that support the forming apparatus in a manner such that the deformation that results from thermal creep has a minimum effect on the thickness variation of the glass sheet.
[0017] The glass “Sheet Forming Apparatus” normally designed for use in “The Overflow Process” (U.S. Pat. No. 3,338,696) relies on a specifically shaped forming structure to distribute the glass in a manner to form sheet of a uniform thickness. The basic shape of this forming trough is described in detail in U.S. Pat. No. 3,338,696. Structurally the forming structure is a beam, which is supported at each end. The sheet glass forming process is conducted at elevated temperatures, typically between 1100° C. and 1350° C. At these temperatures the materials used for construction of the forming structure exhibit a property called thermal creep, which is deformation of the material caused by applied stress at elevated temperatures. Thus, the forming structure deforms under the stress caused by own weight.
[0018] Embodiments of this invention suspend the forming structure from the top in a manner such that the thermal creep, which inevitably occurs, has a minimum impact on the glass flow characteristics of the forming structure. In these embodiments there are no externally applied compression loads on the forming structure and any moments that produce sagging of the forming structure are minimized. Thus sheet glass may be manufactured for a longer time without requiring changing of the forming structure.
[0019] In other embodiments of this invention the glass flows over the ends of the forming structure, thus completely enveloping the forming structure.
[0020] Other embodiments of this invention also allow for the doubling of the length of the forming structure, thus proportionally increasing the production rate.
[0021] Like the present overflow process, this invention forms the sheet glass surfaces from virgin glass from the center of the glass flow stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A is a side view of the prior art overflow downdraw sheet glass forming apparatus.
[0023] FIG. 1B is a cross-section of the forming structure shown in FIG. 1A across lines B-B.
[0024] FIG. 1C is a top view of the prior art overflow downdraw sheet glass forming apparatus.
[0025] FIG. 1D is a cross-section of the forming structure shown in FIG. 1A across lines D-D.
[0026] FIG. 2A is an illustration of the thermal creep deformation of the glass forming structure under the load of its own weight.
[0027] FIG. 2B is an illustration of the thermal creep deformation of the glass forming structure under an applied load that minimizes vertical deformation.
[0028] FIG. 2C is an illustration of the thermal creep deformation of the glass forming structure under excessive applied load.
[0029] FIG. 2D is an illustration of the thermal creep deformation of the glass forming structure under an applied load that minimizes vertical deformation over the extended period of a production campaign.
[0030] FIG. 3A is a side view of the prior art overflow downdraw sheet glass forming apparatus showing the edge directors, the support and compression blocks, and the end support structures for both the inflow end and the far end of the forming structure.
[0031] FIG. 3B is a cross-section of the forming structure shown in FIG. 3A across lines B-B.
[0032] FIG. 3C is a partial top view of the prior art overflow downdraw sheet glass forming apparatus shown in FIG. 3A .
[0033] FIG. 3D is a cross-section of the forming structure shown in FIG. 3A across lines D-D.
[0034] FIG. 4A is a side view of the prior art inflow end edge director.
[0035] FIG. 4B is an end view of the prior art inflow end edge director.
[0036] FIG. 4C is a top view of the prior art inflow end edge director.
[0037] FIG. 4D is a side view of the prior art far end edge director.
[0038] FIG. 4E is an end view of the prior art far end edge director.
[0039] FIG. 4F is a top view of the prior art far end edge director.
[0040] FIG. 5A is a side view of an embodiment of the present invention schematically illustrating a center support web that provides for the support of the forming structure from the top.
[0041] FIG. 5B is a cross-section of the forming structure shown in FIG. 5A across lines B-B.
[0042] FIG. 5C is a partial top view of the embodiment of this invention shown in FIG. 5A .
[0043] FIG. 5D is a cross-section of the forming structure shown in FIG. 5A across lines D-D.
[0044] FIG. 6A is a side view of an embodiment of the present invention schematically illustrating the components and assembly for the forming structure that is shown in FIGS. 5A through 5D .
[0045] FIG. 6B is a cross-section of the forming structure shown in FIG. 6A across lines B-B.
[0046] FIG. 6C is a partial top view of the embodiment of this invention shown in FIG. 6A .
[0047] FIG. 6D is a cross-section of the forming structure shown in FIG. 6A across lines D-D.
[0048] FIG. 7A is a side view of an embodiment of the present invention schematically illustrating a center support web that provides for the support of the forming structure from the top and has no end support structure.
[0049] FIG. 7B is a cross-section of the forming structure shown in FIG. 7A across lines B-B.
[0050] FIG. 7C is a partial top view of the embodiment of this invention shown in FIG. 7A .
[0051] FIG. 7D is a cross-section of the forming structure shown in FIG. 7A across lines D-D.
[0052] FIG. 8A is a side view of an embodiment of the present invention schematically illustrating the components and assembly for the forming structure that is shown in FIGS. 7A through 7D .
[0053] FIG. 8B is a cross-section of the forming structure shown in FIG. 8A across lines B-B.
[0054] FIG. 8C is a partial top view of the embodiment of this invention shown in FIG. 8A .
[0055] FIG. 8D is a cross-section of the forming structure shown in FIG. 8A across lines D-D.
[0056] FIG. 9A is a side view of an embodiment of the present invention schematically illustrating the center support web that provides for the support of the forming structure from the top, has no end support structure, and has a shape that requires no edge directors.
[0057] FIG. 9B is a cross-section of the forming structure shown in FIG. 9A across lines B-B.
[0058] FIG. 9C is a partial top view of the embodiment of this invention shown in FIG. 9A .
[0059] FIG. 10A is a side view of an embodiment of the present invention schematically illustrating the components and assembly for the forming structure that is shown in FIGS. 9A through 9C .
[0060] FIG. 10B is a cross-section of the forming structure shown in FIG. 10A across lines B-B.
[0061] FIG. 10C is a partial top view of the embodiment of this invention shown in FIG. 10A .
[0062] FIG. 11A is a side view of an embodiment of the present invention showing the forming structure supported by end mounts.
[0063] FIG. 11B is a cross-section of the forming structure shown in FIG. 11A across lines B-B.
[0064] FIG. 11C is a partial top view of the embodiment of this invention shown in FIG. 11A .
[0065] FIG. 11D is a cross-section of the forming structure shown in FIG. 11A across lines D-D.
[0066] FIG. 11E is a cross-section of the mounting block shown in FIG. 11A across lines E-E.
[0067] FIG. 12A is a side view of an embodiment of the present invention showing the forming structure supported by end mounts.
[0068] FIG. 12B is a cross-section of the forming structure shown in FIG. 12A across lines B-B.
[0069] FIG. 12C is a partial top view of the embodiment of this invention shown in FIG. 12A .
[0070] FIG. 13A is a side view of an embodiment of the present invention showing a forming structure that produces glass sheet with substantially twice the width of the prior art sheet.
[0071] FIG. 13B is a cross-section of the forming structure shown in FIG. 13A across lines B-B.
[0072] FIG. 13C is a partial top view of the embodiment of this invention shown in FIG. 13A .
[0073] FIG. 14A is a side view of an embodiment of the present invention showing a forming structure which produces two sheets of substantially the same width as the prior art sheet.
[0074] FIG. 14B is a cross-section of the forming structure shown in FIG. 14A across lines B-B.
[0075] FIG. 14C is a partial top view of the embodiment of this invention shown in FIG. 14A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0076] The refractory materials from which the forming trough and its support structure are made have high strength in compression and low strength in tension. Like most structural materials they also change shape when stressed at high temperature by a process termed “Thermal Creep”. These material characteristics and how these characteristics affect the manufacturing process are the reason for this invention.
[0077] FIGS. 5A through 5D illustrate a forming structure ( 51 ) which is supported from the top at surface ( 59 ) by a center support web ( 57 ). The support web ( 57 ) is attached to the bottom ( 56 ) of the trough in the forming structure ( 51 ). For clarity of illustration the support web ( 57 ) is shown as being rectangular in cross section and having a longitudinal length less than that of the weirs ( 54 ) on the forming structure ( 51 ). In practice the longitudinal length of the support web ( 57 ) is optionally the full length of the weirs ( 54 ) and could even extend back into the inflow pipe ( 68 ). The cross section would be streamlined to facilitate smooth flow of the glass. Because the support web ( 57 ) is attached on the centerline of the forming structure ( 51 ) it produces a restriction to the glass flow. The width of the forming structure ( 53 ) between the weirs ( 54 ) will be greater than the forming structure width in the prior art. Attached to the support web ( 57 ) is a flow control web ( 58 ) which guides flow to the far end unusable edge of the formed glass sheet.
[0078] FIGS. 6A through 6D show the forming structure ( 51 ) as part of the assembled sheet glass forming apparatus. The glass ( 2 ) is fed to a downcomer pipe ( 7 ), which feeds an inflow pipe ( 68 ) similar to the prior art inflow pipe ( 8 ) that is adapted to fit the wider forming structure ( 51 ). The edge directors ( 61 ) and ( 62 ) are similar to the prior art edge directors ( 41 ) and ( 42 ), but adapted to fit the wider forming structure ( 51 ). The glass ( 2 ) flows down the two parallel troughs past the support web ( 57 ) and the flow control web ( 58 ), flows over the weirs ( 54 ), down the inverted wedge surfaces to the root ( 55 ) of the forming structure ( 51 ) and forms the glass sheet ( 10 ).
[0079] The shape and size of the flow control web ( 58 ), the cross-section and length of the support web ( 57 ) where it is submerged in the glass ( 2 ), and the width ( 53 ) between the weirs ( 54 ) in combination with the shape of the trough bottom ( 56 ) and of the weirs ( 54 ), would be determined using the simulation technologies of Computational Fluid Dynamics (CFD) and Oil Modeling.
[0080] FIGS. 7A through 7D illustrate another embodiment of this invention whereby the forming structure ( 71 ), which is supported from the top at surface ( 59 ) by a center support web ( 77 ), has a weir ( 74 ) encircling the top of the forming structure, and has rounded ends ( 70 ) and ( 72 ). The center support web ( 77 ) is attached to the bottom ( 76 ) of the trough in the forming structure ( 71 ). The glass flows over the weir ( 74 ) and down all sides of the forming structure ( 71 ) joining at the root ( 75 ) of the forming structure ( 71 ) such that the glass completely envelopes the forming structure ( 71 ).
[0081] FIGS. 8A through 8D show the forming structure ( 71 ) as part of the assembled sheet glass forming apparatus. The glass ( 2 ) is fed to a downcomer pipe ( 87 ) similar to that in the prior art, which discharges the glass directly onto the top surface of the glass in the forming structure. No edge directors are shown, but some type of flow control apparatus would be required at each end ( 70 ) and ( 72 ). The glass ( 2 ) flows down the two parallel troughs past the support web ( 77 ) and flow control web ( 78 ), flows over the weir ( 74 ) on each side and each end ( 70 ) and ( 72 ), down the inverted wedge surfaces to the root ( 75 ) and forms the glass sheet ( 10 ). The shape of the bottom and the location of the bottom of the downcomer pipe ( 87 ) are both critical to maintaining uniform flow over the weir ( 74 ). The bottom of the downcomer pipe ( 87 ) may be below the glass surface as shown in FIG. 10A .
[0082] The shape and location of the bottom of the downcomer pipe ( 87 ), the shape and size of the flow control web ( 78 ), the cross section and length of the support web ( 77 ) where it is submerged in the glass ( 2 ), the shape of the ends ( 70 ) and ( 72 ), and the width ( 73 ) between the weirs ( 74 ), in combination with the shape of the trough bottom ( 76 ) and of the weirs ( 74 ), would be determined using the simulation technologies of Computational Fluid Dynamics (CFD) and Oil Modeling and would be periodically improved based on manufacturing experience.
[0083] FIGS. 9A through 9C illustrate a forming structure ( 91 ) which is supported from the top at surface ( 99 ) by two support webs ( 97 ). The support webs ( 97 ) are attached to the bottom ( 96 ) of the trough in the forming structure ( 91 ). The cross section of the support webs ( 97 ) is streamlined to facilitate smooth flow of the glass. The weirs ( 94 ) completely encircle the top of the forming structure ( 91 ). The forming structure has a shape in the horizontal plane that is substantially an ellipse. This somewhat elliptical shape is such that edge directors are not required at the ends ( 90 ) and ( 92 ). The angle ( 98 ) of the inverted slope varies in the longitudinal direction such that the increase in the gravitational force in the longitudinal direction on the vertically flowing glass ( 2 ) is such to counteract the effect of the surface tension of the glass ( 2 ) as it flows to the root ( 95 ) of the forming structure ( 91 ).
[0084] FIGS. 10A through 10C show the forming structure ( 91 ) as part of the assembled sheet glass forming apparatus. The glass ( 2 ) is fed to a downcomer pipe ( 107 ), similar to that in the prior art, which discharges the glass under the top surface of the glass ( 2 ) in the forming structure. The glass ( 2 ) flows in the parallel troughs past the support web, flows over the weir ( 94 ) on each side and each end ( 90 ) and ( 92 ), down the inverted wedge surfaces to the root ( 95 ) of the forming structure ( 91 ) and forms the glass sheet ( 10 ). The shape of the bottom and the location of the bottom of the downcomer pipe ( 107 ) are both critical to maintaining uniform flow over the weir ( 94 ). The bottom of the downcomer pipe ( 107 ) may be above the glass surface as shown in FIG. 8A .
[0085] The shape and location of the bottom of the downcomer pipe ( 107 ), the horizontal cross section of the forming structure ( 91 ), the variation of the inverted slope angle ( 98 ), the cross section and length of the support webs ( 97 ) where they are submerged in the glass ( 2 ), and the width ( 93 ) between the weirs ( 94 ), in combination with the shape of the trough bottom ( 96 ) and of the weirs ( 94 ), would be determined using the simulation technologies of Computational Fluid Dynamics (CFD) and Oil Modeling and would be periodically improved based on manufacturing experience.
[0086] The somewhat elliptical horizontal shape of forming structure ( 91 ) in FIGS. 9A through 9C can also be incorporated as a feature in the shape of the ends ( 70 ) and ( 72 ) of the forming structure ( 71 ) in FIGS. 7A through 7D . In the embodiment shown in FIGS. 9A through 9C , the somewhat elliptical horizontal shape is shown as encompassing the entire periphery of the forming structure. In additional embodiments the somewhat elliptical horizontal shape may be limited to the end portions ( 90 ) and ( 92 ) of the forming structure.
[0087] The support webs ( 57 ), ( 77 ), and ( 97 ), which support the weight of the forming structure and the glass ( 2 ) in and on the forming structure are loaded in tension. The refractory materials, Zircon and Alumina, normally used to construct the forming structure would not be suitable for this part of the forming apparatus assembly. A refractory metal, such as molybdenum, would be preferable for the construction of the support webs ( 57 ), ( 77 ), and ( 97 ). The molybdenum would preferably be clad in platinum or platinum alloy to protect it from oxidation. The refractory material of the forming structure, such as Zircon, would then be attached to the support webs ( 57 ), ( 77 ), and ( 97 ).
[0088] FIGS. 11A through 11E show a forming structure ( 117 ) similar in shape to forming structure ( 71 ) of FIG. 7A through 7D supported from the ends by mounting blocks ( 117 ) at each end. The mounting blocks ( 117 ) have a thin streamlined profile as shown by the section in FIG. 11E such as to have minimum interference with the molten glass ( 2 ) flowing over the ends (( 110 ) and ( 112 )) of the forming structure ( 111 ) and down each side of the mounting blocks ( 117 ). The vertical flow of the glass ( 2 ) at each end ( 110 ) and ( 112 ) is on a substantially vertical surface at angle ( 18 ). The range of angle ( 18 ) is 0 to 20 degrees. The glass ( 2 ) flows over the weir ( 114 ) on each side and each end ( 110 ) and ( 112 ), down the wedge surfaces to the root ( 115 ) and forms the glass sheet ( 10 ). The shape of the bottom and the location of the bottom of the downcomer pipe ( 87 ) are both critical to maintaining uniform flow over the weir ( 114 ). The bottom of the downcomer pipe ( 87 ) may be below the glass surface as shown in FIG. 10A .
[0089] The shape and location of the bottom of the downcomer pipe ( 87 ), the shape and angle ( 118 ) of the ends ( 110 ) and ( 112 ), and the width ( 113 ) between the weirs ( 114 ), in combination with the shape of the trough bottom ( 116 ) and of the weirs ( 114 ), would be determined using the simulation technologies of Computational Fluid Dynamics (CFD) and Oil Modeling and would be periodically improved based on manufacturing experience.
[0090] FIGS. 12A through 12C show a forming structure ( 121 ) similar in shape to forming structure ( 91 ) of FIGS. 9A through 9C supported from the ends by mounting blocks ( 127 ) at each end ( 120 ) and ( 122 ). The mounting blocks ( 127 ) have a thin streamlined profile similar to that shown by the section in FIG. 11E so that there is minimum interference with the molten glass flowing over the ends (( 120 ) and ( 122 )) of the forming structure ( 121 ) and down each side of the mounting blocks ( 127 ). The vertical flow of the glass ( 2 ) at each end ( 120 ) and ( 122 ) is on a substantially vertical surface at angle ( 128 ). The range of angle ( 128 ) is preferably 0 to 20 degrees. The glass ( 2 ) flows over the weir ( 124 ) on each side and each end ( 120 ) and ( 122 ), down the inverted wedge surfaces to the root ( 125 ) and forms the glass sheet ( 10 ). The shape of the bottom and the location of the bottom of the downcomer pipe ( 107 ) are both critical to maintaining uniform flow over the weir ( 124 ).
[0091] The shape and location of the bottom of the downcomer pipe ( 87 ), the shape and angle ( 128 ) of the ends ( 120 ) and ( 122 ), and the width ( 123 ) between the weirs ( 124 ), in combination with the shape of the trough bottom ( 126 ) and of the weirs ( 124 ), would be determined using the simulation technologies of Computational Fluid Dynamics (CFD) and Oil Modeling and would be periodically improved based on manufacturing experience.
[0092] Either the angle ( 118 ) or ( 128 ), which are shown in FIGS. 11A and 12A respectively, may be optionally incorporated in the shape of the ends of the embodiments of forming structures ( 71 ), ( 91 ), ( 111 ), and ( 121 ).
[0093] A refractory metal, such as molybdenum, would be preferable for the construction of the mounting blocks (( 117 ) and ( 127 )) because the thin profile implies high loading which would result in substantial thermal creep. The molybdenum would preferably be clad in platinum or platinum alloy to protect it from oxidation.
[0094] Another method of protecting the refractory metal, such as molybdenum, from oxidation is to operate the process in a reducing atmosphere.
[0095] FIGS. 13A through 13C show an embodiment of this invention whereby the production rate of the forming apparatus may be substantially increased. This embodiment comprises two forming structure blocks ( 139 ) of length ( 136 ) placed end to end such that the combined length of the forming structure ( 131 ) is length ( 133 ). Length ( 136 ) is the maximum length isostatically pressed refractory that can be procured. Combining two blocks end to end produces a forming structure ( 131 ) with twice the width ( 133 ), which in turn makes a glass sheet ( 130 ) that is substantially twice as wide as prior art sheet. The forming structure blocks ( 139 ) are compressed together by the mounting blocks ( 137 ) and join at the plane ( 135 ). A keying mechanism, not shown, would be required at plane ( 135 ) to insure correct alignment of the two forming structure blocks ( 139 ).
[0096] In the embodiments of this invention shown in FIGS. 10A through 10C , FIGS. 12A through 12C , and FIGS. 13A through 13C the most challenging technical development is controlling the glass flow over the weirs ( 94 ), ( 124 ), and ( 134 ) in the center of the forming apparatus near the bottom of the downcomer pipe ( 107 ). If the glass ( 2 ) flow control is not accurate in this region of the sheet ( 130 ), the quality in area ( 132 ) in the center of the sheet ( 130 ) will not meet specification. The two useable width ( 138 ) sections of the sheet ( 130 ) will be substantially the same sheet width as made with an apparatus that uses a single piece forming structure.
[0097] FIGS. 14A through 14C show an embodiment of this invention which produces two strips of sheet ( 140 a ) and ( 140 b ). Two forming structure blocks ( 149 ) of length ( 146 ) are compressed together at plane ( 145 ) by the mounting blocks ( 137 ) to make the forming structure ( 141 ). A flow divider ( 142 ) is provided at the center plane of the forming structure ( 141 ) to separate the glass flow such that two separate sheets ( 140 a ) and ( 140 b ) are formed. The sheets each have useable widths ( 148 ) which are substantially the same sheet width as made with an apparatus that uses a single piece forming structure.
[0098] The forming structures ( 71 ), ( 91 ), ( 111 ), and ( 121 ) are normally made from refractory materials such as Zircon and Alumina. An additional feature of the embodiments of this invention that use forming structures ( 71 ), ( 91 ), ( 111 ), and ( 121 ) is that the forming structure is completely enveloped in glass during glass sheet forming operations. The forming structure material would then optionally be a refractory metal such as molybdenum. The glass, which encases the molybdenum forming structure structure, would protect the molybdenum from oxidation.
[0099] Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | The present invention discloses improved apparatuses for forming sheet glass. In one embodiment, the invention introduces a structural web that supports the forming structure in a manner such that the thermal creep which inevitably occurs has a minimum impact on the glass flow characteristics of the forming structure. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is an enhanced chair for usage in connection with honoring guests at various celebrations. More particularly, the invention is an improved “Simcha Chair,” or chair traditionally used at Jewish weddings, Bar Mitzvahs, and other affairs, wherein an honoree is seated in a chair and elevated by celebrants above the height of dancing guests. As such, there are inherent safety risks associated with the activity, and the improved chair of the present invention mitigates the incidence of potential damage and injury.
[0003] 2. Description of the Prior Art
[0004] Many innovations for safe chairs have been provided in the prior art, described as follows. Although these inventions are suitable for the purposes they address, they differ from the present invention as contrasted herein. Following is a summary of patents most relevant to the invention at hand, including description of differences between features of the invention and those of the prior art.
[0005] 1. U.S. Pat. No. 5,015,037, Invented by Giblin et al., Entitled “Chair Assembly Having Non-Slip Seat”
[0006] The patent to Giblin et al. describes an assembly of a highchair having a smooth seat, and a thin, flat, compliant pad freely covering the seat surface. The pad is made from one piece of solid, rubbery material providing a high coefficient of friction, and it has a matrix of apertures formed through it, each defined by a sharp peripheral edge at its juncture with the faces of the pad. The pad conforms to the seat in an anti-slip relationship, and it provides good mechanical interengagement with the diaper or garment of a baby seated upon it, despite the lightness of the baby's body.
[0007] 2. U.S. Pat. No. 5,346,278, Invented by Dehondt, Entitled “Non-Slip Cushion”
[0008] The patent to Dehondt describes a non-slip high chair cushion, having globules of rubbery polymeric material deposited on a scrim fabric as by dipping same in a plastic foam material, preventing an infant from sliding forwardly out of the high chair.
[0009] 3. U.S. Pat. No. 4,177,807, Invented by Ocel et al., Entitled “Restraining Belt For Patients In Wheelchairs, Stretchers Or The Like”
[0010] The patent to Ocel et al. describes a restraining belt for securing a patient to a wheelchair, stretcher, bed or similar implement and for inhibiting the accidental uncoupling thereof or the intentional uncoupling by a patient being restrained. The belt comprises a flexible strap of a desired length which is adapted to be passed around the body of the patient and around the implement to which the patient is being secured and has the cooperating parts of a Velcro-type hook and loop fastener elements disposed on opposed surfaces thereof and extending a predetermined distance from the ends of the belt towards its center, such that when the ends are overlapped, the Velcro hook pad abuts the Velcro loop pad. Further included is a flexible, fabric sleeve, having a length generally the same as that of the Velcro pads. The sleeve is attached to one end of the strap at a point intermediate the two ends thereof and can be drawn back or collapsed so as to expose the Velcro pad on one of the ends. After the two ends are overlapped and thereby coupled, the flexible sleeve may be extended to substantially enclose the entire area of the Velcro fastener.
[0011] 4. U.S. Pat. No. 4,898,425, Invented by Mundy, Entitled “Seat Belt Kit For Wheelchairs”
[0012] In the patent to Mundy, a wheelchair seat back kit is disclosed, including a seat back defining shell having a generally upright back portion, and two integral sides leading forward there from. The outside dimension between the sides is less than the clear distance between the back posts of a wheelchair. Attachment points are provided for securing the shell with respect to the back posts at upper and lower seat back attachment points, with the back of the shell positionable rearward of the plane of the back posts. Preferably, at least the lower portions of the sides of the seat back project forward sufficiently to provide lateral hip support for a user of the wheelchair, and padding is positionable on the inside of the lower portions of the sides to narrow the dimension between the lower portions as required to provide the hip support for any given user. Bracket assemblies may be used to provide different seat back positions and angles. For example, the bracket assemblies may each include a vertical seat back support plate extending rearwardly from each back post, each support plate having several upper and lower attachment points.
[0013] 5. U.S. Des. Pat. No. 342,348, Invented by Panarelli, Entitled “Wheel Chair Safety Strap”
[0014] The patent to Panarelli depicts the ornamental design for a wheel chair safety strap, as shown and described.
[0015] 6. U.S. Des. Pat. No. 373,253, Invented by Maple, Entitled “Arm Chair With Ornamental Back”
[0016] The patent to Maple depicts the ornamental design for an arm chair with ornamental back, as shown and described.
[0017] 7. U.S. Des. Pat. No. 253,208, Invented by Claman, Entitled “Chair”
[0018] The patent to Claman depicts the ornamental design for a chair, as shown and described.
[0019] Although various prior art patents show usage of a chair with a non-slip seat surface, such are utilized in entirely different contexts than the present invention, such as for high chairs for infants and small children. Although additional prior art patents show “chairs” that utilize seat belts, such are primarily wheelchairs or other devices designed to facilitate transport of the handicapped or injured. As such, the prior art fails to teach the usage of an enhanced chair with a non-slip seat, seat belt, and hand grips for user safety, as well as shoulder supports for persons lifting the chair for celebratory purposes.
SUMMARY OF THE INVENTION
[0020] As noted, the present invention is an enhanced chair for usage in connection with honoring guests at various celebrations. More particularly, the invention is an improved “Simcha Chair,” or chair traditionally used at Jewish weddings, Bar Mitzvahs, and other affairs, wherein an honoree is seated in a chair and elevated by celebrants above the height of dancing guests. As such, there are inherent safety risks associated with the activity, and the improved chair of the present invention mitigates the incidence of potential damage and injury.
[0021] The enhanced chair features a non-slip seat surface, at least one seat belt, and multiple hand grips for the security of the occupant. To provide additional safety, persons hoisting the chair may utilize shoulder supports to greatly reduce tipping or dropping of the chair and occupant. In a further enhanced embodiment, the chair may be manufactured of a specially lightweight material, for ease in lifting and control.
[0022] In addition to providing a sturdy and safe alternative to the traditional Simcha chair, the present invention may also bear a meaningful inscription in Hebrew or another language, perhaps commemorating the celebration at which it is used. Finally, the present invention may be produced in the form of multiple chairs, each specifically designed for a previously-determined type of honoree, such as a bride, groom, retiree, or a host of additional persons.
[0023] In total, the novel features considered characteristic for the invention are set forth in the claims. The invention itself both as to its construction and method of operation, will be best understood from the following description of the embodiments when read and understood in connection with the drawings provided.
BRIEF DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] [0024]FIG. 1 is a front three-quarter perspective view of a first embodiment of the enhanced celebratory chair, illustrating preferred location of various safety elements thereon.
[0025] [0025]FIG. 2 is a front three-quarter perspective view of a second embodiment of the enhanced celebratory chair, illustrating preferred location of various safety elements thereon.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring to FIG. 1, which is a front three-quarter perspective view of a first embodiment of the enhanced celebratory chair ( 10 ), illustrated are: seat portion ( 12 ), back portion ( 14 ), back portion front side ( 14 A), back portion rear side ( 14 B), arms ( 16 ), hand grips ( 16 A), legs ( 18 ), shoulder supports ( 18 A), and seat belt assembly ( 20 ), each designed to prevent the occupant from falling from the chair while the same is hoisted above dancing guests at a celebration.
[0027] The chair itself ( 10 ) may be of a traditional size and shape, so as to render the invention suitable for a great variety of occasions. In one embodiment, the chair may be very similar to traditional chairs already found in such locations as catering halls and restaurants. Such will decrease potential manufacturing costs and render the invention relatively easy to produce.
[0028] Seat portion ( 12 ) may include a non-slip surface thereon, to prevent the occupant from slipping in any way during hoisting of the chair. The non-slip surface may be applied to the seat portion ( 12 ) in either a generally centered portion of the seat, or alternatively may comprise the entire surface of the seat portion, for maximum safety.
[0029] The back portion front side ( 14 A) may bear graphics, indicia, or text thereon, to enhance the appearance of the chair or to create a specialized keepsake item for the honoree. For instance, such surface may include an inscription relating to the honoree or the particular event being celebrated. Such inscription is intended to be meaningful in nature, and may be in Hebrew for the aforementioned Jewish celebrations. It should be noted, however, that the same may also be in any other language so as to make the invention available to people of any nations and religions.
[0030] It should further be noted that such text or indicia may be located upon the surface of the back portion front side itself ( 14 A), or may be upon a separate material, such as a decorative and aesthetically pleasing silk or satin that is draped over the chair. Due to the above, the chair of the present invention may be designed particularly for a bride, a groom, a bar mitzvah honoree, bat mitzvah honoree, or virtually any other honoree at the celebration. For the purposes of versatility, a generic simcha chair may even be produced, so as to be used a great variety of celebrations.
[0031] The back portion front side ( 14 A) may bear graphic material thereon, such as a Hebrew inscription relating to the honoree or event. Again, the chair may include additional decorative elements, such as tassels or the like extending from the sides or back ( 14 B) of the chair in any of a variety of colors and styles.
[0032] The chair arms ( 16 ) shall be of a size and location suitable for the occupant to conveniently grip the same in a secure manner during hoisting of the chair. The arms will be manufactured of a configuration that will not interfere will the view of the honoree being hoisted, and will similarly not interfere with locations of the chair being grasped by lifters thereof.
[0033] Hand grips ( 16 A) preferably appear at the distal ends of the chair arms ( 16 ), such that the occupant can naturally and conveniently grip the same for additional support and safety. Such hand grips ( 16 A) may be in the form of two generally vertical members that are of sufficient length as to allow the user's entire hand to wrap therearound. In an enhanced embodiment, the hand grips ( 16 A) may comprise multiple grooves thereon to function as finger grips for better gripping thereof.
[0034] The chair legs ( 18 ) are preferably four traditional legs, one extending downwardly from each comer of the generally square seat portion ( 12 ). Importantly, each leg ( 18 ) includes a shoulder support member ( 18 A) thereon to provide the utmost in safety in lifting the chair and occupant. In the preferred mode, the shoulder support members ( 18 A) extend outwardly from each leg, from a location approximately half the vertical height of the legs ( 18 ). The shoulder support members ( 18 A) are slightly curved in a convex manner, so as to correspond to the contour of the shoulders of those hoisting the chair. As such, the shoulder support members ( 18 A) allow persons to lift the chair upwardly, rest the chair upon their shoulders, and move the chair side to side, forwardly, or backwardly in the safest manner possible.
[0035] Referring to FIG. 2, which is a front three-quarter perspective view of a second embodiment of the enhanced celebratory chair ( 110 ), illustrated are: seat portion ( 112 ), back portion ( 114 ), back portion front side ( 114 A), back portion rear side ( 114 B), occupant hand grips ( 124 ), legs ( 118 ), shoulder rests ( 122 ), carrier hand grips ( 126 ), and seat belt assembly ( 120 ), each designed to prevent the occupant from falling from the chair while the same is hoisted above dancing guests at a celebration.
[0036] As in the case of the first embodiment, the chair ( 10 ) may be of a traditional size and shape, or similar to traditional chairs found in catering halls and restaurants. Once again, the seat portion ( 12 ) may include a non-slip surface upon a portion thereof or the entirety of the seat portion, for enhanced safety and security.
[0037] The back portion front side ( 14 A) may bear graphic material thereon, such as a Hebrew inscription relating to the honoree or event. Again, the chair may include additional decorative elements, such as tassels or the like extending from the sides or back of the chair in any of a variety of colors and styles.
[0038] Importantly, this embodiment of the Simcha chair does not include arms, rendering the same more similar to traditional chairs used at affairs such as weddings and Bar Mitzvahs. To compensate for the loss of such a safety feature, this embodiment includes occupant hand grips ( 124 ) which extend from the sides of the seat portion ( 112 ). Such occupant hand grips ( 124 ) may be relatively small in size, and generally rounded or semi-circular in shape. The occupant hand grips ( 124 ) will constructed of a durable material, and function to allow the user to conveniently keep their arms at the sides, grasping the handle-like grips at a location adjacent their thighs or upper legs.
[0039] Moreover, the second embodiment of the enhanced celebratory chair includes multiple shoulder rests ( 122 ), also extending outwardly from the left and right sides of the seat portion ( 112 ). Specifically, the preferred mode utilizes a total of four the shoulder rests ( 122 ), with two on each side. The shoulder rests ( 122 ) are generally flat and rectangular in nature, and allow the lifters of the chair and occupant to rest the chair upon their shoulders in a safe and stable manner.
[0040] Accordingly, the shoulder rests ( 122 ) extend from the sides of the seat portion ( 112 ) to a length sufficient to accomplish their purpose, with creating a burdensome device that is difficult to move or store. For increased compactness and convenience, the shoulder rests ( 122 ) may fold out from underneath the chair, or may extend outwardly in telescopic fashion from the sides thereof. It is important to note that the shoulder rests ( 122 ) may further comprise padding thereon, for the comfort of those lifting the chair.
[0041] Finally, as yet another safety feature of the celebratory chair, the legs ( 118 ) may include additional hand grips ( 126 ) thereon, for the purpose of allowing lifters of the chair to grip the same a previously-determined locations. In the preferred mode, each leg ( 118 ) includes a generally rounded or semi-circular grip member ( 126 ) at a bottom portion thereof, such grip members ( 126 ) constructed of a durable material that can support significant weight and stress.
[0042] Based upon all of the foregoing, it is respectfully submitted that the present invention provides a unique celebratory chair that is truly both utilitarian and decorative in nature. While the invention has been described as embodied, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the invention.
[0043] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can readily adapt it for various applications without omitting features that, from the standpoint of prior art, constitute essential characteristics of the generic or specific aspects of this invention. What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | An enhanced chair for usage in connection with honoring guests at various celebrations. More particularly, the invention is an improved “Simcha Chair,” or chair traditionally used at Jewish weddings, Bar Mitzvahs, and other affairs, wherein an honoree is seated in a chair and elevated by celebrants above the height of dancing guests. As such, there are inherent safety risks associated with the activity, and the improved chair of the present invention mitigates the incidence of potential damage and injury through the usage of safety belts, a variety of hand grips for both the occupant and lifters, and a variety of shoulder supports for persons lifting the chair. | 0 |
FIELD AND BACKGROUND OF THE INVENTION
The invention relates to a process for the control of turbo compressors with regard to the avoidance of surging and to a device for the execution of this process.
In compressors, surging is the pulsating or periodical reflux of a pumping medium from the delivery side to the suction side. This situation arises e.g. when the delivery pressure or the delivery pressure to suction pressure ratio is too high and/or the volume rate of flow is too low. Therefore, a surge limit line can be defined univocally in the performance graph (a graph of the relationship of turbo compressor parameters) which divides the performance graph into a stable and an instable section. As a rule, the surge limit line is curved, i.e. its ascending gradient changes within the performance graph. In a frequently used characteristics diagram, wherein the coordinates are volume rate of flow and pressure, e.g., the surge limit curve flattens as the pressure increases. For other performance graphs featuring guide blade position, rpm, head of the compressor etc. the same applies.
In order to prevent compressors from surging, a blow-off curve, or anti-surge control curve, may be defined on the performance graph at a safety distance from and parallel to the surge limit curve. When the actual working point approaches the blow-off curve, a blow-off valve or by-pass valve is opened to a small extent or a great extent depending upon the system. Due to this the actual value of a controlled variable, in particular the value of the volume rate of flow, does not surmount the set value determined by the blow-off curve and the command variable, in particular the delivery pressure. The anti-surge control can be considered a flow control with a variable flow set point, which is determined from the actual measured compressor discharge pressure (or pressure ratio if this is plotted on the vertical axis). The anti-surge controller output is changed to such an extent that the flow to the process plus the flow through the blow-off or by-pass valve is identical to the flow at the blow-off line at the respective actual discharge pressure. If process flow decreases, controller output changes to open the blow-off valve, so that the set point value, i.e. flow at the blow-off line, and the actual value match. If the blow-off curve has a constant gradient, the relationship between pressure changes and set point changes is constant. If the blow-off curve has a gradient which is not ccnstant, the set point changes are small where the blow-off curve is steep, and the set point changes are large where the blow-off curve gradient is less steep. Therefore, the gain or amplification of the system is not constant.
There are also automatic controls wherein the volume rate of flow serves as the command variable for the determination of the set value and wherein the delivery pressure is the controlled variable to be adjusted with regard to the set value.
The curved course of the blow-off curve results in a preset change of the command variable, or controller output, (e.g. discharge pressure) at various points on the blow-off curve which results in changes in the set value for the controlled variable. This results in variations in the control loop amplifications.
Anti-surge limit control means are safety control means and are normally activated to work near the stability limit in order to guarantee the best compressor protection possible. The stability limit is the limit where the closed control loop becomes unstable due to a too-high closed loop gain or amplification. The position of the stability limit is heavily influenced by the overall amplification of the control loop. A high degree of overall amplification is most likely to lead to instability cf the system. However, to get the best control results, the gain should be selected as high as possible. The higher the gain, the better the control result.
In order to achieve the most constant overall amplification possible, it is suggested in compliance with the EP-A-O 223 208 (see also U.S. Pat. No. 4,789,298) to compensate the influence of the valving line on the amplification factor by taking into account the ascending gradient of the valving line in various characteristic sections. However, it has turned out that a constant overall amplification can be achieved only within limits as the non-linear gradient cf the compressor's characteristic curve also creates a change in the sectional amplification and thus influences the overall amplification.
SUMMARY AND OBJECTS OF THE INVENTION
Accordingly, the object of the invention is to provide a process and a means for its execution, wherein an optimal adaptation of the reaction of the control device to the various sections of the performance graph and operational states of the compressor is possible.
The invention provides a system and device for balancing the effects of the descending gradient of the compressor's characteristic, which changes with the command variable on the overall control loop amplification, and a respective change of the amplification factor in opposite direction. (The command variable is the value on the vertical axis of the performance graph). This results in an overall amplification independent of the course of the characteristic. This basic principle can also be realized approximately by switching between two or more different values of the amplification factor of the control means.
According to the invention, a method and apparatus is provided for controlling a turbocompressor to avoid surging of the turbocompressor. A system is employed which continuously measures the actual value of a command variable, such as pressure, and the value of a controlled variable, such as volumetric rate of flow. The command variable and the controlled variable define the position of the turbocompressor working point forming a characteristic curve plotted in a turbocompressor performance graph. A blow-off curve is also plotted in the turbocompressor performance graph which is used for controlling a blow-off valve. A set value for the controlled variable is determined by selecting a set value for the controlled variable corresponding to the measured actual value of the command variable along the blow-off curve in the performance graph. A correction signal is generated by comparing the measured actual value of the controlled variable and the determined set value of the controlled variable. The amplification factor of the control device is changed depending upon the actual value of the command variable. The amplification factor is then changed in dependence on the descending gradient of the turbccompressor characteristic curve based on the measured actual value of the working point so as to attenuate influences of the descending gradient of the turbocompressor characteristic curve on the control system amplification.
It is an object of the invention to provide a turbocompressor with a method and apparatus for compensating for the influence of a bent, or curved blow-off line and characteristic curve in order to get a constant closed loop gain in the entire operating range of the compressor.
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 obtained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a simplified diagram of a system for the control of a turbo compressor to avoid surging;
FIG. 2 shows a diagram of the courses of a valving line A and a characteristic line K in the performance graph;
FIG. 3 shows a detail of the control means in a first embodiment; and
FIG. 4 is a detailed diagram of the control system according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIG. 1 the pressure is sensed by sensors 3, 5 in front of and behind a throttle in the compressor intake 1. A measuring transmitter 7 forms the actual value for the compressor volumetric rate of flow V on the suction side. On the compressor delivery side a sensor 9 measures the actual value of the delivery pressure P, which is fed into a computer 13 by a measuring transmitter 11. The computer 13 has a memory which contains the course of the valving line or blow-off curve A in the compressor performance graph defined by P and V. The computer 13 calculates the set value for the volumetric rate of flow V from the actual value P and the blow-off line. The actual value and the set value of the volumetric rate of flow are compared in a comparator or differential element 15 and the calculated difference is fed as an input signal into a control device 17 with proportional-integral-and/or differential behavior. The output signal of the control device 17 is used as a command variable for a blow-off valve 19 branching from the compressor delivery side venting to the atmosphere or is advantageously a by-pass valve leading back to the suction side of the compressor.
In the compressor performance graph formed by the volumetric rate of flow V as the abscissa and the delivery pressure P (or the delivery pressure--suction pressure ratio) as the ordinate, both the blow-off line, or curve A and the compressor characteristic line or curve K are curved, as shown in FIG. 2. Therefore a specific change ΔP of the delivery pressure serving as the command variable results in changes of different magnitudes ΔX 1 and ΔX 2 of the actual value and ΔW 1 and ΔW 2 of the set value for the volumetric rate of flow. The variances will result in changes in the overall amplification of the control loop if the control device 17 shows a constant amplifier factor or gain. The steep bottom section of the course of the curves in FIG. 2 corresponds to a small amplification and the flattened upper section of the course corresponds to a large amplification.
However, as an alternative the tasks of the command variable and the controlled variable are advantageously switched, i.e. the volumetric rate of flow V is used as command variable and for the set value the delivery pressure P is used. The relationship is thereby switched, and the amplification is large in the steep section and small in the shallow section.
The overall amplification of the control loop is the sum of the amplification resulting from the ascending gradient of the blow-off curve and the amplification factor of the control device 17 plus the so-called control gain of the system, i.e. the amplification factors given by the controlled system, particularly by the compressor and the blow-off valve. According to the invention, the amplification factor in the control device 17 is changed as a function of the characteristic of the compressor and, if necessary, of the course of the blow-off curve in order to compensate for the influence of the compressor on the amplification.
In a given change of the pressure the variance X d supplying the difference between the actual value and the set value is as follows:
ΔX.sub.d =ΔW-ΔX
With low pressure the variance hardly changes at all and the value ΔX d /ΔP is small. In the upper section, however, this value is much higher, thus the control device reacts much stronger to a pressure change by the rate of ΔP in the upper performance graph section than in the bottom section.
The gain of the closed control loop depends on the gain provided by the system controller and on the gain of the compressor with the pipe work system. The gain of the closed control loop should be constant over the entire operating range of the compressor. Because the gain of the compressor is non-linear, the gain of the loop is non-linear. With the introduction of a compensation factor, this non-linearity can be compensated for.
This means that the "control gain of the system" which depends on the course of the turbo compressor or characteristic K and of the blow-off curve A is not linear. The total amplification factor V R can be represented as the product of the proportional gain or amplification KP and the amplification component depending on the characteristic V K :
V.sub.R =V.sub.K ×kP.
By introducing V comp compensation term a constant overall amplification can be achieved by choosing V comp =1V K .
Often, the shape of the compressor performance curve, as shown in FIG. 2, can be defined by the function:
X=F(P+g (Y.sub.L))-K.sub.2 g(Y.sub.L):
Where X is the horizontal axis and Y L is the guide vane position, K=constant, f and g are non-linear functions. This means that the gain factors change, which depends on the shape of the curve and can be shown as:
K (P)=f (P+g(Y.sub.L))-K.sub.2 ×g(Y.sub.L)
If the blow-off curve is called A (P), a pressure change of 2 P results in a pressure-dependent compensation factor of ##EQU1##
Here the first term corresponds to the reciprocal ascending gradient of the blow-off curve and the second term corresponds to the reciprocal ascending gradient of the compressor's characteristic for the transition Δp→0. There is only one blow-off curve. Therefore, it is very easy to store the reciprocal shape of a blow-off line.
The first term can be stored as a whole as h (P) in a function generator. The second term cannot be stored as a single function as the first term because there are many compressor performance curves for different guide vane positions.
FIG. 3 shows the structure of an embodiment for the realization of a control loop with constant overall amplification. The original values P, ΔP and g(Y L )) form the value for f (P+Δp+g(Y:)) in the operational unit 101. They form the value f (P-p+g(Yr)) in the operational unit 103, and form value h (P) in the operational unit 105. The received values are then added or subtracted in the addition unit 107, thereby arriving at the compensation factor V comp . Then the preset proportional amplification kP in the division unit 109 is divided by this compensation value, so that there is a constant overall amplification V R at the exit of unit 109. Then the overall amplification V R is fed into the control means 17 in FIG. 1. The above process can also be executed so that instead of the secant formation, i.e. of the difference formation, the respective reciprocal values of the ascending gradients of different compressor performance curves can be fed into the respective function generator immediately. Each performance curve being for constant guide vane position. The output signals of the function generators are handled respectively.
In the simplified embodiment in FIG. 4 instead of representing the exact course of the compressor characteristic curve, this curve is approximated by straight lines, and the resulting discrete descending gradient values of the straight lines are used for the determination of the compensation value. FIG. 4 shows a diagram for the determination of the discrete values. Herein the input signal P is fed into a comparator 201, which compares whether the input value lies above or below a threshold. The comparator controls a change-over switch 203, which passes the respective discrete ascending minimum and maximum gradient values on to the substraction element 207. The substraction element 207 is fed the value h (P) by the function generator 205, and the output signal serves as a divisor for the proportional amplification KP in the division element 209, so that a respective output signal V' R for the overall amplification is achieved.
In a further simplification the function of unit 205 can also be given to the comparator, so that 207 is no longer necessary either.
Instead of a change-over between two discrete values, the change-over switch 203 can be laid out for switching between a multitude of discrete values. This corresponds to an adjustment of the characteristic through several straight line sections.
A different solution for controlling the system by means of a comparator and a change-over switch would be to appoint these functions to a function generator. In addition, the value h(p) can be formed in the function generator so that the function of units 201, 203, 205 and 207 of FIG. 4 are performed in one unit. In this case the calculation of the aforementioned formulas takes place during the initial operation of the system (start-up) and the function generator delivers a sequence of values fed in advance for V' R as a function of P.
In normal control algorithms an abrupt change-over leads to an abrupt change of the controller output. To avoid this, it is advantageous in the present invention to use a recursive control algorithm. Herein the present correcting variable y(t) is not only dependent on the amplification V' R and the momentary variance x d (t), but also from the variance x d and the controlling variable y at the point of time (t-T S ) in a previous scanning, i.e. a point of time earlier by the sampling point T S of the control device.
Control can e.g. be effected according to the following control algorithm, wherein T N is the reset time of the control device: ##EQU2##
By means of this kind of control, which takes into account former values of the variance and of the correcting value, jerky changes in the correcting value can be avoided.
The field of application of the invention is not limited to the performance graph presentation used in this example, but it can also be employed in other representations, i.e. in pressure ratio to intake volume flow, rpm to volume flow guide blade position to volume flow or a combination of the above representations.
While specific embodiments of the invention have 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. | In the surge limit control for turbo compressors the amplification factor of the control device producing the control signal for a blow-off valve is varied according to the ascending gradient of the compressor's characteristic corresponding to the respective working point. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 277,033, filed Aug. 1, 1972, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a process for the manufacture of discontinuous fibrils by the abrupt release of pressure on a two-phase liquid mixture of molten polymer and solvent which is under elevated pressure and at elevated temperature.
It is well known that one can produce continuous fibrillated structures or rovings by similar processes. For example, in U.S. Pat. No. 2,372,695, issued May 15, 1940, and assigned to Celanese Corp. of America there is a description of the production of a downy mass formed of very fine filaments connected with one another by bringing about an abrupt pressure release through an appropriate orifice of a solution of a cellulose derivative which is at elevated temperature and pressure.
According to Belgian Pat. No. 568,524 of June 11, 1958, in the name of E. I. Du Pont de Nemours, continuous structures consisting of a multitude of fibrillous strands or sections, which come together and separate at random intervals to form a "unit fibrillous plexus", are obtained by extruding a solution of synthetic polymer, which is at a temperature higher than the normal boiling point of the solvent and under autogenous pressure or under a higher pressure, through an orifice of suitable shape into a zone of lower pressure.
The fibrillated structures obtained according to the processes described above take the form of continuous rovings. Moreover, as is stated in Belgian Pat. No. 568,524, these structures are produced at a very high speed (which may reach as much as 13,700 m/min), which makes it impossible to cut them up by mechanical means.
The subsequent processing of these continuous rovings produced at very high speed is very difficult. Moreover, for a large number of applications, it is essential to use the fibrillated products in a shreaded form, that is to say in the form of discontinuous structures of relatively short length, for example of the order of a few millimeters. That is why, as can be seen from French Pat. No. 1,246,379 of Nov. 17, 1959, in the name of E. I. du Pont de Nemours, it is necessary to reduce the length of the continuous fibrillated rovings by a treatment in a grinding apparatus. This treatment is harmful to the physical qualities of fibrillated structures and calls for a supplementary operation which necessitates tying up large amounts of capital and requires a considerable amount of power.
It is apparent that a process of the type described above, but leading to the direct acquisition of short fibrils could in numerous cases permit a more economical and easier use of the products obtained and also improve their quality.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a process which will avoid the above-mentioned disadvantages. The present invention relates to a process for the manufacture of discontinuous fibrils in which the abrupt pressure release of a two-phase liquid mixture of molten polymer and solvent, which is at elevated temperature and pressure, brings about the instantaneous vaporization of the solvent and solidifies the polymer. According to the invention, a make-up fluid is introduced into the two-phase liquid mixture before the pressure release is complete.
By the designation "discontinuous fibrils" is meant elongated fibrillated structures consisting of very slender filaments, of a thickness of the order of a micron, connected with one another so as to form a three-dimensional network. These fibrils which are of a fluffy appearance generally have an elongated shape. Their length varies from 1 mm to about 5 cm and their diameter from about 0.01 to 5 mm. The specific surface area of these products is greater than 1 m 2 /g. These fibrils are particularly suitable for the production by the usual methods of non-woven textiles and synthetic papers.
The process according to the invention may be carried out by using any polymer which is suitable for spinning. Among the polymers which can be used one may mention the polyolefins such as polyethylene, polypropylene, ethylene/propylene copolymers, polyisobutylene, etc., polyamides, polyesters, polyurethanes, polycarbonates, vinyl polymers such as polyvinyl chloride, which may also be postchlorinated, polyvinyl fluoride, acrylic polymers such as the homopolymers and copolymers of acrylonitrile, etc. This list is by way of example and is not restrictive.
Nevertheless, applicants prefer to use crystallizable polymers whose rate of crystallinity measured by X-ray diffraction is at least 10% and preferably at least 20% because the stretch to which these polymers are subjected, as a result of the action of vapors released during the abrupt pressure release, imparts to them an orientated structure which results in good mechanical properties.
Among these polymers, the polyolefins such as high-density polyethylene, isotactic polypropylene and isotactic poly-4-methylpentene-1 lead to the best results.
The solvent is preferably chosen according to the polymer used as well as the following criteria. The solvent must not dissolve more than 50 g/liter, and preferably not more than 10 g/liter, of polymer under normal conditions of temperature and pressure (20° C. and 1 atmosphere). Moreover, it must possess at normal pressure a boiling point which is more than 20° C. and preferably more than 40° C. lower than the melting or softening point of the polymer used. Furthermore, it must permit the formation of a two-phase liquid mixture under operational conditions just prior to the abrupt pressure release.
Among the solvents which can be used one may mention the aliphatic hydrocarbons such as pentane, hexane, heptane, octane and their homologues and isomers, the alicyclic hydrocarbons such as cyclohexane, the aromatic hydrocarbons such as benzene, toluene, etc., the halogenated solvents such as the chlorofluoromethanes, methylene chloride, ethyl chloride etc., the alcohols, ketones, esters and ethers.
Applicants define below what is meant by the expression "two-phase liquid mixture".
When one subjects a mixture of suitable solvent and polymer, with a suitable concentration of polymer, to very elevated temperature and pressure, one observes that the mixture takes the form of a single homogeneous liquid phase. If then, while maintaining all the other conditions constant, one gradually reduces the pressure, one observes that, as from a certain pressure onwards, which varies according to the case, the solution of polymer becomes turbid because of the establishment of a system of two liquid phases consisting of a continuous liquid phase which is poor in polymer and in which there is dispersed, in the form of droplets, a second liquid phase which is rich in polymer. The value of the pressure at which this phenomenon makes its appearance may be determined experimentally.
In the process according to the invention it is therefore advisable to choose the pressure of the mixture which is subjected to the abrupt pressure release in such a way that it is present in the form of a two-phase liquid mixture. The same applies to the concentration of polymer and the temperature.
In practice one may prepare a solution with a single liquid phase at a higher pressure than that at which the formation of a two-phase liquid mixture takes place and then carry out a sufficient prior release of pressure to bring about the establishment of the system with two liquid phases.
The temperature of the two-phase liquid mixture subjected to abrupt pressure must be such that the latent heat stored by the solvent and the molten polymer is sufficient to bring about the complete vaporization of the solvent during the abrupt pressure release. This temperature must not however exceed a maximum value, otherwise the quantity of heat consumed by the vaporization of the solvent would be insufficient to bring about the solidification of the polymer. Furthermore, it must enable the apparatus to operate at a pressure at which the formation of the two-phase liquid mixture takes place. Finally, the temperature must be lower than the critical temperature of the solvent. Generally speaking, the temperature of the mixture is between 100° and 300° C. and preferably between 125° and 250° C.
The concentration of polymer in the mixture used is also selected so as to permit a two-phase liquid mixture to be obtained. It may vary from 1 to 500 g/kg of mixture. However, applicants prefer to use mixtures containing from 10 to 300 g of polymer per kg of mixture and preferably 50 to 200 g/kg.
For each particular polymer, therefore, it is necessary to choose a solvent complying with the criteria defined above and then to determine the concentration of polymer, the pressure and the temperature of the mixture which is subjected to instantaneous pressure release. These parameters are therefore chosen not only so as to give a two-phase liquid mixture, but also so that the solvent vaporizes instantaneously and completely during the abrupt pressure release. These conditions are the same as those imposed on two-phase liquid mixtures used according to the prior art to manufacture continuous fibrillated rovings.
The two-phase liquid mixtures are subjected to an abrupt pressure release, that is to say their pressure is brought to a value close to atmospheric pressure, preferably to a pressure lower than 3 kg/cm 2 absolute, within a very short period of time, preferably less than 1 second. This pressure release may be brought about by passing the mixture through any device which is capable of creating high load losses, such as a diaphragm, a Venturi or a valve. However, it is preferable to use dies whose cylindrical orifices have a diameter of between 0.1 and 3 mm, and preferably between 0.3 and 1 mm, and a length/diameter ratio of between 0.1 and 10, and preferably between 0.5 and 2.
It is obvious that the two-phase liquid mixture used may also contain other usual additives for polymers such as stabilizers to the action of heat and light, reinforcing agents, fillers, pigments, antistatic agents, nucleation agents, etc.
The make-up fluid injected into the two-phase liquid mixture before the pressure release is complete may be of any kind and may be a gas, a vapor or a liquid.
However, it will be obvious that this fluid must not exert any harmful action on the continuous fibrillated structure produced by the abrupt pressure release of the mixture. In particular, the use of a fluid which exerts a solvent or swelling action on the polymer used at ambient temperature must be ruled out.
As has been stated above, the fluid used may be of any desired kind. In particular, applicants have obtained excellent results when this fluid was nitrogen, water vapor, water or an organic liquid. Applicants have also found that it is possible to use as fluid the solvent used to make the two-phase liquid mixture.
When the make-up fluid is water under pressure, applicants have found that it is advantageous to incorporate a wetting agent in it.
The pressure under which the make-up fluid is injected must obviously be higher than the pressure of the two-phase liquid mixture at the point of injection.
The make-up fluid may be at any desired temperature. This temperature is preferably selected so that the supply of calories to the two-phase liquid mixture cannot hinder the instantaneous vaporization of the solvent and the solidification of the polymer during the abrupt pressure release of the mixture.
This temperature is preferably between 20° C. and the boiling point of the fluid at the working pressure, that is to say at its pressure of injection.
When the make-up fluid is a liquid, its temperature is preferably higher than its boiling point at the pressure of the pressure release chamber, that is to say the pressure obtained at the outlet from the abrupt pressure release orifice.
The ratio between the volume of make-up fluid and the volume of two-phase liquid mixture may vary between 0.3 and 10. However, applicants prefer this ratio to be from 0.7 to 5 and preferably from 1 to 3.
The make-up fluid may be injected into the two-phase liquid mixture either before the abrupt pressure release or during this release. In the former case, the make-up fluid is injected into the two-phase liquid mixture at a point situated before or upstream of the abrupt pressure release orifice. In the latter case, the make-up fluid is injected into the two-phase liquid mixture during its passage through the pressure release orifice.
The residence time of the make-up fluid in the pressure release device is preferably less than 2 seconds. The best results are achieved when the residence time is less than 5.10 - 1 , and preferably 10 - 1 , second.
By adjusting the quantity of make-up fluid and its various parameters it is possible to determine experimentally the conditions for obtaining, after pressure release, fibrils of the desired length.
Applicants have attempted to give a physical explanation for the phenomena which lead, according to the process of the invention, to the formation of discontinuous fibrillated structures of short length.
As has been stated above, the two-phase liquid mixture prior to abrupt pressure release consists of droplets or bubbles of solution with a high concentration of polymer emulsified in a material consisting of a continuous solution with a low concentration of polymer.
According to known processes, during the abrupt pressure release of the two-phase liquid mixture, these droplets or bubbles each cause the formation of a fibrillated structure due to the abrupt vaporization of their solvent and these different structures weld together to give the continuous structure or fibrillated roving already known.
Applicants therefore think that the injection of a make-up fluid into this two-phase mixture prior to the pressure release being complete probably has the effect of increasing the distance separating the droplets or bubbles suspended in the dilute phase, and in this way creating a certain heterogeneity inside the mixture consisting of two liquid phases and leading to a subsequent pressure release of an intermittent nature bringing about discontinuities in the fibrillated structure produced.
However, it is possible that a more thorough study of the phenomena would subsequently lead to a different explanation.
In any case it is obvious that the explanation put forward cannot in any way influence the value of the present invention.
As has been stated, in order to carry out the process according to the invention, applicants prefer to bring about the abrupt pressure release of the two-phase mixture by passing it through a die.
This die may be of the same type as those used for the process described in Belgian Pat. No. 568,524 already cited, apart from the fact that it is advisable to provide one or more channels intended for the injection of the make-up fluid.
These channels may open out either upstream of the abrupt pressure release orifice or into the wall of this orifice according to whether it is desired to inject the make-up fluid prior to, or during, the abrupt pressure release of the two-phase liquid mixture.
These channels may be arranged perpendicularly in relation to the direction of flow of the two-phase liquid mixture or they may merely be inclined in relation to this direction.
Furthermore, these channels may be connected normally or tangentially to the pipes containing the two-phase liquid mixture. Applicants have also observed that the tangential injection permits a more energetic agitation and leads generally to better results.
The diameter of the channels for the make-up fluid at the point of injection is of the order of 0.1 to 5 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a die used in conjunction with the process according to the invention.
FIG. 2 is an exploded view in sectional elevation of another die which can be used for carrying out the invention.
FIG. 3 is a cross-sectional view taken along the line A--A' of FIG. 2.
FIG. 4 shows another form of die in an exploded elevational, sectional view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first example of the process of the invention is carried out with a die of the form shown in FIG. 1.
This die has a prerelease chamber 1 situated after a laminating orifice 2 of a diameter of 1.5 mm, the function of which is to subject the mixture of polymer and solvent to a sufficient load loss to cause the formation of a system with two liquid phases.
Two injection channels 3 for the make-up fluid with a diameter of 1.5 mm open at an angle α of 45° into the abrupt pressure release channel 4. This channel has a length of 16 mm and a diameter of 2 mm.
EXAMPLE 1
Through the laminating orifice 2 there is passed a mixture of ELTEX 54 001 (high-density polyethylene produced by Solvay & Cie., Brussels, Belgium) and methylene chloride. This mixture, which is at a pressure of 48 kg/cm 2 and a temperature of 215° C. in the prerelease chamber 1, has a polyethylene concentration of 10%. In this chamber the mixture is under conditions which cause the formation of two liquid phases. The flow rate of the feed is 3 kg of polymer per hour.
Through the injection channels 3 there is simultaneously injected nitrogen at a pressure of 50 kg/cm 2 , at a temperature of 20° C., and at a flow rate of 80 normal m 3 per hour.
The abrupt pressure release of the mixture at the end of the channel 4 causes the formation of discontinuous fibrils whose length is of the order of a millimeter and whose specific surface area is of the order of 5 to 6 m 2 /g. The production of fibrils is 3 kg/hr.
The product obtained is perfectly suitable for the production of non-woven textiles and synthetic papers.
When one gradually reduces the rate of flow of make-up fluid, one observes that the length of the fibrils increases to give finally a continuous fibrillated structure.
FIGS. 2 and 3 illustrate another arrangement for carrying out the invention. In order to show the details of the device more clearly, the injection nozzle 5 for the make-up fluid is shown outside its housing 6 in the die. The orifice of the injection channel 5' has a diameter of 1 mm.
The die contains a prerelease chamber 7 with a diameter of 5 mm in which the mixture of polymer and solvent is injected tangentially by a prerelease orifice 8 having a diameter of 1.5 mm. The abrupt release orifice 8' has a length and a diameter of 1 mm.
EXAMPLE 2
In the device of FIG. 2, a mixture identical to that of Example 1 is passed through the die in such a way that in the prerelease chamber 7 it is under the same conditions of pressure and temperature as in Example 1. The flow rate is 5 kg/hr of polymer.
Through the nozzle 5 there is continuously injected, at a flow rate of 35 normal m 3 per hour, nitrogen under a pressure of 50 kg/cm 2 and at a temperature of 20° C.
The abrupt pressure release of the mixture at the lower end of the die causes the formation of discontinuous fibrils, the length of which varies from 1 to 10 mm and the specific surface area of which is of the order of 7 m 2 per gram.
FIG. 4 shows another embodiment of a die for carrying out the invention. For reasons of clarity, the various components which make up the die are shown in exploded form.
As can be seen in FIG. 4, the die has a prerelease chamber 9 provided with a housing 20 intended to receive a deflector 11 which has the effect of causing a turbulent movement in the two-phase liquid mixture prior to the injection of the make-up fluid.
This chamber 9 is connected tangentially to a pipe 12, with a diameter of 4 mm, for the injection of make-up fluid.
Underneath the prerelease chamber 9 there is the abrupt release orifice 13, which has a diameter of 2 mm and a length of 1 mm. This orifice may be replaced if desired by a valve with adjustable aperture.
The die is extended by an acceleration and shredding channel 14 of a length of 20 cm and a diameter of 10 mm.
The deflector 11 may impart to the two-phase liquid mixture either a turbulent movement in the same direction as that caused by the tangential injection of the make-up fluid, or a turbulent movement in the opposite direction.
EXAMPLE 3
In the device of FIG. 4, a mixture of ELTEX 54 001 and hexane of technical quality "polymerization grade" at a temperature of 190° C. and with a concentration of 180 g of polymer per kg of mixture is passed through the die. The pressure of this mixture is regulated so that its pressure in the prerelease chamber is 40 kg/cm 2 , at which pressure this mixture presents two liquid phases.
Through the channel 12 one injects at the same time at a flow rate of 240 liters per hour water under a pressure of 42 kg/cm 2 and at a temperature of 190° C.
By operating under these conditions, there is obtained 25 kg per hour of fibrils having a length of 10 mm and a specific surface area of 15 m 2 /g.
EXAMPLE 4
Use is made of a die identical with that described in Example 1. Through the laminating orifice 2 there is passed a mixture of SOLVIC 228 (a product of Solvay & Cie., Brussels, Belgium, composed of polyvinyl chloride produced by polymerization in suspension) and dichlorethane, the polyvinyl chloride being stabilized by means of IRGASTAB 17 MO (tin-based stabilizer produced by CIBA-GEIGY). This mixture which, in the prerelease chamber in is at a pressure of 70 kg/cm 2 and at a temperature of 165° C., has a concentration of 150 g of polymer per kg of solution. In this chamber, the mixture is present under conditions provoking the formation of two liquid phases. The supply rate is 30 kg of polymer per hour.
Via the channels 3, nitrogen is simultaneously injected at a pressure of 70 kg/cm 2 and at a temperature of 25° C. at a flow rate of 50 normal m 3 per hour.
The abrupt pressure release of the mixture at the end of the channel 4 provokes the formation of discontinuous fibrils having a length of the order of 5 mm and a specific surface area of the order of 5-10 m 2 per gram. The rate of production of fibrils is 30 kg per hour.
EXAMPLE 5
A die is used which is identical with that described in Example 2. Through the orifice 8 there is injected a mixture of SOLVIC 228 stabilized by IRGASTAB 17 MO and dichlorethane. This mixture which, in the prerelease chamber 7, is at a pressure of 70 kg/cm 2 and a temperature of 170° C., has a concentration of 200 g of polymer per kg of solution. The flow rate is 45 kg of polymer per hour.
Via the nozzle 5 is simultaneously and continuously injected dichlorethane heated to 170° C. and under a hydraulic pressure of 70 kg/cm 2 , the flow rate being 300 liters per hour.
The abrupt pressure release at the extremity of the die provokes the formation of discontinuous fibrils having a length which varies between 5 and 15 mm and a specific surface area which varies between 5 and 10 m 2 per gram. The rate of production of fibrils is 45 kg per hour.
EXAMPLE 6
Use is made of a die identical with that described in Example 3.
A mixture of polyvinylidene fluoride and methylene chloride at a temperature of 180° C. and a concentration of 100 g of resin per kg of solution is passed through this die. The pressure of this mixture is regulated so that its pressure in the prerelease chamber is 35 kg/cm 2 , at which pressure this mixture presents two liquid phases. The rate of delivery is 5 kg of resin per hour.
Through the channel 12 there is simultaneously injected nitrogen at a flow rate of 20 normal m 3 per hour, the nitrogen being at 20° C. and under a pressure of 40 kg/cm 2 .
By operating under these conditions, there is obtained 5 kg of fibrils per hour, the fibrils having a length of less than or equal to 5 mm and a specific surface area of 15 m 2 /g.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A continuous fibrillated structure, formed by the abrupt pressure release of a two-phase liquid mixture of polymer and solvent at elevated temperature and pressure so as to cause the instantaneous vaporization of the solvent, is shredded by introducing a make-up fluid into the two-phase liquid mixture before the pressure release is complete. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to JP 2008-277474 filed in Japan on Oct. 28, 2008, the entire disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
This invention relates to an electrical junction box and a method for assembling the same. Particularly, the electrical junction box may includes features that allow a circuit board to be securely mounted within the electrical junction box in a manner that prevents a load placed on a supporting member that supports the circuit board from being transferred to the circuit board, thereby protecting the circuit board from stress, damage and deformation and thereby preventing an electronic component mounted on the circuit board from being detached from the circuit board.
A vehicle-mounted electrical junction box or the like may contain, in high density, a wide range of circuit members stacked on one another. In some embodiments, a multilayered circuit board assembly that mounts a circuit member such an electronic component is contained in the electrical junction box.
Embodiments of the electrical junction box may include a casing that includes an upper casing member and a lower casing member. The stacked circuit member may be contained in the casing. Accordingly, it is necessary to hold the multilayered circuit board assembly in the electrical junction box.
For example, FIG. 11 shows a related art electrical junction box, which has been disclosed in JP 2007-134506 A. As shown in FIG. 11 , a circuit board 101 is mounted on lower bosses 100 a and 100 b projecting from a bottom wall of a lower casing member 100 . A plate 102 disposed above the circuit board 101 is provided on a bottom surface at positions faced to the lower bosses 100 a and 100 b with upper bosses 102 a and 102 b . The lower boss 100 a and upper boss 102 a clamp the circuit board 101 in a vertical direction. The upper boss 102 b passes through the circuit board 101 and enters a receiving aperture 100 b - 1 provided in an upper end of the lower boss 100 b . Thus, the circuit board 101 is positioned and held on the lower casing member 100 .
As described above, when the circuit board 101 is clamped directly between the upper bosses 102 a , 102 b and the lower bosses 100 a , 100 b , a load is applied directly to the points of contact between the circuit board 101 and the bosses 100 a to 102 b . Consequently, there is a possibility that the circuit board will be subject to strain, deformation and/or damage and, thus, there is a possibility that an electronic component mounted on the multilayered circuit board assembly will be detached from the assembly.
In view of the above problems and other problems, the exemplary embodiments provide an electrical junction box that can position and hold a circuit board in a casing so that a positioning member does not contact directly with the circuit board, thereby preventing detachment of electronic components from the circuit board.
SUMMARY
An electrical junction box in accordance with an exemplary embodiment may include a casing including a lower casing member and an upper casing member, and a multilayered circuit board assembly that may include a lower layer circuit board, an upper layer circuit board, and an insulation plate disposed between the upper and lower circuit boards. An electronic component may be mounted through the insulation plate on a top surface of the lower layer circuit board without contacting a bottom surface of the upper layer circuit board. The upper and lower layer circuit boards may be secured to the insulation plate. A rib assembly and a boss may project from the lower casing member. The rib assembly and the boss may contact the insulation plate to support the plate without contacting surfaces of the upper and lower circuit boards in the multilayered circuit board assembly on which the electronic component is mounted.
The boss may be a cylindrical support post standing upward from the bottom wall of the lower casing member at a position apart from the peripheral wall of the lower casing member. The rib assembly may stand upward from the bottom wall of the lower casing member and may be continued to the peripheral wall of the lower casing member.
As described above, in an embodiment in which the multilayered circuit board assembly is mounted in the electrical junction box, the circuit boards may be attached to the insulation plate in the box. Using such an approach, the circuit boards may contact the insulation plate and the boss projecting from the lower casing member may contact the insulation plate, thereby supporting the multilayered circuit board assembly without contacting a surface of the circuit board on which the electronic component is mounted.
Thus, no load is applied to the surface of the circuit board, because the rib assembly and boss do not contact directly with the surfaces of the circuit board on which the electronic component is not mounted. Accordingly, no stress or strain is applied to a surface of the circuit board and it is possible to prevent the mounted electronic component from being detached from the circuit board.
The multilayered circuit board assembly may include embodiments in which a single upper layer circuit board and a single lower layer circuit board are used, and embodiments in which the upper and lower circuit boards are stacked on each other without interposing any insulation plate between them.
The rib assembly may include a first rib member and a second rib member. The first rib member may pass a peripheral edge of the lower layer circuit board and may contact a bottom surface of a peripheral edge of the insulation plate. The boss may pass through a through-hole in the lower layer circuit board and may contact a bottom surface of the insulation plate or a bottom surface of the upper layer circuit board. The second rib member may pass a peripheral edge of the insulation plate and may contact a bottom surface of the upper layer circuit board.
Also, the lower layer circuit board and insulation plate may be connected by a second screw. The insulation plate and upper layer circuit board may include screw apertures that may be aligned with each other. A first screw may be screwed through the screw apertures into a screw cylinder projecting from an inner surface of the upper casing member.
In the electrical junction box of the present invention, as described after, the upper casing member may be turned upside down and held on an assembling jig. The upper layer circuit board, insulation plate, and lower layer circuit board may be installed in order in the upper casing member. Then, the lower casing member, from which the boss and the rib assembly project, may be aligned with, mounted and locked on the upper casing member. Accordingly, the upper layer circuit board may attach to the upper casing member before the insulation plate is attached to the upper casing member. A screw cylinder projecting from the upper casing member may be inserted into the screw apertures in the upper layer circuit board and insulation plate, and a first screw may be used to fasten the upper layer circuit board and the insulation plate to the screw cylinder. A second screw may be used to fasten the lower layer circuit board to the insulation plate.
Thus, the upper and lower layer circuit boards are positioned and held in the upper and lower casing members.
The circuit boards may be previously bonded to the insulation plate by an adhesive without using any screws.
Preferably, the boss may be positioned substantially in a central position of a triangular area defined by three first screws.
By positioning the boss in a central position relative to the triangular area defined by three first screws, the boss and the vertices of the triangle may absorb and moderate stress from the upper casing member.
Embodiments of the present invention provide a method for assembling an electrical junction box described above. The method may include, turning the upper casing member topside down to direct an opening upward, disposing the turned upper casing member on an assembling jig, inserting the upper layer circuit board and the insulation plate in order in the upper casing member, interconnecting the insulation plate and upper layer circuit board by an upper casing screw, inserting the lower layer circuit board into the upper casing member, interconnecting the lower layer circuit board and insulation plate by a screw, attaching the lower casing member to the upper casing member, and bringing the first rib member and boss projecting from an inner surface of the lower casing member into contact with the insulation plate and bringing the second rib member into contact with a bottom surface of the upper layer circuit board to position and hold the circuit board assembly in the casing.
After the electrical junction box is assembled by the above manner, the electrical junction box may be turned so that the bottom surface of the lower casing member is directed downward. The boss and the rib assembly projecting from the inner surface of the bottom wall of the lower casing member can position and hold the insulation plate and the upper and lower layer circuit boards mounted on the upper and lower surfaces of the insulation plate.
As described above, in the electrical junction box that contains the multilayered circuit board assembly in the casing comprising the upper and lower casing members, because the boss and the rib assembly for positioning and holding the multilayered circuit board assembly do not directly contact the surfaces of circuit boards on which an electronic component is mounted, it is possible to prevent the circuit boards from deforming or straining by the stress caused by contact between them and thereby prevent detachment of an electronic component from the circuit boards.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of an embodiment of an electrical junction box in accordance with an example embodiment of the present invention. FIG. 1B is a front elevation view of the electrical junction box shown in FIG. 1A . FIG. 1C is a bottom view of the electrical junction box shown in FIG. 1A ;
FIG. 2 is a longitudinal section view of the electrical junction box taken along lines II-II in FIG. 1A ;
FIG. 3 is a plan view of a lower casing member, illustrating an interior of the lower casing member;
FIG. 4A is a longitudinal section view of the lower casing member. FIG. 4B is a cross section view of the lower casing member;
FIG. 5A is a top view of an upper layer circuit board. FIG. 5B is a bottom view of the upper layer circuit board;
FIG. 6 is a bottom view of a multilayered circuit board assembly interposing an insulation plate between an upper layer circuit board and a lower layer circuit board;
FIG. 7A is a bottom view of an insulation plate. FIG. 7B is a bottom view of the insulation plate, illustrating the insulation plate attached to the upper layer circuit board;
FIG. 8A is a bottom view of an upper casing member, illustrating an interior of the upper casing member. FIG. 8B is a side elevation view of the upper casing member shown in FIG. 8A . FIG. 8C is an enlarged view of a main part of the upper casing member shown in FIG. 8B ;
FIG. 9 is an exploded schematic view of a casing and a multilayered circuit board assembly, illustrating a method for assembling the electrical junction box in accordance with an example embodiment of the present invention;
FIG. 10 is a sectional view of a main part of the casing and multilayered circuit board assembly, illustrating them under an assembled position; and
FIG. 11 is a sectional view of a main part of a prior art electrical junction box.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring now to the drawings, an example embodiment of an electrical junction box in accordance with the present invention will be described below.
An electrical junction box 1 shown in FIGS. 1A to 1C may be mounted in a motor vehicle. FIG. 1A is a plan view of an example embodiment of electrical junction box 1 in accordance with the present invention. FIG. 1B is a front elevation view of electrical junction box 1 shown in FIG. 1A . FIG. 1C is a bottom view of electrical junction box 1 shown in FIG. 1A . FIG. 2 is a longitudinal section view of electrical junction box 1 taken along lines II-II in FIG. 1A .
Electrical junction box 1 may include a casing that may include an upper casing member 2 and a lower casing member 3 . The casing members 2 and 3 may be locked to each other to constitute the casing. A multilayered circuit board assembly may be contained in an interior of the casing. As shown in FIG. 2 , the multilayered circuit board assembly may include an upper layer circuit board 7 , a lower layer circuit board 5 , and an insulation plate 6 disposed between lower layer circuit board 5 and upper layer circuit board 7 . Also, an insulation plate 8 may be disposed between upper layer circuit board 7 and an upper wall 2 a of upper casing member 2 .
FIG. 9 schematically shows a method of assembling electrical junction box 1 . Upper casing member 2 may be turned upside down so that an upper wall 2 a becomes a bottom side. Turned upper casing member 2 may be held on an assembling jig 50 . Insulation plate 8 , upper layer circuit board 7 , insulation plate 6 , lower layer circuit board 5 may be installed in order in the upper casing member 2 . Finally, lower casing member 3 may be mounted and locked on the upper casing member 2 .
Upper casing member 2 and lower casing member 3 may be resin molding products and may be formed into elongated configurations.
As shown in FIG. 1A , upper casing member 2 may be provided on the upper wall 2 a with a fuse-containing section 12 , a relay-containing section 13 , and a connector-containing section 14 . As shown in FIG. 2 , an attaching piece 9 a bent from a bus bar 9 may be pressed into and held in a receiving aperture provided in an inner surface of the upper wall 2 a . Tabs provided on bus bar 9 may be inserted into terminal apertures in the fuse-containing section 12 , relay-containing section 13 , and connector-containing section 14 .
Peripheral wall 2 b of upper casing member 2 may have dimensions that are matched to the dimensions of insulation plate 8 , which may be disposed inside the peripheral wall 2 b . Therefore, a height of peripheral wall 2 b may be relatively small in a vertical direction. On the other hand, a peripheral wall 3 b of the lower casing member 3 may have dimensions that surround the multilayered circuit board assembly including upper lower circuit board 7 and lower circuit board 5 and insulation plate 6 , so a height of peripheral wall 3 b may be relatively great in the vertical direction.
Upper casing member 2 may include locking portions 2 c ( FIG. 2 ) on an outer surface of the peripheral wall 2 b , while the lower casing member 3 may include locked portions 3 c ( FIG. 2 ) on an outer surface of the peripheral wall 3 b . When locking portions 2 c lock the locked portion 3 c , the upper and lower casing members 2 and 3 are interlocked to each other to form the casing.
As shown in FIG. 3 , the lower casing member 3 may include a cylindrical boss 20 projecting from a central area on an inner surface of a bottom wall 3 a . Also, as shown in FIGS. 4A and 4B , an L-shaped rib assembly including first rib members 21 and second rib members 22 may project from an inner peripheral surface of the bottom wall 3 a to the inner surface of the peripheral wall 3 b.
As shown in FIGS. 5A and 5B , upper layer circuit board 7 may be a rectangular configuration. An outer peripheral surface of upper layer circuit board 7 may have a size that may be fitted inside the peripheral wall 3 b of the lower casing member 3 . As shown in FIG. 5A , terminals 30 may be directly soldered on a top surface 7 x of upper layer circuit board 7 . Although connectors 31 are soldered on the top surface 7 x , no electronic component is mounted on the upper surface 7 x . Although a connector 32 is soldered on a bottom surface 7 y of upper layer circuit board 7 , as shown in FIG. 5B , no electronic component is mounted on the bottom surface 7 y.
As shown in FIG. 6 , when upper layer circuit board 7 is mounted on insulation plate 6 , lower layer circuit board 5 becomes a rectangular configuration except for a cutout space 5 b in a part of a side edge 5 a . The connector 32 mounted on the bottom surface 7 y of the upper layer 7 may be disposed in the cutout space 5 b . A part of side edge 5 a (a portion that is not provided with the cutout space 5 b ) may extend along the peripheral wall 3 b of the lower casing member 3 . A side edge 5 c may be faced to the side edge 5 a and spaced apart from the peripheral wall 3 b of the lower casing member 3 by a given distance, so that a part of the insulation plated 6 is exposed. Side edges 5 d and 5 e perpendicular to the side edges 5 a and 5 c may extend along the peripheral wall 3 b of the lower casing member 3 and are provided with rib-receiving cutout spaces 5 f spaced apart from one another.
As shown in FIG. 6 , an electronic component mounting section 35 including microchips (not shown) may be provided on the bottom surface 5 y of lower layer circuit board 5 and a connector may be soldered on the bottom surface 5 y.
FIG. 7A is a bottom view of the insulation plate 6 that may be interposed between the lower circuit board 5 and upper layer circuit board 7 . FIG. 7B is a bottom view of the insulation plate 6 attached to upper layer circuit board 7 . As shown in FIG. 7A , parts of the insulation plate 6 may be cut out at three edges B-B, C-C, and D-D. A whole edge A-A of the peripheral wall 6 a of the insulation plate 6 may extend along the inner surface of the peripheral wall 3 b of the lower casing member 3 . The insulation plate 6 may be provided on three edges B-B, C-C, and D-D of the peripheral wall 6 a with cutout spaces C 3 , C 1 , and C 2 , respectively. Peripheral walls 6 b , 6 c , and 6 d , which are not provided with the cutout spaces C 1 , C 2 , and C 3 , may extend along the peripheral wall 3 b of the lower casing member 3 .
Connectors 37 mounted on upper layer circuit board 7 may be disposed in cutout space C 1 and in cutout space C 2 . Connector 32 mounted on upper layer circuit board 7 may be disposed in cutout space C 3 . Connectors 37 may serve to interconnect conductors on upper layer circuit board 7 and lower layer circuit board 5 to one another.
As shown in FIG. 4A , a height H 1 of each of first rib members 21 provided on lower casing member 3 may be set to be smaller than a height H 2 of each of second rib members 22 provided on lower casing member 3 by a thickness of insulation plate 6 , e.g., H 1 <H 2 .
An upper end 21 a of each first rib member 21 may pass an outside of a peripheral edge of lower layer circuit board 5 and cutout spaces 5 f in the peripheral edge to contact a bottom surface of the peripheral edge of insulation plate 6 .
An upper end 22 a of each second rib member 21 may pass the peripheral edge of lower layer circuit board 5 and cutout spaces 5 f in the peripheral edge to contact bottom surface 7 y of upper layer circuit board 7 on which no electronic component is mounted.
As shown in FIGS. 4A and 4B , reinforcing ribs 23 , each having a height lower than that of each first rib member 21 , may be provided between first rib member 21 and second rib member 22 in order to reinforce peripheral wall 3 b of lower casing member 3 . Upper ends of reinforcing ribs 23 do not contact the bottom surface of lower layer circuit board 5 .
Boss 20 may penetrate a through-hole 5 k ( FIG. 9 ) in lower layer circuit board 5 and contacts with the bottom surface of insulation plate 6 . A height of boss 20 may have substantially the same height of each first rib member 21 .
Furthermore, lower layer circuit boar 5 and insulation plate 6 may be provided substantially on central parts with screw apertures 5 n and 6 n that are aligned with each other upon assembling. A second screw 40 is screwed into the aligned screw apertures 5 n and 6 n.
Insulation plate 6 and upper layer circuit boar 7 may also be provided with three screw apertures 6 m and 7 m that are aligned with one another upon assembling them. As shown in FIG. 8C in greater detail, each screw aperture 6 m in insulation plate 6 may be provided with an upper opening 6 m - 1 , a lower opening 6 m - 2 , and an intermediate opening 6 m - 3 in a thickness direction of the insulation plate 6 . Intermediate opening 6 m - 3 may be provided between the upper and lower openings 6 m - 1 and 6 m - 2 and may have a smaller opening area than that of each of the openings 6 m - 1 and 6 m - 2 . Each screw aperture 6 m may include a space S 1 for receiving a head of a first screw mentioned after and a space S 2 for receiving a distal end of a screw cylinder 43 .
As shown in FIGS. 8A to 8C , the respective screw apertures 6 m and 7 m may be provided in portions corresponding to the three screw cylinders 43 projecting from the inner surface of the upper wall 2 a of the upper casing member 2 . Screw apertures 6 m , 7 m , and screw cylinders 43 may be aligned on the same line and each of the first screws 44 may be screwed into each of the screw apertures 6 m . Thus, because the head of each first screw 44 is contained in each space S 1 without exposing the head outward, and because the distal end of each screw cylinder 43 is contained in each space S 2 , the upper casing member 2 , upper layer circuit board 7 , and insulation plate 6 are securely fastened to one another.
Three screw cylinders 43 may be provided substantially on the central part of upper wall 2 a of upper casing member 2 and on opposite sides of at least one edge of peripheral wall 2 b . An area enclosed by a triangle defined by the three screw cylinders 43 may be disposed on a back side of the fuse-containing section 12 , relay-containing section 13 , and connector-containing section 14 on the upper casing member 2 . Also, boss 20 projecting from bottom wall 3 a of lower casing member 3 may be disposed in the area enclosed by the triangle. Thus, it is possible for the three screw cylinders 43 and boss 20 to moderate a stress caused when electrical components (not shown) are coupled to fuse-containing section 12 , relay-containing section 13 , and connector-containing section 14 . Consequently, it is possible to prevent stress from affecting the electronic mounting section 35 (e.g., that may result in detachment of the electronic component), in particular, on lower layer circuit board 5 .
Insulation plate 8 which may be interposed between upper circuit board 7 and upper casing member 2 may also be provided on positions corresponding to the screw cylinders 43 with screw apertures 8 m.
In addition, a positioning boss 46 may project substantially from a central part of the upper wall 2 a of upper casing member 2 while a position-adjusting boss 47 may project from a corner of the upper wall 2 a . On the other hand, insulation plate 8 , upper layer circuit board 7 , insulation plate 6 , and lower layer circuit board 5 may be provided in positions corresponding to boss 46 with circular apertures 8 h , 7 h , 6 h , and 5 h and in positions corresponding to boss 47 with elongated apertures 8 i , 7 i , 6 i , and 5 i.
Next, an example embodiment of a method for assembling electrical junction box 1 in accordance with the present invention will be described.
FIG. 9 schematically shows a method of assembling electrical junction box 1 . When assembling electrical junction box 1 , upper casing member 2 may be turned upside down so that upper wall 2 a becomes a bottom side. Turned upper casing member 2 may be held on an assembling jig 50 .
Attaching piece 9 a , previously bent from each bus bar 9 , may be pressed into and held in the inner surface of upper wall 2 a of upper casing member 2 to secure bus bar 9 to upper casing member 2 . However, bus bar 9 may be secured to upper casing member 2 with member 2 being held on assembling jig 50 .
Insulation plate 8 may be inserted into upper casing member 2 held on assembling jig 50 described above. Then, boss 46 may pass through circular aperture 8 h , boss 47 may pass through elongated aperture 8 i , and screw cylinder 43 may pass through screw aperture 8 m.
After insulation plate 8 is attached to upper casing member 2 , upper layer circuit board 7 may be attached to upper casing member 7 . Then, boss 46 and boss 47 , and each screw cylinder 43 may be inserted into circular aperture 7 h , elongated aperture 7 i , and screw aperture 7 m in upper layer circuit board 7 , respectively.
Next, insulation plate 6 may be attached to upper casing member 2 , and boss 46 , boss 47 , and each screw cylinder 43 may be inserted into spaces S 2 in circular aperture 6 h , elongated aperture 6 i , and screw aperture 6 m , respectively, in insulation plate 6 .
Under this condition, each first screw 44 may be screwed into each screw cylinder 43 . In this manner, as shown in FIG. 2 and FIG. 10 , insulation plate 6 , upper layer circuit board 7 , and insulation plate 8 may be secured to the upper casing member 2 .
Next, lower layer circuit board 5 may be attached to upper casing member 2 , and boss 46 and boss 47 may pass through circular aperture 5 h and elongated aperture 5 i , respectively. Each screw aperture 5 n in lower layer circuit board 5 may be aligned with each screw aperture 6 n in insulation plate 6 to be communicated with each other. Each second screw 40 may be screwed into each of screw aperture 5 n and screw aperture 6 n . In this manner, as shown in FIG. 2 and FIG. 10 , lower layer circuit board 5 may be secured to insulation plate 6 . Because insulation plate 6 together with upper layer circuit board 7 are secured to upper casing member 2 by first screws 44 , after lower layer circuit board 5 is mounted on insulation plate 6 , lower layer circuit board 5 can be secured to insulation plate 6 by a single step of fastening second screws 40 .
Finally, lower casing member 3 may be turned upside down, so that bottom wall 3 a becomes an upper surface, and mounted onto upper casing member 2 . When assembling, boss 20 projecting from bottom wall 3 a of lower casing member 3 may penetrate a through-hole 5 k in lower layer circuit board 5 so that a distal end of boss 20 contacts the bottom surface of insulation plate 6 , thereby positioning and holding insulation plate 6 .
First rib members 21 may be inserted into cutout spaces 5 f provided in an outside and an outer peripheral edge of lower layer circuit board 5 , and distal ends of first rib members 21 contact with a bottom surface of a peripheral edge of insulation plate 6 .
Second rib members 22 may pass through cutout spaces 5 f provided in an outside and an outer peripheral edge of lower layer circuit board 5 and may further pass the peripheral edge of insulation plate 6 . Distal ends of second rib members 22 may contact a bottom surface of upper layer circuit board 7 , on which no electronic component is mounted.
Thus, boss 20 and first rib members 21 position and hold insulation plate 6 fixed to lower layer circuit board 5 by second screws 40 and the second rib members position and hold upper layer circuit board 7 fixed to insulation plate 6 by first screws 44 .
Finally, after lower casing member 3 is aligned with upper casing member 2 , and locking portions 2 c and locked portions 3 c are interlocked to one another. Boss 46 and boss 47 projecting from upper casing member 2 may be inserted into screw cylinders 25 on lower casing member 3 and third screws 48 ( FIG. 2 ) may be screwed into boss 46 and boss 47 . Thus, the process for assembling the electrical junction box 1 is completed.
As described above, when positioning and holding lower layer circuit boards 5 and upper layer circuit board 7 , boss 20 , first rib member 21 and second rib member 22 projecting from the lower casing member 3 do not contact the bottom surface of lower layer circuit board 5 , on which an electronic component may be mounted. The distal ends of the second rib members 22 may contact a peripheral edge of the bottom surface of upper layer circuit board 7 , but no electronic component is mounted on the bottom surface of upper layer circuit board 7 . That is, boss 20 , first rib member 21 and second rib member 22 do not contact with the surface of the multilayered circuit board assembly on which the electronic component is mounted. Thus, no load is applied to upper layer circuit boards 7 and lower layer circuit board 5 . Consequently, no stress is caused on the surface of the multilayered circuit board assembly, on which an electronic component is mounted, thereby eliminating a possibility of detachment of the electronic component.
The present invention is not limited to the exemplary embodiments described above.
For example, upper layer circuit board 7 may be previously bonded to the top surface of insulation plate 6 by an adhesive, and lower layer circuit board 5 and insulation plate 6 may be connected by second screws 44 to previously integrate them. Alternatively, lower layer circuit board 5 and upper layer circuit board 7 may be bonded to the top and bottom surfaces of insulation plate 6 by an adhesive.
Furthermore, insulation plate 6 may be provided with a through-hole that receives boss 20 projecting from lower casing member 3 , a distal end of boss 20 may contact with the bottom surface of upper layer circuit board 7 , on which no electronic component is mounted, so that boss 20 supports upper layer circuit board 7 .
In addition, because bus bar 9 may be directly secured to the inner surface of upper wall 2 a of upper casing member 2 in embodiments described above, insulation plate 8 may be disposed in upper casing 2 . However, in embodiments in which the bus bar 9 is not fixed directly on upper casing member 2 , it is not necessary to provide insulation plate 8 .
Although upper casing member 2 may be turned topside down and upper layer circuit board 7 and lower layer circuit board 5 may be inserted into upper casing member 2 in embodiments described above, lower layer circuit board 5 , insulation plate 6 , upper layer circuit board 7 , and insulation plate 8 , in order, may be inserted into lower casing member 3 and then upper casing member 2 may be mounted on lower casing member 3 .
The present invention is not limited to the embodiments described above and any embodiments that do not depart the spirit of the present invention fall within the scope of the present invention. | An electrical junction box may include a casing with a lower casing member and an upper casing member. A multi-layered circuit board may be retained in the electrical junction box. The multi-layered circuit board may contain a lower layer circuit board, an upper layer circuit board and an insulation plate that is disposed between and supports the lower layer circuit board and the upper layer circuit board. A rib and a boss may project from the lower casing member and may contact the insulation plate without contacting either the lower layer circuit board or the upper layer circuit board. In this manner, no physical stress is applied to a surface of either the lower layer circuit board or the upper layer circuit board thereby preventing detachment of an electronic component from the multi-layered circuit board. | 8 |
CROSS REFERENCE
Continuation-in-part of Ser. No. 07/798,530, filed Nov. 27, 1991, SINGHAL T., now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention
A tiled surface when it is installed at a nontiled surface juncture such as a tiled wall abutting a bath tub, the space between the tile edge and the tub surface is filled with the tile grout material. In addition the tub tile joint is further water sealed by application of caulking material.
This means of waterproofing a tiled and a non-tiled surface juncture is not permanent and does give trouble after a few years. The caulking material develops separation where it joins the tile, as it ages and gets mouldy and dirty from the water falling on it. The grout between the tub and tile develops hairline cracks because when the tub is put weight into of water and people, the tub surface separates from the grout. As a result after some time water starts leaking to the side of the tub, and then inside the walls. This water leakage causes damage to the underlying wood frame structure and to the plaster covering the wood frame structure.
This invention concerns a waterproof tile installed as part of the tiled surface for tub tile corners for providing a permanent solution to tub and tile joint leakage problems.
2. Description of Related Art
Identified by the examiner in Ser. No. 07/798,530.
SUMMARY OF THE INVENTION
A waterproof tile, installed at the tub and tile corner, has a foot shaped edge. The surface on the bottom side of the foot shaped edge of the tile is corrugated, with alternating ridges and valleys. This surface is sealed with a rubber like sealant against the horizontal tub edge keeping the water away from the tub tile corner. The finished side of the tile has a curvature made by varying the width of the tile. The curvature helps in directing the water away from the tub and tile corner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a: A perspective view of the tile showing all its features.
FIG. 1b: Side view of the tile showing the curvature on the front side of the tile.
FIG. 1c: Side view of the tile showing method of installation of the tile with the tile's back side cemented to the wall and its bottom side sealed to the tub surface.
FIG. 2: Application of the tile to horizontal tile surface and sink surface joint.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A tile when it abuts a bath tub, the space between the tile and the tub surface is filled with the tile grout material. In addition the joint is further water sealed by the application of tile caulking material between the tile and tub corner. This means of water proofing the tub and tile joints is not permanent and does give trouble after a few years because the caulking material develops separation where it joins the tile as it ages and gets mouldy and dirty from the water falling on it.
The grout between the tile and tub develops hairline cracks because when the weight of water and people is put into the tub or sink, the tub surface separates from the grout. As a result after some time water starts leaking to the sides of the tub, to the inside of the walls, which causes damage to underlying wood frame structure and to the plaster covering the wood frame structure.
This invention concerns a waterproof tile for tub tile corners which provides a permanent solution to tub and tile leakage problems. This invention solves the basic and long existing problem of tub/tile joints but does so in a manner that is different as well as superior in many respects to the prior art.
Refer to FIGS. 1a showing a tile useful for sealing the junction of a tiled surface and a non-tiled surface, such as a tub or counter top (1). The tile has a body having a top, bottom, back, front, left and right sides.
The top side is rectangular and has a width of W and a thickness of T (2). The bottom side is rectangular and has a width of W and a thickness which is greater than T (3). The bottom side is disposed parallel to the top side and the distance between the top and bottom side is H. The back side is rectangular and has a width of W and a height of H and is perpendicular to the top and bottom sides (4). The front side has the width of W (5) and the left and right sides each has the height of H (6). The left and right sides are disposed perpendicular to the top, bottom, back and front sides. The left and right sides are parallel and the distance between the left and right sides is W.
The thickness of the grout or the space between this tile and the other tiles on the tiled surface is G.
The bottom side of the tile is covered with a corrugated surface (8). The corrugated surface at the bottom side comprises a plurality of ridges and valleys (9). These ridges and valleys are disposed parallel to the width of the bottom side.
The ridges and valleys extend past the tile width on one side of the tile as at 7 about nearly the width of the grouting G that is used between the sides of the tiles. Alternatively, the extension could also be one-half G on both the left side and the right side. This extension provides for continuity of the rubber type sealant seal to the space between two of these tiles on the tiled wall where the grout is used.
The tile is made of a hard substance the tiles are usually made of such as ceramic or china. The front side of the tile is finished/glazed. The backside is unfinished/unglazed and is used for cementing the tile to the wall surface.
See FIG. 1b. The front side o the tile is curved by varying the thickness of the tile (10). The thickness of the tile is T at the top side (11), the thickness of the tile is less than T between the top and bottom sides (12) and the thickness of the tile is greater than T at the bottom side (13). The thickness of the tile decreases from the top side to approximately one-half T between the top and the bottom side and subsequently increases to approximately two T at the bottom side. The thickness of the tile decreases gradually from the top side to approximately one-half T between the top and the bottom side (14) and, subsequently the thickness increases rapidly to approximately two T at the bottom side (15).
A method of installing the tiles is disclosed as follows. See FIG. 1c. A method for sealing the junction between a tiled wall, the tile having a thickness of T, and a non-tiled surface, such as a tub or counter top, the method requires the step of simultaneously cementing the tile to the wall while applying the sealant between the bottom side of the tile and the non-tiled surface.
First a rubber like sealant bead, approximately greater than T wide, approximately T thick and approximately (W+G) in length is placed on the edge of the tub near the tub tile juncture. (16) Then cement is applied to the backside of the tile. (17) The bottom of the tile is then placed on the rubber like sealant bead so that it is riding the rubber like sealant bead and its ridges and valleys press into the sealant with the bottom side of the tile nearly touching the edge of the tub. Simultaneously the backside of the tile is pressed to the tile wall cementing it to the wall. (18)
When water is coming against the tiled wall surface it flows away from the tub tile joint. The rubber like sealant and the corrugated edged keeps water and moisture away from the tub tile joint.
This tile is also suitable for use with those tiles that are specifically designed for inside and outside corners and turns in the horizontal or vertical or other angle tile surfaces where these tile surfaces abut the tub and sink type enclosures. FIG. 2. shows the application of this tile where the tile surface is horizontal (19). | A tile for waterproofing the juncture of a tiled surface and a non tiled surface such as a tub and tile juncture by use of a water proof tile. The waterproof tile consists of a glazed tile surface having a curvature which directs the water away from the juncture, a non glazed surface which is cemented to the tiled wall and a bottom side which holds sealant for sealing against the non tiled surface. | 4 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a new proceess for the shaping agglomeration of finely divided particulate solids using binders and to the use of the new agglomeration process for the production of, in particular, free-flowing granular materials which may be used for a variety of applications. More particularly, the invention seeks to use (in a conceptionally new formulation), reactive binder systems which are converted from the soluble into the insoluble state in the course of the process. The measured use of these auxiliaries in the multi-stage process described in the following provides for a simplified and economic process for the production of, in particular, pourable and free-flowing agglomerates which may contain a wide range of inorganic and/or organic components as valuable material.
SUMMARY OF THE INVENTION
This invention affords a process for producing shaped, agglomerated, particulate solids, wherein
I. In a Preliminary Phase:
(A) a polymeric binder having available anionic acid moieties (particularly suitable for forming insoluble salts), is dissolved in
(B) a liquid carrier, (preferably water); to form a solution and then in a
II. First Phase:
(C) finely divided solids which are to be shaped and agglomerated, and
(D) the solution of (A+B), are mixed together until they become a shapeless, viscid mass, and then optionally are shaped; after which, in a
III. Second Phase:
(E) the amorphous mass (C+D), is combined with
(F) a solution (preferably aqueous) containing dissociated (preferably polyvalent) metal cations (which are capable of reacting with the anionic moieties of the polymeric binder), so as to form shaped particulates, which cations are minimally present in an amount sufficient to react with sufficient anionic acid moieties in binder A to form shaped agglomerated particulate solids.
According to the invention, the new process for the shaping agglomeration of finely divided particulate solids suspended in a liquid phase using a binder is characterized in that: the binders used are polymers which are soluble in the liquid phase selected and which contain acid groups suitable for forming insoluble salts which may even be present in the form of soluble salts. The binders dissolved in the liquid phase are mixed with the particulate solids to be agglomerated to form a paste-like formable mass. This mass is shaped and then combined in shaped form with a solution of cations which react with the acid groups of the polymeric binder to form the insoluble solid.
Accordingly, the first step of the process according to the invention is characterized by the selection and combination of the following elements:
The valuable materials to be agglomerated are used in sufficiently finely divided form together with a liquid phase in which these valuable materials are at least partly and, preferably, at least predominantly insoluble so that finely divided solids suspensions can be formed. At the same time, a polymeric binder is used which, in this first step of the process, is soluble in the liquid phase selected, but contains certain functional groups which readily enable the soluble polymer subsequently to be converted into the insoluble state. In the context of this invention, the above functional groups are acid groups which are suitable for forming insoluble salts between the utilized polymeric binder compound and the utilized (preferably polyvalent) metal cations.
The multi-component mixture of liquid phase, dissolved polymeric binder and suspended solids is formed into the desired three-dimensional shape of the agglomerate particles to be produced and is then exposed to the effect of cations of the type which react with the acid groups of the polymeric binders to form the insoluble solid. It has been found that the salt-forming reaction, which is normally spontaneous, results in such rapid solidification of, initially, the outer regions of the shaping multi-component body that adequate stabilization of the predetermined shape and prevention of unwanted caking together of the agglomerate particles are guaranteed. In an optional afterreaction phase, the stabilization and solidification by formation of the insoluble polymer salts may be allowed to advance into deeper layers of the particular agglomerate, penetrating to the point where the material as a whole solidifies.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about".
In the preferred embodiment, the process according to the invention uses two liquid-containing phases which are combined in the course of the process to form a single system. Intermiscible liquids are used in the two phases, which are initially kept separate. Since the salt formation on the polymeric binder is the crucial step for permanent shaping, it is of particular advantage to use aqueous or aqueous/organic liquids. Water is preferably used as the liquid in both the first reaction phase and the second reaction phase of the system.
The multi-phase component of the process according to the invention which contains the solid to be agglomerated and the polymeric binder is described first in the following. In the interests of simplicity, the solvent is generally characterized as water although, as already mentioned, the teaching according to the invention in its broadest sense is not confined to water but may include one or more alcohols, or any other organic solvents for both the polymer and metal cation salts.
Particulate Solids
The material to be agglomerated is generally present in the form of powders or as a free-flowing solid or mixture of solids all of which are substantially insoluble in the aqueous phase. Examples of such materials are metal powders, insoluble metal compounds, (such as corresponding metal oxides or metal sulfides), insoluble metal salts, (for example metallic mixed oxides), and the like. The materials in question are components which are themselves the valuable material for the intended use of the agglomerate, or may be converted into the active valuable material in situ by suitable reaction of the agglomerate, for example by reduction or oxidation.
In addition to or instead of the above inorganic components, finely divided solids based on carbon or carbon compounds which are insoluble in the liquid phase also may be agglomerated by the process according to the invention. One particularly important example in this regard is active carbon which may be used on its own, (for example for the production of active carbon beds), or together with metallic and/or other inorganic components of the above types. Important application for such combinations are in the field of catalyst production, for example in the simplified production of granular, free-flowing catalysts. However, the process according to the invention also comprises the shaping agglomeration of insoluble, finely divided organic components of any kind, under the generally mild and gentle conditions of the inventive process.
Polymeric Binders
Suitable water-soluble binders are polymer compounds of natural and/or synthetic origin which contain suitable salt-forming anionic groups in the polymer structure. Acid groups of this kind are, in particular, derived from carboxylic and/or sulfonic acids, although the invention is by no means limited to such groups. Other groups acting as anions and suitable for forming insoluble salts are equally suitable.
Preferred binders of natural origin are soluble, (in particular water-soluble), polysaccharide derivatives containing corresponding salt-forming anionic groups. Preferred such binders are carboxymethyl cellulose, carboxymethyl starch and/or carboxymethyl-substituted guar compounds. Instead of the carboxymethyl groups specifically mentioned here, it is possible to use other carboxyalkyl or polysaccharide derivatives of the type containing anionically active acid moieties substituted directly on the polysaccharide matrix.
Synthetic water soluble polymeric binders may be used in addition to or instead of binders of natural origin. Corresponding anionically reacting synthetic polymers include homopolymers and/or copolymers of lower (C 1-6 ), olefinically unsaturated nono- and/or polycarboxylic acids. Suitable starting monomers containing carboxyl groups are, in particular, lower α, β-unsaturated carboxylic acids, more especially acrylic acid and methacrylic acid, and corresponding lower olefinically unsaturated dicarboxylic acids, more especially maleic acid or maleic anhydride. Also suitable are acryloyloxypropionic acid, crotonic acid, itaconic acid, itaconic anhydride, isocrotonic acid, cinnamic acid, semiesters of maleic acid and fumaric acid, such as maleic acid monobutyl ester and fumaric acid, and the like. The properties of the polymeric binder may be varied in several ways and adapted to the requirements of the invention through the choice of the type and quantity of the monomeric constituents containing acid moieties and/or of the copolymers copolymerized with these unsaturated carboxylic acids.
Anionic polymers particularly suitable for use as watersoluble binders are ethylene/maleic anhydride copolymers containing up to about 50 mol-% maleic anhydride and vinyl methyl ether/maleic anhydride copolymers of comparable maleic anhydride content. One example of a suitable polyemric sulfonic acid compound is poly-2-acrylamido-2-methylpropane-sulfonic acid.
An important property of the polymeric binder is its adequate solubility in the aqueous medium, to ensure homogeneous distribution of the binder throughout this reaction component. Another important property is that the inventive binders may also be used in the form of their water-soluble salts. Suitable water-soluble salts are in particular alkali salts, ammonium salts, amine salts and polyamine salts. For example, the adequate solubility in water of polymeric binders of the described type in this reaction component may be established by alkalizing this reaction component with sodium, pH values of from 8 to 13 being suitable. The selected concentration of anionically reacting acid groups in the polymerized binder influences the crosslinking density formed during the reaction with the cationic second reaction component. Furthermore, particularly temperature-stable binders may be used by employing copolymers of the above-mentioned lower unsaturated mono- and/or polycarboxylic acids with, in particular, lower α-olefins.
It has been found to be of advantage in the process according to the invention to use polymeric binders containing at least 5 mol-%, preferably at least 20 mol-%, of monomers containing acid moieties. Particularly suitable copolymers contain approximately 20 to 60 mol-% lower carboxylic acid units of the type mentioned which are copolymerized with lower α-olefins, such as ethylene and/or propylene, and/or with other olefinic components, such as mehtyl vinyl ether.
Suitable water-soluble polymeric binders of the above-mentioned type have number average molecular weights (MN) of 500 to 5,000,000 preferably 1,000 to 500,000. Preferred binder concentrations in the first reaction phase are minimally an agglomeration-effective amount, preferably 1-30, more preferably 2-20, most preferably 2-10% by weight based on the combined weight of the formable paste-like mass of water, polymeric binder and solid to be agglomerated. The concentration of the polymeric binder and its average molecular weight influence the viscosity of the multicomponent mixture of water, binder and finely divided solids which is to be processed by shaping or forming. The viscosity of the multi-component mixture may be selected within a wide range, depending upon the particular procedure adopted, as described below in further detail. Suitable viscosities of the solids suspension are 100 to 2,000,000 mPa.s. Fluid to paste-like formable solids suspensions containing 1 to 15% by weight polymeric binder, 10 to 60% by weight finely divided solid, and 20 to 90% by weight water (the percentages by weight are based in each case on the three-component mixture of water, binder and finely divided solid) have proven to be particularly suitable.
Particulate Formation Process
The suspensions containing the binder and the finely divided solid may be shaped or formed by, in particular, two types of process, although all other mechanical processes are contemplated by this invention.
A first embodiment uses comparatively thin-flowing solids suspensions which preferably have viscosities of around 100 to 4,000 mPa.s. Fluid masses such as these may be solidified in shaped form after adequate homogenization by dropwise addition of this multi-phase mixture to a solution of the precipitating metal ions. The solidification of such low viscosity shapeless masses may be considered "precipitation", in that the shapeless mass, upon contact with the cationic solution, will form insoluble solids and sink to the bottom. Use of the term "precipitation" herein thus may be distinguished from the usual "precipitating out" from solution. Depending on the particular process conditions selected, roughly lenticular to spherical reaction bodies are generalloy obtained, assuming their shape directly upon entering the aqueous solution of the precipitating cations and largely retaining it in the further course of the process. Depending on the process conditions selected, it is possible to obtain largely filled, possible even hollow, sphere-like precipitation products of the described type.
In a second embodiment, a comparatively highly viscous suspension containing binders and finely divided solids (having a viscosity of 2,000 to 2,000,000 mPa.s.), is formed under the effect of mechanical forces and then introduced into the cationic precipitation solution, if desired after size-reduction. For example, filament-like strands may be introduced (as such or after size-reduction) into the solution of the precipitating cations and solidified therein by cross-linking of the binder through salt formation. If desired, the solidified material may be further size-reduced mechanically, even after the second reaction phase.
Cationic solutions
The reactant used to crosslink the polymeric binder by salt formation is a preferably aqueous solution of at least one dissociating salt of which the cations react with the anionically reacting acid moieties of the polymeric binder to form insoluble salts which precipitate from or are formed during the second reaction phase. Virtually any metal cations are suitable for this purpose, although selected (especially polyvalent) cations may be particularly important for reasons of stability and/or with regard to the intended application of the solidified masses. Suitable cations in this connection include calcium, barium, magnesium, aluminum and/or heavy metals, such as divalent copper, iron, chromium, zinc, nickel and/or cobalt. Of these, the aluminum, calcium, copper, ferric iron and ferrous iron are preferred. Divalent copper is particularly effective, leading to optimal results for many applications, particularly in the form of an aqueous sulfate solution. Suitable polyvalent metal salts besides copper sulfate include aluminum chloride, calcium chloride and corresponding sulfate salts and also corresponding salt solutions of divalent and trivalent iron, chromium, manganese and barium.
The aqueous metal salt solutions used in the second reaction phase may contain the corresponding salts of the polyvalent metal ions in quantites of from about 1% by weight to saturation, preferably 3 to 20% by weight, based on the salt solution total weight. Approximately 10% by weight copper sulfate solutions have proven to be a universal precipitant/crosslinker for the process according to the invention. In general, no particular significance is attributed to the anion of the cationic salt solution, providing unwanted interference through reaction with other constituents of the multi-component mixture can be ruled out from the outset on the strength of general chemical knowledge. Thus, the anion associated with the polyvalent metal cation need only be one which freely dissociates and for which the cation has lower affinity than the free anionic moiety of the polymeric binder.
The temperature for the second reaction phase may be selected from virtually the entire temperature range in which aqueous solutions are typically used, i.e. from about 0° to 80° C.
The minimum content of cations in the second reaction phase salt solution can be established by stoichiometric considerations in consistency with the content of available acid moieties from the other (polymeric binder) reaction component. It is not necessary to use stoichiometric ratios. The crosslinking of even some of the anionic acid moieties in the polymeric binder by polyvalent metal cations may be sufficient for adequate crosslinking of the binder and hence of the shaped mass. However, it may be preferable to use at least substantially stoichiometric quantities of the cations, and generally an excess concentration.
In one important embodiment of the process according to the invention, the reaction component containing the shaping binder and the solid to be agglomerated is introduced into an excess of aqueous cations solution and, if desired, the mass to be solidified is allowed to remain in this precipitation solution for a time adequate to achieve the desired degree of hardening. For example, ratios of the mass to be solidified to the aqueous cationic solution of 1:2-10 parts by volume have proven effective. this ensures that the viscid solid (granular or bead-like) reaction component introduced into the aqueous cationic solution is fully engulfed and, if desired, thoroughly wetted by an excess of the polyvalent metal cation solution. This embodiment is particularly suitable for comparatively fluid or thinly pasty reaction mixtures which, for example, are added dropwise to the cation solution. In other embodiments of the invention, however, it is also possible to prepare comparatively solid, (i.e. higher viscosity) shaped reaction mixtures based on the polymeric binder, aqueous phase and solid to be aggomerated, and to spray these mixtures after shaping with a sufficient quantity of the cation solution, for example a thin layer.
As already mentioned, it may be desirable to keep the initially solidified material in contact for a certain time with the solution containing the metal ions to initiate thorough mixing of the viscid mass and cationic solution and hence pervasive salt formation in the solid. If desired, the solidified bodies separated from the excess precipitation solution may be washed and dried.
Subsequent modification of the surface of the solidified bodies may be appropriate for certain applications. It has been found that the bodies obtained may have more or less smooth or compact surfaces according to the process conditions selected. Where the shaped bodies have an undesirably smooth and compact surface, the surface may be opened, i.e. made porous, and thus adapted to the previous overall structure of the material formed by simple mechanical and/or chemical treatment. For example, a solid formed according to this invention in granular or bead-like form may simply be rolled as such, in which case minimal abrasion of its surface is all that is necessary to reestablish direct access to the porous inner structure of the grains or beads. However, treatment with suitable solvents may produce the same result.
In cases where it is desired to subject the shaped solids (which already have been solidified by salt formation) to an after-reaction in the precipitation solution, the shaped solids may be left in the cation solution as long as is necessary for substantially all the polymeric available acid moieties to react with the cations of the solution, and preferably for a period of up to 45 minutes. In general, a residence time of 20 to at most 30 minutes is sufficient for thorough hardening of formed granular material having an average grain size of up to about 10 mm.
Accordingly, the invention affords in particular the use of the above-described shaping agglomeration process for the production of free-flowing granular materials having average particle sizes of from about 1 to 10 mm and preferably of from about 2 to 7 mm, from finely powdered starting materials of virtually any fine particle size.
Solids to be aggomerated
Specific examples of the finely divided solids to be agglomerated may be deduced from the intended application of the shaped bodies produced in accordance with the invention. Of particular importance are typical catalyst componets, for example insoluble compounds or finely powdered metals based on platinum, palladium, rhodium, or nickel, in the absence or presence of supports such as active carbon and kieselguhr, as well as aluminum oxide, calcium carbonate, and the like. Oxidic catalyst components, such as copper chromite, which are insoluble in water, are also particularly suitable for treatment by the inventive process.
In one preferred embodiment of the invention, the process is used for the agglomeration of activated carbon or multicomponent mixtures containing activated carbon ("A carbon") to form corresponding catalysts, for example those containing heavy metals.
To prepare particularly suitable solids suspensions, anionic polymer solutions of the type described previously may be adjusted in the pre-reaction step to a pH of 10 to 13 by addition of aqueous sodium hydroxide, after which the solids to be aggomerated are incorporated. These solids suspensions are then introduced into the cation-containing bath, which preferably is an aqueous solution containing 5 to 15% by weight copper sulfate, the ratio by volume of the aqueous precipitation solution to the volume of the material to be crosslinked preferably being 2-10:1. The agglomerated granular material may remain in the bath, for 15 minutes, advantageously at a moderately elevated temperature (40° to 60° C.). The excess cationic solution is then separted and the agglomerated and hardened material washed with water and dried.
The shaped solids according to this invention may be dried, for example, in recirculating air at temperatures above 100° C. or by any other means. Originally shiny looking surfaces may be converted into dull porous surfaces by brief rolling on a roll stand or by brief storage in a 0.1% ammonia solution.
The following Examples illustrate typical procedures for the production of agglomerated solids according to this invention.
EXAMPLES
1. General procedure for the preparation of dropped shaped bodies
Starting materials
Polymers:
(a) carboxylmethyl cellulose (CMC) (Henkel Corporation, sold as CMC/Relatin™ 7000)
(b) ethylene/maleic anhydride copolymer (Monsanto Company, sold as EMA™ 21)
(c) vinyl methyl ether/maleic anhydride copolymer (GAF Company, sold as Gantrez™ AN 139)
Distilled water
Sodium hydroxide, 50% solution
Copper (II) sulfate x 5 water (MW 249.68)
Procedure:
In a pre-reaction step, CMC was dissolved in water. The solution obtained had a pH or 7-8. EMA™ 21 or Gantrez™ AN 139 were stirred into distilled water and the mixture adjusted to pH 11.0 with 50% sodium hydroxide solution (pH meter).
Depending on the stirring conditions and the size of the batch, the polymer solution underwent an increase in temperature to 45-50° C. In the first reaction step, the particular fine particle solid to be treated was introduced in portions into this warm solution and dispersed therein.
The following procedure has proven to be appropriate, depending upon the size of the batch.
TABLE 1______________________________________Quantity of Stirrer speed Dispersionslurry Stirrer type r.p.m. time in mins______________________________________100 g propeller stirrer 2000 106000 g dissolver φ 80 mm 2800 20______________________________________
For the second reaction step, after dispersion, the warm slurry was poured into a V4A vessel having a 2 or 4 mm diameter orifice in its base (depending on the viscosity of the slurry) and added dropwise into an aqueous solution of polyvalent cations, to form unhardened shaped bodies.
After remaining in the cation bath for 15 minutes (as an after-treatment), the hardened shaped bodies were isolated by filtration under suction and subsequent washing with water. The moist shaped bodies were dried at 125° C. in a recirculating air drying cabinet.
1.1 Slurry pH variation
Taking the production of shaped bodies of copper chromite powder as an example, the influence of the pH of the slurry used on the properties of the shaped bodies was demonstrated.
Through the dispersion of copper chromite (BET =25-47 m 2 /g) in the aqueous polymer solution having a pH of 11.0, the pH changed to 9.0-9.4. However, when the pH was purposely raised to 9-11, the strength of the beads deteriorated so that the slurries were only further processed at pH 9. The pH is therefore preferably adjusted for maximum product strength, to a value which will vary with the particular salt used as the polyvalent cation source.
1.2 Variation of the cationic bath volume
The influence of the cationic bath volume used on the properties of the shaped bodies was determined in the production of shaped copper chromite bodies by dropwise addition of a copper chromite/polymer slurry to copper sulfate solution.
Basic formulations:
______________________________________(1) EMA™ 21 Water/NaOH K13/Cu-Cr catalyst 6% 54% 40%(2) Gantrez™ Water/NaOH K13/Cu-Cr catalyst AN 139 55% 40% 5%______________________________________
In each case, quantities of 100 g slurry were added dropwise to different quantities of 10% CuSO 4 solutions.
TABLE 2__________________________________________________________________________ Appearance of Ratio by volume shaped bodies Strength in NBasic formulation slurry:CuSo.sub.4 Orifice after drying at room temper-of slurry solution φ (mm) at 125° C. ature__________________________________________________________________________1 1:10 3 beads 22 1:7.5 3 beads 22 1:5 3 beads 25 1:5 2 beads 23 1:4 3 beads 20 1:3 3 beads 20 1:2 3 beads, some 20 1:1 3 beads, some 15 split2 1:10 2 beads 17 1:5 2 beads 15 1:3 2 beads 15__________________________________________________________________________
Table 2 shows that the volume of the cationic solution bath can be reduced to a ratio of slurry to CuSO 4 solution of 1:3. volume reductions to a ratio of 1:2 or 1:1 have an adverse effect on the stability of the beads (some split beads).
In the tests described in detail in the following, the slurry was generally added dropwise to 10 times the bath volume.
1.3 Strength (N) of the shaped copper chromite bodies as a function of the copper sulfate concentration of the precipitation bath
The same basic formulations as described under (1) and (2) in 1.2 were used.
Quantities of 100 g slurry were added dropwise to 1 liter of a cationic bath solution of copper sulfate in the following concentrations.
TABLE 3______________________________________ Concentration of the precipitation Appearance ofBasic formulation bath on CuSo.sub.4 the shaped *Hardness inof slurry % by weight bodies N______________________________________1 15.0 beads 10 13.5 beads 21 10.0 beads 25 9.0 beads 18 8.0 beads 15 7.0 beads split -- 6.0 beads, split -- 5.0 beads, split --2 15.0 beads 10 13.5 beads 17 10.0 beads 17______________________________________ *The hardness of the shaped bodies was measured with an instrument for measuring the compressive strength of tablets identified as "Model 4M", sold by Dr. Schleuniger Productronic AG. Hardness was measured at a constant and defined load rate of 20 N/sec. by controlled drive (measurement range : 5-300 N).
The hardness of the shaped bodies was measured with an instrument for measuring the compressive strength of tablets identified as "Model 4M", sold by Dr. Schleuniger Productronic AG. Hardness was measured at a constant and defined load rate of 20 N/sec. by controlled drive (measurement range: 5-300N).
As can be seen from Table 3, a 10% concentration of CuSO 4 in the cationic bath produces the best properties with regard to the hardness (N) and stability of the shaped bodies.
Excessively high or excessively low concentrations of CUSO 4 in the cationic bath lead to reduced strengths of the shaped bodies.
1.4 Replacement of CUSO 4 by other cations
The polymer/catalyst dispersions of known formulation were added dropwise to the following divalent and trivalent cationic solutions (10% by weight) and isolated: Ba 2+ ; Ni 2+ ; Fe 2+ ; Fe 3+ ; Zn 2+ ; Ca 2+ ; Mn 2+ ; Cr 3+ ; Co 2+ ; Al 3+ .
It was found that all the cation solutions shown are suitable to a greater or lesser extent for hardening the shaped catalyst bodies, Ca 2+ , Al 3+ , Fe 2+ and Fe 3+ solutions being particularly suitable.
1.5 Increasing the activity of the shaped bodies
Shaped bodies were produced by the described inventive procedure and partially subjected to a mechanical or a chemical surface treatment to increase their activity.
(a) Mechanical treatment: 30 minutes - rolling on a roll stand (Multifix)
(b) Chemical treatment: 5 minutes - in a 0.1% ammonia solution
Visually, the originally shiny surfaces had changed to dull and porous.
Unless otherwise specifically stated in the tests described in the following, cationic solution bath concentrations of 10% by weight were used. Accordingly, only the following parameters were changed in the following tests:
1. polymer
2. polymer concentration in the slurry
3. solid particles
4. concentration of the solid particles
5. counter-ion effect
2. Shaped bodies produced with CMC as binder
TABLE 4______________________________________Composition of the slurrySolid Cation Shaped bodyCMC % in Appear- Strength% by wt. type by wt. solution: ance N______________________________________1.0 Cu chromite 25 Cu.sup.2 + beads 8.61.0 Cu chromite 17 Cu.sup.2 + beads 8.01.0 Cu chromite 10 Cu.sup.2 + beads 5.01.0 Cu chromite 25 Fe.sup.2 + lenticu- 6.0 lar1.0 Cu chromite 25 Al.sup.3 + lenticu- 5.0 lar______________________________________
3. Shaped bodies produced using EMA™ 21 as binder
TABLE 5__________________________________________________________________________Composition of the slurry Cation Shaped bodyEMA ™ 21 Solid in Strength% by wt. type % by wt. solution: Appearance N__________________________________________________________________________3.0 Cu chromite 35 Cu.sup.2+ lenticular 43.0 Cu chromite 40 Cu.sup.2+ lenticular 73.0 Cu chromite 45 Cu.sup.2+ lenticular 224.5 Cu chromite 40 Cu.sup.2+ beads 174.5 Cu chromite 45 Cu.sup.2+ beads 346.0 Cu chromite 35 Cu.sup.2+ beads 136.0 Cu chromite 40 Cu.sup.2+ beads 256.0 A carbon 30 Cu.sup.2+ beads 126.5 Ni/A carbon 35.5 Cu.sup.2+ beads 176.6 Pd/A carbon 31.6 Cu.sup.2+ beads 126.0 Ni/SiO.sub.2 35 Cu.sup.2+ beads 126.0 CaCO.sub.3 40 Ca.sup.2+ beads 377.0 A carbon 30 Ca.sup.2+ beads 236.3 A carbon 31.6 Cu.sup.2+ beads 116.0 Al.sub.2 O.sub.3 40 Ca.sup.2+ beads 156.0 Cu chromite 40 Ca.sup.2+ beads 106.0 Cu chromite 40 Al.sup.3+ beads 146.0 Cu chromite 40 Fe.sup.2+ beads 206.0 Cu chromite 40 Fe.sup.3+ beads 11__________________________________________________________________________
4. Shaped bodies produced using Gantrez™ AN139 binder
TABLE 6__________________________________________________________________________Composition of the slurryGantrez ™ Cation Shaped bodyA139 Solid in Strength% by wt. type % by wt. solution: Appearance N__________________________________________________________________________4.0 Cu chromite 45 Cu.sup.2+ beads 194.0 Cu chromite 50 Cu.sup.2+ beads 305.0 Cu chromite 40 Cu.sup.2+ beads 186.0 Cu chromite 35 Cu.sup.2+ beads 118.0 Cu chromite 35 Cu.sup.2+ beads 64.7 A carbon 28.5 Cu.sup.2+ beads 85.5 Ni/A carbon 33 Cu.sup.2+ beads 84.6 Pd/A carbon 27 Cu.sup.2+ beads 55.7 Rh/A carbon 24 Cu.sup.2+ beads 155.0 Pt/A carbon 40 Cu.sup.2+ beads 25.0 Ni/SiO.sub.2 35 Cu.sup.2+ beads 145.0 CaCO.sub.3 40 Ca.sup.2+ beads 255.0 CaCO.sub.3 40 Cu.sup.2+ beads 105.0 Al.sub.2 O.sub.3 40 Al.sup.3+ beads 85.0 Al.sub.2 O.sub.3 40 Ca.sup.2+ beads 55.9 A carbon 30 Ca.sup.2+ beads 115.0 Cu chromite 40 Ca.sup.2+ lenticular 85.0 Cu chromite 40 Al.sup.3+ beads 45.0 Cu chromite 40 Fe.sup.2+ beads 95.0 Cu chromite 40 Fe.sup.3+ beads 11__________________________________________________________________________
5. Production of shaped catalyst bodies with CuCO 3 /ZnCO 3
TABLE 7______________________________________Polymer % Catalyst % Appearance______________________________________Gantrez ™ AN 139 5 Cu/Zn 40 porous beadsEMA ™ 21 6 Cu/Zn 40 porous beads______________________________________
Production was carried out in the same way as described in Example 1.
TABLE 7______________________________________Polymer % Catalyst % Appearance______________________________________Gantrez ™ AN 139 5 Cu/Zn 40 porous beadsEMA ™ 21 6 Cu/Zn 40 porous beads______________________________________
The shaped catalyst bodies were still in the precipitation bath with a stable, compact surface. Only after drying at 100°-125° C. did the beads become porous and unstable. | A process for producing shaped, agglomerated, particulate solids, by combining finely divided solids with a polymeric binder solution and curing the combination with polyvalent metal cations; and the products of such process. | 1 |
REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 11/520,962 filed Sep. 14, 2006, which claims the benefit of U.S. Provisional Application No. 60/716,844 filed Sep. 14, 2005.
BACKGROUND
Prior Art
[0002] The increase in bacterial immunity to modem antibiotics is problematic and one of the chief vectors of infection is the human hand. Hence, when not in the proximity of a washroom to disinfect one's hands, it would be useful to have a means to accomplish such sanitation. Also, in the midst of daily activities, it can be inconvenient to uncap bottles of disinfecting gels or hand lotions to otherwise treat the hands.
[0003] Fortunately, it has been established that ethyl alcohol is a most effective antiseptic for gram-negative pathogens; it is of low viscosity, easily dispensed from a portable container, and does not require the use of a material wipe or cloth because of the speed of evaporation. Further, an adequate dose for sanitizing the hands comprises but a few drops of this antiseptic. To prevent chafing, glycerin can be added to the alcohol without levels of viscosity increase that would be deleterious to the dispensing process.
[0004] Various methods of portable disinfectant or lotion dispensers have been disclosed in the prior art. These include body-mounted dispensers, wrist bracelet dispensers, and others. U.S. Pat. No. 6,371,946 discloses a dispensing tube that drips liquid onto the hand. U.S. Pat. No. 6,053,898 discloses a tube-fed finger dispenser. A body-worn dispenser of form factor similar to a pager is disclosed in U.S. Pat. No. 5,927,548.
[0005] What has not been demonstrated is a low cost dispenser that is wrist-worn that provides ease of actuation, is leak-proof, and offers fashion appeal.
SUMMARY OF THE INVENTION
[0006] The present invention discloses a wrist-worn device for dispensing a small amount of alcohol-based disinfectant hand rub, moisturizer, other skin medicaments, or even pharmaceutical products that would be used for treating various dermatologic or systemic maladies (the latter being treated through skin absorption of the treatment material).
[0007] In a preferred embodiment of the invention, the device is in the form of a low profile, wrist-mounted dispenser with a slit-based diaphragm valve, much like the tricuspid valve of the human heart, that produces a small amount of dispensed medicinal or sanitary treatment when the device is actuated. Various other embodiments of the invention are disclosed which exhibit the following main features: a unibody reservoir/wristband with an inserted valve component, a unibody reservoir/wristband with a valve formed in the reservoir wall, a multiple reservoir device, a reservoir housing and wristband base, a self-contained reservoir that affixes to a wristband, and a self-contained reservoir that removably attaches to a wristband. This latter embodiment permits use of pre-filled disposable reservoirs or selection of reservoirs of different shape or aesthetic appearance. For refill of the device, a simple cap accessory is disclosed that fits commercially-available bottles of hand disinfectant
[0008] To achieve simplicity of construction and yet avoid unintended dispensing and leakage of skin treatment material from the device, the slit-based diaphragm valve can be constructed from material of sufficient stiffness to prevent leakage. Alternatively, the characteristics of the construction material can be used to select a material to achieve this goal. Additionally, various embodiments include caps to mitigate any leakage.
[0009] Because only a few drops of alcohol-based disinfectant comprise a dose adequate to achieve sanitation of the hands, the device can dispense hundreds of doses of disinfectant before requiring refill or disposal.
[0010] Following is a lexicon of terms that more particularly define the invention and support the meaning of the claims:
[0011] Bonded—means adhesively adhered or physically fused together.
[0012] Body attachment means—is the physical mechanism for attaching the dispensing device to a human body such as an arm, wrist, leg, or ankle.
[0013] Locally-convex—in the context of the invention, means having the shape of a shallow or low amplitude nipple, and exhibiting a curvature that is a departure from that of the surrounding surface.
[0014] Single construction—refers to a unibody structure comprising a single component. In the present invention, this definition includes a single molded structure.
[0015] Skin treatment—comprises medicinal or sanitary treatment for either dermatological or systemic purposes.
[0016] Valve axis—is the axis perpendicular to the plane of the valve and passing through the lateral centroid of the valve.
[0017] Wristband—comprises any structure or structures that contribute directly to the wrist attachment function. Hence any extension of the reservoir body, such as a strap, fastener, loop, feature with a slit, etc., that facilitates wrist attachment is included as part of the wristband.
Objects and Advantages
[0018] Several objects and advantages of the present invention are:
[0000] (a) Provide a convenient, portable means for dispensing skin treatments;
(b) Provide a cost-effective means for dispensing skin and other topically-delivered medical treatments;
(c) Provide an unobtrusive means of dispensing skin and other topically delivered medical treatments;
(d) Provide an easily actuated means of dispensing skin and other topically-delivered medical treatments:
(e) Provide wrist-mounted means of dispensing skin and other topically-delivered medical treatments;
(f) Provide a wrist-mounted disposable means of dispensing skin and other topically-delivered medical treatments;
(g) Provide an easy-to-manufacture skin and other topically-delivered medical treatment dispenser using a slit-based diaphragm valve;
(h) Provide a fashionable dispensing device that is a desirable apparel accessory;
(i) Provide a method of refilling portable means for dispensing skin and other topically-delivered medical treatments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a pictorial diagram of an exploded view of the preferred embodiment of the invention.
[0020] FIG. 2 is a pictorial diagram of the fully constructed preferred embodiment of the invention.
[0021] FIG. 3 a is a cross-sectional exploded diagram of the preferred embodiment of the invention incorporating a slit-based diaphragm valve exhibiting a convex outer surface.
[0022] FIG. 3 b is a cross-sectional diagram of the preferred embodiment of the invention incorporating a slit-based diaphragm valve exhibiting a convex outer surface with the valve installed in the device reservoir.
[0023] FIG. 3 c is a pictorial diagram of a dual reservoir embodiment of the invention.
[0024] FIG. 3 d is a cross-sectional diagram of the device of FIG. 3 c.
[0025] FIG. 4 is a pictorial diagram of a slit-based diaphragm valve having a convex outer surface.
[0026] FIG. 5 comprises top and bottom views along with a side cross-sectional diagram of the valve of FIG. 4 .
[0027] FIG. 6 is a pictorial diagram of a slit-based diaphragm valve having a flat outer surface.
[0028] FIG. 7 comprises top and bottom views along with a side cross-sectional diagram of the valve of FIG. 6 .
[0029] FIG. 8 a is a cross-sectional diagram of the device of FIG. 2 depicting the extension of the reservoir wall to form the wristband.
[0030] FIG. 8 b is a pictorial diagram of the preferred embodiment of the invention exhibiting a first wristband geometry.
[0031] FIG. 8 c is a pictorial diagram of the preferred embodiment of the invention exhibiting a second wristband geometry.
[0032] FIG. 8 d is a pictorial diagram of the preferred embodiment of the invention exhibiting a third wristband geometry.
[0033] FIG. 9 a is a pictorial diagram of two mold halves and a mold insert for manufacture of the body of the device comprising in combination the reservoir and wristband.
[0034] FIG. 9 b is a pictorial diagram of one half of the mold containing the mold insert.
[0035] FIG. 9 c is a pictorial diagram of the mold halves together with the captivated insert showing the molding of contained polymer into the form of the reservoir and wristband body of the device.
[0036] FIG. 9 d is a pictorial diagram showing separation of the mold halves with the resulting molded body of the device containing the mold insert.
[0037] FIG. 10 a is a pictorial diagram of the molded body of the device.
[0038] FIG. 10 b is a pictorial diagram of the body of the device under deformation for the acceptance of the valve component.
[0039] FIG. 11 a is a pictorial diagram of an embodiment of the device having a slit-based diaphragm valve formed by slits placed in a raised (nippled) area of the reservoir wall and including a capped refill opening.
[0040] FIG. 11 b is a cross-sectional diagram of the device of FIG. 11 a.
[0041] FIG. 11 c is a pictorial diagram of an embodiment of the device having a slit-based diaphragm valve formed by slits placed in a flat (planar) area of the reservoir wall and including a capped refill opening.
[0042] FIG. 11 d is a cross-sectional diagram of the device of FIG. 11 c.
[0043] FIG. 12 is a pictorial diagram that shows a reservoir with snap in slit-based diaphragm valve and polymeric band.
[0044] FIG. 13 is a pictorial diagram of an integral injection molded reservoir top with slit-based diaphragm valve and a separate injection molded reservoir base that is to be bonded to the reservoir top.
[0045] FIG. 14 a is a pictorial diagram of an injection molded wristband with attachable blow molded reservoir housing containing a slit-based diaphragm valve.
[0046] FIG. 14 b is a cross-sectional diagram highlighting the topology of the device of FIG. 14 a.
[0047] FIG. 15 a is a pictorial diagram of a wristband-attachable reservoir housing seated in a receiving wristband showing the cross-section of the attachment geometry around the perimeter of the reservoir.
[0048] FIG. 15 b is a top view pictorial diagram of an attachable reservoir housing with wristband.
[0049] FIG. 15 c is side view pictorial diagram of an attachable reservoir housing with wristband.
[0050] FIG. 15 d is a front view pictorial diagram of an attachable reservoir housing with wristband.
[0051] FIG. 16 a comprises pictorial, plan, and section views of the dispenser reservoir housing.
[0052] FIG. 16 b comprises pictorial, plan, and section views of the dispenser wristband.
[0053] FIG. 16 c comprises plan and section views of the composite dispenser.
[0054] FIG. 17 a is a pictorial view of the reservoir and wristband attachable by snap means showing the protrusions under the reservoir.
[0055] FIG. 17 b is a pictorial view of the reservoir and wristband attachable by snap means showing the receiving apertures in the wristband.
[0056] FIG. 18 a is a pictorial view of a unibody valve-wristband body.
[0057] FIG. 18 b is a pictorial view of a blow molded reservoir that exhibits a groove for snap fitting into the body of FIG. 18 a.
[0058] FIG. 18 c is a pictorial view of the reservoir being inserted into the valve-wristband body.
[0059] FIG. 18 d is a pictorial view of the assembled dispenser of FIG. 18 c.
[0060] FIG. 19 a is a pictorial diagram of a dispenser body having provision for a D-ring-based cap mechanism.
[0061] FIG. 19 b is a cross sectional view of a D-ring cap mechanism.
[0062] FIG. 19 c is a plan view diagram of the dispenser body of FIG. 19 a , highlighting the notches that hold the D-ring cap mechanism.
[0063] FIG. 19 d is a pictorial diagram of the dispenser of FIG. 19 a including the D-ring cap mechanism in the open position.
[0064] FIG. 19 e is a pictorial diagram of the dispenser of FIG. 19 a including the D-ring cap mechanism in the closed position.
[0065] FIG. 20 a is a pictorial diagram of the wristband shown in FIG. 15 .
[0066] FIG. 20 b is a pictorial diagram of a reservoir housing to be used with the wristband of FIG. 15 which exhibits an attached snap cap.
[0067] FIG. 20 c is a cross sectional view of the reservoir housing of FIG. 20 b with the cap in the open position.
[0068] FIG. 20 d is a side view of the reservoir housing of FIG. 20 b with the cap in the closed position.
[0069] FIG. 21 a is a cross sectional view of a reservoir with a deformable dispensing valve in the closed position.
[0070] FIG. 21 b is a cross sectional view of a reservoir with the deformable dispensing valve of
[0071] FIG. 21 a in the open position.
[0072] FIG. 22 a is a pictorial diagram of a reservoir with a flap closure.
[0073] FIG. 22 b is a cross sectional view of the reservoir of FIG. 21 a.
[0074] FIG. 22 c is an exploded diagram detailing a mode of construction of the reservoir of FIG. 22 a.
[0075] FIG. 23 a is a pictorial diagram of a dispenser with wristband having holes that receive a nipple at the end of the wristband for adjustable attachment to the wrist.
[0076] FIG. 23 b is a pictorial diagram of the device of FIG. 23 a with the end of the wristband having the nipple advanced through a slot in the reservoir.
[0077] FIG. 23 c is a pictorial diagram of the device of FIG. 23 a with the nipple pushed through one of the wristband holes.
[0078] FIG. 24 a is a pictorial diagram of a dispenser having a tape wristband with an adhesive backed end.
[0079] FIG. 24 b is a pictorial diagram of the dispenser of FIG. 24 a slipped over the hand.
[0080] FIG. 24 c is a pictorial diagram of the dispenser of FIG. 24 a attached to the wrist by adhering the adhesively backed end of the wristband tape to the wristband in a secure fashion.
[0081] FIG. 25 a is a pictorial diagram of a reservoir that is attachable to a semi-rigid, flexible wristband by means of posts molded into the wristband.
[0082] FIG. 25 b is a pictorial diagram of the device of FIG. 25 a fully assembled.
[0083] FIG. 25 c is a pictorial diagram of the device of FIG. 25 a worn on the wrist
[0084] FIG. 25 d is a pictorial diagram of the device of FIG. 25 a showing the underside of the wristband.
[0085] FIG. 26 a is a pictorial diagram of a method of reservoir refill.
[0086] FIG. 26 b is a pictorial diagram of the refill mechanism attachable to standard form factor bottles of hand treatment material.
DETAILED DESCRIPTION OF THE INVENTION
[0087] The present invention encompasses various embodiments that variously emphasize ease of manufacture and use, or both.
Preferred Embodiment
[0088] FIG. 1 depicts a preferred embodiment of the wrist-worn, treatment device comprising two components, a) a device body 2 further comprising dispensing reservoir 6 and body attachment means in the form of a wristband 11 , and b) a slit-based diaphragm valve 1 . The valve 1 exhibits valve slits 3 in the top button 15 of the valve and has a bottom flange 5 that mounts against the inside surface of the reservoir 6 . To affix the device to a person's body, the wristband 11 circumscribes the body extremity and the end is threaded through aperture 19 . The protuberance 17 is then snap fit into an appropriate one of the perforations 13 exhibited along the length of the wristband. FIG. 2 depicts the embodiment of FIG. 1 with the valve 1 installed. FIGS. 3 a and 3 b are cross-sectional views of the device of FIG. 1 . In FIG. 3 a is shown the valve 31 having a convex outer surface 33 , a cylindrical standoff ring 37 , and a flange 35 . The device body 42 comprises a treatment material reservoir 39 that encloses the treatment volume 41 and a wristband 43 . The reservoir wall is shown to be of single construction, i.e. not constructed of joined parts, but a single molding with the wristband. The valve 1 is installed in aperture 38 within the reservoir 39 to form a fluid seal with the reservoir around the valve's perimeter. The device is affixed to a body extremity by insertion of the end of wristband 43 through aperture 45 (this will be shown in greater detail below relative to FIG. 23 a through 23 c ). FIG. 3 b depicts the position of the valve installed in device 51 . A dual reservoir version 52 of the device is shown in FIGS. 3 c and 3 d . In the cross-sectional view of the device in FIG. 3 d , two reservoir compartments 55 and 57 with associated valves 53 and 54 , are depicted respectively. The compartments are shown separated by a thick wall 56 which provides sufficient stiffness to isolate the dispensing pressure for the two compartments.
[0089] The valve geometry is shown in FIGS. 4 through 7 . Prior art slit-based diaphragm valves for dispensing applications are typically inwardly concave to facilitate certain dispensing features. The present invention favors the use of either a convex or flat surface in the vicinity of the dispensing aperture or valve to inhibit accumulation of dispensed material and to facilitate dispensing in ways described below. FIG. 4 is a pictorial diagram of a valve 61 having an outwardly convex exterior surface 62 . The detailed structure of the valve is provided by the top, bottom and side cross-sectional view of FIG. 5 . Slits 63 are present in the top button 65 to create valve flaps. The top button 65 exhibits a convex outer surface and rests atop a cylindrical ring 67 which is atop a flange 69 . When the valve is installed in the reservoir of the device, the flange 69 is mounted against the inside surface of the reservoir surrounding aperture 38 of FIG. 3 a . The valve exhibits a cylindrically symmetric hollow interior 71 through which treatment material is dispensed from the reservoir. FIG. 6 is a pictorial diagram of a valve 79 having a flat outer surface 80 . The corresponding detail of the valve is provided in FIG. 7 . Slits 82 are placed in the button 83 which exhibits a flat outer surface. Button 83 is atop cylindrical ring 85 which in turn is atop flange 89 . The valve exhibits a cylindrically symmetric hollow interior 89 .
[0090] The fundamental topology of the device body is illustrated in FIGS. 8 a through 8 d . The device body comprises the reservoir and the wristband. The cross-sectional diagram of FIG. 8 a depicts the wristband 123 as comprising an elongation or extension of the reservoir wall 121 at opposite ends 125 and 127 of the reservoir (at opposing positions about the interior of the reservoir). For the purposes of this disclosure, the wristband is defined as comprising any structure or structures that contribute to the wrist attachment function. So in FIG. 8 a , the wristband includes both the portion 124 of the device containing the wristband slit as well as the linear strap 126 . This topology is common to the three variations in wristband geometry shown in FIGS. 8 b through 8 d . FIG. 8 b depicts a wristband having a strap 135 at one end of the reservoir and a receiving portion 131 of the wristband at the other end of the reservoir. In FIG. 8 c , the wristband straps 141 and 143 extend from both ends of the reservoir and in FIG. 8 d , the wristband 151 is a continuous connection between the two reservoir ends.
Manufacture of the Preferred Embodiment
[0091] The preferred embodiment can be manufactured using liquid injection molding, insert molding, or transfer molding as is well known in the prior art. Hence, liquid polymer precursors can be introduced through channels into the assembled mold and molding and vulcanization can occur quickly under high temperature. Alternatively, solid polymer can be laid into the separated mold at appropriate locations and the mold halves brought together under pressure and heat to produce the molded article. This would be accomplished for the device body (reservoir with wristband) and separately for the valve. Depending on the process used, there may be the need to remove flashing from the molded article. Also, the molded valve body will need to have slit cut into it to form the functioning valve. This can be accomplished by punch cutting with blades. Most, if not all, of the manufacturing process steps can be automated; this includes insert placement, mold assembly, polymer introduction, molding, mold release, flashing removal, slit formation in the molded valve, device body fixturing for adhesive administration and valve insertion.
[0092] FIGS. 9 a through 9 d depict the use of molds that can represent either press molding of solid polymer or liquid injection molding. For simplicity of illustration, only mold cavities for a single device are depicted, but it should be understood that a multiplicity of device cavities can be included in a single mold set. The mold halves 161 and 163 along with mold insert 165 and associated insert neck 166 are depicted in FIG. 9 a . The bottom half 163 of the mold is shown containing the bottom portion of the mold cavity 167 following the mold contour 169 that shapes the molded reservoir for compliance with the wrist or other curved body surface.
[0093] In FIG. 9 b , the mold insert 165 that will form the device reservoir cavity upon filling of the mold with polymer or polymer precursors is shown placed in its proper position within the upper portion of the mold cavity 171 , contained in the upper half 161 of the mold. The neck 166 of the insert 165 passes through channel 173 in the upper half 161 of the mold. Neck 166 creates the reservoir aperture into which the valve will be inserted subsequent to molding and provides a means for seating the insert 165 so that it stands off from the mold cavity thereby permitting the reservoir to be formed. The assembled mold is shown in cross section in FIG. 9 c . The mold halves 161 and 163 are brought together with the insert 165 contained therein. The mold cavity 183 is depicted as filled with either polymer or polymer precursors. Separation of the mold halves 161 and 163 and depiction of the molded device body 191 with the protruding insert neck 166 is shown in FIG. 9 d . The insert can be removed from the reservoir of the molded device body either manually or automatically. Manual removal involves stretching the reservoir adjacent the insert neck 166 and peeling it off the insert. To facilitate automated removal, pressurized air passages can be made part of the insert. These passages, internal to the insert, would extend from the insert neck 166 to the surface of the insert that would be covered with polymer. Pressurization of the passages during molding would prevent polymer intrusion into such passages. Pressurization of the passages after device release from the mold would balloon the reservoir for insert removal using manipulators that would pull the polymer away from the insert. A more expensive alternative that might be justified by very large volume production involves use of a mechanically collapsible insert that could be withdrawn from the molded reservoir through the reservoir aperture without substantial deformation of the reservoir.
[0094] Subsequent to production of the device body and the valve, the valve can be installed in the device body either manually or automatically. FIG. 10 a depicts the device body 201 exhibiting the valve aperture in the reservoir. In order to install the valve 205 shown in FIG. 10 b , first adhesive or polymer precursor is applied to the perimeter of the aperture 207 . Then the reservoir 209 must be deformed to elastically enlarge the aperture 207 . This is shown being accomplished by manipulators 203 which can be clamps or can be fingers that achieve frictional traction on the surface of the reservoir. The valve 205 is placed in the aperture and the reservoir permitted to seat against the valve cylindrical ring 67 shown in FIG. 5 . Optionally, heating can be applied to cure the adhesive or polymer precursor.
[0095] Candidate polymers for molding of the device include the many silicone elastomer formulations. These polymers are alcohol permeable, but for many uses of the present invention, ethyl alcohol contents of the reservoir will be consumed by use of the invention before significant permeation loss occurs. Nevertheless, application of alcohol-impermeable fluoropolymer overcoatings for the reservoir and valve can be considered. Such coatings would adequately match the elasticity of the underlying silicone polymer. Alternatively, use can be made of an ethyl alcohol impermeable polyisobutylene replacement for silicone rubber formulated by Professor Judit Puskas of the University of Akron.
Alternate Embodiments
[0096] The slit-based diaphragm valve can be created by the formation of slits in the wall of the device reservoir. FIGS. 11 a through 11 d depict variations on this embodiment of the invention. FIG. 11 a shows a slit-based diaphragm valve formed by cutting slits 231 into a shallow convex surface, or nipple 225 , extending above the surrounding surface of the reservoir 223 . The refill aperture 227 accommodates the mold insert neck during molding and receives the refill cap component 229 to complete manufacture of the device. The refill cap component 229 is a snap closure with a tether connecting the cap lid to the cap body. It is sealed into the refill aperture 227 in a fashion similar to the sealing of the diaphragm valve component of FIG. 10 b into the valve aperture. The cross-sectional view of the device body of FIG. 11 a is shown in FIG. 11 b . FIG. 11 c shows a slit-based diaphragm valve formed by cutting slits 247 into a flat (planar) surface region 245 , of the reservoir 243 . The cross-sectional view of the device body of FIG. 11 c is shown in FIG. 11 d.
[0097] FIG. 12 depicts a wrist-worn, treatment-dispensing device 301 comprising a blow-molded reservoir body 302 having an aperture 307 for receipt of a snap-in slit-based diaphragm valve component 305 . A pronounced region 303 of the reservoir provides structural support of the slit-based diaphragm valve component 305 . A candidate material for the reservoir body 302 is 0.5 millimeter thick low density polyethylene. The injection molded valve component 305 can be made from silicone rubber shore A—15 to 20 hardness with die cut slits 306 . Slots 309 at opposing ends of the reservoir provide for the introduction of a polymeric wristband 311 similar to novelty wristbands currently on the market. The reservoir is constructed of pliable polymer material so that adequate manual pressure to the upper surface of the reservoir will cause hand treatment material to be dispensed from the slit-based diaphragm valve component 305 .
[0098] FIG. 13 is a pictorial diagram of a wrist-worn, treatment-dispensing device 313 comprising an injection molded reservoir top 315 with integral slit-based diaphragm valve 318 cut into a shallow convex surface, or nipple 319 , extending above the surrounding pronounced region 317 of the reservoir top 315 , a wristband 321 , and a separate injection molded reservoir base 323 that is to be bonded to the reservoir top 315 . Similarly to the exterior surface geometry of the valve in FIG. 3 b , the nipple 319 serves several purposes, providing: a) a visual indication of the dispending region of the device, b) a proud surface for an easy dean and wipe after dispensing, c) tactile feedback for the dispensing location, promoting ease of casual, surreptitious dispensing (avoiding the need to look at the dispenser when dispensing that might draw the attention of others), d) a crown that provides adequate stiffness for leak prevention, and e) an indexing surface for secondary manufacturing operations such as slit placement. Also, the interior surface of this nipple can be tapered radially from its center to promote valve flap operation. The pronounced region 317 of the reservoir top 315 provides structural support to the integral slit-based diaphragm valve 318 . The reservoir top 315 can be manufactured easily from a 1.0 millimeter thickness of silicone rubber, shore A—15 to 20 hardness with die cut valve slits. Candidate materials for the reservoir base include urethane or propylene. A standard watchband buckle 325 can be used with wristband 321 .
[0099] A blow-molded reservoir housing 329 and separate wristband 333 comprise the wrist-worn, treatment-dispensing device 327 of FIG. 14 a . Again, the slit-based diaphragm valve 328 is shown integral to the reservoir 329 . The valve slits are cut into a shallow convex surface, or nipple 330 . The depression region 335 of wristband 333 , which forms the lower portion of the reservoir, exhibits a scalloped ridge 331 within the perimeter of this depression region. FIG. 14 b is a cross-sectional diagram representing the topology of the device of FIG. 14 a . The dispensing reservoir 329 exhibits an interior volume 338 formed by an upper portion 336 and a lower portion 337 of reservoir 329 and the flexible wristband 333 comprises elongation or extension of the lower reservoir portion 337 at substantially opposing positions 339 about said interior volume 338 .
[0100] The ridge 331 will permit attachment of the reservoir 329 to the wristband 333 as shown in FIG. 15 a , a pictorial view of the attachment region with a hidden cross-sectional view 341 of the attachment of reservoir to wristband. Attachment is achieved by snapping the male insert 343 , protruding at various positions from the perimeter of the reservoir housing 329 , into a corresponding female channel 347 of the wristband 345 . A female channel 347 is created in the molding of each apex of scalloped ridge 331 of FIG. 14 a . This geometry allows the flexibility of the reservoir housing 329 to be maintained when the reservoir and wristband are bonded together. FIGS. 15 b through 15 d provide top, side and front views, respectively, of the wrist-worn device 327 of FIG. 15 a.
[0101] FIGS. 16 a , 16 b , and 16 c provide the plan and associated section views of the reservoir, wristband, and composite dispenser of FIG. 14 a , respectively. Shown are pictorial views 351 and 357 of reservoir and wristband, respectively, plan views 353 , 359 , and 363 of reservoir, wristband, and composite dispenser, respectively, and section views 355 , 361 , and 365 of reservoir, wristband, and composite dispenser, respectively.
Alternate Reservoir to Wristband Attachment Approaches
[0102] FIGS. 17 a and 17 b depict a means of snap fitting the reservoir 375 to wristband 371 . In FIG. 17 a the snap protrusions 377 are shown on the underside of the reservoir 375 and the corresponding receiving holes 373 are shown in the wristband 371 . In FIG. 17 b the cylindrical mounts 379 with receiving holes are shown. This amounts to having sets of complimentary gender snap components on the reservoir and wristband, respectively.
[0103] An alternate means of reservoir attachment is shown in FIGS. 18 a through 18 d . In FIG. 18 a , is shown a unibody valve-wristband body, preferably manufactured from silicon polymer, comprising the band 381 , slit-based diaphragm valve 383 surrounded by support surface 389 , and a ring of material 387 that surrounds the space 385 for the reservoir. The reservoir 391 is shown in FIG. 18 b having a groove 393 that will permit its snap fit into the ring 387 of FIG. 18 a . FIG. 18 c depicts the insertion of the reservoir 391 into the valve-wristband body. The fully assembled device 395 is shown in FIG. 18 d . The support surface 389 of the valve-wristband body will need to be bonded or mechanically attached to the reservoir so that valve 383 is seated over a hole (not shown) in reservoir 385 .
[0104] Yet another category of attachment approaches involves the use of guide tracks with complimentary guides so that the wristband and reservoir can be slid together and “locked” in place with a simple captivating tab. The guide can be a linear feature on one component (wristband or reservoir) that fits a complimentary linear keyway on the other component.
Valve Caps
[0105] FIGS. 19 a through 19 e depict the use of a cap that is slid into place to prevent leakage and inadvertent dispensing. In FIG. 19 a , is shown a reservoir 409 attached to wristband 401 . The slit-based dispensing valve area 405 is made concave to accept the dimple-shaped cap and a feature 407 is added to the reservoir housing to hold the cap in place. In FIG. 19 c , notches 410 are shown in the perimeter of the reservoir that will accept the D-ring 417 of FIG. 19 b . This D-ring can be fabricated from rigid or semi-rigid materials such as metal or plastics. The cap 415 is shown in cross section in FIG. 19 b . FIGS. 19 d and 19 e show the device with the D-ring and cap in the open and closed positions, respectively.
[0106] FIGS. 20 a through 20 d show a snap cap embodiment. FIG. 20 a is a pictorial diagram of the wristband component 421 that will, as before, accept the reservoir having the presently-described cap design. Shown attached to the reservoir 431 of FIG. 20 b is a cap 423 exhibiting a tapered plug 424 that is inserted into the valve 427 to achieve closure. The cap attachment band 425 features a thinned region 429 in the vicinity of attachment that promotes ease of flexion. FIG. 20 c is a cross section view of the reservoir of FIG. 20 b . It is shown that the plug 424 is integral to a cylindrical base 443 of short height and is inserted through a hole in cap 423 . FIG. 20 d is a side pictorial view of the reservoir with the cap placed to seal the valve area.
Alternate Valves and Closures
[0107] FIG. 21 a is a cross sectional view of deformable valve mechanism that is in the closed position. The reservoir housing 453 is attached to the wristband 451 to provide a volume 455 containing the material to be dispensed. The upper surface of the reservoir and a portion of seating area of the wristband are modified to achieve the valve function of this embodiment. A protuberance 457 is provided so that manual pressure can easily be applied at this location to effect actuation of the valve. The reservoir housing 453 contributes to the valve functionality by means of a slanted vertical wall 459 , a depression 461 , and a shallow nipple 463 having a dispensing aperture 465 on the side away from the depression 461 . The wristband component contributes ridges 466 that cooperate with the depression 461 to interlock and seal off the aperture 465 from the dispensing volume 455 when there is no left-directed horizontal pressure applied to protuberance 457 . Actuation to open the valve and permit fluid communication 469 between volume 455 and aperture 465 is depicted In FIG. 21 b with the application of force in direction 467 .
[0108] FIG. 22 a is pictorial diagram of a reservoir 471 that incorporates a flap 473 to provide closure of a dispensing aperture 477 . A shallow nipple 475 on the underside of the flap 473 ensures aperture closure. A cross sectional view of this closure scheme is provided in FIG. 22 b . FIG. 22 c depicts a method of construction of this reservoir embodiment.
Alternate Wristband Embodiments
[0109] Innumerable methods of removable attachment of a self-contained reservoir to a wristband are feasible including use of snap mechanisms, tab inserts, interlocking mechanisms, and even Velcro™. Such removable attachment would facilitate the use of pre-filled, disposable reservoirs or differently shaped or decorated reservoirs.
[0110] FIG. 23 a is a pictorial diagram of a dispenser 481 having a wristband that exhibits holes 183 much like those in a belt and a nub 487 located at the end of the wristband. Once the end of the wristband strap 485 is threaded through the wristband slit 489 at the other end of the dispenser as shown in FIG. 23 b , the nub 487 will be pressed into one of the holes 483 to secure the device to the wrist as shown in FIG. 23 c.
[0111] An adhesive-based approach is shown in FIGS. 24 a through 24 c . A reservoir 501 is shown in FIG. 24 a having an attached tape wristband 505 that has the adhesively-backed end 503 of the wristband 505 beyond slot 507 in the dispenser. This end of the wristband is too large to be pulled back through the slot 507 . As shown in FIG. 24 b , the device first is slipped over the hand and as in FIG. 24 c , the wristband pulled snug about the wrist and the end adhesively adhered to the appropriate location along the wristband.
[0112] FIGS. 25 a through 25 d depict a reservoir 531 that is snap fit to the wristband 537 . Holes 535 molded into the reservoir receive the posts 533 molded into the wristband to achieve a snap attachment.
Method of Refill
[0113] A means of refilling the wrist-worn, treatment-dispensing devices that uses slit-based diaphragm valves is depicted in FIGS. 26 a and 26 b . In FIG. 26 b , a refill attachment 567 is shown that screws onto to a standard commercially-available bottle 565 of hand sanitizing gel. FIG. 26 a depicts the use of this attachment to fill a wrist-worn, treatment dispensing device 551 with slit-based diaphragm valve 553 . The attachment comprises a threaded cap portion 559 , a tapered nozzle 555 , a ridge 561 , running from the tip of the nozzle 555 to flange 557 . The tip of nozzle 555 is inserted into the dispensing device 551 through slit-based diaphragm valve 553 to an extent where the flange 557 contacts the dispensing device 551 . As treatment material from bottle 563 is introduced into dispensing device 551 , ridge 561 provides an air escape path by holding the flaps of the slit-based diaphragm valve sufficiently open to permit such air escape from the dispensing device 551 . Alternatively, a small tube or air channel could be included along the side of the nozzle for this purpose.
Method of Use
[0114] A common method of using the various embodiments of the present invention involves attaching a treatment filled dispensing device to a person. The different attachment schemes disclosed permit attachment to the forearm, wrist, leg, or ankle. One might also consider attachment about the neck or abdomen upon use of a longer attachment band. The device is designed to permit dispensing by a single hand in the following fashion. While attached to a person, the body of the reservoir is seated against an extremity of the body and deformed by pressure from the dispensing hand. This could be achieved by using the fingers, palm, back of the hand, or side of the hand to apply pressure to the device reservoir. Such pressure would result in pressure on the contained treatment fluid sufficient to cause dispensing through the diaphragm valve. Dispensing can be directly onto the actuating hand or onto the valve exterior surface for hand collection by wiping the valve area free of dispensed treatment. It is important for dispensing to be achieved without the need for a person to look at the dispenser. The pronounced geometry of the diaphragm valve surface in certain embodiments of the device facilitates the ability of the user to discern the dispensing location by tactile means. This is addresses both convenience and the prospect for needing to be covert about dispensing in certain social settings. Experience from trial marketing of the invention in hospital and other healthcare settings suggests that the amount of pressure to be applied for the desired dispensing volume is easily learned and repeated. Further, the invention has been viewed as a major convenience when highly mobile personnel require frequent hand sterilization.
SUMMARY
[0115] The invention disclosed herein highlights numerous embodiments, but it is understood that changes and variations to these embodiments are anticipated and are within the scope of the invention and the appended claims. | A flexible, body attached device is disclosed for dispensing skin treatment and topically-absorbed medicinal treatments. The device comprises a dispensing reservoir that is caused to dispense treatment through a slit-based diaphragm valve upon the application of simple pressure to the device. Various embodiments of the invention include variations in the structure of the valve, reservoir, and body attachment means. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a seat control system and a wire harness structural body, and more particularly to a seat control system for controlling loads disposed on respective seats of a vehicle and a wire harness structural body used in the seat control system.
BACKGROUND ART
[0002] Conventionally, as the above-mentioned seat control system, there has been proposed a seat control system shown in FIG. 5 , for example. As shown in the drawing, the conventional seat control system 100 includes: a plurality of motors M which form loads disposed on respective seats of a vehicle; a control ECU 101 for controlling these motors M; and a wire harness W connected between the control ECU 101 and the motors M.
[0003] The wire harness W is branched in plural corresponding to the respective seats, and a connector C 10 is mounted on respective terminals of branched wire harnesses. The plurality of motors M disposed on the respective seats is connected to the connector C 10 . In the connector C 10 , a communication circuit capable of performing multiplex communication with the control ECU 101 , a drive circuit for driving the motors M and a sensor circuit for detecting drive amounts of the motors M are incorporated (none of them shown in the drawing).
[0004] The communication circuit incorporated in the connector C 10 performs communication with the control ECU 101 , and drives the motors M in accordance with commands from the control ECU 101 . The connector C 10 is also connected to switches for operating the motors M, and outputs operation signals of the switches to the control ECU 101 . The control ECU 101 performs a control of the respective motors M based on the operation signals.
[0005] As described above, the connector C 10 relays the communication between the control ECU 101 and the plurality of motors M and hence, it is unnecessary to respectively establish connection between the respective motors M and the control ECU 101 thus enhancing wiring property of the wire harness W and suppressing the increase of a weight of the wire harness W.
[0006] The seat control system 100 described above is an effective means for relaying signal levels. In driving electric loads such as the motors M or the like as described above, however, it is necessary to incorporate the drive circuit and the censor circuit in the connector C 10 and hence, the connector C 10 becomes large-sized thus giving rise to a drawback that mountability of the seat control system is lowered. Further, it is necessary to change the specifications of connectors in conformity with the specifications of loads mounted on a vehicle thus also giving rise to a drawback that the standardization of the seat control system becomes difficult.
SUMMARY OF INVENTION
Technical Problem
[0007] Accordingly, it is an object of the present invention to provide a seat control system capable of easily realizing miniaturization and standardization of connectors and a wire harness structural body incorporated in the seat control system.
Solution to Problem
[0008] The invention according to a first aspect in order to solve the above-mentioned issue is a seat control system including: a plurality of loads disposed on seat of a vehicle; a control unit for controlling the loads; a operation units for operating the loads disposed on the seat of the vehicle; a wire harness formed of power source line and signal line connecting the control unit, the operation unit and the loads; a drive connector mounted on a terminal of the wire harness on the load side, the drive connector incorporating a drive circuit for driving the loads therein; and a signal connector mounted on a terminal of the wire harness on the operation unit side, the signal connector being capable of transmitting an operation signal indicative of state of the operation unit, wherein the drive connector and the signal connector are provided as parts separate from each other, and the control unit, the drive connector and the signal connector are configured to perform multiplex communication through the signal line.
[0009] The invention according to a second aspect is the seat control system according to the first aspect, wherein the plurality of loads, the drive connector and the signal connector are disposed on a plurality of seats, and the control unit is configured to transmit a drive command of the loads to the drive connector such that the loads disposed on the plurality of seats are not driven simultaneously.
[0010] The invention according to a third aspect is the seat control system according to the second aspect, wherein priority is set in advance with respect to the plurality of seats, and the control unit, upon determination that the operation unit disposed on the plurality of seats is operated based on an operation signal from the signal connector, transmits a drive command of the load only to the signal connector corresponding to the seats having higher order in priority among the signal connectors to which the operation signal is transmitted.
[0011] The invention according to a fourth aspect is the seat control system according to any one of the first to third aspects, wherein the plurality of drive connectors is provided corresponding to the one seat.
[0012] The invention according to a fifth aspect is a wire harness structural body including: a wire harness formed of a power source line and a signal line connecting a control unit for controlling a plurality of loads disposed on a seat of a vehicle, and an operation unit and the loads disposed on the seat of the vehicle; a drive connector mounted on a terminal of the wire harness on the load side, the drive connector incorporating a drive circuit for driving the loads therein; and a signal connector disposed on a terminal of the wire harness on the operation unit side, the signal connector being capable of transmitting an operation signal indicative of state of the operation unit, wherein the drive connector and the signal connector are provided as parts separate from each other, and the control unit, the drive connector and the signal connector are configured to perform multiplex communication through the signal line.
Advantageous Effects of Invention
[0013] As has been described heretofore, according to the inventions described in the first to fifth aspects, the drive connector for loads which requires the drive circuit and the signal connector which transmits an operation signal are provided as parts separate from each other and hence, the respective connectors can be miniaturized. Further, even when the number of loads mounted on the vehicle is increased, it is sufficient to add the drive connectors or to change the signal connectors corresponding to the increase of the number of loads while maintaining the existing drive connectors and hence, the standardization of the drive connector can be realized.
[0014] According to the invention described in the second aspect, the control unit controls the drive connector such that the loads disposed on the plurality of seats respectively are not simultaneously driven. With such a configuration, a maximum value of a current which flows through a power source line of the wire harness can be suppressed and hence, a diameter of an electric line can be reduced thus realizing the reduction of weight of the seat control system.
[0015] According to the invention described in the third aspect, even when the operation units disposed on the plurality of seats are simultaneously operated, a load corresponding to the seat having higher priority can be driven with priority.
[0016] According to the invention described in the fourth aspect, the plurality of drive connectors can be provided corresponding to the number of loads.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a circuit diagram showing one embodiment of a seat control system of the present invention.
[0018] FIG. 2 is a perspective view of a drive connector and a signal connector shown in FIG. 1 .
[0019] FIG. 3A is an electric constitutional view of the drive connector shown in FIG. 1 .
[0020] FIG. 3B is an electric constitutional view of the signal connector shown in FIG. 1 .
[0021] FIG. 4 is a circuit diagram of a seat control system according to another embodiment.
[0022] FIG. 5 is a circuit diagram showing one example of a conventional seat control system.
DESCRIPTION OF EMBODIMENTS
[0023] Hereinafter, a seat control system which incorporates a wire harness structural body of the present invention is described hereinafter with reference to FIG. 1 to FIG. 3 . As shown in the drawing, the seat control system 1 includes: motor units 2 D and 2 P which form a plurality of loads respectively disposed on, for example, a D seat and a P seat of a vehicle; switch units 3 D and 3 P which form operation units for the motor units 2 D and 2 P; a control ECU 4 which controls the plurality of motor units 2 D and 2 P in response to operations of the switch units 3 D and 3 P; and a wire harness structural body 5 which connects the motor units 2 D and 2 P, the switch units 3 D and 3 P and the control ECU 4 to each other.
[0024] The motor units 2 D are disposed on the D seat of the vehicle, and the motor units 2 P are disposed on the P seat of the vehicle . These motor units 2 D and 2 P are units for adjusting the positions of the D seat and the P seat in the longitudinal direction and the inclination of backrests of the D seat and the P seat seats, and are respectively mounted on the D seat and the P seat . The motor units 2 D and 2 P are respectively formed of : a motor M for driving each seat; and a sensor S for outputting a sensor signal corresponding to a displacement amount of the seat when the motor M is driven.
[0025] The above-mentioned switch unit 3 D is disposed on the D seat of the vehicle, and the switch unit 3 P is disposed on the P seat of the vehicle. These switch units 3 D ad 3 P are respectively formed of a plurality of switches which are operated by respective users seated on the D seat and the P seat respectively at the time of adjusting positions of the seats in the longitudinal direction and the inclination of back rests of the seats.
[0026] The control ECU 4 is formed of a microcomputer which controls the entire seat control system 1 , and is provided with an external connector (not shown in the drawing) which is connected to the wire harness structural body 5 described later.
[0027] The wire harness structural body 5 is formed of: a wire harness W; and a connector C 1 , drive connectors C 2 d and C 2 p , signal connectors C 3 d and C 3 p which are respectively connected to terminals of the wire harness W.
[0028] The wire harness W is formed of: a main line W 1 drawn out from the control ECU 4 ; two branched lines W 2 d , W 2 p which are branched from the main line W 1 corresponding to the D seat and the P seat; two branched lines W 21 d and W 22 d which are branched from the branched line W 2 d corresponding to respective units 2 D, 3 D disposed on the D seat; and two branched lines W 21 p and W 22 p which are branched from the branched line W 2 p corresponding to respective units 2 P, 3 P disposed on the P seat.
[0029] The connector C 1 is mounted on one end of the main line W 1 , and the main line W 1 is connected with the control ECU 4 through the connector connection. The drive connectors C 2 d and C 2 p are respectively mounted on terminals of the branched lines W 21 d and W 21 p (=terminals on a motor unit 2 D, 2 P side). The drive connectors C 2 d and C 2 p are connectors which are respectively connected to unit-side connectors C 4 d and C 4 p respectively connected to the plurality of motor units 2 D. The signal connectors C 3 d and C 3 p are respectively mounted on terminals of the branched lines W 22 d and W 22 p (=terminals on a switch unit 3 D, 3 P side). The signal connectors C 3 d and C 3 p are connectors respectively connected to the switch units 3 D and 3 P.
[0030] These main line W 1 , branched lines W 2 d , W 21 d , W 22 d , W 2 p , W 21 p and W 22 p are respectively formed of: a power source line L 1 and a ground line L 2 provided for supplying a power source to the respective motor units 2 D, 2 P and the switch units 3 D, 3 P; and a signal line L 3 through which various signals such as control signals from the control ECU 4 and operation signals from the signal connectors C 3 d , C 3 p are transmitted by multiplex transmission (serial transmission).
[0031] By connecting the connector C 1 of the wire harness structural body 5 having the above-mentioned configuration to the control ECU 4 , by connecting the drive connectors C 2 d , C 2 p to the motor units 2 D, 2 P, and by connecting the signal connectors C 3 d , C 3 p to the switch units 3 D, 3 P, a power source is supplied to the respective units 2 D, 2 P, 3 D and 3 P through the power source line L 1 and the ground line L 2 from the control ECU 4 and, at the same time, the control ECU 4 , the drive connectors C 2 d , C 2 p , and the signals C 3 d , C 3 p are communicably connected to each other through the signal line L 3 .
[0032] Next, the configurations of the drive connectors C 2 d , C 2 p and signal connectors C 3 d , C 3 p are described with reference to FIG. 2 . As shown in the drawing, these connectors C 2 d , C 2 p , C 3 d , C 3 p are respectively formed of: an outer housing 6 indicated by a dotted line; a power source terminal fitting T 1 , a ground terminal fitting T 2 and a signal terminal fitting T 3 ( FIG. 3 ) which are connected to the wire harness W; terminal fittings T 4 respectively connected to respective units 2 D, 2 P, 3 D, 3 P; and an electronic printed circuit board 7 housed in the outer housing 6 .
[0033] The outer housing 6 is formed into a flat cylindrical shape using an insulating synthetic resin, and includes a hood portion 6 A and a board housing chamber 6 B which is contiguously formed with the hood portion 6 A and in which the electronic printed circuit board 7 is housed as integral parts thereof. The above-mentioned power source terminal fitting T 1 , ground terminal fitting T 2 and signal terminal fitting T 3 are respectively formed of a well-known crimp terminal or the like, and are respectively electrically connected to the power source line L 1 , the ground line L 2 and the signal line L 3 which form the wire harness W. The terminal fittings T 1 to T 4 are connected to the electronic printed circuit board 7 .
[0034] One end of the terminal fitting T 4 is connected to the electronic printed circuit board 7 , and the other end of the terminal fitting T 4 is housed in the inside of the hood portion 6 A. When the above-mentioned connectors C 2 d , C 2 p , C 3 d , C 3 p are respectively connected to the units 2 D, 2 P, 3 D, 3 P through the connector connection, power source is supplied to the respective units 2 D, 2 P, 3 D, 3 P through the terminal fittings T 4 and, at the same time, various signals are inputted to and outputted from the electronic printed circuit board 7 .
[0035] As shown in FIG. 3A , the microcomputer (hereinafter referred to as micon) 8 , a drive circuit 9 for driving the motor M, and a sensor circuit 10 which obtains a displacement amount of the seat upon reception of a sensor signal from the sensor S are mounted on the electronic printed circuit board 7 of the drive connector C 2 d , C 2 p.
[0036] The micon 8 is electrically connected to the above-mentioned terminal fittings T 1 to T 3 so as to receive the supply of a power source, and is communicably connected with the control ECU 4 through the signal line L 3 . The micon 8 is connected to the drive circuit 9 , and drives the motor M by controlling the drive circuit 9 in accordance with a control signal transmitted from the control ECU 4 . Further, the micon 8 is connected to the sensor circuit 10 , and transmits a displacement amount of the seat obtained by the sensor circuit 10 to the control ECU 4 .
[0037] As shown in FIG. 3B , a micon 11 is mounted on the electronic printed circuit boards 7 of the above-mentioned signal connectors C 3 d , C 3 p respectively. The micon 11 is connected to the terminal fittings T 1 to T 3 , receives the supply of a power source, and is communicably connected to the control ECU 4 through the signal line L 3 . Further, the micon 11 is connected to the terminal fittings T 4 thus being connected to a switches of the switch units 3 D and 3 P so that the micon 11 can detect a state of the switches. A micon 12 outputs an operation signal indicative of a detected switch state to the control ECU 4 .
[0038] Next, the manner of operation of the seat control system 1 having the above-mentioned configuration is described. Firstly, the basic manner of operation is described. When a user operates the switch which constitutes the switch unit 3 D, 3 P, the micon 11 of the signal connector C 3 d , C 3 p connected to the operated switch detects such a switch operation, and transmits an operation signal to which an ID of the operated switch is added to the control ECU 4 .
[0039] The control ECU 4 can grasp which switch of which seat is operated from the ID added to the operation signal, and outputs a drive command to the motor unit 2 D, 2 P of the seat which corresponds to the switch. When the drive connector C 2 d , C 2 p receives a drive command which is addressed to the motor unit 2 D, 2 P connected to the drive connector C 2 d , C 2 p , the drive connector C 2 d , C 2 p drives the motor unit 2 D, 2 P which is the destination of the drive command by controlling the drive circuit 9 . At this stage of operation, the drive connector C 2 d , C 2 p may transmit a displacement amount of the seat obtained by the sensor circuit 10 to the control ECU 4 , and the control ECU 4 may transmit a drive command such that the seat takes a seat position preliminarily set based on the displacement amount of the seat.
[0040] The control ECU 4 may control the drive connectors C 2 d , C 2 p such that the motor units 2 D, 2 P respectively disposed on a plurality of seats are not driven simultaneously. To be more specific, priority is assigned to the D seat or the P seat in advance. In this embodiment, the description is made assuming that the D seat has priority over the P seat. When the control ECU 4 determines that the switch units 3 D, 3 P respectively disposed on the D seat and the P seat are simultaneously operated based on operation signals from the signal connectors C 3 d , C 3 p , the control ECU 4 transmits a drive command only to the D seat having higher priority by comparing the operation signals respectively transmitted from the signal connectors C 3 d , C 3 p.
[0041] Because of such an operation, although a user seated on the D seat can drive own seat by operating the switch unit 3 D, a user seated on the P seat cannot drive own seat even when the switch unit 3 P is operated. In this case, the seat control system may inform a user that the driving of the P seat is restricted by an alarm sound, a meter or an information terminal such as a navigation system. Further, the seat control system 1 may centrally control the motor units 2 D, 2 P disposed corresponding to all seats by operating a switch unit (not shown in the drawing) disposed on a driver's seat.
[0042] According to the above-mentioned embodiment, the drive connectors C 2 d , C 2 p for the motor units 2 D, 2 P each of which requires the drive circuit 9 and the signal connectors C 3 d , C 3 p each of which transmits operation signals are provided as parts separate from each other and hence, the respective connectors can be miniaturized. Further, even when the number of motor units 2 D, 2 P mounted on the vehicle is increased, it is sufficient to add the drive connectors C 2 d , C 2 p or to change the signal connectors C 3 d , C 3 p corresponding to the increase of the number of the motor units 2 D, 2 P while maintaining the existing drive connectors C 2 d , C 2 p.
[0043] For example, when the number of motor units 2 D, 2 P mounted on a vehicle is increased more than the number of motors mounted on a standard vehicle shown in FIG. 2 , as shown in FIG. 5 , it is sufficient to add drive connectors C 2 d , C 2 p having the same configuration as the existing drive connectors C 2 d , C 2 p . That is, it is sufficient to provide the plurality of drive connectors C 2 d , C 2 p having the same configuration corresponding to the number of the motor units 2 D, 2 P thus realizing the standardization of the drive connectors C 2 d , C 2 p.
[0044] According to the above-mentioned embodiment, the control ECU 4 controls the drive connectors C 2 d , C 2 p such that the motor units 2 D, 2 P respectively disposed on the D seat and the P seat are not simultaneously driven. With such a configuration, as a current which flows through the power source line L 1 of the wire harness W, it is sufficient to make a current which can drive the motor unit 2 D, 2 P corresponding to one seat flow through the power source line L 1 . Accordingly, a maximum value of a current can be suppressed and hence, a diameter of an electric line can be reduced thus realizing the reduction of weight of the seat control system.
[0045] According to the above-mentioned embodiment, even when the switch units 3 D, 3 P are operated simultaneously at the D seat and the P seat, the motor unit 2 D, 2 P corresponding to the seat having higher priority can be driven with priority.
[0046] According to the above-mentioned embodiment, when the switch units 3 D, 3 P are operated simultaneously at the D seat and the P seat, only the motor unit 2 D, 2 P corresponding to the seat having higher priority is driven. However, the present invention is not limited to such an operation. For example, the seat control system may assign priority to the switch unit which is operated first out of the switch units 3 D, 3 P disposed on the D seat and the P seat respectively.
[0047] According to the above-mentioned embodiment, the description is made with respect to the example where, in the seat control system 1 of the present invention, the drive connector C 2 d , C 2 p and the signal connectors C 3 d , C 3 p are disposed on the D seat and the P seat respectively. However, the present invention is not limited to such a configuration. The drive connector and the signal connector maybe disposed only one seat, and may be disposed on three or more seats.
[0048] In the above-mentioned embodiment, the motor M is used as a load. However, the load is not limited to the motor M. A heater or a lighting apparatus disposed on the respective seats may be the load.
[0049] Further, the above-mentioned embodiment merely shows the representative configuration of the present invention, and the present invention is not limited to the above-mentioned embodiment. That is, various modifications can be carried out without departing from the gist of the present invention.
Reference Signs List
[0000]
1 : seat control system
2 D: motor unit (load)
2 P: motor unit (load)
3 D: switch unit (operation unit)
3 P: switch unit (operation unit)
4 : control ECU (control unit)
5 : wire harness structural body
W: wire harness
C 2 d : drive connector
C 2 p : drive connector
C 3 d : signal connector
C 3 p : signal connector
L 1 : power source line
L 3 : signal line | A wire harness includes a power source line and a signal line which connect a control ECU for controlling motor units disposed on each seat of a vehicle, switch units for operating the motor units and the motor units to each other. Drive connectors in which drive circuits for driving the motor units are incorporated are provided to terminals of the wire harness on a motor units side. Signal connectors for transmitting operation signals indicative of states of the switch units are mounted on terminals of the wire harness on a switch units side. The drive connectors and the signal connectors are provided as parts separate from each other, and the control ECU, the drive connectors and the signal connectors are provided that multiplex communication is possible among them through the signal line. | 1 |
BACKGROUND OF THE INVENTION
A. Field
The present invention concerns a cloth.
B. Related Art
In particular, the invention concerns a cloth to be provided with at least one permanent fold.
In some cases it is desirable or necessary that a cloth has one or several folds. Thus, in some cases, a zigzag folded cloth is required.
From BE 2002/0267 is known a cloth designed to be provided with at least one permanent fold, whereby a cloth consisting of weft threads bound by warp threads was taken as a basis, whereby in the folding zones, where a fold is to be formed, a folding thread is woven in the direction of the warp threads by means of a shrink thread, making use of the technique of the staggering warp threads.
Although the folds that are formed in this cloth are of a good quality, the method for weaving in the folding threads is time-consuming and difficult, which results in a relatively high production cost.
Moreover, it is found in practice that faults occurring during the weaving in of such a shrink thread according to the technique of the staggering warp threads are difficult to detect and, as a consequence, are usually not corrected.
The invention aims a cloth which provides a solution to the above-mentioned and other disadvantages.
BRIEF SUMMARY OF THE INVENTION
To this end, the invention concerns a cloth designed to be provided with at least one permanent fold, whereby at least one shrink thread is woven in said cloth and whereby the shrink thread or shrink threads are woven in the cloth according to a general direction extending crosswise over the folding zone.
Preferably, at the height of the folding zone, the shrink threads will be situated over a larger distance on a single side of the cloth than outside said folding zone.
An advantage of the cloth according to the invention is that the shrink threads can be woven in a simple and fast manner, such that the production speed can be driven up and the production cost can be lowered.
Another advantage of this cloth is that the shrink threads which have been woven in incorrectly can be easily detected before forming the folds, as the shrink threads are provided in a straight line over the folding zone.
The present invention also concerns a method for manufacturing a cloth with at least one permanent fold.
This method is characterised in that the fold, at least there where a fold should be formed, is subjected to a treatment to make the shrink thread or shrink threads shrink at least in said folding zone.
DESCRIPTION OF THE DRAWINGS
In order to better explain the characteristics of the invention, the following preferred embodiments of a cloth and a method according to the invention for manufacturing a cloth with at least one permanent fold are described as an example only without being limitative in any way, with reference to the accompanying drawings, in which:
FIG. 1 represents a part of the cloth according to the invention;
FIG. 2 represents a section according to line II-II in FIG. 1 to a larger scale;
FIG. 3 represents the part from FIG. 2 after a permanent fold has been formed according to the method of the invention;
FIG. 4 schematically represents a view in perspective of a cloth with folds made according to the method of the invention;
FIG. 5 represents a section according to line V-V in FIG. 4 ;
FIG. 6 represents a variant of FIG. 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 represent a part of a cloth 1 according to the invention, which cloth 1 is in this case woven from weft threads 2 which are bound by warp threads 3 but whereby, at regular distances from each other, in the weft direction, shrink threads 4 are woven in according to a pattern which differs from the pattern elsewhere in the cloth 1 at the height of folding zones 5 , which in this case extend in the direction of the warp.
The difference in the weaving pattern consists in that, at the height of the folding zone 5 , the shrink threads 4 are situated on a single side of the cloth 1 over a larger distance than anywhere else in the cloth 1 , in other words on a single side of the warp threads 3 .
In the given example of FIG. 1 the folding zone 5 extends over three warp threads 3 whereby the shrink threads 4 extend on a single side of these three warp threads 3 in the folding zone 5 whereas, outside said folding zone 5 , the shrink threads 4 are woven in the same conventional manner as the other weft threads 2 , namely alternately above and under the successive warp threads 3 .
The term ‘thread’ has to be interpreted in a broad sense here, which implies that monofilaments as well as yarns or mixtures thereof are to be understood by it.
The yarns can be spun yarns or filament yarns, either or not textured, and even elastic yarns.
The thread may consist of natural material as well as of synthetic material or a combination thereof, and it can possibly be provided with a coating.
The weft threads 2 and the warp threads 3 can be made of different materials.
The shrink threads 4 are made of a material which, under the influence of a thermal, mechanical/thermal, ultrasonic, high-frequency or another appropriate treatment, undergoes a permanent longitudinal shrinkage, preferably of minimum 5%. More precisely, the shrink threads 4 are made of a material that shrinks, on application of an appropriate treatment, with at least 5% more than the material of which are made the remaining threads 2 , 3 that are woven in a general direction parallel to said shrink threads 4 , whereby this shrinkage may be evaluated in a non-woven condition of the threads 2 to 4 .
These shrink threads 4 are preferably spun of yarn which consists, partly or as a whole, of one or several synthetic fibres, of continuous filament yarn, consisting of one or several synthetic filaments, of monofilament consisting of one or several synthetic base materials, or of elastic yarns or filaments.
As an example, the cloth 1 can be woven of polyethylene weft threads 2 , which under influence of a thermal treatment will shrink in length with about 5 to 7%. In that case, shrink threads 4 may be used that are woven in a general direction parallel to said weft threads 2 , which shrink threads 4 are spun of another polyethylene material, that will shrink in length for about 30 to 35% under the influence of said thermal treatment.
In order to form a permanent fold 6 , the cloth 1 is subjected to the above-mentioned treatment for making the shrink threads 4 shrink, at least in the required folding zone 5 .
It is clear that, as a result of this shrinkage of the shrink threads 4 , the warp threads 3 abutting the folding zone 5 on either side of said folding zone 5 are drawn towards each other, so that the weft threads 2 are folded, as represented in FIG. 3 .
The shrinkage is irreversible, which implies that a permanent fold 6 is obtained.
It is clear that the folding of the weft threads 2 towards one or other side of the cloth 1 is determined by the side along which the shrink threads 4 extend over the folding zone 5 .
FIGS. 4 and 5 represent a cloth 1 which is obtained according to the above-mentioned method of the invention starting from a cloth 1 , whereby the shrink threads 4 alternately extend on either side of the successive folding zones 5 .
This implies that the shrink threads 4 in the cloth 1 , which are at the basis of the successive folds 6 , successively extend unbound over the folding zone 5 , on either side of the cloth 1 , and thus of the warp threads 3 .
The size of the shrinkage and the distance B, or in other words the number of overlapped warp threads 3 over which the shrink threads 4 extend unbound on a single side of the warp threads 3 , determine the opening of the folds 6 or, in other words, they determine how strongly the warp threads 3 are drawn towards each other on either side of the folding zone 5 , and thus how large the angle A between these neighbouring parts will be, provided they are free to diverge.
Naturally, the folds 6 can be pushed together, so that the parts of the cloth 1 situated between the successive folding zones 5 are brought together, whereby the above-mentioned angle A is practically reduced to zero.
FIG. 6 represents a variant of a part of a cloth 1 according to the invention, whereby the warp threads 3 are woven farther away from each other in the folding zone 5 , as a result of which the shrink threads 4 in this folding zone 5 will be automatically situated over a larger distance B on a single side of the cloth 1 than anywhere else in the cloth 1 , outside the folding zone, folding zones 5 respectively.
A cloth 1 with permanent folds 6 is also in this case obtained in the above-described manner by applying the treatment which makes the shrink threads 4 shrink.
In all the above-mentioned embodiments, a cloth 1 with dimensionally stable folds 6 is obtained which are in this case formed in the direction of the warp, whereby these folds 6 can be opened in a flexible manner.
The cloth 1 can be any fabric whatsoever, such as a gauze or the like, with any weave whatsoever between the weft threads 2 and the warp threads 3 .
The cloth 1 must not even necessarily be a fabric. It can also be a knitting or even a non-woven. In the latter case, the shrink threads 4 must be provided after the non-woven has been manufactured.
The cloth 1 provided with folds 6 can be an insect screen, a sun screen, a curtain, packaging material, a carrier bag, an attaché-case or a part thereof, the lining of a suitcase, a filtering cloth or, as a matter of fact, any object made of fabric material provided with one or several permanent folds 6 .
It is clear that, in the different embodiments according to the invention, the shrink threads 4 can be woven in the direction of the warp, whereby the folding zones 5 extend in the direction of the weft if necessary.
The invention is by no means limited to the above-described embodiment represented in the accompanying drawings; on the contrary, such a cloth and such a method for manufacturing a cloth with at least one permanent fold can be made in all sorts of variants while still remaining within the scope of the invention. | Cloth designed to be provided with at least one permanent fold, wherein at least one shrink thread is woven in said cloth. The shrink thread or shrink threads are woven in the cloth according to a general direction extending crosswise over the fold line. | 3 |
FIELD OF THE INVENTION
This invention relates to the production of crystalline fructose. More specifically, it provides a method for large scale, high capacity, high yield production of crystalline fructose through the use of a crystallizer with optimal heat and mass transfer properties.
BACKGROUND OF THE INVENTION
The present invention relates to an improved method for crystallizing anhydrous fructose crystals from water solution. Disclosed herein is an economic method for producing large scale, high yields of crystalline fructose. Crystalline fructose is generally obtained by seeding supersaturated fructose solutions to induce crystalline growth. Due to the solubility and stability characteristics of fructose and high viscosity of fructose solutions, however, it is often problematic to maintain the optimum conditions to insure the economic production of a pure crystalline product.
Fructose is very soluble in water and the solutions are extremely viscous. A large amount of heat due to high crystallization heat of fructose, mixing heat and additional cooling of the mass must be removed during fructose crystallization. In addition, because fructose has a very narrow metastable zone, the temperature difference between the solution and the cooling surface must be quite low thus making the crystallization very difficult.
To overcome this difficulty, several prior art processes involve the use of organic solvents to crystallize fructose from aqueous solutions. In Finnish Patent Application No. 862025, for example, a continuous fructose crystallization method using organic solvents is described. The viscosity of the fructose solution, however, results in a lowering of productivity, thus the yield is only about 40% and the productivity about 0.17 t/m 3 /d even if the mass is pumped through a vertical crystallizer. The productivity (t/m 3 /d) is defined as the production rate of crystals (metric tons) per the total volume of the crystallizer (cubic meter).
Crystallization from an organic solvent or water solvent mixture is also described in Staley's European patent 015617. The use of organic solvents, however, creates disadvantages with large scale crystallizations. These include fire hazards as well as the fact that solvents are toxic and therefore unsuitable because small residues remaining in the crystalline product will leave it unsuitable for use in foods.
Several methods have been developed which avoid the use of organic solvents in the fructose crystallization process, but these methods are often disadvantageous economically because of the high viscosity and unstable nature of supersaturated fructose solutions. UK Patent Application 2172288A teaches a method for the continuous crystallization of fructose from an aqueous solution. The syrup is rapidly mixed with seed and put onto a surface until a cake is formed, which is then comminuted to a free flowing granular product. Although this method avoids the problem of continuous handling of viscous solutions, the granular amorphous product contains all of the impurities that were in the feed syrup. In addition, the extra grinding and drying stages raise the operation costs considerably. Similar costs are incurred using the method described in U.S. Pat. No. 4,199,373, wherein syrup is seeded with crystalline fructose and allowed to stand in a mold or container, after which the crystalline material is recovered, dried, and ground.
Several patents describe processes wherein fructose is allowed to selectively crystallize from an aqueous solution. In Japanese application 118,200, two towers, one for graining and one for crystallization are described. Feed from the first tower, containing 33-50% fructose syrup, is mixed with massecuite (crystal-containing) overflow from the second tower. The resultant mixture is cooled as the product moves downward in laminar flow. The crystalline fructose is then obtained by centrifugation. Although this process avoids the additional drying and grinding steps of other crystallization processes, its productivity is low and the scale up capacity is limited because of the necessity for vertical laminar flow and heat transfer demands.
One effective procedure for crystallization of fructose from aqueous solutions is described in U.S. Pat. No. 3,928,062.
The patent described a method wherein a supersaturated solution is seeded and then evaporated and/or cooled under moderate stirring while maintaining the concentration and temperature within certain ranges. By continuously concentrating the mother liquor, it can be used to produce multiple crops of fructose crystals. Although a suggestion is also made that cooling alone can be used, such a procedure is not considered as advantageous as those using continuous evaporation because the mother liquid must be reconcentrated at the start of each batch. Although such a procedure is useful for producing small batches of crystalline fructose, such a process could not be used in an industrial scale production due to heat transfer constraints as well as lack of adequate mixing and control of supersaturation.
According to U.S. Pat. No. 3,883,365, large fructose crystals are obtained in a two stage batch method from water solution by adjusting the pH of the solution and slowly cooling the mass to create a supersaturated solution which, when seeded, is optimal for crystal formation. Because of the long crystallization time of the process, a pH adjustment must be done and the productivity of the method is only about 0.25 t/m 3 /d.
Although all of the above processes have been used successfully for the production of crystalline fructose, it has heretofore been thought to be impossible to produce crystalline fructose on a large scale with high yields, high capacity (productivity) and good purity from its aqueous solutions without resorting to costly processing steps including evaporating, drying, and grinding. An object of the present invention is to provide a cost effective method for large scale, high capacity production of fructose crystals in high yields.
Another object of the invention is to provide a method for crystallization of fructose which does not require the use of organic solvents and without the need of pH adjustment.
Still another object of the invention is to provide a crystallizing apparatus that has optimal heat transfer and mixing capacities for large scale production of high purity fructose crystals.
Further objects will be evident from the description of the invention which follows.
SUMMARY OF THE INVENTION
Disclosed herein is a method for producing crystalline anhydrous fructose whereby a small amount of crystalline fructose, providing a nucleation site, is added to a fructose solution or crystalline seeds are allowed to form spontaneously in the solution. In a multistage crystallization process, all stages except the first are seeded with a crystal foot, which is a mass of crystals and mother liquid (massecuite) from a previous crystallization. The resulting mixture is mixed while cooling slowly to carefully maintain the temperature and degree of saturation for anhydrous crystallization.
In the production of fructose crystals, low supersaturation and a small differential temperature should be maintained. In a preferred embodiment, the temperature differential between the solution and the means used for cooling the solution is less than about 10° C., preferably less than about 6° C., and the fructose solution, although supersaturated, has a supersaturation of no more than 1.25, preferably between 1.1 and 1.2. Such conditions can most readily be controlled in a heat transfer apparatus or crystallizer whereby a heat transfer surface of at least about 5 m 2 /m 3 is provided. When such a crystallizer is used, it is not inclined more than 45 degrees, and it contains means for effective mixing, as well as cooling elements (such as plates or tubes) optimally spaced about 200 to 400 mm apart and having an open sector in the cooling plates of at least 5 degrees along the crystallizer.
In this embodiment, the mixer blades are located in between and not more than 30 mm from the cooling surfaces.
Preferably, the velocity of the mixer blades is at least about 50 mm/sec during the crystallization process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partially in cross section, of a fructose crystallizing apparatus according to the present invention;
FIG. 1A is a right side elevated view, partially in cross section, of a crystallizing apparatus;
FIG. 1B is an enlarged partial section view of the crystallizer shown in FIG. 1A; and
FIG. 2 is a side view, partially in cross section, of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
A. Process in General
According to the present invention it has now been found that it is possible to improve fructose crystallization from water solution by a method where a horizontal cylindrical crystallizer is used both to allow efficient heat transfer within a small temperature differential and to effectuate good mixing of the mass. Although it is not intended to be a limitation to the invention, it is believed that the parameters described herein are adapted to create a dynamic equilibrium between crystalline anhydrous fructose and dissolved fructose such that the growth of the crystalline structure is fast, however, entrapment of water molecules is avoided.
The crystallization is carried out by seeding a saturated or supersaturated fructose solution with a proper amount of seed crystals or allowing the solution to form seeds spontaneously, and then cooling the massecuite according to a gradient which is determined during the crystallization. In a multistage crystallization process the stages from second to final crystallization are seeded with the proper amount of crystalline foot. The proper amount of seeding crystals (M S ) depends on their size (d S ), on the quantity of the finished crystals (M), and the desired crystal size (D) as follows:
M S (tons)=(d S /D) 3 ×M (tons)
The fructose mass is simultaneously mixed to ensure optimum heat transfer and maximum crystal growth rate within the mass. The crystallizing process is a batch process, but it can be made semi-continuous by interconnection of several similar crystallizers. A two-stage method is advantageous if large crystal size of the product is preferable. The cooling program depends on the quality of the feed syrup, but the productivity is typically 0.5-0.8 t/m 3 /d and cooling time is typically 15-30 hours by this improved method.
A crystal yield of 65% of dry substance can be reached in the end of the crystallization. The recovery and drying of the crystals are made by conventional methods. If the yield is very high, air bubbles can be mixed, at no more than 20%, into the mass before the crystals are separated from the mother liquor to reduce the viscosity. This makes the centrifuging easier. The size of the product is typically 0.4-0.6 mm and the purity is over 99.5%.
B. Crystallizer
It is through the use of a crystallizer that the conditions of supersaturation and optimal cooling, mixing, and mass transfer can be accomplished in a large scale manner. For large scale production of fructose, the crystallizer is about 10 to 50 m 3 in size.
With reference to the drawings, there are shown crystallizers that are horizontal or inclined typically 5 degrees, but not more than 45 degrees, to ensure effective axial mixing and drainage of the system. In a crystallizer, the heat transfer surface must be at least about 5 m 2 /m 3 , so that the temperature difference between the fructose mass and cooling elements is not more than about 10° C., even if the cooling rate is 4° C./h.
With reference to FIGS. 1, 1 A and 1 B, which depict an embodiment wherein multiple crystallizing zones are present, effective heat transfer is obtained when cooling water enters a cooling jacket 3 through an inlet 8 and circulates through cooling plates 2 which are situated inside the crystallizer and spaced about 200-400 mm apart. The cooling water passes through the cooling elements and out an outlet 9 located on the opposite end of the crystallizer from the water inlet.
A motor 6 mounted on a supporting stand 7 drives a shaft 4 which, at its point of entrance into the crystallizing apparatus is surrounded by a sealing material 5 . Strong mixer blades 1 extend from-the shaft within the crystallizing apparatus. The mixing blades are situated between the cooling elements 2 so that the distance between the blades and the cooling elements are not more than about 30 mm to ensure proper mixing of the mother liquid near the crystal surfaces. The rotation speed of the mixer is such that the velocity of the top of the mixer blades is typically between about 100 and 300 mm/sec but not less than 50 mm/sec at any moment of the crystallization. Small mixing efficiency was found to be insufficient to keep the crystal growth rate high while too much mixing resulted in spontaneous crystal formation if supersaturation is high.
Fructose syrup to be crystallized (mother liquid) enters the crystallizer through inlet port 10 . A horizontal flow in the crystallizer is effected by a small open sector in the cooling elements at least 5 degrees along the crystallizer. Massecuite containing solution is removed from the crystallizing apparatus through outlet 11 whereupon it is centrifuged to collect the crystalline material.
Referring to FIG. 2, in another embodiment of the invention, the crystallizing apparatus may contain only two crystallizing zones. Such a crystallizer employs the same general components of the crystallizer shown in FIG. 1, but effective heat transfer is accomplished through circulation of cooling water through a cooling water jacket 3 ′ and into a single cooling plate 2 ′ which extends upward through the center of the apparatus. Similarly, only two mixing blades 1 ′ are necessary for mixing of the crystallizing mixture. The motor 5 ′ and shaft 4 ′ are similar to the same components in FIG. 1 .
While FIGS. 1 and 2 illustrate a preferred embodiment of the present invention, other embodiments employ other crystallizers that provide the necessary heat and mass transfer. For example, the cooling elements may be tubes instead of plates.
C. The Crystallization Process
The temperature difference between the fructose mass and cooling elements is kept less than about 6.0° C., and the supersaturation is kept less than 1.25, preferably between 1.1 and 1.2, during the whole crystallization process. The sufficient heat transfer area and mixing efficiency keeps the temperature difference between the fructose mass and cooling elements small enough despite very short crystallization times. The supersaturation which determines the cooling rate is calculated during the crystallization as follows: Y = 10000 × ( Ct - Cml ) Ct × 100 - Cml ) Qml = 100 × [ Qt - Y 100 - Y ] Cml = F ( Qml , Tm ) S = Cml × ( 100 - Cml ′ ) Cml ′ × ( 100 - Cml ) Y = crystal yield, % of dry substance amount Ct = total dry substance concentration, % w/w Cml = measured mother liquid concentration, % w/w Qml = mother liquid purity, % w/w of dry substance Cml ′ = saturation concentration of the mother liquid, % w/w F = experimentally measured solubility function Tm = temperature of the mass, ° C. S = supersaturation Qt = feed purity, % w/w of dry substance
The mother liquid concentration and temperature are measured by, for example, an on-line refractometer and a suitable thermometer. The total dry substance concentration of the mass and the purity of the feed liquid are obtained from laboratory analyses. The solubility of fructose in water is a function of purity and temperature and is obtained experimentally.
The aqueous feed solution contains glucose as a major impurity, and it contains not less than 90% by weight fructose relative to the total weight of dry solids. The dry solids concentration of the mass must be higher than 90 w/w % to get a reasonable yield if the final temperature of cooling is about 25° C. The pH adjustment of the feed syrup is not necessary because of short crystallization times but the optimum pH range of the feed syrup is 4.5-5.5 to minimize the degradation of fructose.
The careful supersaturation control, combined with efficient heat transfer and effective mixing, results in maximal crystal growth rates without spontaneous crystal formation during the entire crystallization process. The productivity of 0.5-0.8 t/m 3 /d achieved in the main crystallization by this improved method is substantially higher than the productivity obtained using the most advantageous method presented in the prior art.
In the preferred embodiment, the fructose solution is placed in the crystallizer after being evaporated to a concentration of greater than about 90% (w/w) dry solids and adjusted to the seeding temperature. During this pre-crystallization phase, the seeding is made and the cooling program is determined as set forth above. Following this stage, a portion of the mass is withdrawn, leaving a crystalline “foot” which serves as the seed in the following main crystallization. Additional, concentrated feed is added and the cooling program continued once again as set out above. After the main crystallization the crystals are separated from the other liquid by centrifugation and then dried.
In another embodiment, the crystal foot is used ini another crystallizer which is filled with additional syrup.
EXAMPLES 1-6
Intermediate Scale Crystallization Parameters
Both the pre- and main crystallization experiments were done with the 6 liter pilot crystallizer shown in FIG. 2 equipped with cooling water jacket and effective mixer. The crystallizer was connected with a programmable thermostat Mgw Lauda RKP 20 . The length of the crystallizer was 18 cm and the diameter was 21 cm. The crystallizer has 42 m 2 /m 3 heat transfer area, and it was slightly inclined.
The crystallizer consists of two crystallization zones, the width of which were 8 cm, and two mixing blades were installed in both zones. The distance between the mixer blades and cooling plates was about 1.5 cm. The rotation speed of the mixer was 11 rpm and the velocity of the top of mixer blades was 130 mm/sec during the examples.
The feed syrup was obtained from an industrial plant and it consisted of 95.5% fructose, 1.0% dextrose, 2.2% oligosaccharides and the rest being mainly salts as analyzed by HPLC. This syrup, which had poor crystallizing properties, was chosen to demonstrate the effectiveness of the present invention. The pH of the feed syrup was 4.1, and it was adjusted to about 5.0 in all examples except No. 4.
The seed crystals were made from commercial fructose crystals by grinding with Fritsh pulverisette type 14.702. The mean particle size of the seed crystals was about 0.03 mm and 90% of the crystals were between 0.02-0.08 mm as analyzed by a PMT-PAMAS particle measuring and analyzing system. The crystallization parameters of the examples are set forth in Table 1 and the results are listed in Table 2.
TABLE 1
The Crystallization Parameters
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Ex. 6
pre
main
pre
main
pre
main
pre
main
pre
main
pre
main
a
91.0
92.6
90.9
92.0
91.3
93.3
91.3
91.8
90.9
92.4
91.0
92.2
b
8.1
8.2
8.1
7.9
8.2
8.6
8.1
8.4
7.9
7.8
8.2
8.8
c
.014
17.7
.038
14.2
.038
9.7
.038
10.8
.036
15.5
.038
10.3
d
56.5
57.0
56.0
57.0
57.0
57.0
56.0
56.5
56.0
57.0
56.0
57.0
e
35.5
28.0
36.0
28.0
40.0
28.0
37.0
24.5
35.0
28.0
37.0
25.0
f
24
21
26
24
24
15
24
20
72
24
24
30
g
5.0
5.1
5.0
4.1
5.0
4.9
a concentration of the mass, % w/w
b amount of the mass, kg
c amount of the seed crystals or crystal foot, % w/w of dry substance
d initial temperature of the crystallization, ° C.
e final temperature of the crystallization, ° C.
f crystallization time, h
g pH of the feed syrup
In Example 1, the fructose solution was first adjusted to pH 5.0 with 5% w/w NaHCO 3 solution. The feed syrup was evaporated to 91.0% w/w and 8.1 kg of it was transferred to the crystallizer which temperature was 56.5° C. When the crystallizer was filled, the syrup was seeded with 0.014% seeds and the cooling program of the pre-crystallization was started. The concentration of the mother liquid was measured with a laboratory refractometer, and the mass was cooled to 35.5° C. so that the calculated supersaturation maintained was less than 1.25. The duration of the crystallization was 24 h, and the yield was 44.3% in the end of the crystallization.
When the pre-crystallization was finished, a part of the mass was pulled off and the rest was left in the crystallizer so that fructose yield of the crystal foot, which determines the crystal size of the product, in the beginning of the main crystallization was 17.7% of dry substance. The crystallizer was filled with evaporated feed syrup which was mixed with the crystal foot so that the temperature gradually rose to 57° C. and the dry substance concentration rose to 92.6%. The cooling program was started when the crystallizer was filled. The mass was cooled to 28° C. so that the supersaturation was maintained at less than 1.25. The duration of the main crystallization was 21 h.
After the main crystallization, the crystals were separated from the mother liquid and washed by a laboratory centrifugal Hettich Roto Silenta 2. The diameter of the centrifugal basket was 21 cm and the amount of the washing water was 1.5-2.5% on the weight of the mass. The crystals were dried by a laboratory fluidization dryer.
The crystal yield was 56.6% of dry substance in the end of the crystallization, and the purity of the crystals was 99% of the dry substance. The mean size of the product was 0.49 mm and the standard deviation from the mean size was 47% as measured by a sieve analysis.
The crystallization procedures as set forth in the remaining examples all had the same operation stages of EXAMPLE 1. The variables were measured during the experiments as described in Tables 2 to 7. The time from the beginning of the cooling in the main crystallization, the cooling water temperature, the concentration and supersaturation of the mother liquid are listed. In each case, the concentration was measured by a laboratory refractometer. The temperature difference between the cooling water and the mass was less than 1.0° C.
Example 1
TABLE 2
Variables in Test Run #1
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
56.5
91.0
1.16
0.0
57.0
91.2
1.15
12.9
52.2
90.5
1.23
0.5
57.0
91.1
1.15
14.1
51.1
90.2
1.23
11.3
50.5
88.5
1.03
15.6
49.7
89.6
1.20
12.5
50.0
88.3
1.02
16.6
48.8
89.4
1.20
14.3
46.9
88.1
1.08
17.5
48.0
89.2
1.20
15.9
44.3
87.7
1.11
18.5
47.0
88.7
1.16
23.0
28.0
84.5
1.13
20.3
42.9
88.3
1.23
24.9
35.5
84.9
1.05
Example 2
TABLE 3
Variables in Test Run #2
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
56.0
90.9
1.17
0.0
57.0
90.8
1.11
0.5
56.0
90.9
1.17
0.5
57.0
90.4
1.06
4.1
54.0
90.9
1.24
1.6
56.2
90.3
1.07
10.7
54.1
90.2
1.14
2.5
55.5
90.0
1.05
22.0
42.9
87.7
1.16
(42.7
28.0
83.2
1.02)
23.5
39.8
87.0
1.15
24.5
37.8
86.4
1.14
26.0
36.0
85.6
1.10
26.8
36.0
85.2
1.07
24.9
Example 3
TABLE 4
Variables in Test Run #3
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
57.0
91.3
1.21
11.2
41.0
87.2
1.12
3.6
56.5
91.1
1.18
12.5
37.0
86.0
1.09
18.0
49.3
88.9
1.12
13.0
35.4
85.7
1.09
19.2
48.0
88.9
1.15
14.6
30.7
84.8
1.10
20.1
46.9
88.5
1.14
15.5
28.2
84.5
1.13
21.4
44.7
87.6
1.10
22.7
42.3
86.9
1.08
24.1
39.9
86.5
1.10
Example 4
TABLE 5
Variables in Test Run #4
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
56.0
91.3
1.23
14.6
39.6
86.8
1.13
0.5
56.3
91.0
1.17
15.6
37.7
86.2
1.12
3.2
55.8
90.0
1.19
16.5
35.5
85.7
1.12
20.5
45.1
87.4
1.07
17.5
32.8
85.2
1.12
21.9
42.4
86.9
1.01
18.5
29.9
85.1
1.18
23.2
39.7
86.6
1.11
19.5
27.0
84.5
1.17
24.5
37.2
85.7
1.09
20.0
24.5
83.8
1.16
Example 5
TABLE 6
Variables in Test Run #5
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
56.0
90.9
1.17
0.0
57.0
91.1
1.15
5.5
55.5
90.9
1.18
1.3
56.2
90.5
1.09
70.6
36.1
85.3
1.07
16.8
43.0
87.3
1.09
19.0
39.5
86.5
1.09
21.9
33.3
85.1
1.09
24.0
28.9
84.4
1.11
Example 6
TABLE 7
Variables in Test Run #6
pre cryst.
main cryst.
Time
Temp
Conc
s
Time
Temp
Conc
s
h
° C.
w/w %
—
h
° C.
w/w %
—
0.0
56.0
91.0
1.18
0.0
57.0
90.5
1.07
0.8
55.9
90.8
1.17
14.5
39.8
87.0
1.14
18.8
47.1
87.9
1.07
15.4
38.0
86.0
1.08
22.1
41.9
86.8
1.09
16.4
35.6
85.4
1.08
22.8
40.5
86.4
1.08
18.1
30.7
84.6
1.10
23.9
38.2
85.9
1.08
18.8
28.9
84.3
1.11
24.5
37.0
85.7
1.09
20.0
25.3
83.7
1/12
TABLE 8
Results of Test Runs in Examples 1-6
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Ex. 6
pre
main
pre
main
pre
main
pre
main
pre
main
pre
main
a
44.3
56.6
40.5
57.5
38.8
62.8
42.6
54.5
41.9
58.8
40.9
57.8
b
—
—
60.6
56.2
58.7
57.1
c
0.17
0.49
0.16
0.62
0.16
0.66
0.13
0.35
0.19
0.62
0.13
0.37
d
47
31
27
59
38
57
e
99
99.5
99.9
—
99.9
—
f
0.52
0.75
0.46
0.70
0.48
0.90
0.52
0.71
0.17
0.67
0.50
0.78
a crystal yield in the end of the pre crystallization and before centrifuging in the main crystallization, % w/w of dry substance
b crystal yield of the product, % w/w of dry substance
c mean size of the product, mm
d standard deviation from the mean size of the product, %
e purity of the product, % w/w of dry substance
f productivity, t/m 3 /day
The mean size and the standard deviation of the product were measured by the sieve analysis and in the end of the pre-crystallization by a laboratory microscope.
Example 7.
Approximately 18,000 kg of crystalline fructose were recovered in 30 hours by crystallizing fructose from solution in a 30 cubic meter cylindrical crystallizer which was inclined approximately 5°. The crystallizer was quipped with efficient cooling and mixing elements. The heat transfer area was 5.8 m 2 /m 3 and the rotation velocity at the end of the mixing elements was between about 130 and 260 mm/sec.
A 5 cubic motor of seed crystal foot (the dry substance content of which was 90.1 weight percent, 97 weight percent of the dry substance was fructose, and the foot had and mean crystal size about 0.2 m) was placed in the crystallizer, Next, concentrated fructose syrup, 92 weight percent dry substance of which about 97 weight percent was fructose, was added to the crystallizer and mixed with the foot. When the crystallizer was filled, the temperature of the mass in the crystallizer was adjusted to about 56° C. A crystal yield about 5-10% of dry substance (“d.s.”) was obtained.
The mass war then cooled to 30° C. over 30 hours at a moan rate of 0.87° C./hr. During cooling, the mean temperature difference (W) in the solution ranged between about 0 and 10° C. following table:
Time, h: (0) 2 5 10 17 20 24 27 30
MTD, ° C.: (0) 2 6 8 4 7 3 7 5
After cooling, the crystals were separated and washed by a conventional centrifuge, dried in a drum dryer, sieved and packed. The fructose yield after cooling was about 58% of the dry substance. The product yield was over 46% of dry substance with a mean crystal size of about 0.53 mm and standard deviation of the mean size of 29%. Fructose content of the crystals was over 99%.
Example 8
A 5 cubic meter seed crystal foot was put in the crystallizer. The foot had a dry substance content of about 90 weight percent, 97 percent of the dry substance was fructose and the foot had mean crystal size about 0.20 mm.
Next, concentrated fructose syrup, of which 92 weight percent was dry substance and 97 percent of the dry substance was fructose, was added to the crystallizer. Thereafter, the fructose syrup was mixed with the foot. The crystallizer and rotation velocity of the mixer were same as that stated in Example 7. After mixing, the mass in the crystallizer had a temperature of 54° C. and a crystal yield of about 20% of d.s.
The fructose syrup and foot admixture was cooled from 54° C. to 29° C. over the course of 30 hours (i.e., at a mean rate of 0.83 OC/h). The mean temperature difference of the solution varied between about 1 and 7° C. The following table shows the recorded temperature differences (MTD) during the cooling period:
Time, h: 1 3 6 12 13 14 18 20 22 24 27 30
MTD, ° C.: 1 5 3 6 7 6 7 6 4 6 3 6
After cooling the crystals were separated and washed in a conventional centrifugal, dried by a drum dryer, sieved and packed. Fructose yield after cooling was about 56% of the dry substance. The product yield was about 46% of dry substance, mean crystal size was over 0.50 mm with a standard deviation of the mean size of about 25%. Fructose content of the crystal was greater than 99%.
Example 9
A 5 cubic meter seed crystal foot having a dry substance content of about 90 weight percent of which about 97 percent was fructose, and mean crystal size about 0.20 mm, was placed in a 30 cubic meter crystallizer. Thereafter, concentrated fructose syrup was added to, and mixed with, the foot. When the crystallizer was filled, the mass inside had a temperature of about 56° C., a dry substance content of about 92.3 weight percent of which about 97.2 percent was fructose and crystal yield about 20% of d.s.
The rotation velocity of the mixer was as described in Example 7.
The mass in the crystallizer was cooled from about 56° C. to about 33° C. over a period of about 18 hours (i.e., at a mean rate of about 1.28° C./h). The mean temperature difference of the mass varied between about 0-12° C. and the effective difference was about 7° C. during the 18 hours cooling. The recorded mean temperature difference (MTD) during the cooling (18 h) as following:
Time, h: (0) 5 10 15 18
MTD, ° C.: (0) 12 7 6 8
After cooling the crystals were separated and washed by a traditional centrifugal, dried by a drum dryer, sieved and packed. Fructose yield in the end of the cooling was about 58 percent of the dry substance. The product yield was over 46 percent of dry substance, mean crystal size was 0.53 mm and standard deviation of the mean size 23 percent. Fructose content of the crystals was over 99 percent. | Methods of crystallizing anhydrous fructose from aqueous solutions using a large scale crystallizer are provided. The various crystallization methods include at least a cooling crystallization step wherein cooling is controlled so as to maintain a temperature difference between the solution and the cooling element of less than about 10° C., and maintain supersaturation of the aqueous solution with respect to the saturated fructose at a ratio between 1.1 and 1.25, whereby optimum heat transfer and a fructose crystal growth rate of at least 0.008 mm/hr is achieved with little or no spontaneous crystal nucleation. | 1 |
[0001] This application is a divisional of co-pending U.S. patent application Ser. No. 14/198,653, entitled “Codebook Construction,” filed Mar. 6, 2014, which in turn claims the benefit of U.S. Provisional Application No. 61/767,896, entitled “Observations on Codebook Construction,” filed on Mar. 7, 2013, U.S. Provisional Application No. 61/775,058, entitled “Observations on Codebook Construction,” filed on Mar. 8, 2013, U.S. Provisional Application No. 61/808,934, entitled “Enhancements to a Structured Codebook,” filed on Apr. 5, 2013, U.S. Provisional Application No. 61/817,150, entitled “Enhancement to the 4 Transmit Antenna Precoding Codebook,” filed on Apr. 29, 2013, U.S. Provisional Application No. 61/817,247, entitled “Enhancement to the 4 Transmit Antenna Precoding Codebook,” filed on Apr. 29, 2013, U.S. Provisional Application No. 61/821,989, entitled “Improvements to the 4 Transmit Antenna Precoding Codebook,” filed on May 10, 2013, the contents of all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to precoding matrix design and, more particularly, to precoding matrix design to derive a precoding matrix as a product of two matrices.
[0003] Wireless communication systems demand for even higher spectral efficiencies to accommodate the higher throughput requirements within the limited frequency bands. Multiple antenna or multiple-input and multiple-output (MIMO) systems and in particular closed loop transmission technologies such as beamforming and precoding have been vastly considered to improve the spectral efficiency. In MIMO precoding schemes, the data to be transmitted is divided into one or more streams, the streams are mapped onto one or more transmission layers, and the data in the layers are precoded with a precoder or precoding matrix before transmission. The number of transmission layers is called transmission rank. The transmission rank can be optimally chosen for a given channel realization by considering, for example, the transmit power and the overall channel statistics.
[0004] In codebook based preceding strategies, a predetermined codebook is made available to the transmitter, i.e., base station (BS), and all receivers, i.e., mobile stations (MSs) or user equipments (UEs). The receiver then chooses a precoder from the codebook which maximizes its performance (e.g. its data rate) and feeds back the precoder index. The selection of precoder rank may also be included in the precoder selection algorithm. The feedback rate may vary from a short-term feedback once every coherent time interval to a long-term feedback once every several coherent time intervals.
[0005] In many systems, the optimal precoders from the codebook tor two adjacent transmission blocks are close with respect to a proper distance measure in the set of all possible precoders. Here, the adjacent blocks may be considered in time or in frequency, e.g., over the set of tones in orthogonal frequency-division multiplexing (OFDM) systems since in practical systems the channel does not change abruptly from one transmission block to the adjacent one. Thus, the precoder used in those blocks can be equal if the channel is pretty steady and the codebook resolution is not too high. By increasing the codebook resolution or having a more dynamic channel, the precoders of the adjacent blocks are not equal anymore, yet, they might be close. The closeness between two precoders can be measured based on a proper distance metric in the space of all such precoders. Some examples of differential, dual and multi-resolution codebooks are disclosed in refs. [5] and [6].
[0006] We consider preceding codebook design for the 4 transmit antenna (TX) MIMO downlink channel and detail a codebook structure that is suitable for both the uniform linear array (ULA) and the cross-pole antenna configurations, in order to obtain a codebook that is efficient, i.e., has a low feedback overhead and is easy to store and search over, and effective over both uniform linear array (ULA) and the cross-pole configurations. Some have proposed codebook designs for specific antenna configurations [7]. The fundamental properties of the spatial correlation matrices that we use have not been exploited in the prior art. The codebook structure herein is derived using fundamental properties of the spatial correlation matrices under the ULA and cross-pole antenna configurations. Each preceding codeword is derived as the product of two matrices which makes them efficient and achieves lower feedback overhead for a given performance level and better performance for a given feedback overhead.
REFERENCES
[0007] [1] Ericsson, ST-Ericsson, “Design and Evaluation of 4 TX Precoder Codebooks for CSI Feedback,” 3 GPP TSG FLAN WG 1 R 1-104847 62, Madrid, August 2010.
[0008] [2] A. Forenza, D. Love and R. Heath, “Simplified Spatial Correlation Models for Clustered MIMO Channels With Different Array Configurations,” IEEE Trans. Veh. Tech ., July 2007.
[0009] [3] S. Loyka, “Channel capacity of MIMO architecture using the exponential correlation model,” IEEE Commun. Letters, 2001.
[0010] [4] D. Love, R. Heath and T. Strohmer, “Grassmannian beamforming for multiple-input multiple-output wireless systems,” IEEE Trans. Inf. Theory , October 2003.
[0011] [5] M, A. Khojastepour et al., “STATIC AND DIFFERENTIAL PRECODING CODEBOOK FOR MIMO SYSTEMS,” U.S. Patent Application Publication US 2008/0232501 A1.
[0012] [6] M. A. Khojastepour et al., “MULTI-RESOLUTION PRECODING CODEBOOK,” U.S. Patent Application Publication US 2009/0274225 A1.
[0013] [7]3GPP TS 36.213 V10.8.0 (2012-12), 3rd Generation Partnership Project; Technical Specification Group Radio Access Network; Evolved Universal Terrestrial Radio Access (E-UTRA); Physical layer procedures (Release 10), http://www.3gpp.org/.
[0014] [8] NEC Group , “DL MU-MIMO Enhancement Schemes,” 3 GPP TSG RAN WG 1 R 1-130364.
[0015] [9] NEC Group, “MU-MIMO: CQI Computation and PMI Selection,” 3 GPP TSG RAN WG 1 R 1-103832.
[0016] [10] NEC Group, “DL MU-MIMO enhancement via Residual Error Norm feedback,” 3 GPP TSG RAN WG 1 R 1-113874.
BRIEF SUMMARY OF THE INVENTION
[0017] An objective of the present invention is to provide a codebook of efficient precoding codewords which require lower feedback overhead for a given performance level and achieve better performance for a given feedback overhead.
[0018] An aspect of the present invention includes a method implemented in a base station used in a wireless communications system. The method comprises having 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission, each codebook including a plurality of precoding matrices, precoding data with one of the plurality of precoding matrices, and transmitting, to a user equipment, the precoded data, wherein each of the 1-layer and 2 layer codebooks comprises a first codebook and a second codebook, and wherein each preceding matrix in the first codebook comprises a first index and a second index.
[0019] Another aspect of the present invention includes a method implemented in a user equipment used in a wireless communications system. The method comprises receiving, from a base station, precoded data, wherein each of 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission includes a plurality of precoding matrices, wherein each of the 1-layer and 2-layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index.
[0020] Still another aspect of the present invention includes a base station used in a wireless communications system. The base station comprises a transmitter to transmit, to a user equipment, precoded data, wherein each of 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission includes a plurality of precoding matrices, wherein each of the 1 -layer and 2 layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index.
[0021] Still another aspect of the present invention includes a user equipment used in a wireless communications system. The user equipment comprises a receiver to receive, from a base station, precoded data, wherein each of 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission includes a plurality of precoding matrices, wherein each of the 1-layer and 2 layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index.
[0022] Still another aspect of the present invention includes a wireless communications system comprising a base station having 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission, each codebook including a plurality of precoding matrices and precoding data with one of the plurality of precoding matrices, a user equipment receiving, from the base station, the precoded data, wherein each of the 1-layer and 2 layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index.
[0023] Still another aspect of the present invention includes a method implemented in a wireless communications system, The method comprises precoding data; and transmitting, from a base station to a user equipment, the precoded data, wherein each of 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna (4TX) transmission includes a plurality of precoding matrices, wherein each of the 1-layer and 2 layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index.
[0024] The first index may be for a plurality of subbands and the second index may be for each subband.
[0025] The second codebook may comprise a legacy codebook or a householder codebook.
[0026] Each of the 3-layer and 4-layer codebooks may comprise a legacy codebook or a householder codebook.
[0027] Each preceding matrix W in the first codebook may satisfy W=W (1) W (2) , where first matrix W (2) is chosen from inner codebook (1) , and second matrix W (2) is chosen from an outer codebook.
[0028] Still another aspect of the present invention includes a method implemented in a base station used in a wireless communications system. The method comprises having a codebook including a plurality of preceding matrices, preceding data with one of the plurality of preceding matrices, and transmitting, to a user equipment, the precoded data, wherein each preceding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (2) is chosen from a second codebook.
[0029] Still another aspect of the present invention includes a method implemented in a user equipment used in a wireless communications system. The method comprises receiving, from a base station, data precoded with one of a plurality of preceding matrices, wherein a codebook includes the plurality of preceding matrices, and wherein each precoding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (1) is chosen from a second codebook.
[0030] Still another aspect of the present invention includes a base station used in a wireless communications system. The base station comprises a transmitter to transmit, to a user equipment, data precoded with one of a plurality of preceding matrices, wherein a codebook including the plurality of preceding matrices, and wherein each precoding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (2) is chosen from a second codebook.
[0031] Still another aspect of the present invention includes a user equipment used in a wireless communications system. The user equipment comprises a receiver to receive, from a base station, data precoded with one of a plurality of precoding matrices, wherein a codebook includes the plurality of precoding matrices, and wherein each precoding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (2) is chosen from a second codebook.
[0032] Still another aspect of the present invention includes a wireless communications system comprising a base station having a codebook including a plurality of precoding matrices and preceding data with one of the plurality of precoding matrices, and a user equipment receiving, from the base station, the precoded data, wherein each precoding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (2) is chosen from a second codebook.
[0033] Still another aspect of the present invention includes a method implemented in a wireless communications system. The method comprises precoding data with one of the plurality of precoding matrices, and transmitting, from a base station to a user equipment, the precoded data, wherein a codebook includes the plurality of precoding matrices, and wherein each precoding matrix W satisfies W=W (1) W (2) , where first matrix W (1) is chosen from first codebook (1) , and second matrix W (2) is chosen from a second codebook.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 depicts a downlink multiuser MIMO system with N T transmit-antennas at the transmitter and N R receive antennas at the receiver.
[0035] FIG. 2 depicts a 3 bit codebook of gain vectors referring to g=[α 1 , α 2 , α 3 , α 4 ] as the gain vector.
[0036] FIG. 3 depicts co-phasing terms in 8-PSK alphabet for Rank-1.
[0037] FIG. 4A depicts co-phasing terms in 16-PSK alphabet for Rank-2.
[0038] FIG. 4B depicts other co-phasing terms in 16-PSK alphabet for Rank-2.
[0039] FIG. 5 depicts co-phasing terms in 8-PSK alphabet for Rank-2.
[0040] FIG. 6A depicts co-phasing terms in 8-PSK alphabet for Rank-1.
[0041] FIG. 6B depicts other co-phasing terms in 8-PSK alphabet for Rank-1.
[0042] FIG. 7 depicts co-phasing terms in 24-PSK alphabet for Rank-2.
[0043] FIG. 8A depicts co-phasing terms in 24-PSK alphabet for Rank-2.
[0044] FIG. 8B depicts co-phasing terms in 12-PSK alphabet for Rank-2.
[0045] FIG. 9 depicts co-phasing terms in 16-PSK alphabet for Rank-2.
[0046] FIG. 10 depicts co-phasing terms in 16-PSK alphabet for Rank-2.
DETAILED DESCRIPTION
[0047] FIG. 1 shows a downlink multiuser MIMO system with N T transmit-antennas at the BS and N R receive antennas at the UE. Multiple-antenna communication system 100 with a multi-level precoding codebook is schematically shown in FIG. 1 . Transmitter 110 transmits from transmitting antennas 111 . 1 - 111 . t over fading channel 130 to r receiving antennas 121 . 1 - 121 . r coupled to receiver 120 . Channel estimator 125 provides an estimate of channel 130 to receiver 120 . The channel estimate is also quantized and provided to transmitter 110 via quantized rate control feedback channel 135 .
[0048] In systems that employ beamforming such as the MIMO systems, the beamforming matrix (referred to also as a precoding matrix, a precoder, a codeword, or a precoding codeword) generated in response to perceived channel conditions is computed and quantized at the receiver first, and then is provided to the source transmitter (e.g., via feedback). A conventional approach to reduce the overhead associated with this feedback is to provide matrix codebook(s) at each of the transmitter and the receiver, each of the codebook(s) comprising a plurality, or set, of potential beamforming matrices that may be used depending on the channel conditions perceived at the receiver. When the receiver has identified the appropriate matrix codebook(s), the receiver will feed back one or more indices (instead of the actual matrix entries) that points to the appropriate codeword in the codebook(s) stored at the transmitter.
I. Example 1
[0049] 1 Uniform Linear Array
[0050] In the following unless otherwise mentioned we may assume the co-polarized antennas to be closely spaced.
[0051] We have the following observations for the uniform linear array (ULA) transmit antenna configuration. Consider a system with N co-polarized transmit antennas and let C denote the transmit spatial correlation matrix. Let us define J to be the matrix which has zeros everywhere except on the cross diagonal elements, i.e., J=[J m,n ] where
[0000]
J
m
,
n
=
{
1
,
n
=
N
-
m
+
1
0
,
otherwise
(
1
)
[0052] A vector is said to be Hermitian if
[0000] x =Jx, (2)
[0000] where x denotes the conjugate of x. We offer the following set of properties. The first observation is regarding the spatial correlation matrix of the ULA transmit antenna configuration and holds true with wide generality (cf. [2]).
[0053] Observation 1 The matrix C is a Hermitian Toeplitz matrix, i.e., C satisfies
[0000] C =JCJ, (3)
[0000] where C denotes the conjugate of C.
[0054] Lemma 1 The eigenspace of any Hermitian Toeplitz matrix can be completely described by Hermitian vectors. In other words, given a Hermitian Toeplitz matrix A and with x being its eigenvector such that Ax=λx, then ∃ y such that y =Jy with
[0000] Ay=λy (4)
[0055] Lemma 2 Suppose λ is an eigenvalue of a Hermitian Toeplitz matrix A with algebraic multiplicity one. Then if x is an eigenvector such that Ax=λx, we must have
[0000] Jx =exp( j δ) x . (5)
[0000] for some δ ∈ [0,2π) and where j=√{square root over (− 1 )}.
[0056] A simplified model for the correlation matrix is the exponential correlation model [3], which is discussed further in the Appendix, and is given by
[0000] C=[C m,n ] m,n=1 N ,C m,n =τ |m−n| exp( j θ( m−n )), m,n∈{ 1, . . . , N}, (6)
[0000] where ρ ∈ [0,1]& θ ∈ [0,2π).
[0057] 2.1 4 TX ULA
[0058] In this section, we consider the case of N=4 co-polarized transmit antennas. First, note that without loss of generality, we can impose the following structure on each eigenvector x of the spatial correlation matrix C,
[0000] x=[α 1 ,α 2 exp( jθ 2 ),α 3 exp( jθ 3 ),α 4 exp( jθ 4 )] T , (7)
[0000] where α 1 , α 2 , α 3 , α 4 ∈ IR + . Recalling that the matrix C must be a Hermitian Toeplitz matrix and invoking Lemmas 1 and 2, we can deduce that we must have
[0000] α 1 =α 4 , α 2 =α 3
[0000] θ 2 +θ 3 =θ 4 . (8)
[0059] Then, consider any two eigen-vectors of the form in (8) given by
[0000] x=[α,b exp( jθ 2 ), b exp( jθ 3 ), αexp( j (θ 2 +θ 3 ))] T (9)
[0000] y=[c,d exp( jγ 2 ), d exp( jγ 3 ), c exp( j (γ 2 +γ 3 ))] T , (10)
[0000] where α, b,c,d ∈ IR + . Then, a sufficient condition to enforce orthogonality among these two eigenvectors is to ensure that
[0000] θ 2 +θ 3 =±π+γ 2 +γ 3
[0000] θ 2 −θ 3 =±π+γ 2 −γ 3
[0000] which can be simplified to
[0000] θ 2 =tπ+γ 2 ,t∈ {0,±1}
[0000] θ 3 =±(1− |t| )π+γ 3 . (11)
[0060] We remark that (11) is not necessary but works for all possible values of the scalars α,b,c,d ∈ IR + .
[0061] 2 Polarized Setup
[0062] Suppose the transmitter has 2N cross-polarized antennas comprising of a pair of N co-polarized antennas each. Then the correlation matrix of each one of these two co-polarized sets is denoted by C which is Hermitian and Toeplitz. The overall 2N×2N correlation matrix {tilde over (C)} can be written as
[0000]
C
~
=
[
1
α
α
_
1
]
⊗
C
(
12
)
[0000] where denotes the kronecker product and α ∈ : |α| ∈ [0,1]. It can be shown that any eigenvector {tilde over (y)} of {tilde over (C)} has the form
[0000] {tilde over (y)}=y x
[0000] where y ∈ 2×1 is an eigenvector of the matrix
[0000]
[
1
α
α
_
1
]
[0000] and x is an eigenvector of C. Furthermore, the two eigenvectors of the matrix
[0000]
[
1
α
α
_
1
]
are
exp
(
j
β
)
2
[
1
α
α
]
T
and
exp
(
j
β
)
2
[
1
-
α
α
]
T
,
[0000] where (.) T denotes the transpose operation and the phase term exp(jβ) can be ignored without loss of optimality. The two eigen-values are 1|α|. Note that the matrix
[0000]
[
1
α
α
_
1
]
[0000] also models the correlation matrix of the 2 transmit ULA.
[0063] 3 Codebook Construction
[0064] We now proceed to specify a codebook using the observations developed in Sections 1 and 2. In particular, we specify a subset of the codebook which is suitable for closely spaced 4TX ULA and cross-pole antenna configurations as well as other configurations. We first consider the rank-1 codebook which comprises of a set of 4×1 vectors. Without loss of generality, we first consider a generic structure x=[α 1 , α 2 exp(jθ 2 ), α 3 exp(jθ 3 ), α 4 exp(jθ 4 )] T , α 1 , α 2 , α 3 , α 4 ∈ IR + We will define three component codebooks out of which the rank-1 codebook is formed. The first, one, referred to as the gain vector codebook and denoted by , is one from which the gains {α j } j=1 4 are drawn. The other two are codebooks to quantize the phase terms {exp(jθ j )} j=2 4 and are denoted by and Let us consider the gain vector codebook . To cover the closely spaced 4TX ULA we need enough vectors in the rank-1 codebook that have a structure of the form in (8). We refer to g=[α 1 , α 2 , α 3 , α 4 ] as the gain vector and provide a 3 bit codebook of gain vectors in FIG. 2 , where
[0000]
Γ
1
=
ψ
2
(
1
+
ψ
)
,
Γ
2
=
1
2
(
1
+
ψ
)
[0000] for some configurable scalar ψ>0. Note that the gain vectors corresponding to indices 0,1,2 follow the constraint in (8) and hence are suitable to the 4 TX closely spaced ULA case. The gain vector corresponding to index 0 is suitable to the 4 TX cross-pole case, whereas the ones corresponding to indices 3, 4 address a scenario referred to here as the power imbalance case (cf. Appendix 8). The index 7 indicates re-use of an existing default codebook while indices 5,6 are included to simply offer more choices.
[0065] Next, to quantize the phases we introduce two phase codebooks, and . We enforce the restriction in (8) that θ 4 =θ 2 +θ 3 so that the vector x can be expanded as
[0000]
x
=
[
a
1
exp
(
j
θ
2
)
a
2
exp
(
j
θ
3
)
a
3
exp
(
j
θ
3
)
exp
(
j
θ
2
)
a
4
]
(
14
)
[0066] We use the codebook to select θ 2 and the codebook to select θ 3 . A simple way to construct these two codebooks is via uniform quantization of [0,2π) using the given number of bits for each codebook. Notice that with this choice of selecting the phases, if we choose the gain vector corresponding to the index 0 in gain vector codebook of FIG. 2 , we see that the resulting vector conforms to the structure of the generic eigen-vector of the correlation matrix of the 4TX cross-pole. Similarly, upon choosing the gain vector corresponding to any one of the indices 0, 1, 2 in the gain vector codebook, we see that the resulting vector conforms to the structure of the generic eigen-vector of the correlation matrix of the 4TX ULA.
[0067] We now consider the rank-2 codebook which comprises of a set of semi-unitary 4×2 matrices. From the observations made in Section 1 we can define a subset of such matrices having the structure
[0000]
X
=
[
a
1
a
1
′
exp
(
j
θ
2
)
a
2
exp
(
j
θ
2
)
a
2
′
exp
(
j
θ
3
)
a
2
exp
(
j
(
θ
3
+
π
)
)
a
2
′
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
exp
(
j
(
θ
3
+
θ
2
+
π
)
)
a
1
′
]
=
[
a
1
a
1
′
exp
(
j
θ
2
)
a
2
exp
(
j
θ
2
)
a
2
′
exp
(
j
θ
3
)
a
2
-
exp
(
j
θ
3
)
a
2
′
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
-
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
′
]
[0068] Note that this structure is complaint with the 4TX ULA (cf. Section 1) and also with the structure of the first two dominant eigenvectors of the 4TX ULA configuration with the exponential correlation model (as discussed in Section 6) and when α 1 =α 1′ =α 2 =α 2′ , it is also suitable for the 4TX cross-pole configuration (as discussed in Section 2). In addition, we can include matrices having the structure
[0000]
X
=
[
a
1
a
1
′
exp
(
j
θ
2
)
a
2
exp
(
j
(
θ
2
+
π
)
)
a
2
′
exp
(
j
θ
3
)
a
2
exp
(
j
θ
3
)
a
2
′
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
exp
(
j
(
θ
3
+
θ
2
+
π
)
)
a
1
′
]
=
[
a
1
a
1
′
exp
(
j
θ
2
)
a
2
-
exp
(
j
θ
2
)
a
2
′
exp
(
j
θ
3
)
a
2
exp
(
j
θ
3
)
a
2
′
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
-
exp
(
j
(
θ
3
+
θ
2
)
)
a
1
′
]
[0000] which are complaint with the 4TX ULA.
[0069] 4 Codebook Construction in Product Form
[0070] We next discuss two codebook constructions, based on the principles outlined in Sections 1 and 2, in which each codeword is derived as a matrix product. In each case, we use the codebook designed in [1] as the base and expand it while conforming to the principles outlined in Sections 1 and 2.
[0071] Let w n =[1 exp(j2 n/16)] T for n=0, . . . , 15. We refer to this codebook as the first embodiment and define its inner (wideband) codebook as
[0000]
(
1
)
=
{
[
A
(
q
)
⊙
W
(
1
)
(
k
)
0
0
B
(
q
)
⊙
W
(
1
)
(
k
)
]
:
W
(
1
)
(
k
)
=
[
W
2
k
mod
16
,
W
2
k
+
1
mod
16
,
W
2
k
+
2
mod
16
,
W
2
k
+
3
mod
16
]
,
k
=
0
,
…
,
7
;
q
=
1
,
…
,
Q
}
(
15
)
[0000] where ⊙ denotes Hadamard product and
[0000]
A
(
q
)
=
[
1
0
0
exp
(
j
2
π
d
q
)
]
[
a
q
a
q
b
q
b
q
b
q
b
q
a
q
a
q
]
B
(
q
)
=
exp
(
j
2
π
γ
q
)
[
1
0
0
exp
(
j
2
π
d
q
)
]
[
b
q
b
q
a
q
a
q
a
q
a
q
b
q
b
q
]
,
q
=
1
,
…
,
Q
,
(
16
)
[0000] where γ q , α q , b q , d q ∈ [0,1] & a q 2 +b q 2 =1/2∀q. The rank-1 outer codebook is defined as
[0000]
1
(
2
)
=
{
[
y
y
]
,
[
y
-
y
]
,
[
y
j
y
]
,
[
y
-
j
y
]
}
(
17
)
y
=
{
e
1
,
e
2
,
e
3
,
e
4
}
,
(
18
)
[0000] where e i denotes the 4×1 column selection vector. The outer rank-2 codebook is defined as
[0000]
2
(
2
)
=
{
[
y
1
y
2
y
1
-
y
2
]
,
[
y
1
y
2
jy
1
-
jy
2
]
}
,
(
19
)
(
y
1
,
y
2
)
=
{
(
e
1
,
e
2
)
,
(
e
2
,
e
2
)
,
(
e
3
,
e
3
)
,
(
e
4
,
e
4
)
,
(
e
1
,
e
3
)
,
(
e
1
,
e
4
)
,
(
e
2
,
e
3
)
,
(
e
2
,
e
4
)
}
(
20
)
[0072] We note that one choice of the scalars a q , b q is
[0000]
a
q
=
ψ
q
2
(
1
+
ψ
q
)
,
b
q
=
1
2
(
1
+
ψ
q
)
[0000] for some configurable scalars ψ q >0.
[0073] In each feedback interval to select the rank-2 codewords, one for each subband, we first select one common matrix from the inner (wideband) codebook (1) , say {tilde over (W)} (1) . Then, on each subband n, a matrix from the outer (subband) rank-2 codebook 2 (2) , say {tilde over (W)} 2,n (2) , is selected and the final precoder selection for that subband is obtained as {tilde over (W)} (1) {tilde over (W)} 2,n (2) . For convenience, we let 2 f ({tilde over (W)} (1) ) denote the (final) codebook corresponding to rank-2, which contains all possible such final precoder selections given the choice of inner precoder {tilde over (W)} (1) . Similar procedure and notation is adopted for the other ranks and other choices of the inner precoder {tilde over (W)} (1) .
[0074] We note that one choice of γ q , d q is to set d q =γ q /2=θ q for some configurable scalars {θ q ∈ [0,1]}. Under this choice, we next describe a way of determining a set of triplets {θ q , α q , b q } q=1 Q . From the discussion in Appendix 7 using the exponential correlation model, we relate
[0000]
exp
(
j
2
π
θ
)
=
a
_
a
.
[0000] so that a good choice is to assume that the (un-quantized) θ is uniformly distributed in [0,1). Thus, a good strategy to obtain a finite set Θ={θ} is via uniform quantization of [0/1) using the given number of bits. An example can be Θ={0, 1/4, 1/2, 3/4} for 2 bits.
[0075] Considering the selection of α q , b q , one possibility is to relate them to the variables p, q discussed in Appendix 7. Accordingly, a finite set of values for the correlation magnitude parameter ρ=|α| can be selected from which a set of vectors S={[p, q]} can be obtained. For example, we can assume the set {1/2, 2/3, 3/4, 1} for correlation magnitude parameter ρ=|α|. Then, invoking the formulas in Appendix 7 we obtain that the set of vectors S is equal to {[0.4352, 0.5573], [0.4571, 0.5395], [0.4680, 0.5301], [0.5000, 0.5000]}. Then the set of triplets {θ q , α q , b q } can be defined as the Cartesian product Θ {circle around (X)} S, where we have used {circle around (X)} to denote the Cartesian product. For instance, using the particular instances of S and Θ given above we see that the Cartesian product Θ {circle around (X)} S is of size 16 or equivalently 4 bits, Another example could be to obtain a Cartesian product of size 15 by using Θ={0,1/5,2/5,3/5,4/5} and the set S={[0.4571, 0.5395], [0.4680, 0.5301], [0.5000, 0.5000]} using only three values {2/3, 3/4, 1} for correlation magnitude parameter. Another example is one where the Cartesian product is of size 16 and is obtained by using Θ={0, 1/8, 2/8, . . . , 7/8} and the set S={[0.4680, 0.5301], [0.5000, 0.5000]} using only two values {3/4, 1} for the correlation magnitude parameter.
[0076] We now consider another alternate codebook, henceforth referred to as the second embodiment, whose codewords are also derived in the product form. We now define the inner wideband codebook to be
[0000]
(
1
)
=
{
[
A
(
q
)
w
n
0
0
B
(
q
)
w
n
]
:
n
=
0
,
…
,
15
;
q
=
1
,
…
,
Q
}
,
where
A
(
q
)
=
[
a
q
0
0
b
q
]
B
(
q
)
=
[
b
q
0
0
a
q
]
,
q
=
1
,
…
,
Q
,
(
21
A
)
or
A
(
q
)
=
[
1
0
0
exp
(
j
2
π
d
q
)
]
[
a
q
0
0
b
q
]
B
(
q
)
=
exp
(
j
2
π
γ
q
)
[
1
0
0
exp
(
j
2
π
d
q
)
]
[
b
q
0
0
a
q
]
,
q
=
1
,
…
,
Q
.
(
21
B
)
[0077] The rank-1 outer codebook is defined as
[0000]
1
(
2
)
=
{
[
1
1
]
,
[
1
-
1
]
,
[
1
j
]
,
[
1
-
j
]
}
(
22
)
[0078] and the rank-2 outer codebook is defined as
[0000]
2
(
2
)
=
{
[
1
1
1
-
1
]
,
[
1
1
j
-
j
]
}
.
(
23
)
[0079] In either ease the rank-3 and rank-4 codebooks can be fixed to the legacy (Householder) rank-3 and rank-4 codebooks. In addition, the entire legacy codebook can be included as a subset.
[0080] Note that the first embodiment has a desirable property which is missing in the second one. This property is that for each rank k, for each choice of inner precoder {tilde over (W)} (1) , assuming that each precoder matrix in the codebook k f ({tilde over (W)} (1) corresponding to that rank can be selected equi-probably, the expected value of each row norm square (i.e., sum of the magnitude squares of elements in that row) of the selected precoder matrix is identical. This property is beneficial for operating (i.e., controlling the backoff of; the power amplifiers and utilizing the available transmit power.
[0081] 4.1 Embedding in a Larger Codebook
[0082] Note that the channel matrix realization depends on both the spatial correlation matrix as well as the short-term (a.k.a. fast) fading. In some scenarios there can be significant variations in the observed channel matrix on account of fast-fading, such as the case where the co-polarized antennas are widely spaced. Thus, a good codebook needs to accommodate such significant variations in the observed channel matrix on account of fast-fading as well, which makes it necessary to include codewords that are designed using other criteria such as minimum chordal distance [4]. A useful way to address such cases would be to embed the codebook obtained using the aforementioned principles as a subset in a larger codebook.
[0083] 5 Conclusions
[0084] We detailed a codebook structure and presented two embodiments which conform to the matrix product form. This structure is motivated by fundamental properties of the spatial correlation matrix and makes codebook optimization feasible.
[0085] 6 Appendix: 4 TX ULA with the Exponential Correlation Model
[0086] Next, we consider the case where we further specialize the correlation matrix to be
[0000]
C
=
[
1
a
a
2
a
3
b
1
a
a
2
b
2
b
1
a
b
3
b
2
b
1
]
,
(
24
)
[0000] where a ∈ such that |α|≦1 and b= α . Note that the matrix C is Hermitian Toeplitz and is also completely characterized by one complex scalar. Thus its eigenvectors can be expected to have more structure in addition to that possessed by an eigenvector of a general Hermitian Toeplitz matrix. We will also exploit this additional structure in the following. The matrix J for this case can be written as,
[0000]
J
=
[
0
0
0
1
0
0
1
0
0
1
0
0
1
0
0
0
]
[0087] We first consider the case |α|1. In this case, the eigen-vectors of any matrix of the form in (24) have the following properties. Consider any matrix C of the form in (24) and let
[0000] C=EΛE † (25)
[0000] denote its eigen-decomposition where (.) † denotes the conjugate transpose operation and Λ=diag{λ 1 , λ 2 , λ 3 , λ 4 } with λ 1 ≧λ 2 ≧λ 3 ≧′ 4 denoting the four real-valued eigenvalues. Then,
[0000] E=D p ( H⊙S ) (26)
[0000] where ⊙ denotes the Hadamard product and D p is a diagonal matrix of the form
[0000] D p =diag{1, exp( jγ ),exp(2 jγ ),exp(3 jγ )} (27)
[0000] for some γ ∈ [0,2π). The matrix S has the following structure
[0000]
S
=
[
p
r
q
s
q
s
p
r
q
s
p
r
p
r
q
s
]
(
28
)
[0000] for some real positive scalars p, q, r, s such that q=√{square root over (1/2−p 2 )} and r=√{square root over (1/2−s 2 )}. The matrix H is a 4×4 real-valued Hadamard matrix, i.e., columns of H are mutually orthogonal and all its elements belong to the set {±1}. Then, since each column of E must satisfy the condition in (5), each column of H=[h 1 , . . . h 4 ] must satisfy the following conditions.
[0000] h 1i h 4i =h 2i h 3i , ∀i=1,2,3,4. (29)
[0000] Also, since E must be a unitary matrix, H must, also satisfy the following additional conditions.
[0000] h 11 h 12 =−h 41 h 42 ,h 21 h 22 =−h 31 h 32 ; h 11 h 14 =−h 41 h 44 , h 21 h 24 =−h 31 h 34 h 22 h 23 =−h 32 h 33 , h 12 h 13 =−h 42 h 43 ;
[0088] An important example H is the following:
[0000]
H
=
[
1
1
-
1
1
1
1
1
-
1
1
-
1
1
1
1
-
1
-
1
-
1
]
[0000] Using H given above and recalling that ρ=|α|, we can derive formulas that yield the scalars p, q, r, s as follows. First we have that
[0000]
exp
(
j
2
π
θ
)
=
a
_
a
.
[0000] Substituting this in (26) yields after some manipulations that
[0000]
q
=
ρ
(
1
+
ρ
)
2
[
ρ
2
(
1
+
ρ
)
2
+
(
ϑ
-
ρ
)
2
]
,
(
30
)
[0000] where
[0000]
ϑ
=
ρ
+
ρ
3
+
ρ
2
(
1
+
ρ
2
)
2
+
4
ρ
2
(
1
+
2
ρ
)
2
[0000] p=√{square root over (1/2−q 2 )}. Note that in the special case when ρ=0 the correlation matrix C reduces to the identity matrix so that we can chose p, q, r, s arbitrarily (subject to the respective norm constraints). Further, for ρ<1, we can determine that
[0000]
r
=
ζ
+
ρ
2
(
2
ζ
+
ρ
+
ρ
3
)
[0000] with s=√{square root over (1/2−r 2 )} where
[0000]
ζ
=
-
ρ
-
ρ
3
+
(
ρ
-
ρ
3
)
2
+
4
ρ
2
(
1
-
ρ
)
2
2
.
[0089] On the other hand when ρ=1 we note that the matrix C is a rank-1 matrix that is
[0090] given by
[0000]
C
[
1
b
b
2
b
3
]
[
1
a
a
2
a
3
]
.
(
31
)
[0000] It can be then shown that the eigen-vector of C corresponding to its one non-zero eigenvalue is of the form
[0000] [1,exp(jγ),exp(2jy), exp(3jy)] T /2 (32)
[0000] where
[0000]
exp
(
j
γ
)
=
a
_
a
[0000] so that p=q=1/2. The choice of r, s can be arbitrary (subject to the norm constraint) since the associated eigen-value is zero.
[0091] 7 Appendix: Accommodating Power Imbalance
[0092] A more general model for the spatial correlation of the cross-pole antenna configuration is the following. Consider a transmitter with 2N cross-polarized antennas comprising of a pair of N co-polarized antennas each. Then the correlation matrix of each one of these two co-polarized sets is denoted by C which is Hermitian and Toeplitz. The overall 2N×2N correlation matrix {tilde over (C)} can be written as
[0000]
C
~
=
[
1
α
α
_
β
]
⊗
C
(
33
)
[0000] where β>0 and and α ∈ : |α|∈ [0,1] such that ≢>|α| 2 . It can be shown that any eigenvector {tilde over (y)} of {tilde over (C)} has the form
[0000] {tilde over (y)}=y x (34)
[0000] where y ∈ 2×1 is an eigenvector of the matrix
[0000]
[
1
α
α
_
β
]
[0000] and x is an eigenvector of C. Notice that the matrix
[0000]
[
1
α
α
_
β
]
[0000] can represent any 2×2 positive semi-definite matrix up-to a scaling factor. Consequently, the 2×2 unitary matrix formed by its two eigenvectors can be any 2×2 unitary matrix. Then, to design codebooks suitable for such scenarios we consider the first embodiment presented in Section 4 and expand its outer codebook (2) as follows.
[0093] The rank-1 outer codebook is now defined as
[0000]
1
(
2
)
=
{
[
δ
q
′
y
1
-
δ
q
′
2
y
]
,
[
δ
q
′
y
-
1
-
δ
q
′
2
y
]
,
[
δ
q
′
y
j
1
-
δ
q
′
2
y
]
,
[
δ
q
′
y
-
j
1
-
δ
q
′
2
y
]
}
(
35
)
y
=
{
e
1
,
e
2
,
e
3
,
e
4
}
,
(
36
)
[0000] where δ ′ , ∈ [0,1]: q′=1, . . . , Q′ are pre-determined scalars for some Q′≧1. The outer rank-2 codebook is now defined as
[0000]
2
(
2
)
=
{
[
δ
q
′
y
1
1
-
δ
q
′
2
y
2
1
-
δ
q
′
2
y
1
-
δ
q
′
y
2
]
,
[
δ
q
′
y
1
1
-
δ
q
′
2
y
2
j
1
-
δ
q
′
2
y
1
-
j
δ
q
′
y
2
]
}
,
(
37
)
(
y
1
,
y
2
)
=
{
(
e
1
,
e
1
)
,
(
e
2
,
e
2
)
,
(
e
3
,
e
3
)
,
(
e
4
,
e
4
)
,
(
e
1
,
e
3
)
,
(
e
1
,
e
4
)
,
(
e
2
,
e
3
)
,
(
e
2
,
e
4
)
}
(
38
)
[0094] Similarly, for the second embodiment the rank-1 outer codebook is defined as
[0000]
1
(
2
)
=
{
[
δ
q
′
1
-
δ
q
′
2
]
,
[
δ
q
′
-
1
-
δ
q
′
2
]
,
[
δ
q
′
j
1
-
δ
q
′
2
]
,
[
δ
q
′
-
j
1
-
δ
q
′
2
]
}
(
39
)
[0000] and the rank-2 outer codebook is defined as
[0000]
2
(
2
)
=
{
[
δ
q
′
1
-
δ
q
′
2
1
-
δ
q
′
2
-
δ
q
′
]
,
[
δ
q
′
1
-
δ
q
′
2
j
1
-
δ
q
′
2
-
j
δ
q
′
]
}
,
(
40
)
[0095] We remark here that the codebooks defined above are also suitable for the case where the transmitter has 4 geographically separated co-polarized antennas comprising of a pair of 2 co-polarized antennas at each location. Then the correlation matrix of each one of these two co-polarized sets is given by C which is Hermitian and Toeplitz. The overall 4×4 correlation matrix {tilde over (C)} can be written as
[0000]
C
~
=
[
d
1
0
0
d
2
]
⊗
C
(
41
)
[0000] where denotes the kronecker product and d 1 , d 2 ∈ [0, 1] are the normalized gain terms reflecting the different average propagation path gains from the two locations.
II. Example 2
[0096] Codebook Construction in Product Form
[0097] We now discuss a structured codebook construction, based on the principles we derived above, in which each codeword is derived as a matrix product.
[0098] Let w n =[1exp(j2πn/N)] T for n=0, . . . , N−1. We define the inner (wideband) codebook as follows. First we define
[0000] W (1) ( k )=[ w kK , . . . , w kK+j−1 ],k' 0 , . . . ,L− 1, (2-1)
[0000] for some positive integers K, J, L where K is referred to as the step, J is referred to as the width and L is referred to as the extent. These parameters are chosen to typically satisfy (L−1)K≦N≦LK and K≦J. Now we detail the inner (wideband) codebook as
[0000]
(
2
-
2
)
(
1
)
=
{
D
(
q
2
)
W
(
1
)
(
k
,
q
1
)
=
D
(
q
2
)
[
A
(
q
1
)
⊙
W
(
1
)
(
k
)
0
0
B
(
q
1
)
⊙
W
(
1
)
(
k
)
]
:
k
=
0
,
…
,
L
-
1
;
q
1
=
1
,
…
,
Q
1
;
q
2
=
1
,
…
,
Q
2
}
,
[0000] where ⊙ denotes Hadamard product and D(q2)=diag{1,1, exp(j2πγ q2 ), exp(j2πγ q2 )}, i.e., D(q2) is a diagonal matrix whose main diagonal contains the vector [1,1, exp(j2πγ q2 ), exp(j2)], where j=√{square root over (−1)} and
[0000]
A
(
q
1
)
=
[
1
0
0
exp
(
j
2
π
d
q
1
)
]
[
a
q
1
1
a
q
1
2
…
a
q
1
j
b
q
1
1
b
q
1
2
…
b
q
1
j
]
B
(
q
1
)
=
[
1
0
0
exp
(
j
2
π
d
q
1
)
]
[
b
q
1
1
b
q
1
2
…
b
q
1
j
a
q
1
1
a
q
1
2
…
a
q
1
j
]
,
q
1
=
1
,
…
,
Q
1
,
(
2
-
3
)
[0000] where α q1 m , b q1 m , d q1 , γ q2 ∈[0,1]& (a q1 m ) 2 +(b q1 m ) 2 =1/2∀m, q1.
[0099] Note that for a given q2, q1 and when a q1 m =b q1 m =1/2∀m, we can introduce an overlap among {W (1) (k, q1)} for consecutive choices of k. In particular, by ensuring that (k+1)K≦kK+J−1 we see that some columns in W (1) (k, q1) are identical to those in W (1) (k+1, q1). This is a useful feature to have in the inner wideband codebook since correlation in time or frequency changes gradually. However this need not hold when for some m α q1 m ≠1/2. To introduce such overlap among different inner codewords in such a case, we can first ensure (k+1)K≦kK+J−1 and then select {α q1 m , α q1 m ,} appropriately for some q1, q1′ ∈ {1, . . . , Q1} (recall that choosing α q1 m (α q1 m ,) also fixes b q1 m (b q1 m ,)) to ensure that columns of W (1) (k, q1) and W (1) (k+1, q1′) have an overlap.
[0100] The rank-1 outer codebook is defined as
[0000]
1
(
2
)
=
{
W
(
2
,
1
)
(
r
,
s
)
=
[
e
r
e
s
]
,
[
e
r
-
e
s
]
,
[
e
r
je
s
]
,
[
e
r
-
je
s
]
}
r
,
s
=
{
1
,
…
,
J
}
,
(
2
-
4
)
[0000] where we mean that W (2,1) (r, s) for a given r, s can be any one of four indicated vectors, where e i denotes the J×1 column selection vector selecting the i th column in the J×J identity matrix. To limit the size only certain combinations of (r, s) referred to here as feasible combinations might be allowed, where we note that r=s can be a feasible combination. For any subband, a rank-1 final codeword is formed by selecting an inner codeword D(q2)W (1) (k, q1) from (1) along with an outer codeword W (2,1) (r, s) from 1 (2) to obtain the final codeword for that subband as D(q2)W (1) (k, q1)W (2,1) (r, s). Note that the choice of the inner codeword may be common across all subbands.
[0101] Next, to expand the selection possibilities in each subband, we can move D(q2) to the outer codebook. In other words, we can define the inner wideband codebook as (1) ={W (1) (k, q1)} with an outer subband rank-1 codebook as
[0000]
~
1
(
2
)
=
{
W
(
2
,
1
)
(
r
,
s
,
q
2
)
=
[
e
r
exp
(
j
2
πγ
q
2
)
e
s
]
,
[
e
r
-
exp
(
j
2
πγ
q
2
)
e
s
]
,
[
e
r
j
exp
(
j
2
πγ
q
2
)
e
s
]
,
[
e
r
-
j
exp
(
j
2
πγ
q
2
)
e
s
]
}
r
,
s
=
{
1
,
…
,
J
}
,
q
2
∈
{
1
…
,
Q
2
}
(
2
-
5
)
[0000] for some feasible combinations (r, s, q2). In all the aforementioned cases, the outer codebook can he made dependent on the choice of the inner codeword. In other words the feasible combinations (r, s) in (2-4) or (r, s, q2) in (2-5) can themselves be functions, respectively, of the choice of the inner codeword. Put differently, two different inner codewords can have different feasible combinations to select codewords from the outer codebook. In each case, the set of feasible combinations for each choice of the inner codeword is pre-determined and known to all users and the base-stations.
[0102] Let us now consider the rank-2 case. The first, possibility is to keep the inner codebook defined in (2-2) together with the following outer subband rank-2 codebook that is invariant to the choice of the inner codeword,
[0000]
C
2
(
2
)
=
{
W
(
2
,
2
)
(
r
,
s
)
=
[
e
r
e
s
e
r
-
e
s
]
,
[
e
r
e
s
je
r
-
je
s
]
}
,
r
,
s
=
{
1
,
…
,
J
}
(
2
-
6
)
[0000] To limit the size only certain combinations of (r, s) might be allowed. Note that since the set of allowed combinations are common across all choices of the inner codeword, we must have that for each allowed (r, s) the columns of D(q2)W (1) (k, q1)W (2,2) (r, s) are mutually orthogonal for each choice of inner codeword. We note that r=s is one such choice which ensures orthogonality for each choice of inner codeword D(q2)W (1) (k, q1).
[0103] To expand the set possible final rank-2 codewords without excessive overhead, we can make the allowed combinations dependent on the choice of the inner codeword. In particular we can define an outer subband codebook that is dependent on the choice of the inner codeword D(q2)W (1) (k, q1) (identified by indices q1, q2, k) that contains codewords denoted by W (2,2) (r, s, k, q1, q2) of the form
[0000]
{
[
e
r
e
s
e
r
-
e
s
]
,
[
e
r
e
s
j
e
r
-
je
s
]
,
[
e
r
e
s
e
s
-
exp
(
j
θ
(
r
,
s
,
k
,
q
1
,
q
2
)
)
e
r
]
,
[
e
r
e
s
je
s
-
j
exp
(
j
θ
(
r
,
s
,
k
,
q
1
,
q
2
)
)
e
r
]
}
,
(
2
-
7
)
[0000] where r, s ∈ {1, . . . , J}. The phase θ(r, s, k, q1, q2) together with the allowed combinations (r, s) must ensure that the two columns of the resulting final codeword D(q2)W (1) (k, q1)W (2,2) (r, s, k, q1, q2) are orthogonal. Notice that due to the structure of our inner codebook, it is sufficient for this phase term to be a function of only r, s & q1 so that we can write the phase term as θ(r, s, q1). To allow more choices in the outer codebook, as done in the rank-1 case we can move D(q2) to the outer codebook. In other words, we can define the inner wideband codebook as (1) ={W (1) (k, q1)} with an outer subband rank-2 codebook that has codewords of the form
[0000]
{
[
e
r
e
s
exp
(
j
2
π
γ
q
2
)
e
r
-
exp
(
j
2
π
γ
q
2
)
e
s
]
,
[
e
r
e
s
exp
(
j
2
π
γ
q
2
)
e
s
-
exp
(
j
2
π
γ
q
2
)
exp
(
j
θ
(
r
,
s
,
k
,
q
1
,
q
2
)
)
e
r
]
[
e
r
e
s
j
exp
(
j
2
π
γ
q
2
)
e
r
-
j
exp
(
j
2
π
γ
q
2
)
e
s
]
,
[
e
r
e
s
j
exp
(
j
2
π
γ
q
2
)
e
s
-
j
exp
(
j
2
π
γ
q
2
)
exp
(
j
θ
(
r
,
s
,
k
,
q
1
,
q
2
)
)
e
r
]
}
[0000] where r, s ∈ {1, . . . ,J}, q2 ∈ {1 . . . , Q2} for some feasible combinations (r, s, q2).
[0104] To further expand the set of rank-2 codewords we can ensure orthogonality among columns of the resulting final codeword in other ways. Suppose that the inner codebook is defined as in (2-2) (we skip the case where the inner codebook is defined as (1) ={W (1) (k, q1)} and D(q2) is moved to the outer codebook since the steps given can be applied after straightforward changes). We then suppose that the rank-2 outer codebook is dependent on the choice of the inner codeword and includes codewords of the form in (2-7). In addition, for a choice of the inner codeword D(q2)W (1) (k, q1), we can also have codewords of the form
[0000] [e(r,s)(D(q2) (1) (k, q1)) + (D(q2)W (1) (k, q1)e(r,s))], (2-8)
[0000] where e(r, s)=[e r T , e s T ] T and (D(q2)W (1) (k, q1)) + is the pseudo-inverse of D(q2)W (1) (k, q1) satisfying D(q2)W (1) (k, q1)(D(q2)W (1) (k, q1)) + =I. (.) is an pre-defined operator such that for any unit-norm vector x, P(x) is a unit norm vector in the sub-space I-xx 554 . Preferably such an operator may have the property that if the vector x possesses the constant magnitude property, which is that all its elements have the same magnitude, then even (x) has that property. An example of such an operator is HH (x, t), which for t ∈ {2, 3, 4} and any unit norm vector x whose first element is real and strictly less than one, yields the t th column of the 4×4 unitary matrix obtained via the Householder transformation
[0000]
I
-
2
(
x
-
e
1
)
(
x
-
e
1
)
†
x
-
e
1
2
.
[0000] Note here that for our constructions, x=D(q2)W (1) (k, q1)e(r, s) satisfies the two conditions needed to define the Householder transformation. Also, if the vector x possesses the constant magnitude property then even HH (x, t) has that property.
[0105] Another example of such an operator is to set (x)=D(x)Px, where P is a permutation matrix and D(x) is a diagonal matrix whose diagonal entries depend on x such that x † D(x)Px=0. Note that when x has the constant magnitude property then it is possible to construct a diagonal matrix D(x) whose non-zero entries have unit, magnitude and ensure that x † D(x)Px=0 as well as constant magnitude property for the vector D(x)Px.
[0106] Note that we can define a different set of inner codewords (i.e., inner codebook) for rank-1 and rank-2 and other ranks albeit where all of them have the generic structure in (2-2). Thus, rank specific inner codebooks can be defined. Recall that the per-subband outer codebook can already be a function of the inner codeword. We also note that in the codebooks described above, de-duplication may be done if needed. In particular, for any rank r, if there exists any two inner codewords that result in an equivalent set of final per-subband rank-r codewords, then only one among those two inner codewords must be retained in the inner codebook for that rank-r. Here we note that two final codewords are equivalent if one is identical to the other up-to column permutation and/or right multiplication by a matrix which is diagonal and all its non-zero entries have unit magnitude.
[0107] Notice that having a larger rank-2 inner codebook compared to rank-1 codebook can be beneficial for MU-MIMO. A larger inner codebook allows for better quantization resolution without increasing the feedback too much since only one inner codeword needs to be reported for all subbands. A better resolution for the higher rank-2 not only benefits SU-MIMO but also MU-MIMO since typically the user under MU-MIMO transmission will be served using a rank lower than what it reported. In this case a better resolution will ensure that the column subsets extracted from the user's reported precoders are also effective, i.e., have enough accuracy and thus allow for MU-MIMO gains.
III. Example 3
[0108] In Release 11 (Rel-11) LTE cellular network it is possible for the network to semi-statically configure multiple CSI processes for the same user. Each Rel-12 and beyond user is required to support both the legacy 4 TX codebook, as well as the enhanced 4 TX codebook. As implied above, these two codebooks can be viewed as two subsets (components) of a larger codebook. Moreover a separate codebook subset restriction can be applied for each CSI process. A useful corollary from these two observations is that the network may be allowed to configure the codebook separately for each CSI process (for a user of interest) in a semi-static manner, i.e., for each CSI process of a given user, the network can configure the component (i.e. legacy or enhanced) codebook that the user can use. In addition, further codebook subset restriction can also be applied on a per-CSI process basis given the choice of component codebooks for those processes. In order to reduce the signaling overhead, we propose to apply only one latter codebook subset restriction per CSI-process. Consequently, even if the CSI process (or equivalently the mode defined for that CSI process) requires the user to report per-subband precoding matrices (i.e., PMIs), all such reported matrices must respect the configured (common) subset restriction for that process.
[0109] Codebook Construction in Product Form
[0110] We first present a generic codebook construction in which each codeword is derived as a matrix product. For convenience, we ignore the normalization factor of ½. Letting w n =[1exp(j2πn/N)] T for n=0, . . . , N−1 denote the 2×1 beam vector, we define the inner (wideband) codebook as
[0000]
C
(
1
)
=
{
[
A
(
q
)
W
(
1
)
(
k
)
0
0
A
(
q
)
W
(
1
)
(
k
)
]
:
W
(
1
)
(
k
)
=
[
w
a
k
mod
N
,
w
(
a
k
+
1
)
mod
N
,
…
,
w
(
a
k
+
j
-
1
)
mod
N
]
,
k
=
0
,
…
,
L
-
1
;
q
=
1
,
…
,
Q
}
,
(
3
-
1
)
[0000] where {αk} are real valued scalars and
[0000]
A
(
q
)
=
[
1
0
0
exp
(
j
2
π
d
q
)
]
,
q
=
1
,
…
,
Q
,
[0000] where d q ∈ [0,1]∀ q. Note that the (angular) separation between the phase terms in any two adjacent beam vectors within a particular inner codeword A(q)W (1) (k) is 2π/N so that N and J together determine the angular span of the phase terms in each inner codeword. Intuitively, a larger angular span would allow us to make the codebook suitable even for less correlated fading scenarios. On the other hand, the scalars {d q } help control
[0111] the separation between the phase terms in any two beam vectors that belong with two inner codewords A(q)W (1) (k) and A(q′)W (1) (k) for some q,q′ ∈ {1, . . . , Q}. Intuitively, a small such separation would be beneficial for exploiting correlation in time and frequency.
[0112] The rank-1 outer (subband) codebook is then defined as
[0000]
C
1
(
2
)
=
{
[
e
i
exp
(
j
θ
s
,
i
)
e
i
]
}
,
s
=
1
,
…
,
S
,
i
=
1
,
…
,
J
[0000] where e i denotes the i th J×1 column selection vector (i.e., the i th column of the J×J identity matrix) and exp(jθ s,i ) is a co-phasing term. The (maximum) size of the Rank-1 codebook is thus JS. A smaller size can be obtained by selecting only a subset of all possible such vectors. The co-phasing terms can be obtained by optimizing a suitable metric such as the average Chordal distance after restricting them to lie in an M-PSK alphabet where the positive integer M≧1 is a design parameter. The optimization can be constrained to ensure that a minimum angular separation is maintained between the co-phasing terms. For rank-2, the outer (subband) codebook is defined as
[0000]
C
2
(
2
)
=
{
[
e
m
e
p
exp
(
j
θ
s
,
m
,
p
)
e
m
-
exp
(
j
θ
s
,
m
,
p
)
e
p
]
}
.
[0000] Note that for different pairs (m, p) and (m′, p′) we can have different number of co-phasing terms. The co-phasing terms can be obtained by optimizing a suitable metric such as the average Chordal distance after restricting them to lie in an M′-PSK alphabet where the positive integer M′≧1 is a design parameter and can be different from M. The optimization can be constrained to ensure that a minimum angular separation is maintained between the co-phasing terms.
[0113] We next propose two specific embodiments. Both embodiments have a 4 bit wideband codebook. For the first embodiment we construct (1) using N=L=8, J=2, α k =k, k=0, . . . , 7 and d q ∈ {0, 1/16}, so that each inner codeword is a 4×4 matrix. The corresponding sub-band codebook is of size 3-bits for both ranks 1 and 2. The co-phasing terms in the rank-1 codebook lie in the 8-PSK. alphabet and are given in FIG. 3 . Note that the notation adopted in the table in FIG. 3 is that when the entry corresponding to some (s, i) is t then θ s,i =2πt/M where M=8 for 8-PSK. For the rank-2 codebook we choose (m, p) ∈ {(1,1), (2,2), (1,2)} along with the co-phasing terms given in FIG. 4A or FIG. 4B . Alternatively, the co-phasing terms can be chosen as in FIG. 5 . Note that we use more co-phasing options in FIG. 5 for the beam combination (1,2).
[0114] For the second embodiment we construct (1) using N=16, L=8, J=4, α k =2k, k=0, . . . , 7 and d q ∈ {0, 1/32}, so that each inner codeword is a 4×8 matrix. The corresponding sub-band codebook is of size 4-bits for both ranks 1 and 2. The co-phasing terms in the rank-1 codebook lie in the 8-PSK alphabet and are given in FIG. 6A or FIG. 6B . For the rank-2 codebook we choose (m, p) ∈ {(1,1), (2,2), (3,3), (4,4), (1,2), (1,4), (2,3), (2,4)} along with the co-phasing terms given in FIG. 7 . Alternatively we can also choose the co-phasing terms given in FIG. 8A or FIG. 8B . Alternatively we can also choose the co-phasing terms given in FIG. 9 or FIG. 10 .
[0115] The rank-3 and rank-4 codebooks can be fixed to the legacy (Householder) rank-3 and rank-4 codebooks. We note that all codeword matrices in the aforementioned codebook satisfy the constant magnitude property.
IV. Example 4
[0116] Another related issue arises when a user is configured to use the legacy 4 TX codebook in one of its CSI processes and where that process (or equivalently the mode defined for that CSI process) requires the user to report per-subband precoding matrices. Here, when the user's preferred rank is 3 or 4, then the size of the legacy codebook (4 bits for both ranks 3 and 4) might be an overkill for per-subband reporting. In other words, the feedback can be reduced without any noticeable impact on performance since such a user is experiencing good average SINR and will typically be scheduled alone on its assigned resources. To achieve feedback reduction the network can define sub-sampled versions of legacy codebooks for ranks 3 and 4 and configure the user to report codewords from these sub-sampled codebooks when its preferred rank is 3 or 4. The sub-sampled rank-3 codebook is obtained by removing one or more codewords from the rank-3 legacy codebook whereas by removing one or more codewords from the rank-4 legacy codebook the sub-sampled rank-4 codebook is obtained. These sub-sampled codebooks are defined by the network and conveyed in advance to all users. Another approach which offers more flexibility is to leverage codebook subset restriction. Here, suppose that the size (per-subband) of the rank-3 codebook is limited to M codewords. Then, the network can determine a subset (in a semi-static and possibly user-specific manner) containing no more than M codewords from the legacy rank-3 codebook and convey this subset to the user. The user then restricts its search (for rank-3 codewords) to this subset on each subband. To report its preferred codeword on each subband, the user adopts lexicographic ordering (labelling), i.e., the codeword in the indicated subset having the smallest index (as in the original rank-3 legacy codebook) is assigned a new index of one, the codeword in the indicated subset having the second smallest index (as in the original rank-3 legacy codebook) is assigned a new index of two. This process continues till all codewords in the subset have been assigned new indices. Clearly the new indices will span from 1 to M′ where M′≦M. Also note that since the subset is common across all subbands, the set of new indices is also common across all subbands and hence must be determined by the user once. The user then reports the new index of its selected precoder on each subband. The same procedure can be applied for rank-4 as well where we note that the value of M can be different for rank 4 and rank 3.
[0117] Finally, to improve MU-MIMO performance, additional feedback can be incorporated for a CSI process (or equivalently the mode defined for that CSI process). As detailed in our previous work [8], the user can also report MU-CQI(s) along with its Single-user (SU) channel state information (CSI) report. This SU-CSI (comprising of wideband or per-subband PMI, and per-subband CQI) is computed using the pilots and resource elements for interference measurement that are configured for that CSI process. Several ways to compute these MU-CQI(s) were detailed in our previous work [9], one of which involved the user using the PMI(s) determined in its SU-CSI report or determined using SU-MIMO rules (referred to below as base-PMI(s)) to compute MU-CQI(s), after assuming (or emulating) a set of co-scheduled interferers (on a subband basis if so configured). Here the set of co-scheduled interfering PMIs (i.e., transmit precoders assigned to the co-scheduled other users) that the user assumes on a subband is a function of abase-PMI it has determined. Each set of co-scheduled interfering PMIs that the user must assume can be configured by the network in a semi-static (and possibly user-specific) manner. The size of the set interfering PMIs (for each choice of base-PMI) can be greater than one. To reduce overhead, the resulting MU-CQI(s) computed on a subband basis can be combined into one or (or at-most two) wideband MU-CQI(s) (as detailed in our work [10] on wideband residual error norm feedback) which are then reported. To further improve performance, multiple such sets of interfering PMIs (for each base-PMI) can be configured. Then the user reports one (or at-most two) wideband MU-CQI(s) for each configured set of interfering PMIs and differential feedback can be leveraged to reduce the feedback overhead. Alternatively, the process described above can be repeated for several choices of base-PMIs and the user can choose one particular base-PMI (using an appropriate selection rule such as the one maximizing an expected MU gain) and report it along with, the associated MU-CQI(s).
[0118] We return to the codebook construction in the following.
[0119] Codebook Construction in Product Form
[0120] We first present a generic codebook construction in which each codeword is derived as a matrix product. Letting w n =[1exp(j2πn/N)] T for n=0, . . . , N−1 denote the 2×1 beam vector, we define the inner (wideband) codebook as
[0000]
C
(
1
)
=
{
[
A
(
q
)
W
(
1
)
(
k
)
0
0
A
(
q
)
W
(
1
)
(
k
)
]
:
W
(
1
)
(
k
)
=
[
w
a
k
mod
N
,
w
(
a
k
+
1
)
mod
N
,
…
,
w
(
a
k
+
J
-
1
)
mod
N
]
,
k
=
0
,
…
,
L
-
1
;
q
=
1
,
…
,
Q
}
,
(
4
-
1
)
[0000] where {α k } are real valued scalars and
[0000]
A
(
q
)
=
[
1
0
0
exp
(
j
2
π
d
q
)
]
,
q
=
1
,
…
,
Q
,
[0000] where d q ∈ [0,1] ∀ q. Note that the (angular) separation between the phase terms in any two adjacent beam vectors within a particular inner codeword A(q)W (1) (k) is 2π/N so that N (which is referred to as granularity) and J (which is equal to the number of beam vectors per inner codeword) together determine the angular span of the phase terms in each inner codeword. Intuitively, a larger angular span (which can be achieved by having a smaller N (i.e., lower granularity or a larger 2π/N) for a given J, or a larger J for a given N) would allow us to make the codebook suitable even for less correlated fading scenarios and would also provide robustness against timing alignment errors. However, the cost of increasing J is a larger size of each outer sub-band codebook whereas choosing a smaller N can degrade performance in closely spaced cross-pole configuration since it hinders localization of beam vectors in a given inner codeword. On the other hand, the scalars {d q } (referred to as staggering factors) help control the separation between the phase terms in any two beam vectors that belong with two inner codewords A(q)W (1) (k) and A(q′)W (1) (k) for some q,q′ ∈ {1, . . . , Q}. Intuitively, a small such separation would be beneficial for exploiting correlation in time and frequency.
[0121] An extension to the inner codebook described above is to use two (or more) sets of granularities, where each granularity can have its own set of staggering factors. This would typically increase the size of the wideband codebook but can better cater to different antenna, configurations. We describe next such a composite inner (wideband) codebook for l different choices of granularities, as
[0000]
C
(
1
)
=
{
[
A
(
q
)
W
(
1
)
(
k
)
0
0
A
(
q
)
W
(
1
)
(
k
)
]
:
W
(
1
)
(
k
)
=
[
w
a
k
mod
N
i
,
w
(
a
k
+
1
)
mod
N
i
,
…
,
w
(
a
k
+
J
-
1
)
mod
N
i
]
,
k
∈
i
&
q
∈
i
,
i
=
1
,
…
,
I
}
,
[0000] where i and Q i are sets of indices associated with the i th granularity N i . Note that J remains fixed across different granularities. In certain scenarios (with very low correlation) it might be advantageous to choose at-least one of the granularities such that two or more of the beamvectors in many of its associated inner codewords are mutually orthogonal.
[0122] The rank-1 outer (subband) codebook is then defined as
[0000]
C
2
(
2
)
=
{
[
e
i
exp
(
j
θ
s
,
i
)
e
i
]
}
,
s
=
1
,
…
,
S
,
i
=
1
,
…
,
J
[0000] where e i denotes the i th J×1 column selection vector (i.e., the i th column of the J×J identity matrix) and exp (jθ s,i ) is a co-phasing term. The (maximum) size of the Rank-1 codebook is thus JS. A smaller size can be obtained by selecting only a subset of all possible such vectors. The co-phasing terms can be obtained by optimizing a suitable metric such as the average Chordal distance after restricting them to lie in an M-PSK alphabet where the positive integer M≧1 is a design parameter. The optimization can be constrained to ensure that a minimum angular separation is maintained between the co-phasing terms. For rank-2, the outer (subband) codebook is defined as
[0000]
C
2
(
2
)
=
{
[
e
m
e
p
exp
(
j
θ
s
,
m
,
p
)
e
m
-
exp
(
j
θ
s
,
m
,
p
)
e
p
]
}
.
[0000] Note that for different pairs (m, p) and (m′, p′) we can have different number of co-phasing terms. The co-phasing terms can be obtained by optimizing a suitable metric such as the average Chordal distance after restricting them to lie in an M′-PSK alphabet where the positive integer M′≧1 is a design parameter and can be different from M. The optimization can be constrained to ensure that a minimum angular separation is maintained between the co-phasing terms.
[0123] Thus, (1) we identified the key structure that each eigenvector of the spatial correlation matrix under the ULA transmit antenna configuration must have and the key structure that each eigenvector of the spatial correlation matrix under the cross pole transmit antenna configuration must have. (2) We then enforced the identified structures on at-least one subset of the precoding codebook to ensure good performance. (3) We also presented embodiments that respect the identified structures and are also efficient.
[0124] The foregoing is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that those skilled in the art may implement various modifications without departing from the scope and spirit of the invention. Those skilled in the art could implement various other feature combinations without departing from the scope and spirit of the invention. | A method implemented in a base station used in a wireless communications system is disclosed. The method comprises having 1-layer, 2-layer, 3-layer, and 4-layer codebooks for 4 transmit antenna ( 4 TX) transmission, each codebook including a plurality of precoding matrices, precoding data with one of the plurality of precoding matrices, and transmitting, to a user equipment, the precoded data, wherein each of the 1-layer and 2-layer codebooks comprises a first codebook and a second codebook, and wherein each precoding matrix in the first codebook comprises a first index and a second index. Other apparatuses, systems, and methods also are disclosed. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a power source apparatus for providing a DC voltage, and particularly, to a technique of balancing currents in such a power source apparatus.
[0003] 2. Description of the Related Art
[0004] FIG. 1 is a view showing a power source apparatus according to a related art. This apparatus has a bridge circuit DB 1 for rectifying an AC voltage from an AC power source AC and a capacitor C 1 for smoothing an output of the bridge circuit DB 1 . Ends of the capacitor C 1 are connected to a series circuit that includes a primary winding P of a transformer T and a switching element Q 1 . The switching element Q 1 is, for example, a MOSFET.
[0005] A secondary winding S of the transformer T is connected to a rectifying-smoothing circuit consisting of an output diode D 5 and a capacitor C 51 . The output diode D 5 consists of a diode D 51 and a diode D 52 that are connected in parallel with each other. The rectifying-smoothing circuit rectifies an AC voltage induced on the secondary winding S of the transformer T, smoothes the rectified voltage, and outputs the smoothed voltage to output terminals +Vout and −Vout.
[0006] Between the output terminals +Vout and −Vout, resistors R 53 and R 54 are connected as voltage dividing resistors for dividing the output voltage Vo. Also between the output terminals +Vout and −Vout, an error detector is connected. The error detector has a light emitting diode of a photocoupler PC 1 , a resistor R 52 , and a shunt regulator Z 51 that are connected in series. The shunt regulator Z 51 has a reference terminal R connected to a connection point of the resistors R 53 and R 54 . Between a connection point of the resistors R 53 and R 54 and a connection point between the resistor R 52 and the shunt regulator Z 51 , a capacitor C 52 is connected.
[0007] The transformer T has an auxiliary winding C that is connected to a rectifying-smoothing circuit composed of a diode D 4 and a capacitor C 2 . The rectifying-smoothing circuit rectifies an AC voltage induced on the auxiliary winding C of the transformer T, smoothes the voltage into a DC voltage, and supplies the DC voltage as a source voltage to a controller CONT.
[0008] The light emitting diode of the photocoupler PC 1 in the error detector sends a feedback signal to a phototransistor of the photocoupler PC 1 . The feedback signal is an error voltage (a difference between the output voltage Vo and a reference voltage) based on which the controller CONT generates a control signal to turn on/off the switching element Q 1 . By controlling a duty factor of the control signal, the controller CONT maintains the output voltage Vo at a predetermined value.
[0009] Operation of the power source apparatus according to the related art of FIG. 1 will be explained. The AC power source AC provides an AC voltage, which is rectified by the bridge circuit DB 1 and smoothed by the capacitor C 1 into a DC voltage. The DC voltage is applied through a starting resistor R 1 to the capacitor C 2 , thereby charging the capacitor C 2 . When the voltage of the charged capacitor C 2 reaches a start voltage of the controller CONT, the controller CONT starts to operate. Namely, the controller CONT supplies a drive voltage from a G-terminal thereof to the gate of the switching element Q 1 , to start a switching (on/off) operation of the switching element Q 1 .
[0010] When the switching element Q 1 is turned on, a current passes through a path extending along the capacitor C 1 , the primary winding P of the transformer T, the switching element Q 1 , and the capacitor C 1 , to accumulate energy in the transformer T. When the switching element Q 1 is turned off, the energy accumulated in the transformer T is rectified and smoothed through the secondary winding S of the transformer T, the output diode D 5 (composed of the diodes D 51 and D 52 ), and the capacitor C 51 into a DC voltage. The DC voltage is provided as the output voltage Vo from the output terminals +Vout and −Vout.
[0011] The output voltage Vo from the output terminals +Vout and −Vout is divided by the resistors R 53 and R 54 and is sent to the reference terminal R of the shunt regulator Z 51 . The shunt regulator Z 51 compares the voltage at the reference terminal R with an internal reference voltage of the shunt regulator Z 51 . If the voltage (proportional to the output voltage Vo) at the reference terminal R is higher than the reference voltage, the shunt regulator Z 51 sets a cathode terminal K thereof to low. This results in passing a current through a path extending along the output terminal +Vout, the light emitting diode of the photocoupler PC 1 , the resistor R 52 , the shunt regulator Z 51 , and the output terminal −Vout, to transmit a feedback signal to the primary side through the photocoupler PC 1 .
[0012] The feedback signal transmitted to the primary side is received by the phototransistor of the photocoupler PC 1 and is sent to a feedback terminal FB of the controller CONT. According to the feedback signal, the controller CONT controls the duty factor of a drive voltage supplied to the gate terminal of the switching element Q 1 . In this way, whenever the switching element Q 1 is turned on/off, energy accumulated in the transformer T is adjusted to maintain the output voltage Vo at a predetermined value.
[0013] If the power source apparatus of FIG. 1 is designed to provide high output power, each element of the apparatus must have a large capacity and the output diode D 5 also must have a large capacity. Any element having large capacity is generally manufactured in small numbers, and therefore, is expensive. For this, it is frequently practiced to connect a plurality of elements having small capacity in parallel with one another and employ the parallel arrangement in place of an element of large capacity because such small-capacity elements are manufactured in large numbers, and therefore, are inexpensive. In the power source apparatus of FIG. 1 , the output diode D 5 is made of the diodes D 51 and D 52 connected in parallel with each other, to achieve high output power.
[0014] The power source apparatus of the related art employs standard silicon (Si) diodes as the output diodes D 51 and D 52 . FIG. 3B shows Vf-If curves of a silicon diode at different temperatures, where “Vf” is a forward voltage of the silicon diode and “If” is a forward current of the silicon diode. The silicon diode has characteristics that the forward voltage Vf increases as the forward current If increases and that a loss increases as the forward voltage Vf increases, to decrease the gradient of the forward current If. In addition, as the temperature increases, the forward current If increases and the forward voltage Vf decreases. When an output diode is made by connecting first and second silicon diodes in parallel with each other, the first silicon diode, for example, may generate more heat than the second silicon diode. In this case, the first silicon diode decreases its forward voltage to pass more current. This results in accelerating the generation of heat in the first silicon diode. To avoid the problem that current and heat concentrate on one silicon diode, the related art selects the diodes D 51 and D 52 from diodes having the same characteristics and installs the diodes on a single radiator so that the diodes are thermally coupled with each other to balance heat and current between the diodes. A dotted line of FIG. 1 around the diodes D 51 and D 52 indicates the thermal coupling achieved by the radiator.
[0015] FIG. 2 is a view showing a power source apparatus according to another related art. This apparatus drives two DC-DC converters in parallel in such a way as to balance output currents of the DC-DC converters. The apparatus includes the first DC-DC converter DD 1 , the second DC-DC converter DD 2 , a diode D 1 , a diode D 2 , a resistor RS 1 , and a resistor RS 2 .
[0016] The first DC-DC converter DD 1 converts a DC voltage supplied to input terminals +IN and −IN into a second DC voltage. Similarly, the second DC-DC converter DD 2 converts the DC voltage supplied to the input terminals +IN and −IN into the second DC voltage. The first and second DC-DC converters DD 1 and DD 2 are connected in parallel with each other with the use of a diode OR configuration.
[0017] Namely, a first output terminal of the first DC-DC converter DD 1 is connected through the reverse-current preventing diode D 1 to the output terminal +Vout and a second output terminal thereof is connected through the current detecting resistor RS 1 to the output terminal −Vout. Similarly, a first output terminal of the second DC-DC converter DD 1 is connected through the reverse-current preventing diode D 2 to the output terminal +Vout and a second output terminal thereof is connected through the current detecting resistor RS 2 to the output terminal −Vout.
[0018] The output terminal −Vout is connected to the first and second DC-DC converters DD 1 and DD 2 . The first and second DC-DC converters DD 1 and DD 2 are connected to each other through respective current balance terminals. The current detecting resistor RS 1 provides a detected voltage, which is amplified by an amplifier. The amplified voltage is passed through an impedance element and is outputted from the current balance terminal of the first DC-DC converter DD 1 . Similarly, the current detecting resistor RS 2 provides a detected voltage, which is amplified by an amplifier. The amplified voltage is passed through an impedance and is outputted from the current balance terminal of the second DC-DC converter DD 2 .
[0019] Each of the first and second DC-DC converters DD 1 and DD 2 is configured like, for example, FIG. 1 and employs feedback control to stop if the output voltage Vo exceeds a predetermined value. Resumption from a complete halt needs a certain time, and therefore, dynamically responding to load is unachievable if the first and second DC-DC converters DD 1 and DD 2 are designed to separately drive load. Therefore, it is a usual practice to connect two DC-DC converters in parallel with each other through diodes, to form a diode OR structure. In the diode OR structure, each of the DC-DC converters can continuously operate with one of the DC-DC converters that provides a lower output voltage is put in a no-load state.
[0020] The diode OR structure usually employs silicon diodes. When passing a current, the silicon diode generates heat to decrease a forward voltage Vf and further increase an output current, thereby causing a current unbalance between the diodes that form the diode OR structure. To avoid the problem, the power source apparatus of the related art shown in FIG. 2 employs a current balancing scheme. Namely, a detected voltage from the current detecting resistor RS 1 (RS 2 ) is amplified by the amplifier, and the amplified voltage is passed through the impedance element and is output from the current balance terminal of a corresponding one of the first and second DC-DC converters DD 1 and DD 2 . If there is a current difference, the ends of each impedance element produce a voltage. In order not to produce such a voltage, each of the first and second DC-DC converters DD 1 and DD 2 adjusts the output voltage Vo. Consequently, a current provided by the first DC-DC converter DD 1 balances with a current provided by the second DC-DC converter DD 2 .
[0021] Another current balancing technique is disclosed in Japanese Unexamined Patent Application Publication No. H06-339263. This disclosure is an output current balancing DC-DC converter capable of balancing output currents and stabilizing operation even if the output voltage of one power source abnormally increases. According to this DC-DC converter, an output voltage corrector is arranged between the anode and cathode of an OR diode. The output voltage corrector includes a first amplifier. An inverting terminal of the first amplifier is connected to a voltage detecting resistor that is connected to the cathode of the OR diode, and a non-inverting terminal of the first amplifier is connected to a voltage detecting resistor that is connected to the anode side of the OR diode. An output terminal of the first amplifier is connected through a correction resistor to a connection point between two output voltage detecting resistors. A connection point between the two output voltage detecting resistors is connected to an input terminal of a second amplifier arranged in a controller. The second amplifier compares an output voltage of the output voltage corrector with a reference voltage and sends a comparison result to a power source adjusting feedback circuit.
SUMMARY OF THE INVENTION
[0022] The related art shown in FIG. 1 thermally couples the two diodes D 51 and D 52 with each other to balance currents, and therefore, has a problem that a current unbalance easily occurs if there is a large thermal resistance or if the diodes have different characteristics.
[0023] The related art shown in FIG. 2 must arrange the current detecting resistors RS 1 and RS 2 on the output side of the DC-DC converters DD 1 and DD 2 , and therefore, has a problem that the resistors cause losses. In addition, each DC-DC converter should have an internal circuit for balancing currents, to increase the number of parts and the cost.
[0024] According to the present invention, a power source apparatus capable of minimizing losses and the number of parts and balancing currents can be provided.
[0025] According to a first aspect of the present invention, provided is a power source apparatus having a series circuit connected between output terminals of a DC power source and including a primary winding of a transformer and a switching element; a controller configured to control an ON/OFF operation of the switching element; and an output diode connected between terminals of a second winding of the transformer and configured to rectify an alternating current that is induced on the secondary winding when the controller turns on/off the switching element. The output diode includes a plurality of diodes that are connected in parallel with one another and are made of wide-gap semiconductor.
[0026] According to a second aspect of the present invention, provided is a power source apparatus having a first power source unit configured to output a direct current; a second power source unit configured to output a direct current; a first diode made of wide-gap semiconductor and having an anode connected to an output terminal of the first power source unit; and a second diode made of the wide-gap semiconductor and having an anode connected to an output terminal of the second power source unit and a cathode connected to a cathode of the first diode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a view showing a power source apparatus according to a related art;
[0028] FIG. 2 is a view showing a power source apparatus according to another related art;
[0029] FIG. 3A is a view showing Vf-If curves of an SiC diode;
[0030] FIG. 3B is a view showing Vf-If curves of an Si diode;
[0031] FIG. 4 is a view showing a power source apparatus according to a first embodiment of the present invention; and
[0032] FIG. 5 is a view showing a power source apparatus according to a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Embodiments of the present invention will be explained in detail with reference to the accompanying drawings.
First Embodiment
[0034] FIG. 4 shows a power source apparatus according to the first embodiment of the present invention. This power source apparatus utilizes a forward voltage drop occurring in a diode made of wide-gap semiconductor, to balance currents passing through output diodes. The wide-gap semiconductor is, for example, III-V-group semiconductor, in particular, nitride semiconductor such as gallium nitride (GaN) and silicon carbide (SiC).
[0035] FIG. 3A is a view showing Vf-If curves of a diode made of SiC which is wide-gap semiconductor and FIG. 3B is a view showing Vf-If curves of a diode made of widely used silicon (Si). The diode made of SiC is hereinafter referred to as “SiC diode” and the diode made of Si as “Si diode.” The difference between the SiC diode and the Si diode will be explained with reference to the Vf-If curves of FIGS. 3A and 3B .
[0036] In FIG. 3B , the standard Si diode shows an increase in the forward voltage Vf in proportion to an increase in the forward current If, and therefore, can balance a current if conditions are ideal and the temperature is unchanged. In practice, however, the forward voltage Vf causes a loss to increase the temperature of the diode. The Si diode has a characteristic that the forward voltage Vf decreases as the temperature thereof increases. Namely, in practice, an increase in the forward current If does not result in an increase in the forward voltage Vf, and therefore, no current balance is achievable.
[0037] In FIG. 3A , the SiC diode shows an increase in the forward voltage Vf in proportion to an increase in the forward current If, and in addition, the forward voltage Vf increases as the temperature of the diode increases. When devices (for example, diodes) or circuits (for example, DC-DC converters) are connected in parallel with each other, the forward voltage Vf of each diode increases as the forward current thereof increases, thereby balancing currents passing through the devices or the circuits.
[0038] The power source apparatus according to the first embodiment of the present invention shown in FIG. 4 differs from the related art shown in FIG. 1 in that Example 1 employs an output diode D 5 a consisting of diodes D 53 and D 54 instead of the output diode D 5 consisting of the diodes D 51 and D 52 of the related art. The difference will be explained in more detail.
[0039] In FIG. 4 , the diodes D 53 and D 54 of the output diode D 5 a are connected in parallel with each other, to cope with high power. The diodes D 53 and D 54 are made of wide-gap semiconductor such as SiC and GaN and are connected to separate radiators, respectively.
[0040] Unlike the diodes D 51 and D 52 of the related art shown in FIG. 1 , the diodes D 53 and D 54 of Example 1 are not required to be thermally coupled with each other. The diodes D 53 and D 54 are provided with the separate radiators as indicated with dotted lines in FIG. 4 .
[0041] The SiC or GaN diode increases the forward voltage Vf thereof as the forward current If thereof increases. The forward voltage Vf of the SiC or GaN diode also increases as the temperature thereof increases. When devices (for example, the diodes D 53 and D 54 ) made of wide-gap semiconductor are connected in parallel with each other, the forward voltage Vf of each device increases as the forward current If thereof increases, thereby balancing currents passing through the parallel devices.
[0042] In FIG. 4 , the diodes D 53 and D 54 are provided with the respective radiators, to balance currents at high sensitivity. It is possible to connect the two diodes to a single radiator like the related art of FIG. 1 . The single-radiator arrangement also provides the effect of the present invention due to the characteristics of the wide-gap-semiconductor diodes. Namely, the wide-gap-semiconductor diodes such as SiC and GaN diodes can easily balance currents passing through the diodes only by simply connecting the diodes in parallel with each other.
[0043] The first embodiment has other advantages that no thermal coupling is required between the two diodes D 53 and D 54 and that these diodes can easily be operated in parallel. Variations in the forward voltages Vf of the diodes D 53 and D 54 are compensated by temperature increase, and therefore, currents passing through these diodes can ideally be balanced. The currents are balanced while the output voltage Vo is being kept at a constant value, and therefore, the output power of the diodes is balanced. Even if the diodes D 53 and D 54 are operated at a bias point where the forward current If is low in FIG. 3A , a resultant temperature increase will make the diodes operate at a stable point where currents passing through the diodes balance.
[0044] According to the first embodiment, the diodes D 53 and D 54 are made of wide-gap semiconductor such as gallium nitride (GaN) and silicon carbide (SiC). The diodes D 53 and D 54 may each have a Schottky barrier diode structure.
[0045] In this way, the power source apparatus according to the present embodiment employs the output diode for rectifying an alternating current induced on a secondary winding of a transformer from a plurality of wide-gap-semiconductor diodes that are connected in parallel with one another. Due to a forward voltage drop occurring in each wide-gap-semiconductor diode, currents passing through the diodes are balanced. The apparatus according to the present embodiment employs no special circuit for balancing currents, and therefore, causes no loss. Namely, the apparatus of the present embodiment can balance currents with a small number of parts, and therefore, is highly efficient, inexpensive, and reliable.
Second Embodiment
[0046] FIG. 5 shows a power source apparatus according to the second embodiment of the present invention. This apparatus utilizes the forward voltage drop characteristics of wide-gap-semiconductor diodes, to balance output currents of two DC-DC converters.
[0047] Compared with the power source apparatus of the related art shown in FIG. 2 , the power source apparatus of the second embodiment shown in FIG. 5 does not have the current detecting resistors RS 1 and RS 2 and the current balance terminals provided for the first and second DC-DC converters DD 1 and DD 2 . Although not shown in FIGS. 2 and 5 , the elements such as amplifiers related to the current balancing operation arranged inside the first and second DC-DC converters DD 1 and DD 2 of the related art are also not installed in the apparatus of FIG. 5 .
[0048] Instead of the reverse-current preventing diodes D 1 and D 2 of the related art of FIG. 2 , the second embodiment of FIG. 5 employs reverse-current preventing diodes D 6 and D 7 made of wide-gap semiconductor such as SiC and GaN. The first DC-DC converter DD 1 of FIG. 5 corresponds to a first power source unit according to the present invention and the second DC-DC converter DD 2 of FIG. 5 corresponds to a second power source unit according to the present invention.
[0049] The power source apparatus according to the second embodiment employs wide-gap-semiconductor diodes as the reverse-current preventing diodes D 6 and D 7 for the parallel DC-DC converters DD 1 and DD 2 . These diodes each increase a forward voltage Vf in proportion to an increase in a load current. Accordingly, the apparatus of the second embodiment can balance output currents of the two DC-DC converters without employing current detecting circuits or current balancing circuits.
[0050] Any variation in the forward voltages Vf of the diodes D 6 and D 7 is compensated by a temperature increase, to realize an ideal current balance. The current balance is achieved with an output voltage Vo being kept at a constant value, and therefore, output power is naturally balanced.
[0051] According to the present embodiment, the diodes D 6 and D 7 are made of wide-gap semiconductor such as gallium nitride (GaN) and silicon carbide (SiC). The diodes D 6 and D 7 may each have a Schottky barrier diode structure.
[0052] In this way, the power source apparatus according to the present embodiment includes the first wide-gap-semiconductor diode D 6 having an anode connected to an output terminal of the first power source unit DD 1 and the second wide-gap-semiconductor diode D 7 having an anode connected to an output terminal of the second power source unit DD 2 and a cathode connected to a cathode of the first diode D 6 . Due to a forward voltage drop occurring in each wide-gap-semiconductor diode, currents passing through the first and second diodes are balanced. The apparatus according to the present embodiment employs no special circuit for balancing currents, and therefore, causes no loss. Namely, the apparatus of the present embodiment can balance currents with a small number of parts, and therefore, is highly efficient, inexpensive, and reliable.
[0053] The present invention is applicable to switching power source apparatuses of high output power and power source systems that drive a plurality of power source units in parallel.
[0054] This application claims benefit of priority under 35USC §119 to Japanese Patent Application No. 2006-291505, filed on Oct. 26, 2006, the entire contents of which are incorporated by reference herein. Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the teachings. The scope of the invention is defined with reference to the following claims. | A power source apparatus has a series circuit connected between output terminals of a DC power source, the series circuit including a primary winding of a transformer and a switching element; a controller configured to control an ON/OFF operation of the switching element; and an output diode connected between terminals of a second winding of the transformer and configured to rectify an alternating current that is induced on the secondary winding when the controller turns on/off the switching element. The output diode includes a plurality of diodes that are connected in parallel with one another and are made of wide-gap semiconductor. | 7 |
BACKGROUND OF THE INVENTION
The present invention resides generally in the field of polymers of vinylpyridines. More particularly, the present invention relates to polymerizations of vinylpyridine monomers to prepare linear vinyl pyridine polymers.
As further background, linear polyvinylpyridines and functionalized derivatives and copolymers thereof are useful in a wide variety of applications. For example, conductive polymers prepared from linear polyvinylpyridine and molecular iodine have been utilized as cathode materials in small solid-state batteries in which long life under low current strain is required, such as batteries used in implantable cardiac pacemakers. See, U.S. Pat. Nos. 3,660,163 (1972) and 3,773,557 (1973). Quaternary salts of polyvinylpyridines (e.g. poly(1-alkylvinylpyridinium halides)) have proven to be good negative electron beam resists for microlithography. See, K. I. Lee et al., Proc. SPIE Int. Soc. Opt. Eng., 333, 15 (1982).
Polyvinylpyridines have been used extensively in the repographic and lithographic fields because of the combination of properties ranging from adhesive to electrical properties. See, U.S. Pat. Nos. 4,041,204 (1977); 3,942,988 (1976); Ger. Offen. 3,040,047 (1981); Japan KOKAI 76 30,741 (1976); U.S. Pat. No. 4,032,339 (1977); Ger. Offen. 2,701,144 (1977); and Japan KOKAI 75 124,648 (1975). Polyvinylpyridines have also found applications in the film and photographic area. For example, solutions of polyvinylpyridine or their quaternary salts form thin films that protect the image surface of instant film prints. See, U.S. Pat. Nos. 2,874,045 (1959); 2,830,900 (1958); and 3,459,580 (1969).
Polyvinylpyridines are compatible with synthetic and natural polymers such as polyolefins (including polypropylene), polyethylene terephthalate, nylon, and cellulose, and thus find applications in plastics, alloys and blends. Fibers incorporating polyvinylpyridines show excellent dyeing intensity and are color fast see, e.g. U.S. Pat. No. 3,361,843 (1968)! and polyvinylpyridiniumphosphate imparts permanent fire retardancy to cellulose textiles see U.S. Pat. No. 2,992,942 (1961)! and thus polyvinylpyridines find uses in the textile industry as well.
Polyvinylpyridines further find utility in the treatment of bleached Kraft paper to increase titanium dioxide retention in pulp slurries, and electroplating applications (in particular quaternary salts), as corrosion inhibitors for metals including iron, aluminium, copper, brass, magnesium and solders, as polymerization inhibitors in Li/TiS 2 current-producing electrochemical cells, as emulsion stabilizers and dispersing agents (in particular acid salt and quaternary salt forms), as flocculating agents (particularly acid salt and quaternary ethylhalide forms), in ion exchange membrane preparation and many other applications. These and other uses for linear polyvinylpyridines are reviewed extensively in product literature available from Reilly Industries, Inc., Indianapolis, Ind. U.S.A., entitled "Linear Polyvinylpyridine: Properties and Applications" (1983 and 1989), to which reference can be made for additional information.
As to their preparation, linear polyvinylpyridines have been prepared by various general polymerization techniques. These have included radiation initiated, Ziegler-Natta initiated, free radical initiated and anionic initiated polymerizations. Radiation initiated polymerizations have usually been used for the preparation of graft copolymers. Ziegler-Natta initiated systems usually do not work well for the vinylpyridine systems.
Free radical (addition) polymerizations of vinylpyridines are common in the literature. Generally, there are three differing types of free radical catalyzed polymerizations, those being solution, emulsion and bulk. They are carried out more commonly using initiators such as benzoyl peroxide, cummene hydroperoxide and azobis (isobutyronitrile). Bulk polymerization of vinylpyridine catalyzed by benzoyl peroxide, hydrogen peroxide and certain other per compounds has been reported (French Pat. 849,126 (1939); CA:35:63586 (1941)), as has suspension polymerization of vinylpyridine catalyzed by water-soluble free radical initiator in the presence of small particles of solid polyolefin (U.S. Pat. Nos. 3,828,016, 3,947,526 and 4,824,910). Generally speaking, however, in known free radical-catalyzed processes it has often proven highly difficult to control the molecular weight of the vinylpyridine polymers using free radical initiators.
Anionic low temperature (-78° C.) homopolymerization of 4-vinylpyridine initiated with certain monofunctional alkalai-metal based carbanionic species have been studied in tetrahydrofuran and other solvent mixtures as reported by S. K. Varshney et al. in Macromolecules (26) 701 (1993). A significant disadvantage of this and other anionic polymerizations (see e.g. G. E. Molan et al., J. Polym. Sci. Part A-1, 4, 2336 (1966)) is the requirement of extreme dry conditions for the polymerizations which are directly related to the M w control of the product polymer. Thus, historically, anionic polymerizations of vinylpyridines have been somewhat difficult to control, making it complicated to obtain linear polyvinylpyridines of desired molecular weights, especially at lower molecular weights.
In addition to conventional polymerization methods, vinylpyridines have been reported to spontaneously polymerize upon salt formation with acids or alkyl halides. J. C. Salamone et al., Polymer Letters, 9, 13 (1971); I. Mielke et al., Macromol. Chem. 153, 307 (1972); J. C. Salamone et al, Macromolecules, 6, 475 (1973); J. C. Salamone et al., Polymer Letters, 15, 487 (1977). Such spontaneous polymerizations are relatively disadvantageous because they give rise to a mixture of the normal linear polyvinylpyridines and ionene type polymers.
In light of this background, there are needs for improved methods for polymerizing vinylpyridine monomers so as to achieve the production of linear polyvinylpyridines of controlled molecular weight. Such improved methods would also desirably be facile to conduct using readily available and inexpensive equipment and starting materials, while providing good reaction rates and product yields. The present invention addresses these needs.
SUMMARY OF THE INVENTION
One object of the invention is to provide a process for preparing linear polyvinylpyridine polymers which provides the ability to control the molecular weight of the polymer product.
Another object of the invention is to provide a process for preparing linear polyvinylpyridine polymers which provides molecular weight control without the need for utilizing extreme reaction conditions or large amounts of expensive catalysts.
Another object of the invention is to provide a process for preparing linear polyvinylpyridine polymers which provides high reaction rates to form the product polymers.
Another object of the invention is to provide processes for preparing linear polyvinylpyridine polymers which yield consistent results over a series of runs with respect to rates of reaction and product characteristics.
These and other objects are achieved by the preferred embodiments of the invention, one of which provides a process which has proven to be highly effective for producing linear polyvinylpyridines having molecular weights in the range of about 8000 to about 30000. The inventive process comprises forming a reaction mass by charging to a reactor an aqueous solvent, one or more vinylpyridine monomer(s), and hydrogen peroxide, and reacting the reaction mass to polymerize the vinylpyridine monomer(s) to form a linear polyvinylpyridine having a molecular weight of about 8000 to about 30000. In such processes the molecular weight of the product linear polyvinylpyridine can be regulated by selection of appropriate ratios of vinylpyridine monomer to hydrogen peroxide and/or by selection of appropriate reactant concentrations in the reaction mass. Generally speaking, with all else being equal, increasing hydrogen peroxide to vinylpyridine monomer ratios, and increasing monomer concentrations in the reaction mass, will yield decreasing molecular weights linear polyvinylpyridines. In the present aspect of the invention these parameters can be controlled to provide a linear polyvinylpyridine having a molecular weight in the desired range.
In one preferred mode of operating this process of the invention, the solvent includes alcohol and water. As indicated, this process allows relatively precise control of the molecular weight of the product polymer, with higher amounts of hydrogen peroxide used in a given reaction system providing lower molecular weight polymers, and lower amounts of the hydrogen peroxide initiator providing higher molecular weight polymers. The alcohol/water or other aqueous solvent preferably maintains both the vinylpyridine monomer(s) and the product polymers in solution. Additionally, although the present invention is not limited by any theory, it is believed that the hydrogen peroxide acts as both initiator and as terminator either with or without the alcohol, leading to the control of product molecular weight. Moreover, because the initiator/terminator, hydrogen peroxide, is relatively inexpensive, control of the reactions to obtain low molecular weight linear polyvinylpyridines is achieved without incurring great expense, as may be the case with other, commonly used initiators. Further, processes of the invention provide unexpectedly high reaction rates, for instance being far superior to those obtained when using alcohol alone as the solvent.
Another preferred embodiment provides a polymerization process for preparing a linear polyvinylpyridine in which measures are taken which improve the consistency in the reactivity of the system. In particular, this embodiment provides a process which includes charging to a reactor an aqueous solvent and one or more vinylpyridine monomer(s) to provide a monomer-solvent mixture, and then feeding an inert gas subsurface in the monomer-solvent mixture; After feeding the inert gas for a period of time, hydrogen peroxide is charged to the reactor to form a reaction mass, and then the reaction mass is reacted to polymerize the vinylpyridine monomer(s) to form a linear polyvinylpyridine.
Another preferred embodiment of the invention provides a method of manufacturing a linear polyvinylpyridine with consistency from batch to batch. The method comprises conducting a series of preparative processes in a reaction vessel, each process including the steps of forming a reaction mass by charging to the reaction vessel an aqueous solvent, one or more vinylpyridine monomer(s), and hydrogen peroxide, and reacting the reaction mass to polymerize the vinylpyridine monomer(s) to form a linear polyvinylpyridine; and, periodically in between preparative processes in the series, treating the interior surface of the reaction vessel with an acid so as to maintain the reactivity of its interior surface.
Another preferred embodiment of the invention provides linear polyvinylpyridines which are producable and characterized by the preferred processes of the invention.
Additional objects, features and advantages of the invention will be apparent from the following description.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain of its embodiments 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, further modifications and applications of the principles of the invention as described herein being contemplated as would normally occur to one skilled in the art to which the invention relates.
As indicated above, the present invention provides a unique process for preparing linear polyvinylpyridines while controlling their molecular weight (M w ). The process involves reacting one or more vinylpyridine monomers in an aqueous solvent, preferably including water and an organic co-solvent, such as an alcohol, which increases the solubility of the monomer in the reaction system. The reaction is conducted in the presence of a catalytic amount of hydrogen peroxide, so as to polymerize the monomer or monomers to form a linear polyvinylpyridine polymer.
Preferred vinylpyridine monomers for use in the invention are 2- and 4-vinylpyridine monomers, although other vinylpyridine monomers, for example 3-vinylpyridine monomers, are suitable. The vinylpyridine monomer used in the invention can be obtained commercially or by techniques known to the art and literature, and can be non-substituted or substituted (i.e. on its pyridine ring) with one, two, three or four groups which do not detrimentally interfere with the polymerization reaction, especially lower alkyl groups such as C 1 to C 6 alkyls, i.e. methyl, ethyl, propyl, butyl, heptyl and hexyl substituents (see, e.g., Decout, J. L. et al., J. Prelim. Sci. Prelim. Chem. Ed., 18, 2391 (1980)). More preferred vinylpyridine monomers are non-substituted 2- and 4-vinylpyridine monomers, for example as can be obtained from Reilly Industries, Inc., of Indianapolis, Ind., U.S.A. Although not necessary for the present invention, it is of course preferred that the vinylpyridine monomer(s) used be of high purity, for example 90% to 95% or more pure.
In general, preferred linear polyvinylpyridines produced in accordance with the invention will comprise repeating units of the formula: ##STR1## wherein n is 0 to 4 and R is a C 1 to C 6 alkyl group (in this definition, of course, each R may also differ from the other).
The amount of hydrogen peroxide initiator to use to obtain the desired product molecular weight will depend upon many factors including for example the particular reactants and solvent systems employed as well as their relative amounts (i.e. the concentration level of the reaction), and given the teachings herein will be readily determinable by the ordinarily skilled artisan. For example, as demonstrated in the Examples below, reactions run with equivalent amounts of hydrogen peroxide at higher concentrations (employing less of a given alcohol/water solvent relative to the vinylpyridine monomer(s)) will generally provide polymers of lower molecular weights, and vice versa.
In preferred processes of the invention, these parameters will be controlled to provide linear polyvinylpyridines having polystyrene equivalent M w 's up to about 100,000, more preferably up to about 50,000, and most preferably up to about 30,000, for example in the range of about 8,000 to about 30,000. In these preferred processes, the molar ratio of hydrogen peroxide to vinylpyridine monomer employed will usually be about 1:1 to about 1:1000. More preferably, this ratio will be about 1:1 to about 1:100, and most preferably about 1:1 to about 1:50. Likewise, preferred processes are conducted at reaction concentration levels (i.e. (vinylpyridine monomer weight)/(vinylpyridine monomer weight+solvent weight)) of about 5% to about 50%. To prepare preferred linear polyvinylpridines with molecular weights in the 8,000-30,000 range, hydrogen peroxide/vinylpyridine monomer molar ratios of about 1:5 to about 1:50 will generally be used while reaction concentration levels of about 10% to 50% are used. For instance, at these reaction concentration levels, hydrogen peroxide/monomer molar ratios of about 1:5 to about 1:20 will provide polymers with molecular weights in the range of about 8,000 to about 15,000.
The aqueous solvent system used can vary widely so long as the system provides an environment in which the polymerization proceeds to yield a linear polyvinylpyridine. Generally water plus at least one organic co-solvent will be used, wherein the organic co-solvent improves the solubility of the vinylpyridine monomer in the overall reaction mixture to facilitate polymerization. It has surprisingly been found that even very low amounts of a water-miscible co-solvent substantially improve the polymerizations as compared to corresponding polymerizations in water alone. For example, co-solvent:water volumetric ratios as low as about 1:99 provide substantially improved processes as compared to the use of water alone as the solvent. Thus, generally, co-solvent:water volumetric ratios of about 1:99 to about 95:5 will typically be employed in the present invention, more preferably about 1:99 to about 60:40.
The polymerization reactions of the invention can be solution polymerizations (i.e. the solvent system maintains the vinylpyridine monomer(s) and product polymers in solution) or heterogeneous (i.e. the vinylpyridine monomer(s) and/or product polymers do not remain in solution). In one preferred aspect of the invention, co-solvent:water ratios will be selected to provide solvent systems which maintain the vinylpyridine monomer(s) and polymer product in solution. This ratio will be readily determined by those practiced in the area. In preferred such solution processes, the co-solvent:water ratio will be in the range of about 25:75 to about 95:5, more preferably about 40:60 to about 60:40.
Suitable co-solvents for use in the invention will be those which provide the necessary extent of salvation of the reactants and products and which do not interfere with the polymerization reaction. Suitable such solvents include, for example, alcohols such as water-miscible mono- or polyhydric aliphatic alcohols, generally having up to about 15 carbon atoms, especially lower alcohols (i.e. C 1 to C 5 alcohols such as methanol, ethanol, propanol, butanol, and pentanol (these including both branched and unbranched forms, e.g. n-, i- or t- forms of these alcohols); ketones, for example those having from 2 to about 10 carbon atoms, e.g. dimethyl ketone, methyl ethyl ketone, and the like; esters, for example having from 2 to about 10 carbon atoms; amides, typically having from 1 to about 10 carbon atoms, such as formamide; sulfoxides, e.g. having from 2 to about 10 carbon atoms, for instance dialkylsulfoxides such as dimethylsulfoxide. Generally, low-boiling solvents, for example boiling at temperatures of about 120° C. or below, are preferred since they are more readily removed from reaction products by vacuum distillation. Also, alcohols are preferred co-solvents, especially lower alcohols such as C 1 to C 4 alcohols, most preferably methanol, ethanol, n-propanol, i-propanol, n-butanol, t-butanol, and sec-butanol.
The polyvinylpyridines produced in accordance with the invention can also be functionalized for example including to acid salt forms, N-oxide forms, quaternary salt forms, and the like. The formed free-base form linear polyvinylpyridine polymers can be converted to these functionalized forms by conventional techniques, as discussed further below.
Processes of the invention will be conducted at temperatures sufficient to achieve the desired polymerization of the vinylpyridine monomer. Generally, the temperature of the polymerizations will vary with many factors including the particular monomer or monomers employed. Typically, however, when using preferred low-boiling organic solvents in the solvent system, the polymerization will be conducted at the reflux temperature of the solvent system employed, for example at temperatures of at least about 30° C., more preferably in the range of about 30° C. to about 100° C.
Generally speaking, processes of the invention can be conducted at subatmospheric, atmospheric or superatmospheric pressures. Atmospheric pressures, as employed in the Examples, are conveniently employed and are preferred over pressurized reactions, at least for reasons of convenience and safety. If conducted at superatmospheric pressure, the processes desirably employ only moderate pressures, for example up to about 200 psi.
The hydrogen peroxide, reactants and solvents can be combined in any suitable manner to achieve the polymerization. The hydrogen peroxide can be added to the solvent/monomer mixture, the monomer may be added to the solvent/hydrogen peroxide mixture, or the hydrogen peroxide and monomer can be concurrently added to the solvent, or all can be charged to a reaction vessel concurrently. It is preferred to charge the hydrogen peroxide last, and then heat the reaction mixture to the desired temperature for the polymerization to occur. In this regard, it has been discovered that feeding an inert gas such as nitrogen subsurface in the monomer/solvent mixture prior to the addition of hydrogen peroxide significantly improves the ensuing polymerization process, helping to maintain consistent reactivity in the system. In addition, in preferred processes, an inert gas such as nitrogen is used to blanket the vapor space above the liquid reaction mixture during the polymerization reaction.
It has also been discovered that process consistency from batch to batch can be improved by periodic treatment of the interior surfaces of the reaction vessel with an inorganic acid, such as sulfuric acid. The periodic acid treatment can be carried out after each batch if desired; however, it has been found that treatment after every several batches, for example after every 3 to 10 batches, suffices to provide good batch to batch consistency. In the applicants' preferred work to date, the reaction duration required to achieve a specified level of conversion has been monitored. When that duration begins to increase significantly, the acid treatment is applied.
The polymerization reaction will be continued for sufficient period of time to achieve substantial conversion of the vinylpyridine monomer(s) to the polymer product. The duration of the polymerization reaction required to achieve the conversion will depend upon several factors including the amount of hydrogen peroxide employed and the amounts and types of solvents and reactants employed. Typically, however, the polymerization reactions will be carried out over periods of up to about 24 hours, more typically about 1/2 to about 10 hours. It has been discovered that prolonged heating during the polymerization process adversely affects the color of the final product, and thus shorter reaction times are preferred.
After the polymerization reaction is completed, the linear polyvinylpyridine polymer can be conventionally isolated. For example, the co-solvents can be removed by vacuum distillation, or the reacted medium can be contacted by a precipitation solvent in which the polyvinylpyridine is insoluble but in which the remainder of the reaction components are soluble. The polymer can then be filtered from the precipitation solvent. The use of suitable recovery and isolation techniques for the formed polymer is well within the purview of one of ordinary skill in the art.
The polymer is preferably recovered in substantially pure form (i.e. substantially free from other components of the reaction medium such as unreacted monomer, co-solvent or catalyst residues). Polymer compositions having narrow molecular weight distributions are also favored. Preferred polymer compositions of the invention will have polydispersities (defined as the weight average molecular weight of the polymer divided by the number average molecular weight of the polymer, M w /M n ) in the range of about 1 to 10 and more preferably in the range of about 1 to 3.
Preferred product polymers, especially those resulting from processes utilizing alcohol/water solvents, have also possessed excellent color characteristics. For instance, in the Examples below, the prepared polymers in about 40 weight % solutions (e.g. in alcohol/water) have exhibited Gardner (Varnish) colors in the range of about 5 to about 15.
The isolated linear polyvinylpyridines can be conventionally used and derivatized. For example, functionalized linear polyvinylpyridine polymers can readily be obtained. In this regard, as used herein the term functionalized includes both partially and substantially fully functionalized polymers. In most cases, linear polyvinylpyridine polymers are desired in which at least about 10%, more preferably at least about 50% of the pendant pyridine groups, are functionalized. Representative functional forms include acid salts forms, such as those prepared from strong mineral acids such as sulfuric acid or from hydrohalides such as hydrochloric acid. Quaternary salts can also be prepared by reacting the linear polyvinylpyridines with halogenated organics such as alkyl halides, usually C 1 to about C 10 alkyl halides. The linear polyvinylpyridines can be converted to their N-oxide forms by conventional procedures, for instance by reaction with hydrogen peroxide in the presence of acetic acid. See, e.g., the above-cited publication entitled "Linear Polyvinylpyridines: Properties and Applications" by Reilly Industries, Inc. The linear polyvinylpyridine can also form complexes with many metals or metal ligands, such as Rh 4 (CO) 12 , Co 4 (CO) 12 , Co 2 (CO) 8 or Ru(II) or Rh(I).
To promote a further understanding of the present invention and its features and advantages, the following specific examples are provided. It is to be understood that these examples are illustrative and not limiting in nature. Unless indicated otherwise, M w 's set forth herein are polystyrene equivalent M w 's.
EXAMPLES 1-4
Preparations of Linear Polyvinylpyridines
General Procedure
Examples 1-4 set forth in Table 1 were conducted using the following procedure. To a 500 mL flask, equipped with a stirrer, thermometer, and reflux condenser, is charged 50 g (0.48 mole) 4-VP, 125 mL methanol, 125 mL water, and H 2 O 2 (quantity depends on M w desired). The solution is heated to reflux and held until conversion to polymer is >90% (typically 2-10 hours). The polymer can be isolated by removing the solvents under vacuum. As these Examples demonstrate, variation of the M w of the final product is readily and effectively achieved by varying the ratio of H 2 O 2 to vinylpyridine monomer. Additionally, excellent polydispersities (M w /M n ) were obtained.
TABLE 1__________________________________________________________________________Example Ex. 1 Ex. 2 Ex. 3 Ex. 4__________________________________________________________________________4-VP (moles) 0.48 0.48 0.48 0.48H.sub.2 O.sub.2 (moles) 0.048 0.143 0.24 0.333H.sub.2 O.sub.2 :4-Vp 1:10 3:10 5:10 7:10Solvent MeOH/H.sub.2 O MeOH/H.sub.2 O MeOH/H.sub.2 O MeOH/H.sub.2 OSolvent Amount (mL) 125/125 125/125 125/125 125/125Temperature reflux (82) reflux (82) reflux (82) reflux (82)Time (hrs) 21 5 20 20Conversion (%) >70 >75 >70Mw Main Peak 14170 8349 4081 2677Mw/Mn Main Peak 2 2.3 1.8 1.75__________________________________________________________________________
EXAMPLES 5-9
Additional Polymerizations at High Concentrations
Using the same general procedure as that set forth for Examples 1-4 above, except using 50 mL of methanol and 50 mL of water (instead of 125 mL each), the Examples set forth in Table 2 were carried out. These Examples demonstrate the capacity to carry out processes of the invention at higher concentration levels (about 35% in these instances) while still effectively achieving variation of end product M w and excellent polydispersities. Additionally, in general, these higher concentration runs provided products of lower M w than lower concentration runs (Examples 1-4) employing the same H 2 O 2 /monomer ratios.
TABLE 2______________________________________Example Ex. 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9______________________________________H.sub.2 O.sub.2 :4-VP mole ratio 1:10 2:10 3:10 4:10 5:100Conversion by NMR 95% 93% 84% 85% 96%Mw 8857 5008 3630 2910 22900M.sub.w /M.sub.n 2 1.8 1.7 1.6 2.5______________________________________
EXAMPLE 10
Use of Ethanol/Water Solvent
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 50 g (0.48 mole) 4-vinylpyridine, 6.37 g (0.096 mole at 51.28%) hydrogen peroxide, 125 mL water and 125 mL ethanol. The reaction was heated to reflux (88° C.) and held for 51/2 hours. NMR indicated greater than 90% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=9500 and Mw/Mn=2.26.
EXAMPLE 11
Use of i-Propanol/Water Solvent
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 50 g (0.48 mole) 4-vinylpyridine, 6.37 g (0.096 mole at 51.28%) hydrogen peroxide, 125 mL water and 125 mL i-propanol. The reaction was heated to reflux (85° C.) and held for 20 hours. NMR indicated greater than 90% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=8000 and Mw/Mn=2.1.
EXAMPLE 12
Use of t-Butanol solvent
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 28 g (0.27 mole) 4-vinylpyridine, 3.57 g (0.0315 mole at 30%) hydrogen peroxide, 70 mL water and 70 mL t-butanol. The reaction was heated to reflux (83° C.) and held for 20 hours. NMR indicated greater than 90% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=9570 and Mw/Mn=2.3.
EXAMPLE 13
Polymerization of 2-Vinylpyridine
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 50 g (0.48 mole) 2-vinylpyridine, 6.37 g (0.096 mole at 51.28%) hydrogen peroxide, 125 mL water and 125 mL methanol. The reaction was heated to reflux (82° C.) and held for 8 hours. NMR indicated approximately 75% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=6800 and Mw/Mn=2.3.
EXAMPLE 14
Copolymerization of 2- and 4-Vinylpyridine
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 50 g (25 g, 4-vinylpyridine and 25 g 2-VP, 0.48 mole) vinylpyridine, 6.37 g (0.096 mole at 51.28%) hydrogen peroxide, 125 mL water and 125 mL methanol. The reaction was heated to reflux (82° C.) and held for 24 hours. NMR indicated approximately 75% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=5000 and Mw/Mn=1.88.
EXAMPLE 15
Polymerization of 4-Vinylpyridine
To a reaction flask equipped with a reflux condenser, thermometer, and stirrer was charged 50 g (0.48 mole) 4-vinylpyridine, 0.64 g (0.0096 mole at 51.28%) hydrogen peroxide, 125 mL water and 125 mL methanol. The reaction was heated to reflux (82° C) and held for 5 hours. NMR indicated approximately 80% conversion to polymer. A sample of the reaction solution was analyzed by GPC and found to have Mw=30200 and Mw/Mn=1.9.
EXAMPLES 16-26
Preparations of Functionalized Linear Polyvinylpyridines
The functionalized linear polyvinylpyridines set forth in Table 3 can be prepared by reacting the free base form polyvinylpyridines of the indicated prior Examples with the indicated reagents.
TABLE 3______________________________________Example Polymer Agent Functional Form______________________________________16 Ex. 1 Acetic Acid/H.sub.2 O.sub.2 N-oxide17 Ex. 13 Acetic Acid/H.sub.2 O.sub.2 N-oxide18 Ex. 14 Acetic Acid/H.sub.2 O.sub.2 N-oxide19 Ex. 1 HCl HCl:Acid Salt20 Ex. 13 HCl HCl:Acid Salt21 Ex. 14 H.sub.2 SO.sub.4 H.sub.2 SO.sub.4 :Acid Salt22 Ex. 1 Methyl Iodide Quaternary Salt23 Ex. 13 Methyl Iodide Quaternary Salt24 Ex. 14 Methyl Iodide Quaternary Salt25 Ex. 1 Ethyl Iodide Quaternary Salt26 Ex. 13 Ethyl Iodide Quaternary Salt______________________________________
EXAMPLE 27
Use of 1% Picoline Solvent
A round bottom flask was treated with 10% aqueous sulfuric acid at room temperature, rinsed with water and allowed to thoroughly drain. 4-vinylpyridine, 150 grams (1.43 mole), 2.08 grams of 4-picoline and 206.4 grams of water were combined in the flask equipped with a reflux condenser, nitrogen sparger tube, stirrer and heating mantle. After the mixture was spared with a low stream of nitrogen at room temperature for about one hour with stirring, the sparger tube was raised to deliver nitrogen above the liquid level, 18.03 grams (0.186 mole) of 35% equeous hydrogen peroxide were added to the stirred mixture and heating begun with continued nitrogen flow. After about 30 minutes, reflux began and was continued for approximately 31/2 hours to give a linear poly-4-vinylpyridine having a M w of 9,427 and a M w /M n of 2.22. The conversion of 4-vinylpyridine to polymer was 94.8%.
EXAMPLE 28
Use of 1% Methanol Solvent
To a round bottom flask treated and equipped as in Example 27 was added 150 grams (1.43 mole) of 4-vinylpyridine, 2.08 grams of methanol and 206.37 grams of water. After sparging with nitrogen for about an hour to sparger tube was raised to deliver nitrogen above the liquid level, and 18.05 grams (0.186 mole) of 35% aqueous hydrogen peroxide were added to the stirred mixture and heating begun with continued nitrogen flow. After about 30 minutes, reflux commenced and was continued for about 31/2 hours, forming a heterogeneous reaction mass in which the polymer did not remain in solution. The product linear poly-4-vinylpyridine had a M w of 8,230 and a M w /M n of 2.12. The conversion of 4-vinylpyridine to polymer was 96.0%.
EXAMPLE 29
Use of Dimethylformamide Solvent
4-Vinylpyridine, 150 grams (1.43 mole), 114 mL of water and 114 mL of N,N-dimethylformamide were combined in a round bottom flask fitted with a stirrer, reflux condenser, a nitrogen sparger tube and heating mantle. The sparger tube was lowered so that its tip was below the liquid level in the flask and the mixture was sparged with a slow stream of nitrogen for about one hour with stirring. The sparger tube was raised above the liquid level and nitrogen flow continued providing a nitrogen blanket over the reaction mixture while 14.7 grams of 35% aqueous hydrogen peroxide (0.15 mole) was added to the reaction mixture and heating was commenced. After approximately 30 minutes reflux began and was continued for about 31/2 hours, forming a heterogeneous reaction mass in which the polymer did not remain in solution. The product linear poly-4-vinylpyridine had a M w of 8903 and a M w /M n of 1.97. The conversion of 4-vinylpyridine to polymer was 97.5%.
EXAMPLE 30
Use of methyl ethyl ketone solvent
4-Vinylpyridine, 150 grams (1.43 mole), 114 mL of water and 114 mL of methyl ethyl ketone were combined in a round bottom flask fitted with a stirrer, reflux condenser, a nitrogen sparger tube and heating mantle. The reaction mixture was stirred at room temperature and sparged with a slow stream of nitrogen below the liquid level for about one hour and 14.7 grams of 35% aqueous hydrogen peroxide (0.15 mole) was added. The sparger tube was raised above the liquid level to deliver nitrogen above the reaction mixture and heating was commenced. After approximately 30 minutes reflux began and was continued for about 63/4 hours to give a linear poly-4-vinylpyridine having a M w of 8560 and a M w /M n of 1.81. The conversion of 4-vinylpyridine to polymer was 96.7%.
EXAMPLE 31
Use of DMSO solvent
4-Vinylpyridine, 150 grams (1.43 mole), 114 mL of water and 114 mL of dimethyl sulfoxide were combined in a round bottom flask fitted with a stirrer, reflux condenser, a nitrogen sparger tube and heating mantle. The reaction mixture was nitrogen sparged subsurface with stirring for about one hour. 14.7 grams of 35% aqueous hydrogen peroxide (0.15 mole) was added to the reaction mixture which was then heated to reflux with continued stirring under a nitrogen blanket. Reflux was continued for 1 hour to give a linear poly-4-vinylpyridine having a M w of 9483 and a M w /M n of 1.88. The conversion of 4-vinylpyridine to polymer was 98.0%.
All publications cited herein are indicative of the level of ordinary skill in the art, and each is hereby incorporated by reference in its entirety as if individually incorporated by reference and fully set forth.
While the invention has been described in detail in the foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | Described are preferred processes for producing linear polyvinylpyridines. The processes involve the use of hydrogen peroxide to initiate polymerization of vinylpyridine monomers in an aqueous solvent. Processes of the invention provide good reaction rates and conversions, and are particularly advantageous in achieving control of the M w 's of the final product polymers. | 2 |
RELATED APPLICATIONS
This patent application is related to, and herein incorporates by reference, my issued U.S. Pat. No. 5,108,389 entitled "Automatic Smoke Evacuator Activator System For A Surgical Laser Apparatus And Method Therefor" and my issued U.S. Pat. No. 5,318,516 entitled "Radio Frequency Sensor For Automatic Smoke Evacuator System For A Surgical Laser And/Or Electrical Apparatus And Method Therefor".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an automatic activation system having a sensor which activates a medical apparatus as a result of sensing or detecting an alarm or emergency associated with another apparatus. More specifically, the present invention relates to an automatic activation system having a fiber optic sensor that will sense when a fiber optic is energized and then in turn activate another medical apparatus including, but not limited to an apparatus such as a smoke evacuation apparatus or suction/irrigation apparatus.
2. Description of the Prior Art
In the past, other sensors have been used to activate medical apparatus. For example, as previously mentioned above, my U.S. Pat. No. 5,108,389 is directed to an automatic smoke evacuator system that is triggered to the "ON" position when the laser cutting beam of a laser surgical apparatus is turned on. The automatic smoke evacuator activator system includes a transmitter means for transmitting a beam of electromagnetic radiation, receiver means for receiving the beam of electromagnetic radiation, switch means located between the transmitter and receiver means for causing the electromagnetic radiation beam to generate an electronic signal, and smoke evacuator means coupled to the receiving means for receiving the electronic signal and activating the smoke evacuator system.
Also, in my U.S. Pat. No. 5,318,516 entitled "Radio Frequency Sensor For Automatic Smoke Evacuator System For A Surgical Laser And/Or Electrical Apparatus And Method Therefor" there is shown a method whereby the radio frequency (RF) energy associated with the generation of RF from an electrosurgery unit (ESU), or a laser surgical apparatus, is detected by an RF sensor. The RF sensor in turn generates a control signal which triggers an automatic control system which ensures that a smoke evacuator system is activated during the same time period that either the laser surgery or ESU is being activated for medical procedures.
The previously described patents are directed to sensors which relate to a very broad range of wavelengths and which are designed to activate a specific medical apparatus, namely a smoke evacuation system to be used in conjunction with an electrosurgery unit (ESU) or surgical laser, in order to remove fumes, smoke, and other debris from the surgical area. The present invention is directed to another type of sensor, namely a fiber optic sensor, which will expand the devices which are capable of being activated by its triggering mechanism, as well as the triggering mechanisms described in the previously described patents, to a large number of applications and apparatus including, but not limited to, a suction/irrigation apparatus. The present invention also functions to broaden the range of units which are measured and monitored to activate any medical apparatus. The second apparatus may be activated not only upon the activation of an ESU or laser surgery unit, but also by a fault condition like an alarm or emergency signal related with the first apparatus.
Although a preferred embodiment of the system and method is described herein with reference to activating a smoke evacuator or suction/irrigation device, the automatic activator system of the present invention is directed to monitoring one device such that it is capable of automatically activating a second device. The monitored device includes any device, that once activated through different means, will trigger the activation of another device thereby automatically activating the second device. The automatic activation system of the present invention also includes a system wherein different conditions detected by one apparatus will trigger a second apparatus due to different sensors for a particular condition, where the first apparatus has no direct electrical connection to the second apparatus.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide an automatic activation system which includes a method for activating an apparatus by the detection of a function of another apparatus with no electrical contact between the two apparatus.
It is a further object of the present invention to provide an automatic activation system which includes a method for activating a medical apparatus upon detecting an emergency situation relating to another medical apparatus.
It is still a further object of the present invention to provide an automatic activation system which includes an optical detector or sensor for a fiber optic which, when energized upon detection of a given condition in relation to a first medical apparatus, will trigger another medical apparatus such as a smoke evacuator or suction/irrigation unit for a surgical procedure.
In brief, the automatic activation system of the present invention includes a first medical apparatus with means for generating an output signal during its activation, sensor means for detecting the output signal and in turn emitting a second output signal to a second medical apparatus, and a second medical apparatus that is activated upon receiving the second output signal. The preferred embodiment of this invention is directed toward an automatic activation system which comprises an optical sensor means which includes a fiber optic contained within a housing wherein optic sensors detect laser beams transmitted through the optic fiber. The automatic activation system of the present invention also includes a time delay means for defining an interval of time and delay control means for deactivating the second medical apparatus after the time interval period, upon deactivation of the first medical apparatus. Further, the first medical apparatus may comprise a surgical laser or ESU apparatus and the second medical apparatus may comprise a smoke evacuation means and/or a suction/irrigation apparatus.
The present invention is also directed toward a method for activating a second apparatus by detection of a function of a first apparatus comprising the steps of (1) activating a first apparatus, (2) sensing the activation of the first apparatus by means of a sensor coupled to the first apparatus, (3) sending a signal from the sensor to the second apparatus, and (4) activating the second apparatus upon receiving the signal from the sensor. Here we define "sensor" as being any type of detector which detects and/or monitors a state or condition of one apparatus and then acts to change a state or condition of another apparatus as a result of the state or condition of the first apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of an automatic activation system in accordance with the present invention showing a surgical laser apparatus incorporating a fiber optic for beam delivery wherein an optical sensor for the fiber optic is coupled to a controller capable of activating a second apparatus.
FIG. 2 is a block diagram of the automatic activation system of the present invention for activating a smoke evacuator or suction/irrigation apparatus in relation to a surgical laser or electrosurgery apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A plan view of the automatic activation system 10 of the present invention having a fiber optic sensor is shown in FIG. 1. FIG. 1 depicts a surgical laser apparatus 12 which produces a laser beam output signal that is transmitted via a fiber optic 14 to the patient 16.
The laser beam enters the fiber optic 14 upon the activation of a switch on the handpiece 18 or a foot switch (not shown). The fiber optic 14 passes through an optical sensor unit 20, entering the optical sensor unit 20 at point (a) and exiting the optical sensor unit 20 at point (b). The fiber optic 14 is completely covered and isolated from external light between points (a) and (b) of the fiber optic 14 by a housing 22 for the optical sensor unit 20.
Upon activation of the surgical laser apparatus 12, an intense, narrow beam of light is emitted through the fiber optic 14. The optical sensor unit 20 is coupled to a controller 26. The optical sensors 24 contained within the optical sensor unit 20 are designed to be sensitive enough to detect particular laser wave lengths and to sense the leekage of energy associated with the laser wave lengths (which is very small), amplify the original energy, and transform it into an ON-OFF signal.
The ON signal is transmitted to the controller 26 via a conductor 28. The controller 26 can constitute a separate unit, or it can be incorporated into the second apparatus, such as a smoke evacuator or suction/irrigation unit, which is automatically activated as a result of the conductor 28. The ON signal will remain ON for as long as the surgical laser apparatus 12 is activated plus an additional time period associated with a time delay which is connected to the OFF switch. In other words, when the OFF signal is received, the second apparatus connected to the controller 26 will remain "on" for a short predetermined time period before deactivation. The timed delay period for deactivation may be adjusted by a time delay adjustment knob 30 on the controller 26. The flow rate may be adjusted with flow adjustment knob 25.
FIG. 2 is a block diagram of the automatic activation system 10 of the present invention for activating a smoke evacuator 32 or suction/irrigation unit 34 in response to detection of a given condition or state associated with an electrosurgery unit 36, a CO 2 laser, or other lasers such as YAG, KTP, etc. Three different medical apparatus are designated as the initial medical apparatus which is monitored to detect an emergency situation or defined condition which then triggers activation of a second medical apparatus via a sensor. These three medical apparatus and their automatic activation methods will be addressed below in turn.
A CO 2 laser 38 is designated as the first medical apparatus which will activate a second medical apparatus via a sensor. The CO 2 laser 38 delivers a laser beam to the patient via a laparoscope 42 or a handpiece (not shown) when the foot switch 44 is activated. The sensor, which is installed on the foot switch 44, delivers the signal that the CO 2 laser has been activated to the control unit 46 which in turn will activate the smoke evacuator 32, the suction/irrigation unit 34, or some other medical apparatus.
As previously stated with reference to FIG. 1, the control unit 46 may be a separate, self-contained unit or it may be incorporated into the second medical apparatus that is to be activated. When the smoke evacuator 32 is activated, suction is applied to the proximal end of tubing 48. A cannula is connected to the distal end of tubing 48 for laparoscopic procedures or an electrosurgery (ESU) handpiece 50 is connected to the distal end of tubing 48 for open electrosurgery procedures. A filter and fluid trap 52 are located near the proximal end of tubing 48 for filtering the smoke and debris, and trapping the fluids, from the filter. The clean gas is then passed through the smoke evacuator unit 32 and then through a second filter 54 before being eliminated. The smoke evacuator unit 32 will be activated for as long as the foot switch 44 is activated plus an additional time period that represents a predetermined delay time for deactivating the smoke evacuator unit 32 upon deactivation of the CO 2 laser 38. This time OFF delay allows for the smoke to be cleared from the tubing 48.
Other lasers such as YAG and KTP 40 are also designated as the first medical apparatus which will activate a second medical apparatus via a sensor. A second foot switch 56 or handpiece 57 activates the YAG or KTP laser 40 and a laser beam is emitted through fiber optic 58. The optical sensor 60 is coupled to the controller 46 and upon detection of a given condition or state associated with the YAG or KTP laser 40, the optical sensor 60 transmits an ON signal to the controller 46 which in turn activates the smoke evacuator 32 or the suction/irrigation unit 34. Upon deactivation of the YAG or KTP laser 40, there is a delay in deactivation of the smoke evacuator 32 or the suction/irrigation unit 36 as previously described with reference to FIG. 1.
Finally, with reference to FIG. 2, an electrosurgery unit 36 is also designated as the first medical apparatus which will activate a second medical apparatus via a sensor. Upon activation of the electrosurgery unit 36 by a foot switch or hand switch, an output signal is sent to the ESU handpiece 50 via output path 64. Radio frequency (RF) from output path 64 is detected by RF sensor 62. RF sensor 62 then sends an ON signal to the control unit 46 which in turn will activate a second medical apparatus such as the smoke evacuator 32 and/or the suction/irrigation unit 34. During this procedure, the patient 66 is in contact with a patient ground plate 68 which couples to patient ground return path 70 which couples to the electrosurgery unit 36.
When the second medical apparatus to be activated is the suction/irrigation unit 34, the sensors 44, 60, 62 associated with the CO 2 laser 38, YAG or KTP laser 40, and electrosurgery unit 36, respectively, will send a signal to the control unit 46 upon activation of the first medical apparatus (CO 2 laser 38, YAG or KTP laser 40, or electrosurgery unit 36) but the control unit 46 will only be energized and not activated. When the first medical apparatus, namely the CO 2 laser 38, the YAG or KTP laser 40, or electrosurgery unit 36 is deactivated, then the suction/irrigation unit 34 will turn ON for a predetermined period of time. In some situations, such as with electrosurgery, or YAG or KTP laser surgery, the suction/irrigation unit 34 could work simultaneously with the medical apparatus.
Upon activation of the suction/irrigation unit 34, a pump 72 is activated and irrigation fluid is drawn from irrigation fluid container 74, through irrigation tubing 76, to the suction/irrigation handpiece 78. In contrast, when suction is applied with the suction/irrigation handpiece 78, fluid is drawn from the patient 66, through the suction/irrigation handpiece 78 and suction tubing 80, to the fluid canister 82 and then discarded. Once again, time delays for activation and deactivation may be built within the automatic activation system at various points throughout the system.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that changes in form and detail may be made therein without departing from the spirit and the scope of the invention. For example, numerous other medical apparatus which are capable of optical detection may be coupled with an optical sensor which is capable of emitting a signal to activate a second medical apparatus. | An automatic activation system including a method for activating a second apparatus upon detecting the activation of a first apparatus, or an emergency situation or state relating to a first apparatus, is disclosed. The preferred embodiment of the system includes an optical detector or sensor for a fiber optic which, when energized upon detection of a given condition in relation to a first medical apparatus, will trigger a second medical apparatus such as a smoke evacuator or a suction/irrigation unit for a surgical procedure. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to laundry machines and in particular to laundry washing machines having a spin basket and an independently rotating agitator within the spin basket.
SUMMARY OF THE PRIOR ART
[0002] In 1991 Fisher & Paykel Limited released the first model of their SMARTDRIVE washing machines. This machine included a cabinet, a tub suspended within the cabinet by a plurality of suspension rods extending between the top edge of the cabinet and a lower portion on the tub. A single shaft extended through the base of the tub. The stator of a salient pole electronically commutated brushless DC motor was fixed to the lower side of the tub base. An external permanent magnetic rotor was fitted to the lower end of the shaft to substantially surround the stator. Within the tub a spin basket was supported for rotation on the shaft. Within the spin basket an agitator was fixed to the upper end of the shaft. The agitator was of a central post type with three lateral vanes and a generally conical base portion. The spin basket was supported by the shaft at a lower position, was free to rise on the shaft to an upper position. The spin basket included downwardly facing hollow chambers. Vertical support of the spin basket on the shaft in the lower position included inter-engagement of a downwardly facing castellated clutch on the spin basket and an upwardly facing castellated clutch fixed to the shaft. Accordingly without sufficient wash liquid in the tub for the spin basket and any associated load to float the spin basket remained rotationally fixed to the shaft. With sufficient wash liquid in the tub the float chambers of the spin basket would provide for the basket and load to float and disengage from the shaft such that the spin basket and shaft would rotate. This arrangement is described in U.S. Pat. No. 5,353,613. This direct drive electronically controlled laundry machine has been very successful. A number of competing companies have sought to devise alternative arrangements for selectively transmitting power of the motor to the spin basket.
[0003] U.S. Pat. No. 6,212,722 proposes an improved laundry washing machine for domestic use. This machine is of the top loading type having an outer bowl, a wash basket within the outer bowl and access to the wash basket through a top opening. A motor is provided to drive rotation of the wash basket within the outer bowl. A wash plate is provided in the lower portion of the wash basket to be rotated by the motor with the wash basket or independently of the wash basket. The patent proposes a combination of water level control, wash plate design, wash basket design and movement pattern for the wash plate which leads to an inverse toroidal movement of the laundry load during a wash phase. The sodden wash load is dragged radially inward on the upper surface of the wash plate and progresses upward in the region of the centre. The sodden wash load then progresses radially outward to the wall of the wash basket and downward to the base of the wash basket. This has been found to provide an effective wash action with low water consumption.
[0004] When a wash system of the type disclosed in U.S. Pat. No. 6,212,722 is applied to a machine of the type described in U.S. Pat. No. 5,353,613, the water volume required to operate the floating clutch can be a significant factor in overall water consumption.
[0005] U.S. Pat. No. 4,803,855,Kennedy, describes an agitate and spin drive for a washing machine. The mechanism includes a pair of concentric shafts extending through the lower wall of the wash tub. The upper end of the inner shaft is connected to drive the agitator. The upper end of the outer shaft is connected to drive the wash basket. A pulley at the lowest end of the inner shaft is driven by an electric motor. A lost motion mechanism or clutch in the form of a plurality of stacked disks is mounted on the agitator shaft. A lower end of the lost motion clutch is driven by the pulley. An upper end of the lost motion mechanism drives the lower end of the wash basket shaft. The lost motion clutch mechanism is located in the area between the base of the wash tub and the drive pulley. The overall arrangement requires both the wash basket shaft and agitator shaft to penetrate the wash tub.
[0006] U.S. Pat. No. 2,273,566 illustrates a washing machine with an agitator housed within a wash basket. The wash basket includes a central hub 41 extending up inside the post of the agitator. A lost motion clutch acts between the inner surface of the agitator and the outer surface of the hub. The clutch allows less than one revolution of relative movement between the wash basket before the agitator begins to drive the wash basket.
[0007] U.S. Pat. No. 2,609,697 describes a washing machine with an agitator housed within a wash basket. The wash basket is rotatably supported on the drive shaft. The agitator is fixed to the drive shaft. A downward extending lug on the agitator skirt is positioned to engage against an upward lug on the floor of the wash basket. The clutch allows less than one revolution of relative movement between the wash basket before the agitator begins to drive the wash basket.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a laundry machine which goes some way toward overcoming the above disadvantages or which will at least provide the public with a useful choice.
[0009] In a first aspect the invention consists in a laundry machine comprising:
a tub, a spin basket in said tub, a drive assembly comprising a shaft and agitator, the shaft passing through a wall of the spin basket, said agitator being located within said spin basket, a lost motion clutch physically located in the tub, interconnecting between the drive assembly and the spin basket and absorbing greater than one revolution of relative rotation.
[0014] According to a further aspect of the invention clockwise rotation of said agitator relative to said spin basket ends at a first end condition wherein said drive assembly is engaged to drive said spin basket in a clockwise direction, and
anticlockwise rotation of said agitator relative to said spin basket ends at a second end condition wherein said drive assembly is engaged to drive said spin basket in an anticlockwise direction, said first end condition and said second end condition being greater than one revolution of relative rotation between said agitator and said spin basket apart.
[0016] According to a further aspect of the invention said lost motion clutch includes a rotation member mounted for rotation about said shaft, said rotation member having a first pair of stop surfaces, one facing clockwise and one facing anticlockwise, and a second pair of stop surfaces, one facing clockwise and one facing anticlockwise,
said drive assembly has a pair of stop surfaces, one facing clockwise and one facing anticlockwise, said spin basket has a pair of stop surfaces, one facing clockwise and one facing anticlockwise, and in said first end condition said first pair clockwise surface engages against said drive assembly counter clockwise surface, said second pair anticlockwise surface engages against said spin basket clockwise surface, and in said second end condition said first pair counter clockwise surface engages said drive assembly clockwise surface, and said second pair clockwise surface engages against said spin basket counter clockwise surface.
[0021] According to a further aspect of the invention said rotation member includes a lug, with said clockwise facing surface of said first pair and of said second pair being on one side surface of said lug and said counter clockwise surface of said first pair and of said second pair being on another side surface of said lug.
[0022] According to a further aspect of the invention said drive assembly includes a lug, and said pair of stop surfaces of said drive assembly comprise opposite faces of said lug.
[0023] According to a further aspect of the invention said spin basket includes a lug, and said pair of stop surfaces comprise opposed faces of said spin basket lug.
[0024] According to a further aspect of the invention said drive assembly lug and said spin basket lug do not share the same axial and radial position relative to the rotation, such that said lugs pass by one another with relative rotation of said agitator and said spin basket in the absence of any intervening clutch member.
[0025] According to a further aspect of the invention said drive assembly lug and said spin basket lug overlap in the axial direction but are separated in the radial direction, and the radial extent of said lug of said rotating member overlaps with the outer of the drive assembly lug and the spin basket lug.
[0026] According to a further aspect of the invention wherein there is a clearance of less than 10 mm between said drive assembly lug and said spin basket lug as said lugs pass each other with relative rotation of said agitator and said spin basket.
[0027] According to a further aspect of the invention said drive assembly, but for said lost motion clutch, would be free to rotate relative to said spin basket.
[0028] According to a further aspect of the invention said spin basket is supported for rotation at a fixed axial position on said shaft.
[0029] According to a further aspect of the invention said shaft rotates around a vertical axis, and said tub and said spin basket are accessible through a top opening.
[0030] According to a further aspect of the invention said shaft of said drive assembly protrudes from below a base portion of said tub, a stator of an electric motor is fixed to said tub, and a rotor of said electric motor is fixed to said shaft.
[0031] According to a further aspect of the invention the laundry machine includes a cabinet, and a plurality of suspension members extending between an upper portion of said cabinet and a lower portion of said tub, said suspension members supporting said tub, spin basket, drive assembly and motor within said cabinet.
[0032] According to a further aspect of the invention said motor is of the external rotor type.
[0033] According to a further aspect of the invention said lost motion clutch includes a shock absorber for absorbing engagement impacts at one or both ends of the relative motion.
[0034] According to a further aspect of the invention at least one said stop surface is elastically supported relative to the respective rotation member, drive assembly or spin basket.
[0035] According to a further aspect of the invention said laundry machine includes a power supply circuit connected with windings of said motor, and a microcomputer having outputs connected to said power supply circuit for controlling the application of power to said windings of said motor, said microcomputer being programmed to drive said drive assembly in at least a first mode involving strokes of short duration in alternate directions, and a second mode involving continuous running for many revolutions in the same direction.
[0036] According to a further aspect of the invention said microcomputer is programmed to limit the angular rotation of any single agitation stroke of said drive assembly to be less than about 1.5 revolutions.
[0037] According to a further aspect of the invention said microcomputer is programmed to detect any occasional end condition that occurs during agitation and to terminate the drive of motor in that agitation stroke as soon as the collision is detected.
[0038] According to a further aspect of the invention said microcomputer is programmed to monitor the load on the motor and detect said end condition by an increase in the motor load.
[0039] According to a further aspect of the invention said microcomputer is programmed to detect any directional bias in any residual rotation of the spin basket during agitation.
[0040] According to a further aspect of the invention said microcomputer is programmed to adjust the respective agitator stroke lengths to try to reduce this bias and preferably to reverse the estimated accumulated relative creep in one direction.
[0041] A laundry machine comprising:
a tub, a spin basket in said tub, a drive assembly comprising a shaft and agitator, the shaft passing through a wall of the spin basket, said agitator being located within said spin basket, and
[0045] To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
[0046] The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting each statement in this specification that includes the term “comprising”, features other than that or those prefaced by the term may also be present. Related terms such as “comprise” and “comprises” are to be interpreted in the same manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a cutaway perspective view of a laundry machine according to a preferred embodiment of the present invention.
[0048] FIG. 2 is a block diagram of a control system for a laundry washing machine.
[0049] FIG. 3 is a cross-sectional side elevation of a lower part of the tub and spin basket, the agitator and an upper part of the drive shaft according to a preferred embodiment of the present invention.
[0050] FIG. 4 is a perspective view of a rotating clutch member and spin basket support bush according to a preferred embodiment of the present invention.
[0051] FIG. 5 is a cross-sectional plan view through line AA in FIG. 3 of the components of FIG. 4 and agitator end stop 300 .
[0052] FIGS. 6A to 6D show a sequence of cross-sectional plan views of the type illustrated in FIG. 5 illustrating the range of freedom of relative movement between the spin basket and agitator.
DETAILED DESCRIPTION
[0053] A laundry machine that may incorporate a clutch according to the present invention is illustrated in FIG. 1 . The laundry machine includes a cabinet 100 with a lid 102 and a user console 104 . A controller 106 is located within the body of the user console. The controller 106 includes a power supply and a programmed microcontroller. The power supply receives power from the mains supply and supplies power to the microcontroller, to a power supply bridge for the electric motor and to ancillary devices within the machine such as a pump and valves. Delivery of power to the motor 114 and the ancillary devices is at the control of the microcontroller. The microcontroller receives inputs from a user interface on console 104 .
[0054] A tub 120 is supported within the cabinet. The tub is preferably suspended from the upper edge of the cabinet, for example by suspension rods 121 . The tub may alternatively be supported from below or from the sides of the cabinet. A wash or drain pump is fitted to the lower portion of the tub. The pump is preferably located at a sump portion of the tub.
[0055] A wash basket 122 is supported for rotation within the tub. Opening the lid 102 provides user access to an upper open end of the wash basket.
[0056] An agitator 124 is mounted in the lower portion of the wash basket. The agitator may be of a central post type, with or without additional moving parts, such as augers, or of a wash plate type, such as illustrated in U.S. Pat. No. 6,212,722, or of a pulsator type, or of any other type having independent movement from wash basket 122 . The illustrated agitator is of wash plate type, intended for facilitating low water level wash exhibiting inverse toroidal rollover patterns.
[0057] The improvements and adaptations of the present invention are preferably implemented in a laundry machine of a direct drive type with motor fixed directly to the lower end of a single drive shaft. However other drive systems involving for example gearbox or belts driving a single drive shaft may alternatively be used.
[0058] A motor 114 below the tub directly drives single shaft 128 . The single shaft 128 extends through the lower face of the tub, where it is supported in a pair of bearings 130 . A seal 360 prevents water escaping the tub at the interface between the tub and shaft.
[0059] The wash basket 122 is mounted on the shaft within the tub. The wash basket may typically comprise a base 132 and a perforated cylindrical skin 134 . The perforated cylindrical skin extends up from the base to define an open ended drum. The wash basket may include a balance ring at the upper edge of the cylindrical skin.
[0060] The wash plate 124 is also fitted to the shaft, within the wash basket 122 .
[0061] A clutch arrangement 142 is provided to enable the motor 114 to selectively drive either the wash plate 124 independently of the wash basket 122 , or drive the wash basket 122 . In driving the wash basket the motor may also drive the wash plate. Various mechanisms have been proposed to accomplish. this selective drive. The present invention relates to an improved mechanism which promotes low water consumption while retaining a drive assembly where a single shaft penetrates the tub 120 . This mechanism is described in detail below.
[0062] The controller is part of a control system for coordinating the operations of the laundry machine. The control system is illustrated in the block diagram of FIG. 2 . The controller includes a microcontroller 800 . The microcontroller may include a microcomputer and ancillary logic circuits and interfaces. The microcontroller receives user input commands on user interface 802 . The user interface may include, for example, a plurality of touch controls such as switches or buttons, or may include a touch screen, or may include rotary or linear selection devices. The microcontroller may include a display device 804 to provide feedback to a user. The display device may comprise a plurality of indicators, such as lights or LEDs, or may include a screen display. The display device 804 and the user interface 802 may be mounted to a single module incorporating the microcontroller.
[0063] The microcontroller receives power from a power supply 806 . The microcontroller also controls power switches 808 applying power from supply 806 to drive motor 810 . The microcontroller controls further power switches 812 applying power from supply 806 to a pump 814 . The microcontroller also controls a power switch 830 applying power to a cold water inlet valve 832 and a power switch 834 applying power to hot water inlet valve 836 .
[0064] The microcontroller preferably receives feedback from position sensors 816 associated with the motor. These sensors may for example be a set of digital Hall sensors, sensing changes in rotor position, or may be any suitable encoder. Alternatively rotor position and movement may be sensed from motor drive current or EMF induced in unenergised motor windings.
[0065] The microcontroller also preferably receives input from a water level sensor 818 , which detects the level of water in the tub of the machine, and from a temperature sensor 820 which detects the temperature of water being supplied to the wash tub.
[0066] The preferred controller applies an initial wash plate drive profile to initiate the inverse toroidal motion. The initial drive profile is characterised by higher angular velocity and longer stroke length to start the clothes movement. This movement is subsequently maintained by a maintenance drive profile with lower angular velocity and stroke length. Many drive systems are possible for controlling wash plate drive profiles. One example is described in U.S. Pat. No. 5,398,298.
[0067] The initial drive profile is varied according to load size. The profile is more vigorous for larger load sizes. Load size may be determined from a user entry or selection, or by monitoring the inlet flow and recirculation pump activity, or by one of the many methods described in the prior art.
[0068] Preferably the maintenance drive profile is also varied according to load size. Again the profile is more vigorous for larger load sizes.
[0069] Acceptable wash performance is considered a compromise between achieving regular inverse toroidal turnover of a wash load within the spin basket and wear and tear associated with wash profiles that are too vigorous (and speeds that are too high) or entanglement (angular strokes that are too long). In general agitator wash strokes are between 0.5 revolutions and 1.5 revolutions. In each wash stroke the relative rotation between agitator and wash basket is generally less than 1.5 revolutions.
[0070] According to the invention an improved clutch mechanism is disposed within the tub of the laundry machine. In the preferred embodiment illustrated in the drawings the mechanism is provided in the space between the wash plate 124 and the upper side of the base 322 of the spin basket.
[0071] The spin basket is rotatably supported on the shaft 128 , for example by a pair of bearings 318 . The spin basket is vertically supported on the shaft 128 , for example by a thrust bearing 310 .
[0072] The bearings 318 are fitted within bearing tube 320 of the base portion 322 . The bearings 318 are preferably of a sliding seal type. The bearings 318 provide radial support of the spin basket relative to the shaft. The bearings are vertically spaced on the shaft to provide torsional stability.
[0073] The thrust bearing 310 is fitted to the shaft 128 above the upper radial bearing 318 . The thrust bearing 310 preferably engages over a spline 313 . The thrust bearing 310 has an upwardly facing thrust surface which supports the weight of the spin basket. The lower edge of the thrust bearing 310 is supported on a shoulder 317 of the shaft 128 . A support hub 308 tests on the thrusts surface of thrust bearing 310 and is secured to an upper face of the spin basket base 322 . A lower surface 332 of the support hub 308 bears on thrust surface 334 of thrust bearing 310 .
[0074] A drive ring 302 is mounted to rotate around the axis of shaft 128 . The drive ring includes a drive lug 304 extending radially.
[0075] An end stop 306 extends, preferably upwardly, from the outer surface of base 322 of the spin basket. An end stop 300 extends, preferably downwardly, from the underside of wash plate 124 . The end stop 306 and end stop 300 are positioned and configured such that they move past each other when the agitator rotates relative to the spin basket. In the illustrated arrangement the spin basket end stop 306 is radially inside the inner most extent of agitator end stop 300 . The end stops could alternatively be vertically separated, or have other non-interfering complementary shape and location.
[0076] The drive lug 304 of drive ring 302 extends outwardly sufficient to interfere with both end stop 306 and end stop 300 .
[0077] Either end stop may be in the form of a free standing lug. Alternatively the end stop may be an end portion of a ridge or other formation, so long as the end stops and the drive lug meet the interference requirements of the clutch.
[0078] The agitator 124 is fixed to the upper end of drive shaft 128 . The agitator 124 rotates with drive shaft 128 . Typically the drive will operate in a wash mode where the shaft is reciprocated in alternate directions, and a continuous rotation mode in which the shaft is rotated for longer periods in a single direction.
[0079] For the continuous rotation modes, the end stop 300 of the agitator drives around the drive lug 304 of drive ring 302 when it is rotating and in contact with the lug 304 . Lug 300 continues to drive around the drive lug 304 until drive lug 304 contacts the end stop 306 of the spin basket. Drive lug 304 then in turn drives rotation of the spin basket by end stop 306 . In this condition with rotation of the end stop 300 against lug 304 against end stop 306 , rotation of the drive shaft drives rotation of the agitator and spin basket together.
[0080] From this drive position in a first direction the drive shaft may rotate relative to the spin basket through almost two full revolutions before meeting a second end condition where it drivingly engages the spin basket for rotation in the other direction. The agitator end stop 300 moves nearly one full revolution around the drive shaft 124 before engaging drive lug 304 on the same side as end stop 306 . End stop 300 continues to drive drive lug 304 for almost one further complete revolution before the opposite side of drive lug 304 engages against end stop 306 of the spin basket. At this point rotation of the agitator would proceed to drive rotation of the spin basket via the first end stop, drive lug 304 and second end stop 306 . However this point of rotation is nearly two full relative revolutions away from the other end condition, and so in a typical agitation stroke of up to 1.5 revolutions this condition is not reached.
[0081] In the illustrated embodiment end stop 306 is an upwardly extending lug at the perimeter of support hub 308 . Support hub 308 includes a raised hub portion with an outwardly facing wall 338 and a perimeter flange 330 . The lug 306 extends upward at the periphery of perimeter flange 330 . The annular body 331 of drive ring 302 fits over the hub portion of the support hub 308 , occupying the region inward of lug 306 . Inner face 336 of ring 331 slides against outwardly facing surface 338 of support hub 308 .
[0082] The support hub 308 is fixed to the upper face of the spin basket base 322 , for example by fasteners 312 . Practically, this allows assembly of the spin basket onto the drive shaft by first fitting the radial support bearings over the drive shaft, then fixing the thrust bearing 310 over the lower spline 313 , then support hub 308 is fitted over the drive shaft and fastened to the spin basket base to support the spin basket on thrust bearing 310 , then agitator 124 is fitted to the upper spline on the drive shaft and secured in place by fastener 350 .
[0083] Typical agitator motion during the agitation mode is between 0.5 and 1.5 revolutions. So the almost two revolutions provided by the clutch of the present invention will generally be sufficient to absorb the agitation movement of the drive shaft without engaging to drive the wash basket at the end of each stroke.
[0084] In the preferred electronically commutated drive system an upper limit can be applied to the agitator motion, for example an upper limit of 1.5 revolutions.
[0085] However there may be a directional bias in the relative movement between the agitator and the wash basket. The wash basket will tend to be dragged by the action of the wash load acting as a viscous clutch between the wash plate and wash basket. This dragging action will tend to be compensated by a coast of the spin basket at the end of an agitation stroke. However a residual movement of up to about 20 degrees is observed. In any wash cycle or random part of a wash cycle the residual movement may exhibit a bias in one direction. This will result in the reciprocating agitation stroke operating further toward one end of the range of movement between end conditions. Eventually, and perhaps frequently under some conditions, the clutch will reach an end condition at the end of an agitator stroke. Thus at the end of occasional strokes the spin basket may be driven momentarily by the clutch at the end of the stroke.
[0086] In the preferred electronically commutated drive system we propose to detect any such occasional end condition and to terminate the drive of motor in that agitation stoke as soon as the collision is detected. It is possible for the microcontroller to monitor the load on the motor with reasonable accuracy and frequency by monitoring, for example, the motor current. The end condition may be detected by an increase in the motor load.
[0087] Further, in the preferred electronically commutated drive system we propose to detect any directional bias in the residual rotation of the spin basket. For example we may detect a difference in the motor load while driving the agitator in one direction compared to the other direction, and assume that this indicates greater dragging of the spin basket in the higher load direction. Or, for example, we may detect greater load at the point of reversal of the drive direction, which may indicating that the spin basket is coasting for longer into the new stroke direction. The respective agitator stroke lengths may then be adjusted to try to reduce this bias and preferably to reverse the estimated accumulated relative creep in one direction.
[0088] Further, the clutch construction may be modified so that the impact at the end condition may be reduced.
[0089] For example either end stop may be formed to be soft or springy. For example one end stop may have a buffer on each side, or each end stop may have a buffer on one side. The buffer may be a spring arrangement, preferably elastically absorbing the impact to release the energy in the new stroke direction.
[0090] As a further example, the drive lug on the drive ting may be flexible, for example an outwardly extending leaf of spring steel, which may bend elastically with the impact between the end stops.
[0091] As a less preferably example, either end stop may have a friction clutch engagement to the respective support part (the spin tub or the drive assembly). This is less preferred as the absorbed energy is dissipated as heat. It is expected that with the range of movement available and the control available in the electronically controlled drive system the any pick up at the end condition will be relatively light, and so an elastic shock absorber that returns energy to the system should be sufficient to absorb the impact.
[0092] The drive arrangement according to the present invention allows driving of the agitator in alternate directions through a useful length of stroke with only a single shaft penetrating the tub, and without relying on water level for disengagement. | A laundry machine has a tub and a spin basket in said tub. A drive assembly includes a shaft and agitator. The shaft passes through a wall of the spin basket. The agitator is located within the spin basket. A lost motion clutch is physically located in the tub. The lost motion clutch interconnects between the drive assembly and the spin basket and absorbs greater than one revolution of relative rotation. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to pressure sensitive adhesive compositions which includes a hydrogenated block copolymer such as Kraton G, about 25 to about 250 parts by weight of a hydrocarbon resin of a petroleum or coal tar distillate, aliphatic dienes and mono- and diolefins, cyclic olefins of 5 or 6 carbon atoms and hydrogenated polycyclics per 100 parts by weight of the hydrogenated block copolymer, and about 25 to 200 parts by weight of a polybutene or polyisobutylene per 100 parts of the hydrogenated block copolymer, wherein said mixture of Kraton G, said hydrocarbon resin and said polybutene or polyisobutylene are dissolved in a non-reactive solvent at a concentration level of about 5 to about 25 grams per 100 ml. of non-reactive solvent.
Broadly speaking, synthetic adhesives used in packaging can be classified into four categories: water based, solvent based, reactive and hot melt adhesives. Of these four, currently, the water based are used most extensively. Usually the water based adhesives are based on emulsion polymers and are applied to porous cellulosic substrates. Energy from the outside, in some fashion, is applied to the system to evaporate the water in order that a strong bond may be formed. Beside this energy requirement for the formation of the bond, there is another complication with the use of water based adhesive. For a uniform coating, a good uniform wetting of the substrate surface is desired, which is not easily achieved.
The key requirements for pressure sensitive adhesives are that they should have good cohesive and tackifying properties at ambient conditions. These adhesives should also have good flow characteristics if they are to be used in the bulk state, otherwise they should possess sufficient consistency when dissolved in suitable solvents so that they can be coated or sprayed on the surfaces to be bonded.
The key requirements of resins suitable for pressure sensitive adhesive applications are that they contribute (i) good tackifying characteristics for the polymer; and good physical properties, e.g., good tensile strength at ambient conditions for the formulations.
Certain commercial block copolymers such as Shell's Kraton, Phillip's Solprene and DuPont's EVA copolymers attain the above objectives to a good extent. The adhesives prepared from blends incorporating these polymers have very good adhesive and strength properties at room temperature and can be processed by conventional melt coating and extrusion techniques because of their good flow characteristics. Because of this excellent combination of properties exhibited by ABA type when B represents a polydiene or a polyolefin block, and A represents a polystyrene block at present, the use of Kratons for various pressure sensitive adhesive applications is growing in the industry.
However, the conventional block copolymers which are currently being used in adhesives technology, because of their inherent structure, have one serious drawback with respect to their use as a satisfactory adhesive candidate. Most of the conventional Kraton polymers are block copolymers of polystyrene and a polydiene. The polydiene component in Kratons (of industrial interest) is either polybutadiene or polyisoprene. Since both polybutadiene and polyisoprene are highly unsaturated, the Kraton block copolymers comprising either one of these two polymers are highly susceptible to thermal and oxidative degradation. This imposes many constraints on the adhesive users. For example, in order to minimize the degradation, presently, most often a packaging or a sealant adhesive user has to keep an inert blanket over the adhesive compound, not only during formulation and processing, which is usually done at somewhat elevated temperatures, but during storage as well. This becomes not only expensive, but at times cumbersome for the packager. Another point of caution experienced with the use of Kratons in adhesives is that the long term end use properties of the final product are highly susceptible to degradation due to UV light.
In order to circumvent these undesired properties of adhesives prepared using Kraton block copolymers, steps to modify the structure of these polymers have been taken. Recently, Shell has invented and developed a new generation of Kraton block copolymers in which the mid unsaturated blocks of either polybutadiene or polyisoprene are hydrogenated to yield a saturated mid block. The saturated mid block is stable, not only from a processing point of view, but from UV light during storage and use as well. In practice so far, it has been found that these new saturated mid block Kraton polymers are difficult to tackify. We have found that certain blends of saturated Kratons, when incorporated in certain proportions with selected Escorez resins, together with relatively low molecular weight polybutenes, yield systems which have very good tackifying characteristics. The aggressiveness of tack and other properties of these tertiary blends can be controlled by using carefully selected proportions of these blending ingredients and/or by incorporating certain fillers and plasticizers. All of these blends are mechanically compatible and have good flow properties, as judged during milling. They can also be applied from solution, if it is deemed necessary, for other processing reasons.
The excellent thermal stability inherent in the saturated backbone of Kraton is a very desirable property for adhesives which will be exposed to high temperatures for long times. Most adhesives based on other unsaturated elastomeric backbones can suffer degradation easily under those conditions.
SUMMARY OF THE INVENTION
This invention relates to pressure adhesive compositions, which includes a hydrogenated block copolymer such as Kraton G; about 25 to about 250 parts by weight of a hydrocarbon resin of a petroleum or coal tar distillate, aliphatic dienes and mono- and diolefins, cyclic olefins of 5 or 6 carbon atoms and hydrogenated polycyclics per 100 parts by weight of the hydrogenated block copolymer and about 25 to about 200 parts by weight of a polybutene or polyisobutylene per 100 parts of the hydrogenated block copolymer, wherein the mixture of said Kraton G, said hydrocarbon resin and said polybutene or polyisobutylene are dissolved in a non-reactive solvent at a concentration level of about 5 to about 25 grams per 100 ml. of non-reactive solvent.
GENERAL DESCRIPTION OF THE INVENTION
The present invention relates to unique and novel solvent based pressure sensitive adhesive compositions which comprise a blend of a hydrogenated block copolymer such as Kraton G, a polybutene or polyisobutylene and a hydrocarbon resin, wherein the mixture of said Kraton G, said hydrocarbon resin and said polybutene or polyisobutylene are dissolved in a non-reactive solvent at a concentration level of about 5 to about 25 grams per 100 ml. of non-reactive solvent, wherein, to the compositions can be optionally added an oil, and/or a filler, thereby modifying the physical properties of the pressure sensitive compositions.
A. Hydrogenated Block Copolymers
The hydrogenated block copolymers of the instant compositions are block copolymers of polystyrene and a polydiene which is typically selected from the group consisting of polybutadiene and polyisoprene, wherein the unsaturated mid block of either polybutadiene or polyisoprene are hydrogenated to yield a saturated mid block. As examples, hydrogenated block copolymers are manufactured by Shell Chemical Company and sold under the trade name: Kraton-G. The hydrogenated block copolymers have an Mn as measured by GPC of about 25,000 to about 300,000, more preferably about 30,000 to about 200,000, and most preferably about 50,000 to about 150,000.
B. Polybutene or Polyisobutylenes
Any low molecular weight polybutene polymer having a molecular weight in the range of 500 to 50,000 in appropriate portions could be used. The polybutene used in the present invention were polybutene, Oranite 32 and Oranite 128; also Indopol H-1900, which is quite similar to Oranite 128 and is produced by Amoco. Such polybutenes are composed predominantly of high molecular weight mono-olefins (85-98%) whose olefin structure is predominantly the trisubstituted type (R--CH═CR 2 ). The major component of polybutenes can be readily represented by polyisobutylene structure, and because of this similarity of polybutenes and polyisobutylenes, various grades of polyisobutylenes manufactured by various Chemical companies could be used. A blend incorporating Exxon's Vistanex-LM (Blend No. 134-2 of Table 3) was prepared for illustrative purposes. The properties of this blend, as can be seen from Table 4, are very similar to those prepared by Amoco polybutenes. As well known to those who are familiar with the art, the aggressiveness of tack and properties of most of these adhesive blends can be controlled by suitable control of the amount and type of the various ingredients used and/or by addition of effective external plasticizers.
The polybutene or polyisobutylene is incorporated into the pressure sensitive adhesive composition at a concentration level of about 25 to about 200 parts by weight of the polybutene or polyisobutylene per 100 parts by weight of the hydrogenated block copolymer, more preferably about 50 to about 100, and most preferable about 60 to about 90.
C. Commercial Tackifier Resins
To the pressure sensitive adhesive composition is added a commercial tackifying resin having a softening point of about 0° to about 160° C., more preferable about 50° to about 140° C. and most preferably about 70° to 120° C. A variety of commercial tackifier resins are available. Some of these resins contain α and/or β pinene-base polyterpene resins as the main ingredient, while others are derived from the polymerization of petroleum of coal distillates which consist of aliphatic dienes, mono- and diolefins and cyclic olefins having about 5 to about 6 carbon atoms. The latter type of tackifiers have primarily piperylene and/or isoprene structure. A general but excellent description of tackifying resins derived from Petroleum derivatives can be found in, for example, Encyclopedia of Polymer Science and Technology, Vol. 9, Pages 853 to 860, chapter by John Findlay, Published by John Wiley & Sons, NY (1968).
Typical but non-limiting trade name of these commercial tackifiers are Wingtack of Goodyear, Escorez of Exxon, Piccolyte of Hercules and Zonrez of Arizona Chemicals. Recently, these and various other companies have also started marketing relatively higher softening point resins and very light colored resins. These are generally modified aliphatic hydrocarbon resins and/or hydrogenated polycyclics. The physical appearance of these commercial tackifying resins varies, depending upon their softening point, they can be either viscous liquids or light-colored solids at room temperature. Most often, their initial color (Gardner) is about 3.0 to about 7.0 and the density from about 0.7 to 1.0 gm/cm 3 at room temperature. The acid number of these resins is usually less than 1. In general, the molecular weight of these commercial tackifying resins is not homogeneous, it spreads, the number average molecular weight Mn from about 300 to about 5000 and more, preferably about 500 to about 2000 and most preferably about 700 to 1600.
Frequently, it is desirable to enhance the clear, colorless appearance of the saturated mid block Kraton polymers by using the colorless resins, e.g., hydrogenated resins such as Escorez 5380 and Escorez 5320 of Exxon Chemical Co. U.S.A. Formulations made from these compounds and, preferably, low color polybutenes, form desirable, tacky, almost colorless and aesthetically pleasing adhesives.
These hydrocarbon tackifier resins are incorporated into the pressure sensitive adhesive composition at about 50 to about 150 parts by weight per 100 parts by weight of the hydrogenated block copolymer, more preferably about 60 to about 125 and most preferably about 75 to about 100.
E. Extended Blend Adhesive Composition
To the composition of the pressure sensitive adhesive compositions can be added fillers which are selected from the group consisting of talcs, ground calcium carbonate, water precipitated calcium carbonate, delaminated, calcined or hydrated clays, silicas, and carbon blacks, and mixtures thereof. These fillers are incorporated into the blend composition at about 1 to about 150 parts by weight per 100 parts by weight of the hydrogenated block copolymer, more preferably at about 30 to about 100. Typically, these fillers have a particle size of about 0.03 to about 20 microns, more preferably about 0.3 to about 10, and most preferably about 0.5 to about 10. The oil absorption, as measured by grams of oil absorbed by 100 grams of filler, is about 10 to about 100, more preferably about 10 to about 85 and most preferably about 10 to about 75. Typical fillers employed in this invention are illustrated in Table I.
F. Oil Extended Adhesive Compositions
It is observed that the composition of the instant invention can also include oils to further improve low temperature properties and tack characteristics of the resulting adhesive levels of oil of less than about 25 parts by weight per 100 parts of the hydrogenated block copolymer can be incorporated, more preferably about 1 to about 20 parts. Oils are particularly useful when high levels of petroleum resin tackifiers are used since such materials can harden the resulting composition. Oils can usually further soften and reduce the cost. In some cases, oils can significantly contribute to the degree of tackiness in the final product and thus are helpful in formulating various adhesive products.
TABLE I__________________________________________________________________________ Avg. Particle of oil/100 Specific SizeFiller Code grams of filler Gravity Micron pH__________________________________________________________________________Calcium Carbonate Ground Atomite 15 2.71 9.3Calcium CarbonatePrecipitated Purecal U 35 2.65 .03-.04 9.3Delaminated Clay Polyfil DL 30 2.61 4.5 6.5-7.5Hydrated Clay Suprex 2.6 2 4.0Calcined Clay Icecap K 50-55 2.63 1 5.0-6.0Magnesium Silicate Mistron Vapor 60-70 2.75 2 9.0-7.5__________________________________________________________________________
However, in the present case, if used without the polybutene present, the resulting pressure sensitive adhesive properties are, overall, poorer. Typical oils that can be used may be low viscosity aromatic, naphthenic or paraffinic petroleum oils, having less than 2 weight percent polar type compounds. Typical oils are illustrated in Table II.
DETAILED DESCRIPTION OF THE INVENTION
The advantages of both the physical properties and adhesive characteristics of the compositions of the present invention can be more readily appreciated by references to the following Examples and Tables. Unless otherwise defined, the measurements of the compositions are in parts per hundred by weight.
TABLE II______________________________________ Vis- % % cosity % Aro- Sat-Type Oil Oil Code # ssu Mn Polars matic urate______________________________________Paraffinic Sunpar 115 155 400 0.3 12.7 87.0Paraffinic Sunpar 180 750 570 0.7 17.0 82.3Paraffinic Sunpar 2280 2907 720 1.5 22.0 76.5Aromatic Flexon 340 120 -- 1.3 70.3 28.4Naphthenic Flexon 765 505 -- 0.9 20.8 78.3______________________________________
EXAMPLE 1
The binary blends of Kraton G polymer and tackifying resins failed to show any respectable degree of tackiness; attempts were made to make tertiary blends of Kraton G, tackifying resins and polybutenes.
In Table III, various tertiary (adhesive) blend compositions of Kraton G system are shown. In this series of experiments, it has been shown that besides Kraton G and tackifying resins, a low molecular weight polymer, polybutene must be added. All the blends incorporating polybutene were compatible. Blend No. 132-11, which is a binary blend of Kraton G and a polybutene (H-1900), is included in this Table for comparative purposes. Because of the low molecular weight nature of polybutene, the blend No. 132-11 is somewhat poor in its green strength, as compared to other blends having similar compositions.
Table IV illustrates the properties of various blends of Table III. It is clear, from the last column of Table IV, that all the blends exhibit significant improvements in their tackiness upon incorporation of polybutene. The addition of an equal amount of polybutene, as that of Escorez or Arkon resins used in formulating in the binary adhesive blends improves significantly the tack of the final product. This is especially true for 50--50 blends of Kraton G and resins.
The exact and detailed procedure for preparing the blends of above and following Tables is not a crucial component of the present invention. The blends could easily be prepared by dissolving the desired quantities of various ingredients in a suitable organic solvent. The blends can, if desired, be applied to a backing to form a pressure sensitive sheet with a film of adhesive, generally 1-2 mil on the backing. They can also be made by applying a solution of 5-10 mil to the backing, and flashing off the solvent to form 1-2 mil film of adhesive on the backing.
The bond strength values reported in Table IV, and subsequent Tables, were obtained by a method similar to ASTM D-429 adhesion tests. In brief, the samples were sandwiched between mylar sheets and pressed to a thickness of about 25 mils using a hot press. Rectangular strips of 1/2 inch width and 3 inches long were cut and 90° peel tests were performed on an Instron at room temperature. The resin-free sections of the mylar film were clamped into air jaws to avoid any slippage during pulling. The samples were pulled at 5 inches/minute crosshead speed. The force and elongation of the samples were recorded on a strip recorder. The force necessary to separate the mylar sheets was taken as the bond strength of the blend and a measure of its cohesive strength and adhesive nature. The final plateau values are reported. The qualitative nature of the tackiness of the blends were determined by technician's subjective "finger test" method.
TABLE III______________________________________COMPOSITION OF TERTIARY BLENDS OFKRATON G, TACKIFYING RESINS ANDLOW MOLECULAR WEIGHT POLYBUTENESBlend Number 132-10 132-11* 133-1 133-2 133-3 133-4 134-1______________________________________Kraton G 100 100 100 100 100 100 100Irganox 1 1 1 1 1 1 --Escorez 1310 100 -- -- -- -- -- 100Escorez 5380 -- -- 60 100 -- -- --Arkon P-85 -- -- -- -- 60 100 --Polybutene(H-1900)** 100 100 100 100 100 100 --Vistanex LM*** -- -- -- -- -- -- 100______________________________________ *This binary blend is included here for comparative purposes (see text fo details). **Polyisobutylene, a product of Amoco. ***Polyisobutylene, a product of Exxon. All these samples were melt mixed on a hot mill roll at about 150° C.
TABLE IV__________________________________________________________________________QUALITATIVE AND QUANTITATIVE PROPERTIES OF BLENDS OF TABLE IIIBlendBond StrengthNumber(lbs.) Clarity* Mode of Failure*** Tackiness***__________________________________________________________________________132-102.8 Clear/Very Light Yellow** A.F. Tacky132-110.5 Clear/Transparent A.F. Non-Tacky133-12.5 Clear/Transparent A.F. Non-Tacky133-23.7 Clear/Transparent A.F. Tacky133-32.4 Clear/Transparent A.F. Very Slightly Tacky133-43.8 Clear/Transparent A.F. Tacky134-11.7 Clear/Very Light Yellow A.F. Slightly Tacky__________________________________________________________________________ *Clarity of the film pressed in between mylar sheets. **Due to the color of the resin. ***See footnotes of Table II.
Kraton G is a block copolymer of the structure ABA in which A is a block of styrene (total 15% by weight) whose number average molecular weight is in the range of 10,000 to 30,000. B is a block of hydrogenated polybutadiene in polyisoprene (85%) having a number average molecular weight of about 125,000. Vistanex-LM is a low molecular polyisobutylene and is an Exxon proprietary material described in detail in various U.S. patents. Amoco polybutenes are viscous, non-drying, water white, liquid butylene polymers. They are composed predominantly of high molecular weight mono-olefins (85-98%), the balance being isoparaffinic. The major component of Amoco polybutenes can be represented by polyisobutylene structure. Arkon P-85 and Escorez resins are commercial tackifiers having a melting point in the neighborhood of 80°-90° C. These are hydrocarbon resins derived from petroleum or coal tar distillates, aliphatic dienes and mono-olefins of 5 or 6 carbon atoms.
EXAMPLE 2
In this series of tests, various binary blend compositions of Kraton G and tackifying resins incorporating two types of oils: Tufflo and Shellflex, as an example, were prepared. The composition of such blends and various adhesive characteristics thereof are shown in Table V. These tests were run with mylar coated sheets having 1-2 mil films of adhesive on the plastic backing. The tests used are those published by the Pressure Sensitive Tape Council (PSTC) and widely used in the adhesive industry. They are identified in the footnotes. It is observed that with no additives, which is especially true for low oil loadings, the films are dry. The films prepared from these compositions exhibit poor tack, as determined by polyken tester. Only compositions having high levels of oil (50 phr) exhibit somewhat improved rolling ball tack, but nevertheless, these compositions exhibit poor polyken peel and quick stick adhesive characteristics.
EXAMPLE 3
Various adhesive blend compositions and their properties of this Example are shown in Table VI. In this case, again, the samples were prepared by adding a solution of the blend in toluene to mylar film forming a 5-10 mil film with a blade drawn across the solution, and quickly entering an oven to evaporate the solvent, recovering a 1-2 mil organic film with pressure sensitive adhesive properties. In these experiments, in some compositions of Table VI, an extra additive polybutene (Oranite 128) was added. As can be clearly seen, the addition of this ingredient inparts significant improvements in the adhesive properties of compositions of the previous Table. In particular, it is observed that the polyken tack is doubled from the previous compositions. The polybutene also improves the rolling ball tack.
TABLE V__________________________________________________________________________COMPARISON OF OIL LEVEL ON KRATON G TACKIFICATION1.5 Mil Film Made From Toluene Solutions of Elastomer etc.Resin FormulationKraton G-1657 100Resin, phrEscorez 5380 60 80 80 80 75 100 125 -- -- -- -- -- -- --Arkon P-85 -- -- -- -- -- -- -- 60 80 80 80 75 100 125AdditiveTufflo G056 10 10 20 -- 50 50 50 10 10 20 -- 50 50 50Shellflex 371 -- -- -- 20 -- -- -- -- -- -- 20 -- -- --Adhesive PropertiesRolling Ball Tack, cm (b) 14 10 9.5 10 5 8.5 15 12.5 30+ 9.5 9.5 5 6 17Polyken Tack, gm/cm.sup.2 (c) (a) (a) (a) (a) 200 250 200 (a) (a) (a) (a) 275 330 4390° Quick Stick, 0.3 0.3 0.2 0.8 0.2 0.4 0.2 0.1 0.3 0.7 0.5 0.4 0.7 0.3lbs/in.sup.2 (e)Peel, lbs/in.sup.2 (d) -- 0.6 0.2 1.8 0.3 0.5 0.3 0.1 2.4 1.9 0.3 0.5 1.3 0.8__________________________________________________________________________ (a) Not measured. Dry or poor "finger tack". (b) PSTC6 (c) ASTM D2979 (d) PSTC1 (e) PSTC5
TABLE VI__________________________________________________________________________EFFECT OF POLYBUTENE ADDITIVES ONTHE KRAT G TACKIFICATION__________________________________________________________________________PSA formulationKraton G-1657 100Resin, phrEscorez 5380 60 60 100 100 100 -- -- -- -- --Arkon P-85 -- -- -- -- -- 60 60 100 100 100Escorez 1310 -- -- -- -- -- -- -- -- -- --AdditiveTufflo G056 (a) -- 10 -- 50 -- -- 10 -- 50 --Oranite 128 (b) -- -- -- -- 50 -- -- -- -- 50PSA PropertiesRolling Ball Tack, cm 12 10 18 8.5 5.5 1.7 12.5 30+ 6 13Polyken Tack gms/cm.sup.2 (c) (c) (c) 250 585 (c) (c) (c) 330 70090° Quick Stick lbs/in.sup.2 0.6 0.3 1.3 0.4 1.1 1.4 0.6 0.6 0.7 1.8Peel lbs/in.sup.2 1.0 0.5 2.3 0.5 2.6 2.3 0.1 1.4 1.3 2.7__________________________________________________________________________ (a) Napthenic Oil (b) High molecular weight polybutene (c) Not measured. Dry, poor "finger tack
EXAMPLE 4
The data of these experiments are illustrated in Table VII and VIII. In Table VII, direct comparisons of oil containing adhesive blend compositions incorporating two different grades of polybutenes are shown. As seen in previous examples, it is observed that polybutene improves polyken tack, quick stick and peel strength of the adhesive compositions. Comparing the two polybutenes, it is noticed that the higher molecular weight polybutene is somewhat better in improving the tack characteristics than the low molecular weight polybutene in these formulations. In Table VIII, comparative data of two tackifying resins differing in their softening point are shown. It is observed that the peel strength of these two types of blends is more or less equal. However, the low softening point resin sample tends to form compositions which are somewhat better in regard to their rolling ball tack. The other important point to note is that both resins respond to polybutenes better than oils (e.g., Examples 2 and 3) as judged from the polyken test and quick stick measurements of these samples.
TABLE VII__________________________________________________________________________COMPARISON OF TWO 85° C. SOFTENING POINT RESINS1.5 Mil Film Made From Toluene Solutions of Elastomer etc.Resin FormulationKraton G-1657 100Resin phr.Escorez 5380 75 75 75 100 100 100 -- -- -- -- -- --Arkon P-85 -- -- -- -- -- -- 75 75 75 100 100 100AdditiveOranite 32 (a) 50 -- -- 50 -- -- 50 -- -- 50 -- --Oranite 128 (b) -- 50 -- -- 50 -- -- 50 -- -- 50 --Tufflo G056 (c) -- -- 50 -- -- 50 -- -- 50 -- -- 50Adhesive PropertiesRolling Ball Tack, cm 6 8 5 7.5 5.5 8.5 10 15 5 18 13 6Polyken Tack gm/cm.sup.2 375 450 200 450 585 250 410 570 275 450 700 33090° Quick Stick lbs/in.sup.2 0.8 1.0 0.2 1.0 1.1 0.4 1.1 1.2 0.4 1.3 1.8 0.7Peel, lbs/in.sup.2 1.4 2.0 0.3 2.3 2.6 0.5 1.7 2.4 0.5 2.3 2.7 1.3__________________________________________________________________________ (a) Low MW Polybutene (b) High MW Polybutene (c) Naphthenic Oil
TABLE VIII__________________________________________________________________________COMPARISON OF 85° C. AND 125° C. SOFTENING POINT RESINS1.5 Mil Films Made From Toluene Solution of Elastomer etc.Resin FormationKraton G-1657 100Resin, phrEscorez 5380 (a) 75 75 75 100 100 100 -- -- -- -- -- --Escorez 5320 (b) -- -- -- -- -- -- 75 75 75 100 100 100AdditiveOranite 32 (c) 50 -- -- 50 -- -- 50 -- -- 50 -- --Oranite 128 (d) -- 50 -- -- 50 -- -- 50 -- -- 50 --Tufflo G056 (e) -- -- 50 -- -- 50 -- -- 50 -- -- 50Adhesive PropertiesRolling Ball Tack, cm 6 8 5 7.5 5.5 8.5 11 23 6.8 30 30 12Polyken Tack gms/cm.sup.2 375 450 200 450 585 250 480 600 251 500 740 34590° Quick Stick lbs/in.sup.2 0.8 1.0 0.2 1.0 1.1 0.4 0.7 1.4 0.3 1.4 1.8 0.4Peel, lbs/in.sup.2 1.4 2.1 0.3 2.3 2.6 0.5 1.9 1.3 0.4 1.4 2.2 1.3__________________________________________________________________________ (a) 85° C. Softening Point Resin (b) 125° C. Softening Point Resin (c) Low MW Polybutene (d) High MW Polybutene (e) Naphthenic Oil | This invention relates to pressure sensitive adhesive compositions which includes a hydrogenated block copolymer such as Kraton G, about 25 to about 250 parts by weight of a hydrocarbon resin of a petroleum or coal tar distillate, aliphatic dienes and mono- and diolefins, cyclic olefins of 5 or 6 carbon atoms and hydrogenated poly cyclics per 100 parts by weight of the hydrogenated block copolymer, and about 25 to 200 parts by weight of a polybutene or polyisobutylene per 100 parts of the hydrogenated block copolymer, wherein said mixture of Kraton G, said hydrocarbon resin and said polybutene or polyisobutylene are dissolved in a non-reactive solvent at a concentration level of about 5 to about 25 grams per 100 mil of non-reactive solvent. | 2 |
This is a division of application Ser. No. 06/391,566 filed June 24, 1982, now U.S. Pat. No. 4,505,088 issued Mar. 19, 1985.
SUMMARY OF THE INVENTION
The present invention provides a building structure adapted for use as underground or partially undergound structures. Such building structure is of an arcuate configuration on a concrete foundation slab. The arcuate structure has a central cast concrete keystone of special construction in accordance with the present invention. The remaining blocks used for the building structure extend downwardly from the central keystone and essentially are mortarless modified concrete blocks utilized in the construction industry thereby allowing interchangeability during construction of the building structure of the present invention. Thus, the modified concrete construction blocks do not require a close tolerance but may have tolerances generally found in ordinary concrete construction blocks.
The modified concrete construction blocks are joined together with fastening means comprising elongated substantially flat, rectangular-shaped shear key members. End fastening means are provided to secure each transverse or longitudinal row of blocks and include first and second end members, each of which has a partially recessed opening for receiving a bracket member having first and second tie rods or cables connected thereto and having a threaded member extending from the bracket into such partially recessed opening.
The central keystone member of the arcuate building structure is formed by plywood which is positioned to allow concrete to be poured between the two longitudinal rows of modified concrete construction blocks at the upper portion of the arcuate construction with a steel reinforcing rod being positioned in the concrete fill prior to pouring concrete for the keystone. A pair of metal fabrication are used to provide necessary adjustment and temporary support to each transverse or longitudinal row and support the suspended plywood form. The metal fabrication have slots for two bolts and nuts to allow adjustment of the metal fabrications by movement in the elongated openings in which each of the bolt and nut assembly are positioned. When concrete is poured to become the central keystone block, the metal fabrications are cast into the concrete.
The present invention utilizes repetitive modules or blocks and a building can be constructed with relatively low-skilled labor and with minimal equipment. Because the structure is adapted for total or partially underground use, heating and cooling costs are minimal because of the inherent thermal benefits of the earth. Two factors which have presented problems in the past, moisture and weight, have been overcome through the building structure provided by the present invention and by the use of conventional waterproofing methods.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view showing the building structure of the present invention on a concrete slab and partially covered with soil;
FIG. 2 is an upper, isometric or perspective view of part of the block structure shown in connection with the building structure of FIG. 1;
FIG. 3 is an upper, isometric or perspective view of an individual, modified concrete construction block utilized in practicing the present invention;
FIG. 4 is a longitudinal, sectional, elevational view showing a series of modified concrete construction blocks held together through end fastening means;
FIG. 5 is an upper, isometric or perspective view of one of the end fastening means shown in FIG. 4;
FIG. 6 is a front, transverse sectional view of the central cast concrete keystone utilized at the center and uppermost part of the building structure shown in FIG. 1; and
FIG. 7 is an upper, perspective view of the metal fabrication members shown in FIG. 6.
DETAILED DESCRIPTION
FIG. 1 is a perspective view showing the building structure of the present invention. A concrete slab 10 may be poured in a conventional manner well-known in the construction industry to form a structural concrete slab which may be of any desired concrete specification depending upon the type of soil and other environmental conditions which may be encountered.
Positioned on the concrete slab 10 are two longitudinal rows of blocks, such as row 12 and row 14. These longitudinal rows comprise a plurality of modified concrete construction blocks such as block 12a, 12b, 12c, 12d, 12e, 12f, 12g, 12h and 12i thereby forming a longitudinal row along one side of the building structure having an arcuate configuration and generally identified in FIG. 1 with the reference numeral 15.
It will be appreciated by those skilled in the art to which the present invention pertains that longitudinal row 14 also comprises a plurality of the same modified concrete construction blocks to provide a base support on which additional rows of blocks such as longitudinal rows 16, 18, 20 and 22 are provided. Keystone 100 is centrally located between rows 110 and 112 and is explained in detail in connection with FIG. 6. It will be appreciated that after the connection and joining of the modified concrete construction blocks in accordance with the method of the present invention that an arcuate building structure is provided having a concrete slab and which when completed may be partially covered with soil 30 to provide natural thermal benefits inherent in the earth. Prior to placing soil 30, a second and finished slab 10a is poured over concrete slab 10 for the purpose of providing an adequate counterreaction of the forces of the soil at the base of the structure from pushing the first laid rows inward. The building structure of the present invention provides reduction of heating and cooling costs which are important in the present era of energy-conscious living. It will be appreciated further that the building structure is comprised of repetitive modules and may be constructed with low-skilled labor and minimal equipment, as will be explained in detail in connection with the other drawing figures.
FIG. 2 is an upper, isometric or perspective view showing the modified concrete construction blocks utilized in construction of the building structure 15 shown in FIG. 1. A plurality of blocks, such as blocks 50, 60, 70 and 80 comprise part of the arcuate section of the building structure, block 72 and block 82 are shown positioned and connected to blocks 70 and 80.
Block 50, as explained previously, is a modified concrete construction block and fabricated in a conventional cinder block machine thereby allowing standardization and interchangeability to be practiced in constructing the building structure of the present invention. Block 50 includes a top portion 50a, a side portion 50b.
An elongated substantially flat fastening member 51 is used as a shear key and adapted for slideable engagement in slot 53 of block 50 and the block adjacent to block 50.
It will be appreciated in reviewing the disclosure of FIG. 2 that a plurality of elongated, substantially flat fastening members, such as fastening member 51, are utilized in fixedly positioning blocks 50, 60, 70 and 80 and in fixedly positioning block 70 to block 72 and block 80 to block 82. For example, elongated fastening member 61 may be used in positioning of block 50 to block 60. The elongated fastening member 61 has a top 61a, a side 61b, and an end 61c visible in FIG. 2. Not visible in FIG. 2 is another side, another end, and a bottom portion. The elongated fastening member 61 is typical of the elongated fastening members utilized in constructing the entire arcuate building structure of the present invention.
The easy, reliable, and relatively fast positioning of blocks of standard size and quality are an important aspect of the present invention because of minimal need for conventional construction hardware such as nails, screws, and clamps. It should be noted that an arcuate formwork will be required for the first two or three transverse rows. But after several rows are in place, the subsequent blocks are able to support off of the previous transverse row by the use of the shear key.
FIG. 3 is an upper, isometric or perspective view of an individual, modified concrete construction block, such as block 50 shown in FIG. 2. Block 50 includes a top 50a, a side 50b having a slot 53 as pointed out previously in connection with FIG. 2. Block 50 includes an upper opening 55 and a similar lower opening 57 typical of the modified concrete construction blocks and standard industry blocks. The face 59 of block 50 includes a notch 59a.
FIG. 4 is a longitudinal, sectional, elevational view showing a series of modified concrete construction blocks held together through end fastening means and in a row such as row 21 shown in FIG. 1. Row 21, for example, may have end members 21a and 21b, each of which has a recess 21c and 21d for receiving a cable or tie wire bracket such as tie wire bracket 21e having a threaded portion 21f on which is positioned a nut 21g. Cable or tie wire members 21h and 21i are positioned to each side of member 21j which is the central portion of the modified concrete construction block. The tie wires 21h and 21i have threaded ends and are secured to the bracket 21e with nuts in a manner well known in the construction art as shown in FIG. 4. Specifically, nut 21k is threadedly connected to threaded end 21m of tie wire 21i.
FIG. 5 is an upper, isometric or perspective view of end member 21a having an opening or hole 21n in which threaded portion 21f is positioned. Threaded portion 21f is connected to bracket 21e having tie wires 21h and 21i.
FIG. 6 is a front, transverse sectional view of the central cast concrete keystone utilized at the center and uppermost part of the building structure shown in FIG. 1. As rows of blocks are positioned as has been described previously and the arcuate configuration develops, there ultimately will be a space left between the blocks which have been built starting from each side of the base or concrete slab. This space is filled with concrete to form a keystone member 100 positioned between block rows 110 and 112 shown in FIG. 1. It will be appreciated that rows 110 and 112 are constructed in accordance with the previously disclosed method of the present invention and when the keystone member is ready to be poured with concrete, a keystone fastening means 114 which may be called a compression bracket also is utilized and positioned in notch 116 and notch 118. A similar arrangement is provided at the top of each transverse row of blocks 12, 12a through 12i. An important part of the present invention is the keystone construction wherein keystone fastening means 114 also called compression brackets are utilized and the keystone fastening means 114 will be explained in detail subsequently in connection with the detailed description of FIG. 7.
A plywood or other material form 120 is suspended by tie wires 122 and 124 and a conventional steel reinforcing rod 126 is positioned on top of the keystone fastening means 114. Concrete then is poured in the space or opening between rows 110 and 112 and upon hardening of the concrete, the arcuate building structure is complete and structurally sound. The tiewires 122 and 124 are cut to allow the plywood form to be removed.
FIG. 7 is an upper, perspective view of the metal fabrication members shown in FIG. 6 and also referred to as compression brackets. Keystone fastening means 114 include identical members 114a and 114b. Each of members 114a and 114b has an elongated slot to form openings 114c and 114d when positioned as shown in FIG. 7 to allow adjustment of members 114a and 114b for engagement in the concrete block notches with lips or protrusions 114e and 114f as explained previously in connection with FIG. 6. A bolt 114g having a nut 114h positioned thereon is positioned in slot 114c and, likewise, bolt 114i having nut 114j is positioned in slot 114d. It will be appreciated in viewing the keystone fastening means shown in FIG. 7 that members 114a and 114b may be assembled quickly and adjusted to compensate for the varying distance that may be found between the notches in the blocks adjacent the keystone centerpiece. These brackets keep each half of the arcuate structure from collapsing inward until the concrete keystone is cast.
Thus, it will be appreciated that the present invention provides a new and useful method and apparatus for constructing a building structure adapted for at least partial burial whereby the natural thermal qualities of the earth are utilized to minimize heating and cooling expense when the building structure of the present invention is inhabited.
Although a preferred embodiment of the invention has been shown and described in accordance with the requirements of the United States Patent Laws, it will be appreciated by those skilled in the art to which the present invention pertains that many modifications and improvements may be made without departing from the spirit of the invention defined by the following claims. Although such claims may be presented in an indented format to facilitate reading and understanding thereof, such indented format is not to be construed as a structural or functional limitation of the elements or steps recited in such claims. | A method of assembly adapted for use with underground structures having an arcuate, elongated configuration and constructed of substantially identical blocks joined together with substantially identical fastening means and extending from both sides of a center keystone thereby allowing energy efficient, reliable, low cost structures capable of being mass produced with minimal die or pattern expense. | 4 |
RELATED U.S. APPLICATION DATA
[0001] This application is a continuation of U.S. patent application Ser. No. 13/287,471, filed on Nov. 2, 2011, entitled “Methods for Secure Restoration of Personal Identity Credentials into Electronic Devices;” which is a continuation of U.S. patent application Ser. No. 12/190,064, filed Aug. 12, 2008, entitled “Methods for Secure Restoration of Personal Identity Credentials into Electronic Devices”, now U.S. Pat. No. 8,055,906; which is a divisional of U.S. patent application Ser. No. 10/635,762, filed Aug. 6, 2003, entitled “Methods for Secure Enrollment and Backup of Personal Identity Credentials into Electronic Devices,” now U.S. Pat. No. 7,590,861; which claims priority to U.S. Patent Application No. 60/401,399 filed on Aug. 6, 2002 entitled, “A Secure Enrollment Process for a Biometric Personal Authentication Device;” each of which is herein incorporated by reference in their entireties.
[0002] This application is related to U.S. patent application Ser. No. 12/190,058, filed Aug. 12, 2008, entitled “Methods for Secure Enrollment of Personal Identity Credentials into Electronic Devices” now U.S. Pat. No. 8,127,143; and U.S. patent application Ser. No. 12/190,061, filed Aug. 12, 2008, entitled “Methods for Secure Backup of Personal Identity Credentials for Electronic Devices,” now U.S. Pat. No. 7,788,501; each of which is incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to the field of information security, and more particularly to an enrollment process for devices capable of storing and releasing personal identity credentials based on authentication of a human fingerprint.
[0005] 2. Necessity of the Invention
[0006] Devices and applications that use biometric authentication are increasing in popularity and frequency of use in applications where information security and privacy is critical. The success rates of devices that use biometrics as a form of authorization are dependent on the accuracy of the process by which information is associated with the biometric; for example, it must not be possible for John Doe to intercept Jane Doe's enrollment process and enroll Jane Doe's credentials into a device with his fingerprint. A generalized enrollment process includes capturing a biometric sample, ensuring the legitimacy of the sample and the individual providing the sample, storing the biometric sample in the appropriate location in the device, and enabling access rights to the enrolled individual. If this enrollment process is performed incorrectly or ineffectively then the process of biometric authentication and the implicit guarantee of enhanced security are easily defeated.
[0007] A variety of portable electronic devices with biometric authentication are available to consumers. These include Hewlett Packard's iPAQ Pocket PC h5450, 3M-AiT's VeriMe, Privaris' BPID™ Security Device, and Sony's FIU-900 Puppy®. Each device is capable of storing fingerprints and performing on-board matching. Several of these products are configurable to allow use of cryptographic keys after proof of biometric identification. As discussed in the following section, ownership of cryptographic keys is typically used as a form of remote identification when individuals are communicating digitally. It is imperative, then, that the fingerprint is definitively linked to an individual, so that the cryptographic keys cannot be misused.
[0008] Furthermore, because the enrollment process must necessarily be stringent, and likely time-consuming, it is desirable to have a simple method of archiving and restoring enrolled credentials and fingerprints. Clearly the method must be inherently secure, because the entire enrollment process could be overridden by a compromise of the backup process.
DESCRIPTION OF THE RELATED ART
[0009] Public Key Infrastructure
[0010] The public key infrastructure (PKI) and digital certificates are very common and, when used correctly, can be used to guarantee a ‘cryptographic identity’ of an individual. The most common form of the PKI uses the RSA algorithm, which is now freely available to the public.
[0011] To use the PKI, an individual—Alice—applies for a digital certificate from a trusted authority. After a substantive background investigatory process, the trusted authority decides that Alice is who she claims to be and decides to issue a digital certificate. The certificate includes a public key, one half of an asymmetric key pair, which is assigned only to Alice. She retains the other half of the key pair, the private key. Due to the fundamental principles of public key cryptography, anything encrypted by the Alice's private key can only be decrypted using her public key, and vice versa. Alice is free to distribute the digital certificate and the public key to whomever she wishes.
[0012] When another individual, Bob, wishes to send a message to Alice, he encrypts it with her public key. Alice receives the encrypted message and uses her private key to decrypt it. Because Alice is the unique owner of her public key, Bob knows that she possesses the unique and accompanying private key. Additionally, Bob sees that a trusted authority, which he knows performs substantive background checks, issued the digital certificate issued to Alice. He is assured that the only person who can read the message is truly Alice. This assures one-way security.
[0013] However, Alice cannot be sure that Bob sent her the message, because her public key is freely accessible. To combat this problem, Bob also requests and receives a digital certificate from a trusted authority. Bob writes his message and then creates a digital signature for the message. He first creates a hash of the message; this process creates a fixed-length string that is unique to the message but cannot be used to deduce the message. He then encrypts this hash using his private key and appends the encrypted hash to his message. The message and encrypted hash are now encrypted with Alice's public key, and transmitted to her.
[0014] Alice first decrypts the message with her private key. She can now read the message, as described above. However, she also has the encrypted hash, which she can use to verify that Bob sent the message. She uses Bob's public key to decrypt the digital signature and obtain the hash. Alice then hashes the received message herself, using the same hash algorithm as Bob. If she obtains the same hash value as the one transmitted by Bob, she is assured that the message has not changed, and that he did actually send the message.
[0015] Enrollment Processes
[0016] 3M-AiT's VeriMe stores a biometric template and a cryptographic private key for one user. When the user wishes to use the cryptographic private key, he or she must supply the correct biometric template. According to the VeriMe fact sheet, the private key is generated at the time of “secure registration” of the fingerprint. However, the fact sheet does not describe the secure registration or what it entails; it also does not discuss a secure backup and recovery process.
[0017] Biometric Associates (BAI) produces a fingerprint sensor that can be embedded into a smartcard. The smartcard can then be used to perform local biometric authentication, like the devices described above. According to BAI's website, the cards can enroll up to eight users with the use of a BAI Enrollment Station. The Enrollment Station provides external equipment necessary to instruct the smartcard to start enrolling fingerprints and personal credentials. However, the published information does not describe a secure cryptographic process for accomplishing this. It also does not describe secure backup and recovery processes.
BRIEF SUMMARY OF THE INVENTION
[0018] The invention disclosed herein describes processes for securely enrolling personal identity credentials into devices with means for personal identification. For example, a handheld computer with a biometric sensor may use enrolled fingerprints to identify a user when he requests access to stored information. The enrollment of the fingerprint must tie the user definitively to the fingerprint so that future authorizations are valid.
[0019] The invention described herein provides a process for enrollment wherein a manufacturer of a personal identification device records serial numbers or another unique identifier for each device that it produces, along with a self-generated public key for each device. An enrollment authority is recognized by the manufacturer or another suitable institution as capable of validating an individual before enrolling him into the device-maintains and operates the appropriate equipment for enrollment, and provides its approval of the enrollment. In some embodiments, a biometric personal identification device (BPID) is verified that it is a legitimate device and that it has not been previously enrolled to another individual.
[0020] The BPID is an electronic, secure personal identification apparatus for which the present invention describes enrollment techniques. The security features that it offers, including integration with the public key infrastructure and local-only storage of the biometric, guarantee that the processor has authorized the dissemination of personal information.
[0021] The methods described herein are directed to post-manufacturing processes for the device, as well as the enrollment itself. Additionally, the invention describes methods for securely archiving enrolled personal identity credentials. This is to allow users to restore previously validated credentials into a new device without requiring a completely new enrollment. Correspondingly, the invention describes the restoration process, in which the stored credentials are securely downloaded into the new device.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 : Post-manufacturing process
[0023] 101 Provide manufacturer's public key to device
[0024] 102 Generate key pair for device
[0025] 103 Provide device's public key and unique ID to manufacturer
[0026] 104 Create digital certificate for device
[0027] 105 Provide digital certificate to device
[0028] 106 Store device's public key and unique ID
[0029] 107 Disable device
[0030] FIG. 2 : Enrollment
[0031] 201 Request permission from enrollment authority to enroll credentials into device
[0032] 202 Validate the request
[0033] 203 Present device's digital certificate
[0034] 204 Verify that device is true owner of the certificate
[0035] 205 Present enrollment authority's digital certificate
[0036] 206 Verify that enrollment authority is true owner of the certificate
[0037] 207 Create a session key
[0038] 208 Complete enrollment, encrypting with the session key
[0039] FIG. 3 : Backup
[0040] 301 Create symmetric biometric encryption and decryption key
[0041] 302 Encrypt the biometric with the symmetric biometric encryption and decryption key
[0042] 303 Divide the symmetric biometric encryption and decryption key into two parts
[0043] 304 Encrypt first part with a passphrase
[0044] 305 Digitally sign second part with primary device's private key
[0045] 306 Encrypt digital signature and second part of symmetric biometric encryption and decryption key with the controller's public key
[0046] 307 Create symmetric personal identity credential encryption and decryption key
[0047] 308 Digitally sign personal identity credential with primary device's private key
[0048] 309 Encrypt credential with symmetric personal identity credential encryption and decryption key
[0049] 310 Divide symmetric personal identity credential encryption and decryption key
[0050] 311 Encrypt first part of symmetric personal identity credential encryption and decryption key with passphrase
[0051] 312 Digitally sign second part of symmetric personal identity credential encryption and decryption key with primary device's private key
[0052] 313 Encrypt digital signature and second part of symmetric personal identity credential encryption and decryption key with controller's public key
[0053] 314 Store the encrypted biometric, encrypted credentials, and encrypted symmetric biometric encryption and decryption key and symmetric personal identity credential encryption and decryption key in an electronic storage repository
[0054] 315 Provide user with a digital certificate containing the primary device's public key
[0055] FIG. 4 : Restoration
[0056] 401 Access the electronic storage repository
[0057] 402 Obtain both parts of the symmetric biometric encryption and decryption key
[0058] 403 Decrypt the first part with a passphrase
[0059] 404 Decrypt the second part and the digital signature with the controller's private key
[0060] 405 Verify the digital signature using the primary device's public key
[0061] 406 Combine both parts of the symmetric biometric encryption and decryption key
[0062] 407 Decrypt the biometric
[0063] 408 Store the biometric in the secondary device
[0064] 409 Obtain both parts of the symmetric personal identity credential encryption and decryption key
[0065] 410 Decrypt the first part with a passphrase
[0066] 411 Decrypt the second part and the digital signature with the controller's private key
[0067] 412 Verify the digital signature using the primary device's public key
[0068] 413 Combine both parts of the symmetric personal identity credential encryption and decryption key
[0069] 414 Decrypt the personal identity credential and the associated digital signature
[0070] 415 Verify the digital signature using the primary device's public key
[0071] 416 Store the personal identity credential in the secondary device
[0072] FIG. 1 is a flow chart illustrating the post-manufacturing process for a personal identification device.
[0073] FIG. 2 is a flow chart illustrating the process for enrolling personal identity credentials into the personal identification device.
[0074] FIG. 3 is a flow chart illustrating the backup process for securely storing personal identity credentials for future restoration.
[0075] FIG. 4 is a flow chart illustrating the restoration process.
[0076] FIG. 5 illustrates components of a biometric personal identification device (BPID), according to an embodiment of the invention.
[0077] FIG. 6 is a system diagram illustrating transactions between the BPID of FIG. 5 and a manufacturer database, according to an embodiment of the invention.
[0078] FIG. 7 is a system including the BPID of FIG. 5 illustrating communication channels for the enrollment process, according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0079] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention.
[0080] The invention disclosed herein provides a process for securely enrolling individuals into devices with means for personal identification via use of biometric authentication (hereafter referred to as ‘personal identification devices’). Because these devices are intended for use as trusted authentication devices, it is imperative that all of the information stored within the device be placed there in such a manner that it cannot be altered without proper authorization. There are two participants in the enrollment process, the manufacturer of the personal identification device and an enrollment authority.
[0081] The enrollment process includes identifying the device post-manufacturing and enrolling personal identity credentials and an associated biometric into the personal identification device. Furthermore, the invention also discloses methods for creating secure backup and recovery processes, such that an individual may securely store the enrolled information in an electronic storage repository, such as a hard drive. If his personal identification device fails he can use the recovery process to transfer the stored, enrolled information to a new device.
[0082] The two participants in the enrollment process must be definitely and separately identified for proper enrollment. The first participant in the enrollment system is the manufacturer of the personal identification device. The manufacturer is responsible for maintaining a database of unique identifiers, such as serial numbers, for all of the devices that it produces. This enables it later to determine if it manufactured a particular device. The second party is an enrollment authority, which is responsible for investigating, authorizing and performing individuals' requests for enrollment into a personal identification device. This participant may be a Department of Motor Vehicles, a building security officer, or any other person or organization responsible for issuing personal identification devices.
[0083] Initial Enrollment
[0084] This enrollment system uses the PKI described above. Each manufacturer and enrollment authority is provided with at least one asymmetric key pair that can be used for identification and encryption. The key pairs may be self generated, but the public key for each must be placed in a digital certificate signed by a trusted authority. Additionally, the manufacturer may wish to sign digital certificates owned by the enrollment authority as means for guaranteeing its approval of the enrollment authority.
[0085] FIG. 1 demonstrates the post-manufacturing process that begins the enrollment process for a personal identification device. Immediately following manufacturing, each personal identification device receives a public key possessed by its manufacturer (step 101 ). In the preferred embodiment this key is received as part of a digital certificate. The personal identification device can use this public key to verify the digital signature on messages transmitted from the manufacturer and accept them as legitimate instructions. This step requires that the manufacturing process be secure and tamper-resistant; receiving a key other than a trusted manufacturer's would directly compromise future security verifications.
[0086] The personal identification device now generates an asymmetric key pair for itself (step 102 ). The public key and the device's unique identifier are sent to the manufacturer (step 103 ). The manufacturer, or other legitimate certificate authority, generates a digital certificate for the device (step 104 ). This is now sent back to the device, and can be signed by the manufacturer as a token of its legitimacy (step 105 ). The manufacturer keeps a record of the device's public key and its unique identifier for future reference (step 106 ). At this point all functionality within the personal identification device is disabled, such that it is in a state waiting for future enrollment (step 107 ).
[0087] As seen in FIG. 2 , upon receipt of a personal identification device, an individual requests enrollment rights from an enrollment authority (step 201 ). This may require that the individual be physically present in a specified location, or may be performed remotely. The enrollment authority may establish all rules pertaining to the applicant verification process. The security and authenticity of the personal identification device is only as good as that of the verification process, so it is anticipated that these processes will be as stringent as required by the end application.
[0088] After approving the applicant, the enrollment authority receives the personal identification device's digital certificate (steps 202 and 203 ). The enrollment authority validates the digital certificate by prompting the device to encrypt a predetermined string with its private key (step 204 ). The enrollment authority now decrypts the encrypted string using the public key stored in the device' digital certificate, and verifies that the decrypted string matches the predetermined string. At this point the personal identification device will receive and verify the validity of the enrollment authority's digital certificate (steps 206 and 206 ). It performs the same prompt and verification process described above, and can also verify the manufacturer's signature on the certificate if one exists. After confirming the legitimacy of the enrollment authority, the personal identification device creates a session key, encrypts the session key and securely releases it to the enrollment authority (step 207 ). The personal identification device and the enrollment authority can now communicate freely using the session key (step 208 ). The biometric may be downloaded into the personal identification device along with the personal identity credentials, or may alternatively be sensed locally using the device and stored locally. The enrollment process, at this stage, is application-dependent and requires the establishment of requisite credentials, etc., which are not covered within the scope of this invention.
[0089] Restoration Processes
[0090] It may be necessary in some cases to provide a backup of at least one enrolled personal identity credential and biometric. The backup may be used in the event that the personal identification device fails, such that the individual may re-enroll a new personal identification device without undergoing the entire process described above; these devices are referred to as the ‘primary personal identification device’ and the ‘secondary personal identification device,’ respectively.
[0091] Backup
[0092] There are two distinct parts of the restoration process. The first part describes a method for archiving the enrolled personal identity credential, which allows an enrolled individual to securely store his personal identity credential and biometric to a user-accessible computer disk or other electronic storage repository. This data is only accessible with permission from a device manufacturer, an enrollment authority, or a recovery authority, as specified by the implementer of the system. In the primary embodiment, this system controller will be the manufacturer of the primary personal identification device. The second part of the restoration process describes a method for restoring the stored data to the secondary personal identification device.
[0093] As seen in FIG. 3 , the primary personal identification device generates a symmetric biometric encryption and decryption key (step 301 ). This key is used for encrypting a digital representation of the enrolled biometric (step 302 ), which can be used to unlock the archived personal identity credential(s). After encryption of the biometric, the symmetric biometric encryption and decryption key is divided into two unique and distinct parts (step 303 ); the scheme of separation may be selected at the discretion of the system implementer. The first part of the symmetric biometric encryption and decryption key is encrypted with a user-selected passphrase (step 304 ). The second part of the symmetric biometric encryption and decryption key is signed by a private key possessed by the primary personal identification device (step 305 ), and is then encrypted with a public key owned by the system controller (step 306 ). As described above, in this embodiment the system controller is the primary personal identification device manufacturer. Using the manufacturer's public key forces an individual to request restoration privileges from the manufacturer during restoration, because the individual needs the manufacturer to decrypt the data with its private key. This is discussed in further detail below.
[0094] The primary personal identification device then generates a symmetric personal identity credential encryption and decryption key (step 307 ), which is used for encrypting at least one enrolled personal identity credential. The primary personal identification device first digitally signs the personal identity credential, using a private key (step 308 ), and then encrypts the personal identity credential and associated digital signature (step 309 ). Similarly to the scheme described above, the symmetric personal identity credential encryption and decryption key is divided (step 310 ) into two unique and distinct parts. The first part is encrypted with a user-selected passphrase (step 311 ), which may or may not be the same passphrase as used above. The second part is again signed by the device' private key (step 312 ) and encrypted with the manufacturer's public key (step 313 ).
[0095] All of the encrypted and/or signed data—the biometric, the symmetric biometric encryption and decryption key, the personal identity credential, and the symmetric personal identity credential encryption and decryption key—are now stored in an electronic storage repository (step 314 ). In typical embodiments the electronic storage repository could be a computer hard drive, floppy disk, or network drive. The primary personal identification device releases its digital certificate to the individual for future use of its public key (step 315 ).
[0096] Restoration
[0097] As seen in FIG. 4 , when an individual receives a secondary personal identification device, and wishes to restore data from a primary personal identification device, he must access the electronic storage repository (step 401 ). The individual must first acquire the two encrypted and/or signed parts of the symmetric biometric encryption and decryption key (step 402 ). The secondary personal identification device decrypts the first part of the symmetric biometric encryption and decryption key with the user's passphrase (step 403 ). It then requests the system controller, the manufacturer of the primary personal identification device, to decrypt the second part of the symmetric biometric encryption and decryption key and the associated digital signature using its (the manufacturer's) private key (step 404 ). Once the data has been decrypted, the secondary personal identification device verifies the digital signature using a public key possessed by the primary personal identification device (step 405 ). The two parts of the symmetric biometric encryption and decryption key are now combined appropriately (step 406 ), and can be used to decrypt the biometric (step 407 ). The biometric is now stored in an appropriate location within the secondary personal identification device (step 408 ).
[0098] The individual now obtains the two encrypted and/or signed parts of the symmetric personal identity credential encryption and decryption key (step 409 ). Similarly to the process described above, the secondary personal identification device decrypts the first part of the symmetric personal identity credential encryption and decryption key using a user-selected passphrase (step 410 ). It now requests the system controller, the manufacturer of the primary personal identification device, to decrypt the second part of the symmetric personal identity credential encryption and decryption key and the accompanying digital signature using its private key (step 411 ). Again, the secondary personal identification device verifies the digital signature using a public key possessed by the primary personal identification device (step 412 ). The two parts of the key are reconstructed to form one key (step 413 ). The key is now used to decrypt the personal identity credential and the associated digital signature (step 414 ), and the signature is verified using a public key owned by the primary personal identification device (step 415 ). The decrypted personal identity credential can now be stored appropriately within the secondary personal identification device (step 416 ).
[0099] FIG. 5 illustrates the components of the BPID, according to an embodiment of the invention. As shown in FIG. 5 , the components of the BPID include a processor, a memory, an RF wireless transceiver, a fingerprint sensor, a battery and a graphic liquid crystal display (LCD).
[0100] A BPID is a handheld electronic device that provides multi-factor authentication and allows its registered and/or enrolled owner to control the release and dissemination of stored information such as financial accounts, medical records, passwords, personal identification numbers, and other sensitive data and information. The device has tamper-resistant packaging with from factors ranging from credit card size to key fobs, and further includes a fingerprint scanner. Although those familiar in the art will recognize that this device's biometrics can be interchanged with another biometric technology, it can be observed that Russell's BPID patent application additionally includes a liquid crystal display (LCD) and buttons for user interaction, a wireless interface for communicating with other electronic devices, and a self-generated public key/private key pair for digitally signing data. The device has been developed so that the fingerprint cannot be physically or electronically removed or transmitted from the device, and information cannot be physically or electronically removed or transmitted from the device unless released by the owner of the authorizing fingerprint. All data and processing is performed securely.
[0101] The BPID can store and run multiple applications, allowing an individual to store a variety of personal information, although it is important to note that the applications are fully independent and cannot affect other applications' data. Many of these applications require the owner to transmit information to a terminal; for example, the BPID may wirelessly transmit financial account information to a cash register during an in-store purchase. In order to make the transaction secure, the BPID uses its private key to create a digital signature on all information that the individual chooses to release. Recipients of information from the BPID use the encrypted digital signature and a database of public keys to confirm that the information came from a specific device and that the information has not been altered. If it is desired by, e.g., a driver license verification application and/or other independent applications, the BPID can encrypt all transmitted data and information so that only the intended recipient can decode the information. The BPID places the control of personal and private information in the hands of the individual that owns the information and the organization that issues the device and/or creates device applications.
[0102] FIG. 6 is a system diagram illustrating transactions between the BPID of FIG. 5 and a manufacturer database, according to an embodiment of the invention. The BPID can receive from the manufacturer database the manufacturer public key. The BPID can generate an asymmetric key pair and release/send the BPID public key to the manufacturer database, who issues and signs a certificate for the BPID. The manufacturer database can download the certificate and public key of the manufacturer to the BPID. The BPID can receive from the manufacturer database the BPID serial number.
[0103] FIG. 7 is a system including the BPID of FIG. 5 illustrating communication channels for the enrollment process, according to an embodiment of the invention. The system includes the BPID, a user's personal computer (PC), a manufacturer server and an enrollment authority server. The user's PC can communicate with the BPID, the manufacturer server and the enrollment authority server. The enrollment authority server can communicate with the manufacturer server.
[0104] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. | A method and system for securely enrolling personal identity credentials into personal identification devices. The system of the invention comprises the manufacturer of the device and an enrollment authority. The manufacturer is responsible for recording serial numbers or another unique identifier for each device that it produces, along with a self-generated public key for each device. The enrollment authority is recognized by the manufacturer or another suitable institution as capable of validating an individual before enrolling him into the device. The enrollment authority maintains and operates the appropriate equipment for enrollment, and provides its approval of the enrollment. The methods described herein discuss post-manufacturing, enrollment, backup, and recovery processes for the device. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2011/003488, filed Jul. 13, 2011, which designated the United States and has been published as International Publication No. WO 2012/013297 A2 and which claims the priority of German Patent Application, Serial No. 10 2010 032 442.6, filed Jul. 28, 2010, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to a self-igniting internal combustion engine.
Self-igniting diesel fueled internal combustion engines of motor vehicles have significantly higher soot emissions compared to gasoline operated internal combustion engines of motor vehicles. Because these soot emissions significantly contribute to fine dust contamination of the air, great efforts are made to lower soot emissions. The same is true for other pollutant emissions of internal combustion engines of motor vehicles such as for example nitrogen oxide emissions. One possibility for lowering pollutant emissions of internal combustion engines is to influence the combustion in the combustion chambers of the cylinders in such a way so as to ensure a complete reaction of the injected fuel with the oxygen in the combustion air into carbon dioxide and water vapor. However, a complete reaction is only possible when fuel and combustion air are well intermixed in the combustion chamber. This intermixing depends inter alia on the geometry of the piston or combustion chamber recess, which is arranged opposite the injector in the front side of the piston.
In order to increase turbulence of the flow of the combustion air inside the piston—or combustion recess and with this the swirling, of the fuel which is injected into the combustion chamber to thereby ensure a better combustion of the fuel, internal combustion engines have previously been proposed in which the piston—or internal combustion recess of the pistons generally has an angled or polygonal contour or circumference. This recess shape is intended to cause turbulences to form in the corners of the piston—or combustion recess, which counteract the main flow or interact with the main flow in other ways in order to ensure a better intermixing of combustion air and fuel due to the forming turbulences.
From DE-A2 343 023, an internal combustion engine of the previously mentioned type is already known in which for improving the distribution and atomization of the injected fuel, the piston—or combustion recess has a generally square contour with rounded corners, while the injector is provided with four injection openings, which are arranged in angular distances of 90 degrees and oriented so that the fuel which is ejected from the injection openings impacts the boundary surface of the piston—or combustion recess before the rounded corners at an oblique angle when viewed in the direction of flow or swirl.
Based on the foregoing, the invention is based on the object to improve an internal combustion engine of the previously mentioned type so that the emissions and in particular the soot emissions of the internal combustion engine can be further decreased.
SUMMARY OF THE INVENTION
According to the invention, this object is solved in that the injection openings of the injector have different opening cross sections, and in that the injection openings with the different opening cross sections are directed toward regions of the combustion recess which have different flow cross sections.
The invention is based on the idea that the different opening cross sections of the injection openings of the injector at same rail pressure and same injection duration cause different injected masses with different drop spectra and evaporation rates. As a result, the injection jets also have different swirl requirements which is accounted for by the orientation of the injection openings or the injection jets toward regions with different flow cross sections and with this different flow velocities of the combustion air flowing through the combustion recess.
Preferably the orientation of the injection openings is selected so that the injection jets with higher swirl requirements i.e., the injection jets from the injection openings with the smaller opening cross sections are respectively deflected in a direction in which the piston—or combustion recess has a smaller flow cross section and therefore the flow velocities of the combustion air in the recess is greater, while injection jets with lower swirl requirement i.e. the injection jets from the injection openings with the larger opening cross sections are respectively guided in a direction in which the piston—or combustion recess has a greater flow cross section and thus the flow velocities of the combustion air in the recess are smaller. The swirl requirement of the injection jets depends on the penetration depth and on the evaporation speed of the injection jets and is the smaller the greater the penetration depth is or the longer the evaporation takes. The penetration depth of the injection jet and the time required for its evaporation in turn increase with increasing opening cross section of the injection opening.
The measure according to the invention allows combining the advantages of injection openings with larger opening cross sections at full capacity with the advantages of injection openings with smaller opening cross sections at partial capacity. Further, the air in the combustion chamber can be better captured and mixed with the fuel, which leads to a faster combustion with lower nitrogen oxide and soot emissions.
In order to realize the different flow cross sections inside the piston or combustion chamber recess, the recess can be formed so that the outer circumferential surfaces of the recess which are opposed to the injection openings with the different opening cross sections have different radial distances to the injector and/or different depth. Preferably, the distances and/or depth are greater in the region of the injection openings with the greater opening cross sections so that correspondingly greater flow cross sections are present at this location, while they are smaller in the region of the injection openings with the smaller opening cross sections, so that correspondingly smaller flow cross sections are present at this location.
A further preferred embodiment of the invention provides that the injector has multiple pairs of injection openings which each include an injection opening with greater opening cross section and an injection opening with smaller opening cross section. The injection openings with the greater opening cross section and the injection opening with the smaller opening cross section alternate in circumferential direction of the cylinder and the piston, wherein the injection openings with the greater opening cross section are directed to regions of the piston recess with a greater flow cross section and the injection openings with the smaller opening cross sections are directed to region s of the piston recess with a smaller flow cross section. Neighboring injection openings of same size have preferably the same angular distance as neighboring regions of the piston or combustion chamber recess in which the flow cross section has a maximum or a minimum. Advantageously the piston or combustion chamber recess has multiple diametrical plane of symmetry whose number corresponds to the number of pairs of injection openings and is expediently four. The flow cross sections of the piston or combustion chamber recess have a maximum or minimum in the planes of symmetry and increase or decrease again from there up to the neighboring plane of symmetry.
Advantageously, all injection openings of the injector are arranged in a plane which is perpendicular to the longitudinal center axis of the cylinder and the piston and point obliquely downward in the direction of the piston or combustion chamber recess wherein they are directed towards opposing circumferential surfaces of the recess.
A particularly preferred embodiment of the invention provides that the piston or combustion chamber recess has a contour or circumference which generally corresponds to a rounded polygon with rounded corners and expediently corresponds to a square. Advantageously, the sides of the polygon or square are also curved slightly convex outwardly wherein however the radius of curvature in the regions with greater flow cross section, i.e., at the corners of the rounded polygon or square is smaller than in the regions with smaller flow cross section, i.e., at the sides of the rounded polygon or square.
Advantageously, the outer circumferential surfaces of the piston or combustion chamber recess have no discontinuities, so that inside the recess a detachment of the air flow from the circumferential surfaces and with this the formation of secondary swirls can be avoided as far as possible.
According to a further advantageous embodiment of the invention the piston or combustion chamber recess has a key shaped cross section with an extended bulge portion and a narrowed neck portion, which is arranged between the extended bulge portion and a slightly extended point of entry of the combustion chamber recess into a plane front surface of the piston. In the center of the piston or combustion chamber recess a generally pyramid shaped projection with rounded corners and a rounded tip is advantageously located which protrudes over a bottom of the recess and whose circumferential surfaces together with the outer circumferential surfaces of the recess delimit the different flow cross sections inside the recess.
The circumferential surfaces of the generally pyramid shaped projection can advantageously extend parallel to the sides of the generally polygonal circumference of the piston or combustion chamber however, it is also possible to rotate the projection about the longitudinal center axis of the cylinder and the piston so that its rounded corner are opposed to the sides of the generally polygonal circumference of the recess.
BRIEF DESCRIPTION OF THE DRAWING
In the following, the invention is explained in more detail by way of several exemplary embodiments shown in the drawing. It is shown in
FIG. 1 a simplified cross sectional view of a cylinder of a piston and an injector of an internal combustion engine according to the invention;
FIG. 2 superimposed cross sectional view of a piston recess of the piston in two different sectional planes;
FIGS. 3 a and 3 b plan views onto an upper front side of the piston with the piston recess, wherein the injector is not shown to illustrate two preferred orientations of injection openings relative to the piston recess;
FIG. 4 superimposed cross sectional views of an alternative piston recess in two different cross sectional planes corresponding to FIG. 2 ;
FIG. 5 a plan view onto the upper front side of the piston with the piston recess from FIG. 4 , wherein the injector is also shown;
FIG. 6 a cross sectional view of another alternative piston recess of the piston;
FIG. 7 another cross sectional view of the piston recess of FIG. 6 ;
FIG. 8 a plan view onto the lower front side of the piston with the piston recess of FIG. 6 ;
FIG. 9 a perspective view of the upper front side of the piston with the piston recess of FIG. 6 ;
FIG. 10 a side view of a further alternative piston recess;
FIG. 11 a sectional view taken along line XI-XI of FIG. 10 ;
FIG. 12 a side view of yet a further alternative piston recess of the piston;
FIG. 13 a side view taken along line XIII-XIII of FIG. 12 ;
FIG. 14 an enlarged side view of the lower end of the injector.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the cylinder 2 shown in FIG. 1 which is recessed in a cylinder crank case 1 of a diesel internal combustion engine, a piston 3 is movable back and forth along a longitudinal center axis 4 of the cylinder 2 and the piston 3 .
The cylinder 2 and the piston 3 together with a cylinder head 5 of the internal combustion engine, delimit a combustion chamber 6 . An inlet channel 8 which is closable by an inlet valve 7 serves for conducting combustion air into the combustion chamber 6 . An outlet channel 10 which is closable by an outlet valve 9 serves for discharge of combustion gases out of the combustion chamber 6 . An injector 11 serves for injecting diesel fuel into the combustion chamber 6 , which injector 11 is inserted into a bore of the cylinder head 5 which bore is coaxial to the longitudinal center axis 4 and protrudes from above into the combustion chamber 6 . At its free end, the injector 11 has overall eight injection openings 12 , 13 which are arranged about the longitudinal center axis 4 in angular distances of 45 degrees in a plane which is perpendicular to the longitudinal center axis 4 . The injection openings which have a circular cross section and are oriented obliquely downwards have pair wise different opening cross sections, as best shown in FIG. 14 , wherein in circumferential direction of the injector 11 always one injection opening 13 with a smaller diameter is arranged between two injection openings 12 with greater diameter, and vice versa.
In its upper front side facing the combustion chamber 6 , the piston 3 has a piston recess 14 which is open towards the top, and which is surrounded by a generally ring shaped, plane front surface 15 of the piston 3 which front surface neighbors the cylinder 2 .
The piston recesses 14 shown in FIGS. 1 to 5 and 10 to 13 have a contour or circumference 16 which in relation to the longitudinal center axis 4 of the cylinder 2 and the piston 3 is not rotationally symmetric, but in plan view has the shape of a square with four equally long convexly outwardly curved sides with a greater radius of curvature R 1 and four rounded corners with a smaller radius of curvature R 2 . In plan view, the recess 14 is mirror symmetrical relative to four planes of symmetry 17 , 18 , 19 , 20 which are arranged at angular distances of 45 degrees, two of which 17 , 18 extend through the longitudinal center axis 4 and the centers of the rounded corners of the square and two 19 , 20 through the longitudinal center axis 4 and the centers of the sides of the square, as best shown in FIGS. 3 a , 3 b and 11 and 13 .
The piston recesses 14 shown in FIGS. 6 to 9 on the other hand have a circular contour or circumference 16 which is rotationally symmetric relative to the longitudinal center axis 4 of the cylinder 2 and the piston 3 .
As best shown in FIGS. 1, 2, 4, 6, 7, 10 and 12 , all piston recesses have generally a key shaped cross section, wherein their outer circumference 16 has an extended bulge portion 21 and a neck portion 22 which is slightly narrowed relative to the bulge portion 21 , and which is arranged above the bulge portion 21 between the bulge portion 21 and the front surface 15 of the piston 3 and slightly widens toward the front surface 15 .
In their center, all piston recesses 14 have a projection 24 which protrudes upwards over a bottom 23 of the piston recess 14 and has generally the shape of a square pyramid with rounded corners and a rounded tip as best shown in FIGS. 1, 2, 4, 6 and 7 . The tip of the pyramid is arranged below the injector 11 on the longitudinal center axis 4 of the cylinder 2 and the piston 3 . The four sides of the pyramid between the rounded corners can generally be plane ( FIG. 13 ), slightly convexly curved outwardly in the direction of the circumference 16 of the piston recess ( FIG. 11 ) or slightly concavely curved inwardly in the direction of the longitudinal center axis 4 ( FIGS. 3 a , 3 b and 5 ). The sides and the corners of the pyramid can depending on depth and cross sectional dimension of the piston recess 14 have a steeper ( FIG. 7 ) or shallower ( FIG. 6 ) inclination. The pyramid can be oriented so that its rounded corners are mirror symmetrical to the planes of symmetry 17 , 18 through the centers of the rounded corners of the piston recess 14 , as shown in FIG. 11 . As an alternative, the pyramid can also be oriented so that its rounded corners are mirror symmetrical to the planes of symmetry 19 , 20 through the sides of the piston recess 14 , as shown in FIG. 13 .
The piston recess 14 , due to its generally square contour when viewed in circumferential direction of the cylinder 2 and the piston 3 , has different cross sectional dimensions or diameters D, which vary between a smallest diameter D 1 and a greatest diameter D 2 on the planes of symmetry 17 , 18 through the centers of the rounded corners of the piston recess 14 and respectively continuously increase or decrease between neighboring planes of symmetry. The diameter D at a defined angular position is the greatest distance between the longitudinal center axis 4 and the circumference 16 at this angular position.
The piston recess 14 can have a depth T along its entire circumference. As an alternative, the piston recess 14 can have varying depth T in circumferential direction of the cylinder 2 and the piston 3 , as shown in FIG. 2 as well as 6 and 7 , where shallower regions B and deeper regions C alternate. In the piston recess 14 shown in FIG. 2 , the depth T in the region of the diameters D 1 or on the planes of symmetry 19 , 20 has a maximum T 1 and in the region of the diameters D 2 or on the planes of symmetry 17 , 18 a minimum T 2 .
Due to the different cross sectional dimensions or diameters D and/or the different depth T of the piston recess 14 , the piston recess 14 has varying flow cross sections between the pyramid shaped projection 24 and its outer circumference 16 . In the piston recesses in FIGS. 1 to 5 and 10 to 13 , the maxima or the flow cross sections respectively lie in the planes of symmetry 17 , 18 while the minima respectively lie in the planes of symmetry 19 , 20 . This also causes the flow velocity of the combustion air which is conducted through the inlet channel 8 into the combustion chamber 6 with a swirl to change, which combustion air flows in the direction of the arrows A in the drawing, i.e., counter clockwise about the pyramid shaped projection 24 through the piston recess 14 as indicated by the differently long arrows A. Because the outer circumference 16 of the piston recess 14 has no discontinuities viewed in circumferential direction of the piston 3 , essentially no secondary turbulences are generated in the piston recess 14 .
As best shown in FIGS. 3 a and 3 b by two arrows E of different lengths and in FIGS. 11 and 13 by eight arrows E with two different lengths, the differently sized injection openings 12 , 13 of the injector 11 are directed toward regions of the piston recess 14 which have different flow cross sections.
In the piston recess s 14 shown in FIG. 3 a , the injection openings 12 , 13 are arranged so that the injection jets which exit from the greater injection openings 12 and have the smaller swirl requirement and are designated with the arrow E, lie in one of the planes of symmetry 17 , 18 through the centers of the rounded corners of the piston recess 14 and are thus directed toward regions of the piston recess 14 with the greatest flow cross sections and with this the smallest flow velocities. The injection jets designated with the shorter arrow E which exit from the smaller injection openings and which have a greater swirl requirement lie in one of the planes of symmetry 19 , 20 through the centers of the sides of the piston recess 14 and are thus directed towards regions of the combustion recess with the smallest flow cross sections and with this the greatest flow velocities. Viewed in a plan view, all injection jets are directed towards the piston 3 perpendicular to the opposing circumferential surface of the piston recess 14 .
The same applies to the piston recesses 14 shown in FIGS. 11 and 13 in which injection jets from the great or small injection openings 12 , 13 are also indicated by arrows E of different lengths and the flow velocities are indicated by arrows A of different lengths.
In the piston recess 14 shown in FIG. 3 b on the other hand, the injection openings 12 , 13 are arranged so that the injection jets (longer arrow E) which exit from the greater injection openings 12 and the injection jets (shorter arrow E) which exit from the smaller injection openings 13 enclose acute angles with the two neighboring planes of symmetry 17 , 20 ; 20 , 18 . These angles in piston recess 14 of FIG. 3 b are each 22.5 degrees so that all injection jets in the plan view shown in FIG. 3 b are oriented toward the piston 3 at an angle of 67.5 degrees relative to the opposing circumferential surface of the recess 14 .
3-D simulations have shown that with the arrangements shown in FIG. 3 a and FIG. 3 b the pollutant emission and in particular the soot emissions of the internal combustion engine can be particularly strongly reduced. | A self-igniting internal combustion engine includes at least one cylinder and a piston, which can be moved back and forth in the cylinder and which bounds a combustion chamber together with the cylinder and which has a piston recess facing the combustion chamber, said piston recess having flow cross-sections that vary in a circumferential direction of the cylinder and of the piston, and comprising an injector arranged centrally above the piston recess for injecting fuel into the piston recess, wherein the injector has a plurality of injection openings. In order to reduce the emissions and in particular the soot emissions of the internal combustion engine, at least some of the injection openings have different opening cross-sections, wherein the injection openings having the different opening cross-sections are directed at areas of the combustion chamber recess having different flow cross-sections. | 8 |
RELATED APPLICATIONS
This is a Continuation-in-Part of U.S. Ser. No. 08/113,285, filed Aug. 30, 1993, now U.S. Pat. No. 5,456,139, and incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to strain wave gearing, and more particularly to an improved tooth profile of a flexspline and a circular spline in harmonic drive devices.
2. Prior Art
The original harmonic drive strain wave gearing was introduced by Musser in U.S. Pat. No. 2,906,143. A harmonic drive strain wave gear comprises a rigid circular spline having "n" teeth, a flexspline having fewer than "n" teeth ("n" being a positive integer) and being disposed in the circular spline, and a rotatable wave generator disposed in the flexspline to deform the flexspline into a lobed configuration, such as an oval shape, so as to force the flexspline into engagement with the circular spline at two points of the major axis of the formed ovaloid. The wave generator may include an oval cam plate and a bearing snugly mounted on the outer periphery of the camplate. The outer bearing is matingly inserted into the flexspline so as to deform it to the peripheral contour of the camplate. An input shaft attached to the camplate provides rotation thereto, causing the ovaloid configuration of the flexspline to be correspondingly rotated. During such rotation, the circular spline is induced to rotate relative to the flexspline by an amount proportional to the difference in the number of teeth between the flexspline and the circular spline. When an output shaft is arranged on either the flexspline or the circular spline, that output shaft is rotated very slowly in comparison to its input shaft. Such harmonic drive strain wave gearing has been utilized in machinery requiring a high reduction ratio.
A recent attempt at improved tooth profile design is shown in U.S. Pat. No. 4,823,638 to Ishikawa, wherein the engagement between the flexspline and the circular spline is deemed to be an approximation to that of a rack mechanism. The tooth profile of the engaging splines is defined by a transformation of an original curve by the application of a reduced 1/2 scale to a corresponding similar figure, that is, a mapping curve derived by a similarity transformation from the movement locus of the crest of the flexspline relative to the circular spline.
The design of the '638 gear tooth is therefore based on a simplified traditional rack mechanism approximation.
In fact, the gear teeth are not located on a simple linear rack. The circular spline teeth are located on a circle and the flexspline teeth are located on an oval surface formed by the wave generator. These two curved surfaces cause an inclination angle change between a tooth on the flexspline relative to the circular spline as the tooth moves into the engagement from the minor axis to the major axis. Such inclination angle is ignored when it is assumed that the circular spline and the flexspline are straight racks.
More recently in the referenced U.S. patent application Ser. No. 08/113,285 an improvement in flexspline tooth profiles was obtained by taking into account precessing of the tooth angle at the front and back of the tooth lobe as the oval wave generator is rotated.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention extended tooth contact engagement with reduced tooth stress is achieved by first defining the tooth face profile of one of the gears, preferably the circular spline by a simple well known geometrical arc segment such as a circular, parabolic, or elliptical arc segment. Next, the tooth face profile of the other gear, preferably the flexspline is defined by a curve shape that allows several teeth to remain in contact while the wave generator is rotated. Furthermore, the transition region between tooth flank and tooth face is made continuous, and thereby smoothed out, by using a straight line segment for this portion of the flexspline tooth profile. The aforesaid curve shape that allows several teeth to remain in contact is determined by establishing the movement locus of a point on the flexspline tooth in relationship to a point of contact between the face profile of the flexspline teeth and face profile of the circular spline teeth and subtracting the tangential component shift due to tooth inclination as the wave generator is rotated.
The invention thus comprises an extended contact harmonic drive gearing apparatus for transmitting rotary motion from an input drive to an output drive, comprising: a rigid circular spline having gear teeth thereon; a flexible flexspline having gear teeth thereon arranged radially adjacent the rigid circular spline. The flexspline face tooth profile for a preferred circular arc embodiment of an extended contact harmonic drive gearing apparatus is defined by the following equations: ##EQU1## wherein -u·h is the tooth inclination correction factor ##EQU2##
x 2 is the tangential axis coordinate of a point on the flexspline tooth face curve;
Y 2 is the radial axis coordinate of a point on the flexspline tooth face curve; and the circular spline face tooth profile is defined by a circle with radius R i =√(x c -a) 2 +(y 0 -b) 2 in which a, b are the center coordinates of a circle.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become more apparent when viewed in conjunction with the following drawings, in which:
FIG. 1 is a front partial view of a harmonic drive gearing assembly constructed according to the principles of the present invention;
FIG. 2 is a view of a quadrant of the teeth of a flexspline and a circular spline shown in FIG. 1, showing the progressive points of tooth engagement therebetween;
FIG. 3 is a frontal enlarged view of a flexspline tooth engaging a pair of teeth of the circular spline, showing the tooth engagement of the present invention and superimposed thereon are geometric expressions useful in explaining how the curve equations for the various tooth profiles were determined; and
FIG. 4 is a drawing illustrating the coordinate systems used in drawing the geometric expressions for the profile curve equations of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and particularly to FIGS. 1 and 2, there is shown in an enlarged frontal view, a harmonic drive gearing assembly 10, having a tooth profile which is the subject of the present invention.
The harmonic drive gearing assembly 10 comprises a planar generally oval shaped wave generator (cam plate) 12 having a bore 14 for attachment to a drive shaft, not shown.
The wave generator 12 has an outer periphery 18 with a bearing assembly 16 pressed thereabout. The bearing assembly 16 consists of an inner race 20, an outer race 22, and a plurality of roller members 24 rotatively distributed therebetween. A deformable flexspline 26 is disposed outwardly of and snugly engaged with the outer race 22 of the bearing assembly 16. A rigid fixed circular spline 28 is disposed radially outwardly of the deformable flexspline 26. An array of gear teeth 30 (as shown in FIG. 2) is arranged on the outer periphery of the flexspline 26, and another array of gear teeth 32 is arranged on the inner periphery of the circular spline 28 in a matable relationship therebetween.
The major axis of the wave generator 12 and the flexspline 26 is represented, in FIG. 2, at the 12 o'clock position (35), and likewise, the minor axis in FIG. 2 is at the 9 o'clock position (36). The maximum inclination of the teeth 30 of the flexspline 26 are found at the mid-point (37) between the major and minor axes 35 and 36.
Referring now to FIGS. 3 and 4, the derivation of the curves defining the tooth profiles of the flexspline 26 and the circular spline 28 will now be explained in connection therewith. FIG. 3 depicts one tooth 60 of the flexspline 26 at a point of contact P'(x 1 y 1 ) with the face 62A of a tooth 62 of the circular spline 28. The tooth 60 has an upper face profile curve at 60A and a lower flank profile curve at 60B joined by a straight line transitional profile at 60C. The movement locus of the flexspline 26 describes the path of a point on the flexspline neutral on plane 68 as it is rotated by a wave generator (not shown). The movement locus is designated 54 and is shown by dotted lines. Dashed lines 68 delineate the neutral on plane of the flexspline 26 which does not change length as the flexspline is distorted by the waveform generator (not shown). When the origin of the flexspline is moved from q(0,0) to a point q 0 . q'(x 0 Y 0 ) on its movement locus; the point P(x 2 ,Y 2 ) on the tooth profile face 60A moves to the contact point P' (x 1 Y 1 ) with the face 62A of circular spline 28.
The curve equations for the face of tooth 60 are derived as follows:
The movement locus for the point q the flexspline tooth 60 is: ##EQU3##
x=r·sin(φ-θ) 1(b)
y=r.sub.c -r·cos(φ-θ) 1(c)
wherein -π/2≦θ≦0; and
wherein x is a coordinate in the tangential direction;
Y is a coordinate in the radial direction;
r c is the flexspline major axis radius as shown in FIG. 4;
d/2 is one-half of the displacement d of the deformed flexspline;
θ is the angle of rotation of the wave generator;
(φ,r) are the polar coordinates of the neutral surface of the flexspline.
The addendum arc (circle) equation for the circular spline tooth profile is:
(x.sub.c -a).sup.2 +(y.sub.c -b).sup.2 =R.sub.i.sup.2 2
for a circle with radius R i in which a and b are the center coordinates of the circle.
The point q' is located on the movement locus, q's coordinates are as follows: ##EQU4##
x.sub.0 =r.sub.0 ·sin(φ.sub.0 -θ.sub.0) 1(b)'
y.sub.0 =r.sub.c -r.sub.0 ·sin(φ.sub.0 -θ.sub.0)1(c)'
The coordinates of the contact points P' have the following relationship with points q' of the locus movement:
x.sub.1 =x.sub.2 +x.sub.0 3(a)
Y.sub.1 =Y.sub.2 +y.sub.0 3(b)
φ and θ are related by equation 4 below: ##EQU5##
Since P' is located on the circular arc of the tooth face of tooth 62 of circular spline 28, X c and Y c in equation 2 can be replaced by X 1 and Y 1 .
Since P comes in contact with P', the tangent angle of the flexspline face curve at point P should be the same as the circular spline curve at P';
or: ##EQU6## Coordinates X 2 and Y 2 can therefore be replaced with equations 3a and 3b respectively: ##EQU7## Here, Y 0 and x 0 have only one function θ. Note: φ can be represented by θ by adapting the Newton-Raphson method (see text "Advanced Engineering Mathematics" 2nd Ed. Peter V. O'Neil© 1987, Wadsworth, Inc., pp. 1062-1065 incorporated herein by reference) to equation 4. So that X 1 has two functions: Y 1 and θ. Y 1 needs to be replaced by an equation about X 1 and θ as follows:
First we differentiate Equation 2' about coordinate X 1 , and solve for dY 1 /dx 1 , as follows: ##EQU8## (Y 1 -b) can be replaced by Eq 2'. ##EQU9## dY 1 /dX 1 can be replaced by Eq. 7(b). Making an equation about X 1 -a. ##EQU10## Making an equation about Y 1 -b with Eq. 2' and 10 yields: ##EQU11## dx 0 /dθ and dy 0 /dθ are determined by differentiation of Eq. 1' by θ: ##EQU12## The coordinates of a point P on the face 60A of the tooth profile of the flexspline 26 which maintains contact with a circular profile of tooth 62 on the face of the circular spline 28 throughout a portion of the movement locus 54 are obtained from Eqs. 10, 11, 12, 3 and 1 as follows: ##EQU13## P's coordinate system has its origin on point q. Changing the origin to point O in the diagram on FIG. 3. Then, adding a tooth inclination correction of minus u·h yields: ##EQU14## wherein
h=y.sub.0 -Y.sub.1 18
and ##EQU15##
Equations 16 and 17 define the face curve of a flexspline tooth profile which will stay in substantial contact with a face of a tooth of a fixed circular spline throughout a substantial portion of the movement locus of the flexspline provided the profile of the face of the circular spline is defined by a circular segment. The remainder of the flexspline tooth profile i.e. the flank profile is preferably a circular segment matching the circular spline face segment. A short transition region is also necessary to join the flank and face segments and this should be a smooth linear curve or a straight line segment.
Equivalents
Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to specific embodiments of the invention described specifically herein. For example, while the invention has been explained in connection with a simple circular arc, other arcs, such as, a parabola or an ellipse are contemplated, in which the equation for an ellipse or parabola would be substituted for equation 2 above. Such equivalents are intended to be encompassed in the scope of the following claims. | The present invention relates to an extended tooth contact harmonic drive gearing apparatus for transmitting rotary motion from an input drive to an output drive through mating contact between the gear teeth of a flexspline and a rigid circular spline, the flexspline being rotated into non-circular shape by a wave generator. The profile of the flexspline teeth are generated to cause the teeth of the flexspline to contact more than one tooth of the circular spline by forming a face profile on the flexspline teeth in accordance with a predetermined equation while the flank tooth profile of the circular spline is formed of a known arc segment, such as, a circle, ellipse or parabola. | 8 |
FIELD AND BACKGROUND OF INVENTION
This invention relates to methods of manufacturing blanks for brassieres, brassieres, and the products of such methods. In particular, the methods and products involve circular knitting operations in which the blank is produced as a cylindrical tube, and thereafter cut and sewn to produce a garment having straps knit integrally with a frontal torso portion having breast cups and a dorsal torso portion cooperating with the frontal torso portion in forming a torso band.
It has been proposed heretofore that brassieres may be produced by knitting processes, including full fashioned processes as shown in Braxton et al U.S. Pat. No. 3,500,665 and reciprocatory processes using circular knitting machines as shown in Epley U.S. Pat. No. 3,537,279. With such processes, shaped fabric areas are formed to define breast cups. With other processes, such as that of Novi U.S. Pat. No. 3,772,899, shaping is accomplished by aftertreatment of the manufactured fabric, rather than by knitting of shaped fabric areas.
With both full fashioned and reciprocatory knitting processes, blank and garment production is significantly slower and less efficient than is possible for other garments, such as tubular stockings or pantyhose, where technology has permitted fabric formation by circular knitting. That is, where the cylinder of a circular knitting machine may be driven in continuous rotation as distinct from reciprocation, the rate of fabric production and thus the manufacturing efficiency is significantly enhanced.
BRIEF DESCRIPTION OF INVENTION
With the above discussion in mind, it is an object of this invention to manufacture a brassiere blank in the form of a circular knit, cylindrical tube. In realizing this object of the present invention, a method of manufacturing such a garment blank in accordance with this invention realizes high speed, efficient production while providing a blank which can be readily and efficiently manufactured into the finished garment. Inasmuch as the blank is a circular knit, cylindrical tube, the blank is rapidly produced by a circular knitting machine of the general class used heretofore in the manufacture of pantyhose and the like, and a plurality of blanks may be produced in rapid succession.
Yet a further object of this invention is to provide a blank for the manufacture of a brassiere garment which has a fabric construction shaped to contours desired for the finished garment so as to minimize the manufacturing steps required for completion of the garment. In realizing this object of the invention, a circular knit fabric blank is produced which has distinctive stitch structures in courses so as to form a pair of turned welts at opposite ends of a cylindrical tube; a frontal torso portion knit to one welt and having a pair of breast cups defined by two areas in which the courses are plain knit with the areas being separated by areas of gathered panels in which succeeding courses vary between plain and welt knit courses, the courses defining the frontal torso portion differentially shaping the breast cups with respect to the gathered panels; and a fabric strap and dorsal torso portion knit to the frontal torso portion and the other welt. The blank having such a stitch structure may thereafter be slit longitudinally, opened flat, and fabricated into the finished garment with a minimal number of operations.
Yet a further object of this invention is to provide a brassiere garment fabricated from circularly knit fabric and in which differential stitch structures in coursewise directions accomplish the principal shaping of the finished garment. In such a garment, a torso encircling band portion formed by a frontal turned welt and a dorsal turned welt which are sewn together at lateral seam lines is knit to a frontal torso portion having a pair of breast cups defined by two areas in which the courses are plain knit with the areas being separated by a center gathered panel area in which succeeding courses vary between plain and welt knit courses, the courses defining the frontal torso portion differentially shaping the breast cups with respect to the gathered panel, and is knit to a fabric strap and dorsal torso portion.
BRIEF DESCRIPTION OF DRAWINGS
Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of a brassiere garment embodying the present invention;
FIG. 2 is a front elevation view of a circular knit, cylindrical blank in accordance with the present invention and from which the garment of FIG. 1 is manufactured;
FIG. 3 is a rear elevation view of the blank of FIG. 2; and
FIG. 4 is a front elevation view of the blank of FIGS. 2 and 3 as slit, opened and undergoing manufacture of the garment of FIG. 1.
DETAILED DESCRIPTION OF INVENTION
While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the present invention is shown, it is to be understood at the outset of the description which follows that persons of skill in the appropriate arts may modify the invention here described while still achieving the favorable results of this invention. Accordingly, the description which follows is to be understood as being a broad, teaching disclosure directed to persons of skill in the appropriate arts, and not as limiting upon the present invention.
Referring now more particularly to the drawings, the finished garment of the present invention, as worn by a consumer, is represented generally at 10 and, as shown there, comprises a torso encircling band portion 11 formed by a frontal turned welt 12 and a dorsal turned welt 14 which are sewn together at lateral seam lines (one of which is seen at 15). The band portion 11 is knit to a frontal torso portion 16 which has a pair of breast cups 18 defined by two areas in which the courses are plain knit with the areas being separated by a center gathered panel area 19 in which succeeding courses vary between plain and welt knit courses, the courses defining the frontal torso portion differentially shaping the breast cups with respect to the gathered panel. The frontal torso portion 16 is knit to a fabric strap and dorsal torso portion 20 which includes straps 21 and a dorsal torso portion 22.
In accordance with this invention, the brassiere is of a circular knit construction, with the welts 12, 14 extending in a coursewise direction. Thus, the fabric construction in the frontal torso portion 16 is such that the coursewise direction of the knit fabric is generally circumferential of the body of the wearer of the garment 10. This is a distinction from prior garments of this general class. The courses are knit in such a way as to shape the breast cups 18. In particular, the fabric in the breast cup portions is a "simple" knit, while panels adjacent the breast cup portions are formed by fabric which is gathered by reason of having successive courses varying between "simple" knit and welt knit stitches.
As used herein, reference to "simple" knit is intended to distinguish those stitch constructions possible on a circular knitting machine and in which yarn is taken into a needle during each rotation of the cylinder, such as plain, purl, tuck and combinations thereof. Reference to welt knit is intended to encompass miss-stitch or float-stitch constructions in which loops in certain courses are held without additional yarns being taken and then knit into subsequent courses, thereby gathering the courses together and providing the characteristic turned welt or panel effects referred to above. It is believed that this brief description will enable persons of skill in the knitting arts to comprehend the variations which may be made while attaining the desired result of this invention in the differential shaping of the various portions of the blank and garment here described.
In the brassiere 10 of FIG. 1, the center gathered panel 19 may be constructed with alternate needles producing plain stitches and float stitches, or may be constructed with every fourth needle producing plain stitches and the intervening needles producing float stitches. In either instance, yarn held as in a float stitch is held for a multiplicity of courses, in the range of from three courses to twenty two courses. As will be understood, the degree of shaping will vary, and may be taken into account in accomplishing sizing of the garment. Additionally, the brassiere 10 has side gathered panels (as will become more clear from the discussion which follows with regard to the blank and method of manufacture) which are similarly constructed. Thus the breast cups 18 are defined between the center panel and two side panels. The side panels are located at the lateral seam lines 15 and are joined thereby to dorsal side panels as described more fully hereinafter.
The brassiere 10 is produced from a blank 25 (FIGS. 2 and 3) which is produced on a high speed circular knitting machine as generally mentioned above. The blank 25 is a cylindrical tube, having portions which (upon manufacture of the garment 10) correspond to the portions of the garment described above. For that reason, reference characters corresponding to those used above with reference to FIG. 1 will be applied in FIGS. 2 and 3, with the addition of prime notation. Thus the frontal welt 12' is, in the blank 25, a circular turned welt as is produced on circular knitting machines in well known ways. Similarly, the dorsal welt 14' is a circular turned welt, and the differentially shaped breast cups 18' are defined between the gathered center panel 19' and the (now visible) gathered side panels 26 which extend longitudinally of the tube diametrically opposite the location of the center panel 19'. The side panels 26 define therebetween a cut line 28, for purposes to be made more clear hereinafter.
As will be appreciated, the portions of the tubular blank 25 are integrally knit together and have stitch constructions as described hereinabove. Thus the method of manufacturing the blank will become more clearly understandable and may be characterized as knitting a series of courses defining a first cylindrical tubular fabric portion in the form of a turned welt, and then knitting to the first turned welt portion a series of courses defining a cylindrical tubular fabric frontal torso portion having a pair of breast cups defined by two areas in which the courses are plain knit with the areas being separated one from another by areas of gathered panels in which succeeding courses vary between plain knit and welt knit courses, the knitting of courses defining the frontal torso portion differentially shaping the breast cups with respect to the gathered panels, and then knitting to the frontal torso portion a series of courses defining a cylindrical tubular fabric strap and dorsal torso portion having an elongated area in which the courses are simple knit with the area being divided by an elongated panel area in which succeeding courses vary between simple knit and welt knit courses, and then knitting to the strap and dorsal torso portion a series of courses defining a second cylindrical tubular fabric portion in the form of a turned welt.
As will be apparent from FIG. 3, the elongated panel area which extends through the dorsal portion is, in the blank 25, formed by the side panels 26 and the cut line 28 and extends from and through what will ultimately be both the frontal and dorsal portions of the finished garment 10.
In manufacturing the garment 10 from the blank 25, the fabric of the blank is slit along the cut line 28 and the blank is opened flat to the form shown in FIG. 4. The flat blank is then cut along a neck line 29 and a pair of armhole lines 30 and fabric is removed so as to define the straps 21' and dorsal portion 22'. The slit and cut blank is then folded and the side panels 26 and welts 12', 14' sewn together. Trims and the like may be applied if desired for appearance reasons.
In the drawings and specifications there has been set forth a preferred embodiment of the invention and, although specific terms are used, the description thus given uses terminology in a generic and descriptive sense only and not for purposes of limitation. | This invention relates to methods of manufacturing blanks for brassieres, brassieres, and the products of such methods. In particular, the methods and products involve circular knitting operations in which the blank is produced as a cylindrical tube, and thereafter cut and sewn to produce a garment having straps knit integrally with a frontal torso portion having breast cups and a dorsal torso portion cooperating with the frontal torso portion in forming a torso band. | 3 |
STATEMENT OF ORIGIN
This invention was made in the performance of work under a Government contract and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereby or therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a space navigation device usable as the prime navigation sensor for a completely autonomous spacecraft of satellite navigation system.
2. Prior Art
Systems for determining the angular position between a spacecraft and a source of radiation such as a distant star or other celestial body are known and have been used in a variety of applications. The particular choice of spacecraft navigation system is a function not only of the operation of the spacecraft, but also the type of stabilization system utilized on board the spacecraft. The type of sensors employed can generally be categorized into three broad groupings.
The first grouping comprises analog sensors comprising a pair of photo conductive devices connected as such that a differential output is derived from them. The differential output varies as a function of the projection angle of the vector of the radiation image on the planar surface formed by the photoconductive sensors. These devices, generally known as star trackers, utilize combinations of light baffles and sun shades to provide functions varying as a function of the angular position of the radiant emitting celestial body relative to the detector surface. In order to derive signals indicative of the angular position of the radiant source into two directions, orthogonal to each other, multiple sensors are required. Also, devices of this type require each of the photoconductive sensors to be very closely matched in order to maintain accuracy. The telescopes used in such star trackers are generally large and require extensive thermal and mechanical stability of the photo conductive devices to maintain accuracy and alignment. Hence, the practical application of these devices for making the accurate determinations of angular position which are necessary can be obtained only if the field of view of the detector is relatively narrow, less than 10° of arc. Also, detectors of the photo conductive type generally have an inherently slow response time, and their employment on spin-stabilized spacecraft cannot generally be effectuated. Therefore, the limitations of the use on this type of device as primary navigation sensors have generally been limited with to 3-axis stabilized or gravity gradient stabilized bodies, and in those cases, because of weight restraints, such star tracker devices have been used as a primary sensor, i.e., a lock-on device for a sole star. Also, a further problem inherent with the use of the photo-conductive type of devices of this group is that they cannot usually be employed with lens systems, so that measurements of celestial bodies having relatively low light emission, such as the moon and secondary level stars, are difficult.
A second general type of navigational sensor utilized for space navigation is the reticle time measuring system, and this type of device is applicable only to a spin-stabilized spacecraft. Spin-stabilized bodies generally spin at rates approximating 100 rpm, and a reticle containig a pattern of slits is located in front of a photocell to provide radiation pulses from a celestial body on the photocell in response to the spin of the spacecraft. The time between detection of ajacent radiation pulses is measured to provide the measure of angular position. Obviously, it is necessary to reference the detected time between adjacent pulses to the stable spin period of the spacecraft. The use of analog controllers on the ground, coupled with known orbits, make these particular type of devices relatively simple and inexpensive. However, practical experience has found that the accuracy thereof is limited only to measurements of approximately 1° of arc. Hence, for precision navigation, this type of device is generally unsatisfactory. A modification of the reticle time measuring system, employed for spinning spacecraft, is the digital reticle system. In this type of navigation device, a slit reticle is located in front of a binary of Gray-coded pattern of several photocell detectors. The position of the celestial body image is derived by the binary state of the several detectors in an image plane. For use in spinning vehicles, it is necessary to employ an auxiliary detector to indicate when radiation from the celestial body is in the sensor field of view. Also, to provide measurements of the body in two orthogonal directions, it is necessary to employ a pair of detectors. While digital reticle systems are inherently precise, their resolution is limited as a function of the spectral nature of the radiant energy derived from the body. Working experience with such devices has shown that radiation from the sun subtends an arc of 32 minutes (') which can be detected with the digital type device. If further refinement of the data is required to obtain accuracies, for example, to one arc minute, complex and expensive interpolation using computerized techniques is required. Also, inherent in such devices when utilized on spin-stabilized bodies is that measurements can be derived only once during each spin cycle, and, accordingly, the amount of information which may be derived with such devices is limited.
The patent literature is replete with a variety of attempts of the types mentioned above to achieve a practical and reliable navigation system. For example, a series of patents to Lillestrand, typified by U.S. Pat. No. 3,591,260, and patents to Aroyan et al, typified by U.S. Pat. No. 3,144,555, typify attempts to devise solutions using the reticle system, both in analog and digital contexts. Also, various patents have attempted to devise sextant arrangements which are roughly analogous to the optical star tracker type of devices employed in 2-axis stabilized bodies. As typified by the patent to Carbonara et al, U.S. Pat. No. 2,941,082, a sextant is shown which operates only in a gravitational field by measuring the angle between a heavenly body and a local gravity vector. Also, devices which are hybrids of various techniques are shown. Typical is the patent to Farthing et al, U.S. Pat. No. 3,744,913, which shows the measurement of the center of a radiation emitting celestial body utilizing a detector including four electrodes to determine the image of the body. This type of device is utilized on a spin-stabilized spacecraft primarily as a sun sensor.
SUMMARY OF THE INVENTION
The present invention is an improvement over my copending application entitled "Navigation Sensor" which is commonly assigned. Both inventions are utilized as high altitute autonomous navigation systems for spacecrafts by utilizing a space sextant which measures the scalar angle between a navigation star and the lunar limb, or the lunar limb to an earth-fixed point source of light. In its broadest forms, as set forth in the copending case, the sextant consists of two telescopes gimbaled on a common axis of a momentum wheel. Each tracker is aligned to its respective target, and a very narrow mirror is rotated through an arc crossing each optical path of a respective tracker at a constant angular velocity. As the mirror passes through the optical axis of the first tracker, a timing sensor sees an impulse of light (T 1 ). As the mirror continues in its arc, it will pass through the optical axis of the second tracker, and at that instant, a second timing sensor will see an impulse (T 2 ). The scalar angle between the two collimated light sources is T 1 = W(T 2 -T 1 ). T 1 and T.sub. 2 are respectively the timing pulses used to start and stop a digital counter which counts a precision clock. The corresponding binary number represents the properly scaled scalar angle between the telescope optical axes. As the mirror continues its arc, it will again pass through the optical axis of the first tracker, at which instant the first timing sensor sees an impulse (T 3 ) and the complementary angle T 2 = W(T 3 -T 2 ). This complementary angle provides a second measurement of the included angle (T 1 ) for each revolution of the wheel. Typically, the mirror rotates at an angular velocity of approximately 60.6 radians/second, or 10 revolutions per second. At this angular velocity, 20 statistical measurements of the included angle per second can be made, and by the averaging of these samples, the removing of pointing servodynamic errors from the measurement can be accomplished. While the light generated from the stars or the limb of the moon can be utilized to produce the signal required for the time pulse generation, as in the companion application, the present invention utilizes the light from a light source as a substitute for this ray in the sextant.
This particular invention reduces the number and magnitude of the measurement sensitivities in the system. Specifically, all first order optical sensitivities are eliminated by this invention, and the sensitivity to sensor gain stability is greatly reduced over the period concept as disclosed in my copending application. Moreover, that original concept required cool timing sensors due to the low photon throughput. This invention eliminates the need for cooled sensors. Additionally, this invention is a clear improvement over the prior cencept in two other material areas. One problem of the original concept was that two detectors were required for each telescope, one for tracking and one for pulse generation. A second undesirable feature of the original concept was that the optical devices that correlated the time pulse from one tracker to that of the other were not common. These two requirements in the original concept made that invention highly susceptible to thermal distortions and misalignments.
Accordingly, it is a first object of this invention to eliminate and and improve the difficulties encountered in the design of the first dual-tracker space sextant.
It is another object of this invention to eliminate thermal distortions and misalignments attendant to systems requiring cooled sensors.
Still another object of this invention is to eliminate the requirement for multiple detectors for each tracker.
Yet another object of this invention is to provide a system wherein a light source is used as a substitute for a light originating from the celestial body which was previously required for time pulse generation.
It is another object of the present invention to provide a new and improved device for enabling the angular position between two sources of radiation to be ascertained.
Another object of this invention is to provide a space sextant for enabling the determination of the relative position between a moving spacecraft and two celestial bodies to be derived.
A further object of this invention is to provide a relatively inexpensive, yet highly accurate device for the determination of the position of two celestial bodies to be determined relative to a spacecraft.
Still a further object of this invention is to provide a high accuracy space navigation sextant utilizing radiation from a celestial body and a point source emanating on the surface of the earth.
These and still other objects and advantages of this invention will become apparent from consideration of the following detailed description of one specific embodiment thereof, especially when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the components of the space sextant.
FIG. 2 is a schematic, functional block diagram of the wheel sextant system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a detailed cross-sectional drawing of the space sextant is shown. The sextant measuring head, shown generally at 10, is rotated into the measurement plane by φ gimbal 12 and ψ gimbal 14. Typically, the gimbal limit is + or - 80°. The measurement plane is defined by the star and limb vectors from the sextant. The cross product of the star and limb vectors define the proper orientation of the measurement spin vector, shown as dotted line 16. Each of the two tracker assemblies 18 and 20 are free to rotate independently about the axis 16.
In this invention, since complete symmetry in telescopes exists, it does not matter which tracker is used for star or limb tracking. Assuming that each gimbaled telescope assembly has been driven to its proper angle to see the star/limb, hence resulting in acquisition taking place, the star and lunar limb energy enter the tracker assemblies via rays shown as dotted lines 22 and 24. For purposes of explanation, only the transmission of energy through the tracker 18 will be explained; however, it is apparent that an identity of function occurs in tracker 20. The rays travel through the tracker assembly 18 and are reflected by primary mirrors 26 to the secondary mirrors 28. This reflected path is shown as dotted line 30. The energy is then reflected from secondary mirror 28 onto sensor 32, which is a multiple function sensor. Sensor 32 senses the imaged star/limb energy to derive in plane (tracker gimbal servo error signals) and cross plane error signals to maintain the sextant measurement head orientation in the plane of measurement by driving the ψ and φ gimbals 12 and 14. Additionally, the sensor assembly 32 is used to generate the discrete timing pulses utilized in making the angular measurement.
The timing pulses are generated in the following manner: A light source 34 illuminates a mask 36 which has a 10μ pinhole. The light passing through the pinhole is collimated by a lens 38 and is projected upon a prism assembly 40. The prism assembly 40 translates the collimated light from the collimator axis to the telescope axis as shown in dotted lines 42 and 44. The collimated beam is divided equally between the telescopes 18 and 20. The entire collimated light source, including the prism assembly 40, is mounted on a wheel assembly shown generally as 46. This wheel assembly rotates within the measurement head shown as 48. At a given instant, the collimated rays 42 and 44 will pass through the telescope assembly 18 via the same route as ray 24, as shown by the dotted lines 47 and 48. The collimated rays are imaged by the telescope assembly, and the image sweeps across the sensor assembly 32 to generate the discrete timing pulses.
The trackers are closed-loop servoed to center on the star or lunar limb, and the driving elements to effectuate this function are torque motors 50 and 52.for the respective telescope assemblies. As shown in FIG. 1, torque motor 50, for example, effectuates relative motion of telescope 18 vis-a-vis the head 48 via bearings 54.
The wheel assembly, characterized by casing 46 and measurement head 48, is driven at an angular velocity of approximately 50 radians/sec. which corresponds to 1.0368 × 10 7 arc sec/second by a phase locked loop. A typical phase locked loop is shown in the copending application. The phase locked loop can be commanded to rotate the wheel assembly by means of an oscillator located remotely from the sensor. The feedback (position) for the rotation of the wheel to the phase locked loop is taken by means of an optical transducer disc 56, which is read out via head assembly 58. When the wheel is in motion, the output from the readout head 58 will be a frequency. As in the copending application, the disc 56 has sine 2 11 θ and cosine 2 11 θ functions recorded on it. The sine and cosine functions 57 allow the extraction of phase information, and hence a very wide band high gain phase locked loop can be implemented. The wheel drive motor is shown schematically as a magnetic motor 60, and additional elements such as a rotary transformer 62 to power the collimator light source 34 are shown in FIG. 1.
Referring now to FIG. 2, a functional diagram of the major control loops of the wheel sextant are shown in schematic fashion. Two major subsystems are the φ and ψ gimbal servos used to orient and maintain the measurement head in the plane of measurement. These servos serve to function to control movement of gimbals 12 and 14 as shown in FIG. 1. Basically, two modes of operation are present. The first mode is generally known as slew and is used in making transition between stars. The particular angular relationship to command each of the gimbals to a new angle is computed by the navigation computer from an a priori knowledge of stars, time, attitude, and lunar ephemeris. Each loop is maintained in slew until star and limb acquisition signals are present. At that time, the gimbal loops would then switch to the track mode. The gimbal servo pointing errors are derived from the fine sensors 32, located on the star and limb trackers. These error signals, shown as star sensor Z plane error, star sensor Y plane error, and input from the limb sensor video are resolved into coordinates for the proper gimbal servomotors which then drive to align precisely the measurement head into the plane of measurement. As shown in FIG. 2, the respective inputs are first utilized to determine the X-axis error in processor 70, and the resulting error signals are fed to coordinate transformer 72 which determines the proper coordinate movements for the π gimbal servo 74, ψ gimbal servo 76, which are respectively used to drive the φ ψ gimbal torquers.
Also shown in FIG. 2 are the tracker servos, which are comparable to the gimbal servos, except that they function in three different modes of operation. These tracker servos 78, 80 function in the slew mode, which is a mode used to drive the trackers in the measurement plane for acquisition, and the respective angles are also computed by the navigational computer. The second mode of operation is acquisition, which is a mode that is used to make a transition from coarse (wide field of view) sensors to fine (narrow field of view) sensors. The third mode of operation is the tracking mode, which is a mode that utilizes pointing error signals derived from in-plane fine sensor elements. Pointing servo processor 82 receives star sensor Y-plane errors and generates a signal to drive star tracker servo 78, which in turn is used to provide an input to the star tracker torquer 52. Similarly, the limb sensor video signal is resolved into a servo pointing error through processor 82, and is used to drive the limb tracker servo, which in turn provides a signal to the limb tracker torquer 50.
The next major servo loop in the wheel sextant functional diagram FIG. 2 is the velocity servo for the wheel, which is a phase locked loop. The phase locked loop is shown in greater detail in my copending application. Wheel position error from transducer disc 56, as read out by read-out sensor 58, is shown as an input to this velocity servo 84. Although the feedback is a position signal, when the wheel has an angular velocity, its feedback output is in the form of a frequency. The servo's phase lock logic locks the feedback frequency to a command frequency from a master oscillator 86. For the wheel to have a constant speed, errors in the feedback element must be determined and compensated, and this loop includes means to accomplish that compensation. The output of the wheel velocity signal is generated to the wheel drive motor 60, to effectuate this constant velocity.
The remaining major function, shown in FIG. 2, is that of angle measurement determination. This determination consists of averaging measurements and correcting the measurement for in-plane satellite body rates. These rates are determined very precisely from the telescope that is utilized in tracking the star in the system. A pair of independent measurements are taken for each revolution of the wheel, which consists of the star tracker timing sensor output and the limb tracker timing sensor output. This pair of measurements consists of the direct angle and its complement and is taken every 0.125 seconds. The clock 86 is flagged when the n/2th measurement is taken, and the corresponding average angle is the angle that corresponds to the time that was flagged. This measurement is stored in register 86 and is transferred to the navigational computer via a transfer buffer register 88. As shown in FIG. 2, the only inputs to the angle measurement function are the precise timing pulses from sensors 32 of the star and limb tracker sensors and the clock frequency from the oscillator 86.
Other functional blocks, shown in FIG. 2, are used for support of auxiliary functions. A saturation detector is used to provide an input to a shutter control 90, which has its output to the navigational computer. As a result of intense radiation, which may be encountered, the shutter control is used to actuate shutters, shown schematically in FIG. 1 as the outer casing 21 of the system.
Also shown in FIG. 2 is a temperature control circuit 92 used for the measurement head and error signal processing 94 for control of the chopper drive. These latter functions are common in all spacecraft navigational systems to provide environmental support and form no part of this invention.
While the preferred embodiment of this invention has been shown and described, it should be emphasized that suitable additional modifications, changes, substitutions, and alterations may be made without departing from the invention. | A navigational system for spacecraft utilizes two telescopes gimbaled on a common axis to measure the scalar angle between a star and the lunar limb. The common axis is the axis of rotation of a momentum wheel that carries a light source on it for the generation of timing pulses. This source enhances signal strength by addition of the source generated ray to that received by each telescope. The entire collimated light source is carried by the wheel and the beam is divided equally between telescopes. The collimated rays are imaged by the telescope assembly and this image sweeps across sensor assemblies to generate discrete timing pulses. The trackers employ closed-loop servo systems to center on respective targets and utilize torque motors to drive the trackers relative to the measurement head case. | 6 |
BACKGROUND OF THE INVENTION:
The present invention relates to an information processing and display apparatus such as a personal computer and, more particularly, to a multimedia information processing apparatus.
A conventional multimedia information processing apparatus is an apparatus implemented by information processing apparatuses such as personal computers (hereinafter called PC's). The conventional multimedia information processing apparatus is capable of handling in an integral manner a plurality of information media. The plurality of information media include audio data, animated pictures and still images (simply called images), any of which may come from external sources.
A PC-based conventional multimedia information processing apparatus is configured generally by inserting a circuit board containing electrical circuits for performing a desired function into an extended input/output (I/O) bus slot of the PC. One such board is a scan converter board that converts NTSC (National Television System Committee) standard video signals (hereinafter called NTSC signals) output by video equipment such as a video camera into PC display video signals for display on a display unit of the PC. Another typical board is an audio signal processing board that processes audio signals for audio output via a speaker system.
When the multimedia information processing apparatus processes images, it is common practice to incorporate an image data compression/expansion board in the apparatus. This is because images include huge amounts of data to be processed.
Aside from the above-described boards that handle only one information medium per board, there exist boards each capable of integrally addressing a plurality of information media such as voice and images. Many boards that handle images may be supplemented functionally by an on-board display memory for enhancing the resolution of image display and for increasing the number of display colors available.
A conventional mode of display on PC's is multi-window display. Multi-window display is a manner of display in which the results of processing by a plurality of programs are shown separately in a plurality of rectangular areas (called windows) on the display screen, the positions and sizes of the areas being determined beforehand.
In the conventional multimedia information processing apparatus utilizing multi-window display, the size of each rectangular display area on the screen is set to be a full-screen, a half-screen, a quarter-screen, etc.
Described below are some known examples in which the display data of an image from an external video apparatus are superimposed on the display data of the PC. This process is known as keying. A first example of keying involves superimposing image data onto a specific color of PC display data. This method is called chromakey.
FIG. 17 is a schematic view of a device which implements a chromakey process. In this example, both the image data and the PC display data are in analog format as they are superimposed onto one another. In FIG. 17, reference numeral 1505 is the image data from a video apparatus, 1506 is the PC display data, 1509 is a display data switch for chromakey operation and 1510 is a display data switching signal that is input to the display data switch for switching control. 1502 is a color generator for generating data about the color on which to superimpose the image and 1503 is a comparator for comparing the color data from the color generator 1502 with the PC display data 1506 for color coincidence.
In the color generator 1502 is set beforehand the color on which to superimpose the image data. The display data switch 1509 is usually set to the position of the PC display data 1506 to allow the data 1506 to appear on display 123. The PC display data 1506, besides being fed to the display data switch 1509, is also input concurrently to the comparator 1503 for comparison with the color data generated by the color generator 1502. If a color coincidence is detected in the comparison, the comparator 1503 sends the display data switching signal 1510 to the display data switch 1509 so that the switch 1509 will be switched to the position of the image data 1505. This allows the image data 1505 to appear on the display 123.
Another example of keying will be described below. This example involves using a keying data memory (called a control plane) which is constructed to reflect the same display resolution as that of the PC and which offers at least one bit of storage capacity per pixel. The keying data is data whose values are used unchanged for the switching of display data.
FIG. 18 is a schematic view of a conventional chromakey process using a control plane. In FIG. 18, reference numeral 1501 is the control plane. The remaining components are the same as in FIG. 17. The data of the control plane 1501 is predetermined. For example, a "1" causes the image data 1505 to be displayed and a "0" causes the PC display data 1506 to be displayed. One's are written to those positions in the control plane 1501 which reflect those positions on the display 123 where images are to be displayed. The data of the control plane 1501 is read out concurrently with the data of a PC display data memory, not shown. The data that is read out are input in the form of a display data switching signal 1510 to the display data switch 1509 for and between image data 1505 and PC display data 1506.
An application of the multimedia system is a video conference system. An example of a conventional video conference system based on the multimedia system will now be described. The conventional video conference system is configured by connecting PC's or like terminals established at a plurality of locations via a network. These terminals are interconnected to let their users hold a video conference.
The conventional video conference system works typically as follows. Images coming from a plurality of terminals are composed at each terminal into a single composite picture containing the multiple input images, as disclosed in Japanese Patent Laid-Open No. 2-63288 or No. 2-63289.
FIG. 24 is a view of a display example generated by a conventional video conference system. The figure shows images displayed on a display unit of a terminal configured in the system, the images being sent from other 16 terminals. As indicated, one composite picture comprises images 2201 through 2216 showing waist-up images of 16 participants of the conference.
One aspect of the conventional multimedia system outlined above involves utilizing extension circuit boards having thereon various circuits to implement various functions. The scheme allows PC-based multimedia equipment to be established with ease.
However, there are some boards such as a scan converter board and an audio signal processing board each capable of addressing only one information medium. Each of these boards, lacking compatibility with other boards, is incapable of operating in synchronism therewith. For example, an audio signal processing board cannot provide its audio output in synchronism with images coming from a scan converter board. Where there arises a need to expand the functions of the existing resources to deal with a plurality of information media, the user has heretofore had no choice but to discard the existing resources and to purchase anew a board that would address such multiple information media.
A board capable of addressing a plurality of information media, e.g., a board dealing with video and audio data at the same time, may handle the multiple media in synchronism. However, where it is desired to supplement the board with other functions, the user is faced with the same restrictions as those applied to the above-mentioned scan converter and audio signal processing board. If the user has no need for some of the multiple functions provided by the single board, there is no choice for the user but to make the unnecessary expenditure to purchase the entire board.
If the display memory on the board is expanded to enhance the resolution of image display or to increase the number of display colors, another disadvantage is liable to occur. That is, the increase in the number of pixels or in the number of display colors leads to an increase in the amount of data per pixel. That in turn results in a significantly reduced speed at which to write data to the display memory for display purposes.
Another aspect of the conventional system involves displaying images from external video equipment within a window framework. In this case, the size of image display is controlled easily. However, this feature hampers the ability to change the window display size as desired.
The chromakey process of the conventional system has the advantage of requiring no specific control measures when a mouse cursor or other graphic image is superimposed on an image being displayed. However, if another window is superimposed on a multi-window image being displayed and if the superimposed window has the same color as that of the background image, the background image can become visible in the foreground with the window becoming transparent.
In cases where keying is performed using a control plane arrangement, the background image under a superimposed window does not become visible, with the window kept from becoming transparent. This is because the control plane data of the hidden image part are of values that select PC display data (e.g., 0's). However, if it is desired to display a mouse cursor or like graphic image superimposed on the existing image, the same shape as, say, the mouse cursor must be written to the control plane as needed. This turns out to be a considerable burden on the keying process.
Where the multimedia system is utilized in a video conference system, images from a plurality of sources are composed into a single composite image for display on each terminal. With this configuration, it is impossible to divide the composite image into original images for display at any desired positions on the display screen.
SUMMARY OF THE INVENTION
It is therefore a first object of the present invention to provide an information processing apparatus capable of readily expanding the functions of its display memory and its compression/expansion processor as desired by the user.
It is a second object of the invention to provide a display apparatus which, when displaying images from video equipment in a multi-window framework, positions the images at desired sizes and where desired on the screen according to window size.
It is a third object of the invention to provide a display apparatus using a display memory that prevents the slowdown of the speed at which to write data thereto when the display memory is expanded to display image data over the entire screen.
It is a fourth object of the invention to provide an image superimposing method which, in the case of the chromakey-based superimposing process, prevents the background image from becoming apparent through the window superimposed thereon and which, in the case of the control plane-based superimposing process, eliminates the need to write as required the same shape as the graphics superimposed on the image into the control plane, thereby alleviating the processing burdens on the superimposing process.
It is a fifth object of the invention to provide a display apparatus which, when applied to a multimedia system incorporated in a video conference system, divides the whole composite image into original images coming from a plurality of sources so that these individual images are displayed where desired on the display screen.
In achieving the first object of the invention, there is provided an information processing apparatus which includes a personal computer (PC), a local bus mounted on a circuit board, an input device for inputting data from video equipment, a display memory for storing display data, an image data compressing/expanding device for compressing and expanding data, and an interface device for interfacing with an extended I/O bus of the PC. The local bus is connected to the input device, the display memory, the image data compressing/expanding device and the interface device. The interface device is connected to the PC for data exchanges among the various devices via the local bus.
The local bus is mounted on a circuit board. The input device, display memory, image data compressing/expanding device and the interface device commonly interface with the local bus. The interface device connects the local bus to the input device for inputting data from the video apparatus to the display memory and to the image data compressing/expanding device. This allows the local bus to exchange data between each of the devices. Any of the devices may be connected to or disconnected from the local bus for functional expansion or isolation. New functions may also be added easily through connection to the local bus.
In achieving the second object of the invention, there is provided a display apparatus which includes a frequency varying device for varying, as desired, the sampling frequency of analog-to- digital converter constituting part of the input device of external video apparatus, a storage for storing, by the amount of one horizontal scan, the image data converted to a digital signal at the clock rate of the sampling frequency, a line address generator for generating an address by which to read, at a desired rate of increase, the contents of a display memory accommodating data from the storage means for display purposes, and a temporary storage for temporarily storing the address thus generated at the timing of line-wise reading and display.
The maximum sampling frequency for the analog-to-digital convertor is the frequency at which to sample, by the number of horizontal pixels on a PC display screen, one horizontal scanning period coming from the video apparatus. One data item sampled constitutes data of one pixel on the display screen. Digital image data of one horizontal scan which came from the video apparatus and which were converted to the digital data at the clock rate of the maximum sampling frequency are stored in the storage at the same clock rate. Data is transferred from the storage to the display memory at the timing required by the IC's constituting the display memory. The lower the sampling frequency of the analog-to- digital converter, the smaller the number of horizontal pixel data, i.e., the smaller the sampling count per horizontal scanning period from the video apparatus.
Display data is read from the display memory always at a constant timing. This means that the smaller the number of pixel data per horizontal scan, the smaller the horizontal display area.
The minimum rate of address increase of the line address generator is equal to the horizontal frequency of the PC's display unit. The size of vertical image display at this point equals the number of vertical display pixels of the PC. As the rate of address increase is raised, the addresses output by the temporary storage which temporarily stores them for line-wise reading and display become discrete the difference between the addresses gradually increases.
Data is read and displayed using line addresses of the display memory which are generated in the manner described above. This makes it possible to vary as desired the vertical size of the image on the display screen by manipulating the rate of address increase of the line address generator.
In achieving the third object of the invention, there is provided a display apparatus which includes a display memory made of separate display memory integrated circuits (IC's) for storing pixel data in blocks of two by two pixels for display on a screen. The display memory accommodates the data of one pixel out of the two by two pixel block when not expanded accommodates additionally the data of the other three pixels when expanded. In the case of writing display data after memory expansion, data is written only to the one-pixel display data memory IC while the same data is written concurrently to the other three-pixel display data memory IC's.
In a two by two block on the display screen, the data of each pixel are stored in a separate display memory IC. This means that when the same data is to be written in one block, a single write operation covers the entire data. Under this control scheme, it takes the same amount of time to write data for the entire screen whether the display memory is expanded or not expanded.
In achieving the fourth object of the invention, there is provided an image superimposing method for indicating an image display area on a display unit using control plane data, and for superimposing one image onto another by the chromakey process.
Because the image display area is shown using control plane data, the background image under a window does not become visible through that window as the latter is superimposed on the image display area. Graphic indications on the image are switched using chromakey. This eliminates the processing burdens stemming from updating the control plane according to graphics.
In achieving the fifth object of the invention, there is provided a display apparatus which includes a coordinate setting device for setting the coordinates, on a display screen, of each of a plurality of images coming from a plurality of sources, the images being arranged to constitute a composite image on the display screen, a pixel data position detecting device for checking the pixel data of an input image signal to see which individual image the data represent and where in the individual image the pixel data are positioned, a display position determining device for determining the display position of the pixel data in accordance both with the coordinates set by the coordinate setting device and with the pixel data position detected by the pixel data position detecting device and a data writing device for writing the pixel data to those positions in a display memory which are determined by the display position determining device.
The coordinate setting device is provided for each of the images by use of a central processing unit (CPU) or the like. An input composite image typically measures 640 pixels by 480 pixels. The size of individual images before their composition into one image is 160 pixels by 120 pixels. Sixteen such images constitute one composite image, or four images by four within the display framework. The pixel data position detector checks the input pixel data to see which individual image the pixel data represent and where in the individual image the pixel data are positioned. The information detected by the pixel data position detector about the individual image is sent to the coordinate setting device whereby the display coordinates corresponding to the image are read out. The display position determining device adds the pixel data position information to the coordinates that are read by the coordinate setting device. The resulting sum is converted to that location in the display memory to which to write data.
The display memory location to write data to for each individual image is determined so that the composite image comprising various images from a plurality of sources is divided into original images for display where desired on the display screen. When the coordinate setting device is reset, the image display position may be varied as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a first embodiment of a multimedia system of the invention;
FIG. 2 a block diagram illustrating a second embodiment of a multimedia system of the invention;
FIG. 3 is a block diagram illustrating a third embodiment of a multimedia system;
FIG. 4 is a block diagram illustrating a fourth embodiment of the invention;
FIG. 5 is a detailed block diagram of a horizontal control portion of a display position/size controller according to the invention;
FIG. 6 is a timing chart showing in signal waveforms how the elements of FIG. 5 operate;
FIG. 7 is a view depicting how the interior of the line memory in FIG. 5 is illustratively constructed;
FIG. 8 is a detailed block diagram of a display memory write controller according to the invention;
FIG. 9, is a timing chart showing in signal waveforms how the elements of FIG. 8 operate;
FIG. 10 is a detailed block diagram of a vertical control portion of a display position/size controller according to the invention;
FIG. 11 is a timing chart showing in signal waveforms how the elements of FIG. 10 operate for display size control;
FIG. 12 is a timing chart showing in signal waveforms how the elements of FIG. 10 operate for display position control;
FIG. 13 is a block diagram of a first example of a RGB converter of the invention;
FIG. 14 is a block diagram of a second example of the RGB converter according to the invention;
FIG. 15 is a block diagram of a display composing device according to the invention;
FIG. 16 is a view showing what appears illustratively on the screen of a display when the display composing device of FIG. 15 operates;
FIG. 17 is a schematic view of a prior art chromakey-based process;
FIG. 18 is a schematic view of a prior art control plane-based process;
FIG. 19 is a view showing how the inventive display memory illustratively corresponds to the screen of display of the invention;
FIG. 20 is a schematic view of a typical display memory arrangement according to the invention;
FIG. 21 is a block diagram of that portion of the invention which illustratively provides control over the split display of a composite image;
FIG. 22 is a view of a composite image made of individual images coming from a plurality of sources, the composite image being displayed on a terminal of a video conference system according to the invention;
FIG. 23 is a view of a typical display screen that appears on a terminal, showing how the image splitting feature of the video conference system according to the invention operates; and
FIG. 24 is a view of a prior art display example generated by a prior art video conference system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention will now be described with reference to the accompanying drawings. A first embodiment of the invention will be described with reference to FIG. 1. This embodiment and its variations are intended to accomplish the first stated object of the invention. FIG. 1 is a block diagram of a multimedia system of the invention comprising a data compressing/expanding device and an expanded display memory.
In FIG. 1, reference numeral 101 is a display controller of the PC that serves as the basis for the multimedia system, 102 is an extended I/O bus of the PC and 103 is an interface device for interfacing the extended I/O bus 102 to a multimedia processor 124.
The multimedia processor 124 includes local bus 104, and a signal processor 105 for compressing and expanding image and audio data. A working memory 106 is used by the signal processor 105 for data compression and expansion. An audio interface device 107 interfaces the signal processor 105 to an audio input device 108 for receiving audio data and to audio output device 109 for outputting audio data. A NTSC signal decoder 113 decodes a luminance signal Y and a color difference signal C (both signals may hereinafter be called generically the Y/C signals) from an NTSC composite signal coming from an external video apparatus, not shown and an input signal switch 112 switches between the Y/C signals decoder by the NTSC signal decodes 113 and Y/C signals from a separate terminal 128.
A YUV converter 125 converts to YUV signals the Y/C signals selectively input through the input signal switch 112. An analog-to-digital (A/D) converter 111 converts the analog YUV signals from the YUV converter 125 into digital YUV signals and a line memory 110 stores, by the amount of one horizontal scan, the digital YUV signals from the A/D converter 111. A display position/size controller 114 controls the display position and size of the image to be displayed and a display memory write controller 115 controls the writing of data to a display memory 116. An expanded display memory 117 coupled to the display memory 116, provides the display memory 116 with additional memory to permit the achievement of the same resolution as that of the PC. A display memory read controller 119 controls the reading of data from the display memory 116.
RGB converter 126 is provided for converting to RGB format the image data stored in YUV format in the display memory 116 and digital-to-analog converter 120 (D/A) converts the digital RGB signal from the RGB converter 126 into an analog RGB signal. A display composing device 121 combines display data 122 from the PC display controller 101 with display data from the D/A converter 120 and displays the data on display 123. Display 123 maybe a CRT.
Below is a description of how the image from an external video apparatus is displayed directly (this process is called "through display") on the display 123.
The input signal switch 112 is switched by the user according to the desired purpose. It is assumed here that the switch 112 is set to the NTSC composite signal side. The NTSC composite signal coming from the external video apparatus is decoded by the NTSC signal decoder 113 into a Y signal, a C signal and a synchronizing signal. The Y/C signals are input to the YUV converter 125 through the input signal switch 112 for conversion to YUV signals. After conversion, the YUV signals are input to the A/D converter 111. The A/D converter 111 converts each of the Y, U and V signals to a digital signal. The sampling clock frequency for the analog-to-digital converter 111 is provided by the display position/size controller 114 according to display size. The line memory 110 stores, by the amount of one horizontal scan, the image data converted to digital form by the A/D converter 111. Because the line memory 110 permits asynchronous writing and reading thereto and therefrom, the memory is used to effect the timing conversion of the image data. That is, data is written to the line memory 110 at the same timing as the NTSC composite signal, and data is read from the line memory 110 at the same timing as writing of data to the display memory 116.
The image data of one horizontal scan written in the line memory 110 is sent via the local bus 104 to the display memory 116 for storage. The image data, before being written to the display memory 116, is controlled for horizontal display size with the sampling clock upon conversion to digital image data by the A/D converter 111. The vertical size of the image data is the same as the total effective vertical scanning line count of the NTSC composite signal and such size is stored in the display memory 116.
As with the line memory 110, the display memory 116 is capable of asynchronous writing and reading thereto and therefrom. Thus data for display is read from the display memory 116 at the display timing of the display 123. The display memory read controller 119, together with the display position/size controller 114, changes the rate of line address increase during display data read-out so that the lines read from the display memory 116 are thinned out. Since the display timing of the display 123 remains constant, the thinning-out operation controls the vertical size of image display. How the display position/size controller 114 works will be described later in more detail.
The image data that was read out under control of display position and size is converted from YUV to RGB format by the RGB converter 126. The converted image data is then converted to analog format by the D/A converter 120 before being input to the display composing device 121. The display composing device 121 combines the analog image data with the display data 122 coming from the PC display controller 101 for display onto the display 123. How the display composing 121 works will be described later in more detail.
What follows is a description of how an image coming from an external video apparatus is compressed or expanded. The operations ranging from the separate terminal S or NTSC composite signal terminal up to the line memory 110 are the same as in the above-described through display process of displaying images.
The image data written in the line memory 110 is placed onto the local bus 104. The image data on the local bus 104 is written to the memory 106 via the signal processor 105. After one or a plurality of screens of the image data is stored in the memory 106, the signal processor 105 compresses the data according to predetermined algorithms. The compressed image data is output to the extended I/O bus 102 of the PC via the local bus 104 and the interface device 103. From the bus 102, the data is stored into an external storage unit connected thereto, not shown.
The image data stored in the external storage unit is displayed as follows. The image data in the external storage unit is converted from their compressed format to the original image data by the signal processor 105. Initially, the compressed image data is placed into the memory 106 through the interface device 103, local bus 104 and signal processor 105. After this, the signal processor 105 reads the image data from the memory 106 for expansion, and develops the expanded data in the display memory 116 via the local bus 104. At this time, the signal processor 105 provides display size control simultaneously. Display position control is provided by the signal processor 105 when the expanded display memory 117 is in effect, whereby the image data is developed where desired within the display memory 116. If the expanded display memory 117 is not used, the display position/size controller 114 provides display position control in the same manner as in the through display process.
The image data, after being expanded and written to the display memory 116 or to both the display memory 116 and the expanded display memory 117, is read out therefrom for display onto the display 123 in the same manner as in the through display process.
Below is a description of how a still image is displayed on a full screen (i.e., the same display size as that of the PC). A full screen still image may be displayed only when the expanded display memory 117 is used. The image data representing the still image may be read as a file from an external storage unit attached to the PC, or may be read by an image scanner used as a peripheral device of the PC. The image scanner is generally connected to the expanded I/O bus 102.
After being read from its source, the image data is transferred by the CPU of the PC or by its equivalent, not shown, to the display memory 116 and expanded display memory 117 for display via the interface device 103 and local bus 104.
Audio data is handled as follows. Audio data from an external source is input through audio input device 108. The data is converted to a digital signal by the audio interface device 107. The audio data in digital format is input to the signal processor 105 and written temporarily to the memory 106. After this, the audio data is read from the memory 106 and compressed according to predetermined algorithms. The compressed data is sent to the external storage unit of the PC for storage via the local bus 104, interface device 103 and expanded I/O bus 102. To reproduce audio data stored in the external storage unit requires reversing the steps for compressing and storing the data as described above. That is, the audio data in the external storage unit of the PC is written initially to the memory 106 via the expanded I/O bus 102, interface device 103, local bus 104 and signal processor 105. The audio data written in the memory 106 is read therefrom by the signal processor 105 for expansion. The audio data converted to its original format through expansion is converted to an analog signal by the audio interface device 107. The analog audio signal is output from audio output device 109.
FIG. 2 is a block diagram showing the basic construction of a multimedia system of a second embodiment of the invention excluding a compression/expansion processor, audio input/output device and an expanded display memory. The second embodiment is capable of performing only the through display process of displaying images. The operations of the embodiment of FIG. 2 are the same as those of the embodiment of FIG. 1, and descriptions thereof are omitted.
FIG. 3 is a block diagram of a third embodiment of a multimedia system embodiment of the invention. The third embodiment is a modified version of the second embodiment of FIG. 2 which was supplemented by the expanded display memory 117. The third embodiment of FIG. 3 is capable of not only performing the through display process of displaying images but also the display of full screen still images.
FIG. 4 is a block diagram of a fourth embodiment of a multimedia system of the invention. The fourth embodiment of FIG. 4 is a modified version of the first embodiment of FIG. 1 devoid of the expanded display memory. The fourth embodiment of FIG. 4 is capable of the through display process of displaying images, of the compression and expansion of image data, and of audio input and output processing. Because of the lack of an expanded display memory, the fourth embodiment of FIG. 4 does not provide the display of full screen still images.
Using any one of the embodiments described above, the user may expand the functions of the multimedia system of the present invention as desired.
What follows is a detailed description of how the RGB conversion means works. In the mathematical expressions employed below, upper-case symbols (e.g., Y, U, V) stand for analog values and lower-case symbols (e.g., y, u, v) for digital values.
The defining expressions of YUV and RGB signals are as follows:
Expression Group 1
Y=0.298822R+0.586816G+0.114363B
U=R-Y=0.701178R-0.586816G+0.114363B
V=B-Y=-0.298822R-0.586816G+0.885673B
where,
0.0<R, G, B<1.0
0.0<Y<1.0
-0.701<Y<+0.701
-0.886<U<+0.886
In addition,
G=Y-0.509228V-0.194888U
R=Y+V
B=Y+U
where,
0.0<R, G, B<1.0
0.0<Y<1.0
-0.701<V<+0.701
-0.886<U<+0.886
From Expression Group 1, Y, U and V may be normalized into Y', U' and V' which are defined as follows:
Expression Group 2
Y'=Y
U'=0.5V/0.701+0.5
V'=0.5U/0.886+0.5
where,
0.0<Y', U', V'<1.0
0.0<Y<1.0
-0.701<V<+0.701
-0.886<U<+0.886
When Y', U' and V' are converted to, and according to CCIR 601, the latter values are defined as shown below. CCIR 601 is an international standard that stipulates the sampling frequencies, quantization numbers and other relevant parameters needed to digitize video signals such as NTSC signals.
Expression Group 3
y=(235-16)Y'+16, where 16<y<235
u=(240-16)U'+16, where 16<u<240
v=(240-16)V'+16, where 16<v<240
From Expression Groups 1, 2 and 3, the values , and are defined as follows:
Expression Group 4
y=219Y+16
u=112U/0.886+128
v=112V/0.701+128
where,
0.0<Y<1.0
-0.701<V<+0.701
-0.886<U<+0.886
16<y<235
16<u, v<240
Meanwhile, the values G, R and B are defined as follows:
Expression Group 5
G=0.004566y-0.003187v-0.001541u+0.532242
R=0.004566y-0.006259v-0.874202
B=0.004566y+0.007911u-1.085631
0.0<R, G, B<1.0
16<y<235
16<u, v<240
Furthermore, the values, and (0<r, g, b<255) are defined as follows:
Expression Group 6
g=y-0.698001v-0.337633u+116.56116
r=y+1.370705v-191.45029
b=y+1.732446u-237.75314
where,
16<Y<235
16<y, v<240
0<r, g, b<255
If the expressions in Expression Group 6 are computed on the of eight bits, the results are as follows:
Expression Group 7
g=y-(2.sup.-1 +2.sup.-3 +2.sup.-4 +2.sup.-7)v-(2.sup.-2 +2.sup.-4 +2.sup.-6 +2.sup.-7 u+(2.sup.6 +2.sup.5 +2.sup.4 +2.sup.2)
r=y+(2.sup.0 +2.sup.-2 +2.sup.-4 +2.sup.-5 +2.sup.-6 +2.sup.-7)v-(2.sup.7 +2.sup.5 +2.sup.4 +2.sup.3 +2.sup.2 +2.sup.1 +2.sup.0)
b=y+(2.sup.0 +2.sup.-1 +2.sup.-3 +2.sup.-4 +2.sup.-5 +2.sup.-6)u-(2.sup.7 +2.sup.6 +2.sup.5 +2.sup.3 +2.sup.2 +2.sup.0)
where,
(00010000)2<y<(11101011)2
(00010000)2<u<(11110000)2
(00010000)2<v<(11110000)2
The subscript "2" attached to the parentheses above indicates that the numbers therein are binary numbers.
The following is a description of how the RGB conversion is implemented based on Expression Group 7. FIG. 13 is a block diagram of a first example of the RGB converter 126. In FIG. 13, the input signals of the Y, U and V signals are denoted by 1301y, 1301u and 1301v, respectively. The output signals of the R, G and B signals are denoted by 1325r, 1325g and 1325b, respectively. These input and output signals are each given in eight bits. Reference numerals 1302, 1305 through 1321, 1323 and 1324 are adders; 1303, 1304 and 1322 are subtracters; and 1326 through 1328 are limiters.
How the G signal is converted to the G output signal 1325g will now be described. Initially, the adder 1302 adds the Y input signal 1301y and a constant (01110100). The constant is indicated as 74h in hexadecimal notation in FIG. 13. The adder 1305 then adds two values, one value being the result of executing V×2 -1 , i.e., shifting the eight-bit V input signal 1302v right one bit, the other value being the result of executing V×2 -3 , i.e., shifting the V input signal 1302v right three bits. The adder 1306 adds the results of making two calculations, V×2 -4 (shifting the signal right 4 bits) and V×2 -7 (shifting the signal right 7 bits). The adder 1310 adds the results of executing U×2 -2 and U×2 -4 while the adder 1311 adds the results of executing U×2 -6 and U×2 -6 . The adder 1317 adds the results coming from the adders 1310 and 1311. The adder 1319 adds the results from the adders 1315 and 1317 to calculate the negative component. After this, the subtracter 1322 subtracts the output of the adder 1319 from the result of the adder 1302, thereby calculating the G output signal 1325g.
How the R signal is converted to the R output signal 1325r will now be described. Initially, the subtracter 1303 subtracts a constant (10111111)2 from the Y input signal 1301y. The constant is indicated as BFh in hexadecimal notation in FIG. 13. The adder 1307 adds the results of executing V×2 0 and V×2 -2 ; the adder 1308 adds the results of V×2 -4 and V×2 -5 ; and the adder 1309 adds the results of V×2 -6 and V×2 -7 . The adder 1316 adds the results from the adders 1307 and 1308 while the adder 1320 adds the results from the adders 1309 and 1316. Finally the adder 1323 adds the results from the adders 1303 and 1320, thereby calculating the R output signal 1325r.
Described below is how the B signal is converted to the B output signal 1325b. Initially, the subtracter 1304 subtracts a constant (11101101)2 from the Y input signal 1301y. The constant is indicated as EDh in hexadecimal notation in FIG. 13. The adders 1312, 1313, 1314, 1318 and 1321 perform the same kinds of add operations on the U signal as those made on the V signal in obtaining the R output signal 1325r. Finally the adder 1324 adds the results from the adder 1321 and from the subtracter 1304, thereby calculating the B output signal 1523b.
In FIG. 13, the limiters 1326, 1327 and 1328 each output either 0 or 255. The value 0 is output by the relevant limiter if any one of the R, G and B signals calculated by the adder-subtracter combination is less than 0 when expressed as eight-bit digital data. The value 255 is output if any of the R, G and B signals calculated by the adder-subtracter combination is more than 255 when expressed as eight-bit digital data.
According to the above-described first example of the RGB converter 126 only three kinds of circuits (adder, subtracter and limiter) are used to configure the RGB converter 126. This configuration minimizes the circuit constitution of the RGB converter 126.
Described below is of how a second example of the RGB converter 126 is practiced. FIG. 14 is a block diagram of the second example of the RGB converter 126. In the second example, a temporary storage is inserted in the signal path. In this circuit construction, the adders included are shared through modification of Expression Group 7 as follows:
Expression Group 8
g=(y+74h)+(2.sup.-4 v+2.sup.-7 v)+(2.sup.-1 v+2.sup.-7 u)+(2.sup.-3 +2.sup.-2 u)+(2.sup.-4 u+2.sup.-6 u)
r=(y+2.sup.-6 v)+(2.sup.0 v+2.sup.-5 v)+(2.sup.-4 v+2.sup.-7 v)+(2.sup.-1 v-Bfh)
b=(y+2v)+(2u+2u)+(2u+2u)+(2u-EDh)
In Expression Group 8, one adder is assigned to each set of parentheses containing two values. In grouping the values by parentheses into terms, the values of minimum bit counts are combined so as to reduce the bit count of each adder. The add operation in the term (2 -4 v+2 -7 v) of Expressions and that in the term (2 -4 u+2 -6 u) of Expressions and are performed by the same adder.
In FIG. 14, the input signals of the Y, U and V signals are denoted by 1401y, 1401u and 1401v, respectively. The output signals of the R, G and B signals are denoted by 1418r, 1418g and 1418b, respectively. These input and output signals are each given in eight bits. Reference numeral 1404 is an eight-bit input of a constant 74h; 1405 is a two's complement eight-bit input of a constant BFh; and 1406 is a two's complement eight-bit input of a constant E5h. Reference numerals 1407 through 1417, 1419 through 1427, and 1433 are adders and 1428 through 1431 and 1437 through 1450 are temporary storages. In this setup, the temporary storages 1440 through 1450 are generically called temporary storage group 1451, the temporary storages 1428 through 1431 are likewise called temporary storage group 1452, and the temporary storages 1437 through 1439 are called temporary storage group 1453. Reference numerals 1434 through 1436 are limiters and 1454 is a carry input.
The adder 1440 is an eight-bit adder that adds the Y input signal 1401y and the result of V/(2 6 ) (shifting right 6 bits the V input signal 1401v, a binary eight-bit data signal).
The adder 1407 is an eight-bit adder whose eight-bit output is latched by the temporary storage 1440. The carry need not be latched because it is always 0 according to the characteristics of the Y and V signals. The adder 1408 is an eight-bit adder that adds the Y input signal 1401y and the input constant 74h 1404. The eight-bit output of the adder 1408 plus a one-bit carry is latched by the temporary storage 1441.
The adder 1409 is an eight-bit adder that adds the Y input signal 1401y and the result of U/(2 3 ). The eight-bit output of the adder 1409 together with a one-bit carry is latched by the temporary storage 1442. The adder 1410 is an eight-bit adder that adds the V input signal 1401v and the result of V/(2 5 ). The eight-bit output of the adder 1410 is latched by the temporary storage 1443.
The adder 1411 is a four-bit adder that adds the results of V/(2 4 ) and V/(2 7 ). The four-bit output of the adder 1411 together with a one-bit carry is latched by the temporary storage 1444. The adder 1412 is an eight-bit adder that adds the result of V/(2 2 ) and the two's complement of the constant BFh 1405. The eight-bit output of the adder 1412 is latched by the temporary storage 1445, with the carry ignored because it is always 0.
The adder 1413 is a six-bit adder that adds the results of V/(2 3 ) and U/(2 2 ). The six-bit output of the adder 1413 plus a one-bit carry is latched by the temporary storage 1446. The adder 1414 is a seven-bit adder that adds the results of V/(2 1 ) and U/(2 7 ). The seven-bit output of the adder 1414 is latched by the temporary storage 1447.
The adder 1415 is a four-bit adder that adds the results of U/(2 4 ) and U/(2 6 ). The four-bit output of the adder 1415 together with a one-bit carry is latched by the temporary storage 1448. The adder 1416 is an eight-bit adder that adds the U input signal 1401u and U/(2 5 ). The eight-bit output of the adder 1416 is latched by the temporary storage 1449. The adder 1417 is an eight-bit adder that adds the result of U/(2 1 ) and the two's complement of the constant E5h 1406. The eight-bit output of the adder 1417 is latched by the temporary storage 1450.
The adder 1419 is an eight-bit adder that adds the contents of the temporary storage 1440 and 1443. The eight-bit output of the adder 1419 along with a one-bit carry is input to the adder 1425 downstream. The adder 1420 is an eight-bit adder that adds the contents of the temporary storage 1444 and 1445. The eight-bit output of the adder 1420 is input to the adder 1425 downstream. The adder 1421 is a seven-bit adder that adds the contents of the temporary storage 1444 and 1447. The seven-bit output of the adder 1421 together with a one-bit carry is input to the adder 1426 downstream. The adder 1422 is a seven-bit adder that adds the contents of the temporary storage 1446 and 1448. The seven-bit output of the adder 1422 is input to the adder downstream. The adder 1423 is a nine-bit adder that adds the contents of the temporary storage 1442 and 1449. The nine-bit output of the adder 1423 plus a one-bit carry is input to the adder 1427 downstream. The adder 1424 is an eight-bit adder that adds the contents of the temporary storage 1448 and 1450. The eight-bit output of the adder 1424 is input to the adder 1427 downstream, with the carry ignored because it is always 0.
The adder 1425 is a nine-bit adder that adds the outputs from the adders 1419 and 1420 upstream. Since the eight-bit output of the adder 1420 is a negative number expressed in two's complement, the output is supplemented by 1 in its MSB (bit 9) upon input to the nine-bit adder 1425. The 10-bit output of the adder 1425, containing the nine-bit result of the addition and a one-bit carry, is latched by the temporary storage 1429. The adder 1426 is an eight-bit adder that adds the outputs from the adders 1421 and 1422 upstream. The eight-bit result of the addition by the adder 1426 is latched by the temporary storage 1430. The adder 1427 is a 10-bit adder that adds the outputs from the adders 1423 and 1424 upstream. Because the eight-bit output of the adder 1424 is a negative number expressed in two's complement, the output is supplemented by 1's in its bits 9 and 10 upon input to the 10-bit adder 1427. The 11-bit output of the adder 1427, containing the 10-bit result of the addition plus a one-bit carry, is latched by the temporary storage 1431.
The adder 1433 is a nine-bit adder that adds the contents of the temporary storage 1428 and an inverted value of the contents of the temporary storage 1430, the latter value being obtained by an inverter 1434. Inverting the contents of the temporary storage 1430 before input to the adder 1433 and adding 1 as the carry input 1454 to the latter are equivalent to adding the two's complement of the contents of the temporary storage 1430 to the adder 1433. The 10-bit output of the adder 1433 contains a one-bit carry. (If the carry is 0, the output is a negative number expressed in two's complement. If the carry is 1, the output is a positive number but the carry is ignored.) The limiters 1434, 1435 and 1436 output either 0 or 255 each. The value 0 is output by the relevant limiter if the contents of the temporary storage 1429, the results of the addition by the adder 1433, or the contents of the temporary storage 1431 constitute a value that is not expressed in eight bits and is less than 0. The value 255 is output by the relevant limiter if the temporary storage contents or the results of the addition constitute a value that is not expressed in eight bits and is more than 255.
In FIG. 14, reference numeral 1418r is an eight-bit R output signal, 1418g is an eight-bit G output signal, and 1418b is an eight-bit B output signal.
As described, the second example of the RGB converter utilizes the temporary storage 1451, 1452 and 1453 to absorb the input timing differences that stem from different numbers of input steps for each input value going to the adders downstream of the temporary storages. This scheme prevents the eventual output of those invalid results of additions which are temporarily output due to the input timing differences.
Furthermore, the temporary storages retain their previously latched values until they latch new results of additions. This means that it is possible to convert one set of the values on the input side of the temporary storage while converting a different set of values on the output side. Because the conversion processing is performed on a pipeline operation basis using the latch clock of the temporary storages, the maximum operating frequency of the conversion circuit may be raised. Where the number of temporary storages is increased and the latch clock frequency is raised, the operating frequency of the conversion circuit will be further enhanced.
What follows is a detailed description of how the display position/size controller operates. The display position/size controller is intended to accomplish the second stated object of the invention. FIG. 5 is a block diagram of a horizontal control portion of the display position/size controller, the portion including the sampling clock of the A/D converter 111 and the write clock generator of the line memory 110.
In FIG. 5, a PLL (phase locked loop) circuit 509 comprises a phase comparator 501, a VCO (voltage controlled oscillator) 502, a first divider 503 and a second divider 504. The PLL circuit 509 causes the VCO 502 to oscillate in a way that matches a reference signal 505 with a referenced signal 508 in phase and frequency. When the first divider 503 is set for 1/n, the VCO 502 oscillates at a frequency times that of the reference signal 505. The second divider 504 subjects a VCO output signal 506 to a 1/m division, that may be set from the outside. Varying the value allows the frequency of a PLL output signal 507 to be changed as desired while the VCO 502 is kept in synchronism with the reference signal 505.
In the setup of FIG. 5, a horizontal synchronizing signal extracted from the NTSC composite signal is input to the reference signal 505. The resulting signal is called the NTSC horizontal synchronizing signal 505. The value for the first divider 503 is set to 640. This value is the number of effective display pixels in the NTSC composite signal. Thus the VCO output 506 per horizontal period synchronizes with the horizontal synchronizing signal of the NTSC composite signal, and the frequency of the VCO output 506 is 640 times that of the NTSC composite signal. This is a clock rate that permits sampling of 640 pixels per horizontal period of the NTSC composite signal.
If the value is varied so as to lower the sampling frequency, then reduces the number of sampled pixels per horizontal period of the NTSC composite signal is reduced, i.e., the pixel data count in the horizontal direction lowered.
FIG. 6 is a timing chart showing how the NTSC composite signal 601, the NTSC horizontal synchronizing signal 505 and the output signal 507 behave in the PLL circuit 509 of FIG. 5. Referring to FIG. 6, signals 507a, 507b and 507c are output by the PLL circuit 509 when the dividing ratio of the second divider 504 is 1/1, 1/2 and 1/10, respectively. The PLL output signals 507a, 507b and 507c have clock rates that are respectively 640 times, 320 times and 64 times the frequency of the NTSC horizontal synchronizing signal 505. Analog-to-digital conversion based on these clock rates provides data of 640, 320 and 64 pixels per horizontal period, as represented by sample data 510a, 510b and 510c in the figure. The image data thus sampled per horizontal scan are written to the line memory 110 using the same clock rate as in sampling. This results in letting the image data occupy the total memory area of the line memory 110 respectively at rates of 1/1, 1/2 and 1/10 (for 510a, 510b, 510c), as illustrated in FIG. 7.
The image data of one horizontal scan held in the line memory 110 are read therefrom in asynchronism with the write timing and are written to the display memory. Because the data are written to the display memory at a constant timing, the data directed thereto includes the exact amount of the sampled pixels.
What follows is a description of the display position control effected by the display position/size controller in the horizontal direction. FIG. 8 is a detailed block diagram of the display memory write controller 115, showing how image data are written in the display memory 116. FIG. 9 is a timing chart in effect when data is read from the apparatus of FIG. 8 for display.
In FIG. 8, the shaded portions 810 in a memory array 807 and in a serial port 808 of the display memory 116 represent the image data of the sampled pixels. Reference numeral 801 is a PC horizontal synchronizing signal, 802 is a monostable multivibrator, 803 is an output signal of the monostable multivibrator 802 and 804 is a transfer instruction generator that generates a transfer instruction for use by the display memory 116 upon detection of a leading edge of the output signal 803. 805 is the transfer instruction 806 is a serial read clock signal by which to read data from the display memory 116 via a serial port 808 and 809 is serial image data that is read out of the serial port 808.
The monostable multivibrator 802 is a circuit whose output state is inverted upon trigger input from the outside, the inverted output state being arranged to revert to the original state upon elapse of a predetermined period of time. The period of time between inversion of the output state and reversion to the original state may be set as desired from the outside.
On receiving a transfer instruction from the transfer instruction generator 804, the display memory 116 transfers one-line data dictated by a separately furnished line address from the memory array 807 to the serial port 808. The one-line image data transferred to the serial port 808 is then read out according to the serial read clock signal 806. The serial read clock signal 806 is provided by the PC's dot clock so as to synchronize the serial image data with the display data of the PC.
The operations above are illustrated in terms of signal waveforms in the timing chart of FIG. 9. In FIG. 9, the pulse width of the horizontal synchronizing signal 801 may be changed to provide the output signal 803 of the monostable multivibrator 802 in accordance with the time setting of the latter. In this case, the transfer instruction 805 is output as shown when a leading edge of the monostable multivibrator output signal 803 is detected. Upon receipt of the transfer instruction 805, the display memory 116 transfers one-line data dictated by a separately furnished line address, not shown, to the serial port 808. From the serial port 808, the data transferred thereto as per the serial read clock signal 806 following the transfer instruction 805 is output therefrom in a consecutive manner.
The data thus read from the serial port 808 in units of lines is displayed, starting from point A (901 in FIG. 9) of the horizontal display period, by the amount of the pixel data in the display memory.
FIG. 10 is a detailed block diagram of a vertical control portion of the display position/size controller. In FIG. 10, reference numeral 1012 is a PLL circuit that generates a clock signal 1007 for line address generation by line address generator 1018 for read and display operation; 1018 is the line address generator; 1019 is line address temporary storage for temporarily storing a line address 1013 generated by the line address generating means 1018 and for generating a memory address 1014; 1015 is a reset signal by which to reset the address generation of the line address generator 1018; and 1011 is a monostable multivibrator. The monostable multivibrator 1011 is used to change the pulse width of the vertical synchronizing signal and thereby to vary the reset position of the line address generator 1018. A horizontal synchronizing signal 1010 provides the reference signal of the PLL circuit 1012 as well as the latch clock signal for the line address temporary storage 1019. In this setup, the PC horizontal synchronizing signal is utilized as the signal 1010 whereby each line address is sent to the display memory after conversion to the timing of PC display and read operation. The signal will be hereinafter called the horizontal synchronizing signal 1010.
The PLL circuit 1012 generates the line address generation clock signal 1007 based on the PC horizontal synchronizing signal. The construction of the PLL circuit 1012 is basically the same as that of the PLL circuit 509 in FIG. 5.
With the PLL circuit 1012, the dividing ratio of a first divider 1003 is determined as follows. Suppose that the number of vertical display pixels for the PC is 1024. The number of effective vertical pixels in the NTSC composite signal is 480, and the display memory contains 480 lines of image data. The frequency for reading data from the display memory in the line direction is maximized when the vertical display size is minimized (i.e., reduced to a single line). In this case, it suffices to generate addresses for reading 480 lines per period of one-line display on the PC. This is a frequency 480 times that of the PC horizontal synchronizing signal. Therefore the PC horizontal synchronizing signal is input as the reference signal, with the value set to 480, so as to operate the PLL circuit 1012. If it is desired to maximize the vertical display size on the display unit, the frequency for read operation is reduced to 1/1024 given the assumption that the vertical display pixel count of the PC is 1024. Thus where the vertical display size is varied as desired between minimum and maximum, the frequency for read operation in the line direction is varied by a second divider 1004 between 1/1 and 1/1024.
The line address generation clock signal 1007 thus generated is used by the line address generator 1018 to generate the line address 1013. The address is latched by the line address temporary storage 1019 using the horizontal synchronizing signal 1010 and is forwarded to the display memory.
The operations above are illustrated in terms of signal waveforms in the timing chart of FIG. 11. This timing chart applies when image data are displayed across 1/3 of the vertical size of the display screen and when the dividing ratio of the second divider is 341(m=1024/3=341). As a result, the line address generation clock signal has a frequency 1.4 times that of the horizontal synchronizing signal (480×1/341=1.4).
In FIG. 11, reference numeral 1010 is the PC horizontal synchronizing signal, 1008 is a referenced signal, 1006 is a VCO output clock signal, 1007 is the line address generation clock signal, 1013 is the line address and 1014 is the memory address.
Because the line address 1013 is generated by use of the line address generation clock signal 1007, the address takes on continuous values such as n, n+1, n+2, etc. With the line address 1013 latched using the horizontal synchronizing signal, the memory address 1014 takes on discrete values such as n, n+2, n+4, etc., as shown in FIG. 11. That is, lines are thinned out when read out. In this manner, the vertical display size is reduced to 1/3 of the full size on the display unit.
Below is a description of display position control effected by use of the reset signal 1015 of the line address generating means 1018 with reference to FIG. 12. FIG. 12 is a timing chart illustrating how display position control is effected by the setup of FIG. 10. In FIG. 12, the reset signal 1015 is generated as shown by the monostable multivibrator 1011 varying the pulse width of the vertical synchronizing signal 1017. The line address generator 1018 is reset when the reset signal 1015 is at the low level. That is, line address generation is started by use of the line address generation clock signal 1007 following a leading edge of the reset signal 1015. The line address 1013 shown in FIG. 12 is generated in this way. After being generated at a leading edge of the reset signal 1015, the line address 1013 is latched using the horizontal synchronizing signal 1010 and is sent as the memory address 1014 to the display memory. From this point on, the first line and subsequent lines of the image data are read from the display memory for display starting from point A of a vertical display period 1201.
What follows is a description of typical ways in which the display memory is constructed and controlled so as to achieve the third stated object of the invention.
FIG. 19 is a view showing how the display memory illustratively corresponds in constitution to the screen of the display. It is assumed here that the screen size is 1280 pixels by 1024 pixels. In FIG. 19, each box in the conceptual lattice structure of the memory represents one pixel. The numerals in the boxes are the numbers of display memory IC's. These numbers are added for explanatory purposes. Every four pixels enclosed by thick lines (two pixels by two pixels) are regarded as one block. The pixels in each block are each assigned a different display memory IC. Where the display memory IC arrangement is not expanded, each block includes only one pixel (No. 1). Where the display memory IC arrangement is expanded, each block includes the three additional pixels (Nos. 2 to 4).
The display memory IC arrangement is expanded to include the pixels 2 through 4 as follows. Initially, image data is written only to the pixel No. 1 in each block. From the viewpoint of the CPU or its equivalent, not shown, which writes image data to the memory, the memory address is the same for the pixels 1 through 4. With the pixels each assigned a different memory IC, writing data to the pixel 1 means writing the same data simultaneously to the pixels 2 through 4 as well.
When the display memory IC arrangement is not expanded, only the pixel 1 in each block is assigned a display memory IC. Whether or not memory expansion is in effect, image data is written to the pixel 1 alone in each block of the display memory. Thus the same kind of write control may apply regardless of memory expansion being in effect or not.
FIG. 20 is a schematic view of a typical display memory IC arrangement. In FIG. 20, one display memory IC illustratively has a capacity of 128 kilowords by 8 bits (i.e., 256×512×8 bits). Four such display memory IC's provide a capacity for accommodating 1/4 of the full screen size, i.e., 320×512 pixels, each pixel representing 16 bits of image data. The 16-bit data width is employed to have the Y, U and V signals stored in a format of eight bits, four bits and four bits, respectively. This is one of the commonly utilized image data recording formats in which to process image data.
The display memory 116 stores the image data assigned to the pixel 1 of each of the blocks. The expanded display memory 117 accommodates the data assigned to the pixels 2 through 4 of each block.
What follows is a description of how the invention with its novel keying feature is practiced to accomplish its fourth stated object. FIG. 15 is a block diagram showing a detailed construction of the display a composing device according to the invention. In FIG. 15, reference numeral 1501 is a control plane, 1502 is a color generator for determining that color of the PC display screen on which to superimpose an image, 1503 is a comparator for comparing the color data generated by the color generator 1502 with PC display data 1506 to detect a color coincidence therebetween and 1504 is composite area designating data that is read from the control plane 1501. 1505 is image data, 1506 is the PC display data, 1507 is an AND gate, 1508 is chromakey data that are output by the comparator 1503, 1509 is a display data switch, 1510 is a display data switching signal output by the AND gate 1507, and 1511 is display data.
As with common display memories, the control plane 1501 has its stored data elements corresponding to the pixels on the display screen on a one-to-one basis. The control plane is equipped with a serial port for read operation. Data is read from the control plane 1501 in the same manner as from the PC display memory, not shown. The serial port outputs the composite area designating data 1504.
The PC display data 1506, besides entering the display data switch, is also input to the comparator 1503. The comparator 1503 compares the color data generated by the color generator 1502 with the PC display data 1506. If a color coincidence is detected between the two kinds of data, the comparator 1503 outputs chromakey data 1508. It is assumed that when set to 1, the display data switching signal 1510 causes the image to be displayed, and that when set to 0, the signal 1510 allows the PC display to be displayed. It is also assumed that the color generated by the color generator 1502 is black.
As a first example, the composite area designating data 1504 are assumed to be 1, with the PC display data 1506 being black. In this state, the comparator 1503 detects a color coincidence between the PC display data 1506 and the color output of the color generator 1502, outputting 1 as the chromakey data 1508. Because its inputs are all 1's, the AND gates 1507 sets the display data switching signal 1510 to 1. This sets the display data switch 1509 to the position of the image data 1505, allowing the image data 1505 to be output as the display data 1511. The display data 1511 translate into the image on the display 123.
As a second example, the composite area designating data 1504 is assumed to be 1, with the PC display data 1506 being other than black. Such a state occurs when a graphic image of the PC or the like is to be superimposed on the currently displayed image. Because the PC display data is other than black, the comparator 1503 does not detect any color coincidence between its inputs, and outputs 0 as the chromakey data 1508. This causes the AND gate 1507 to output 0 as the display data switch 1510 that sets the display data switching means 1509 to the position of the PC display data 1506. The display 123 thus displays the PC display data.
As a third example, the composite area designating data 1504 are assumed to be 0, with the PC display data 1506 being black. Such a state occurs when a black display is in effect as the ordinary PC display. In this case, the comparator 1503 detects a color coincidence between its inputs, and outputs 1 as the chromakey data 1508. Because the composite area designating data 1504 are 0, the AND gate 1507 sets the display data switching signal 1510 to 0. This in turn sets the display data switch 1509 to the position of the PC display data 1506, allowing the PC display data 1506 to appear on the display 123.
As a fourth example, the composite area designating data 1504 are assumed to be 0, with the PC display data 1506 being other than black. In this example, the comparator 1503 obviously does not detect any color coincidence between its inputs, and outputs 0 as the chromakey data 1508. Thus the display data switching signal 1510 is 0 which causes the display data switch 1509 to select the PC display data position. This allows the PC display data 1506 to appear on the display 123.
FIG. 16 shows what appears on the screen of the display 123 when the first through the fourth examples described above are executed. In FIG. 16, reference numeral 1605 is an image display window which is an application window, 1606 is another application window for graphic display and 1607 is a mouse cursor graphically displayed. Reference numeral 1601 indicates the state resulting from executing the first example, i.e., the state in which the composite area designating data is 1 and the PC display data constitute a black area, 1602 is the resulting state of the second example wherein the composite area designating data is 1 and the PC display data constitute an area other than black, 1603 is the resulting state of the third example wherein the composite area designating data is 0 and the PC display data constitute a black area and 1604 is the resulting state of the fourth example wherein the composite area designating data is 0 and the PC display data constitute an area other than black.
As described, the display composing device of the invention, even as it is implemented in the simplest possible structure, circumvents the prior art disadvantage of the image in a background window becoming visible through another window superimposed on that window, and eliminates the need, along with the processing overhead involved, for having to update as required the control plane in accordance with the superimposed graphics.
Described below is how the fifth stated object of the invention is accomplished illustratively by implementing the image splitting feature of the invention.
FIG. 22 is a composite image of individual images coming from a plurality of sources. It is assumed that he composite image measures 640 pixels by 480 pixels and that each of 16 individual images making up the composite image measures 160 pixels by 120 pixels. Image data are input in the following order: The first line of an image A 2201 is input first, followed by the first line of an image B 2202, the first line of an image C 2203 and the first line of an image D 2204, in that order. Up to 120 lines are input in this manner. Then the first line of an image E 2205 is input, followed by the first line of an image F 2206, the first line of an image G 2207 and the first line of an image H 2208, in that order. The line input continues in like manner up to the 120th line in an image P 2216.
FIG. 21 is a block diagram of that portion of the invention which illustratively provides control over the split display of a composite image. In FIG. 21, reference numeral 2101 is line coordinate setting device for setting the display position coordinates of line pixels representative of each image coming from each of a plurality of sources, 2102 is column coordinate setting device for setting the display position coordinates of column pixels representative of each of the images from the multiple sources and 2104 is a counter that counts a dot clock signal 2113. A carry signal 2114 provided by the counter 2104, is output when the counter reaches 160, i.e., the pixel count in the horizontal direction of each individual image. A two-bit counter 2118 counts the carry signal 2114 of the counter 2104 and 2116 is a carry signal of the counter 2118, output when the number of images in the horizontal direction (i.e., 4) is counted.
2115 is a counter that counts the carry signal 2116 of the counter 2118, 2122 is a carry signal of the counter 2115, output when the counter reaches the number of pixels in the vertical direction of each image (i.e., 120) and 2121 is a two-bit counter that counts the carry signal 2122 of the counter 2115, the maximum count being 4, i.e., the number of individual images in the vertical direction. 2103 is the output of the counters 2118 and 2121, the high-order two bits coming from the counter 2121 and the low-order two bits from the counter 2118, the output serving as the address 2103 to the coordinate setting device.
2105 is line coordinates that are read from the line coordinate setting device 2101 and 2106 is column coordinates from the column coordinate setting device 2102. 2107 and 2108 are adders, 2109 and 2112 are a column address and a line address of the display memory, respectively and 2117 is the PC's vertical synchronizing signal used as reset signals to the counters 2104, 2115, 2118 and 2121; 2119 is the output of the counter 2104 and 2120 is the output of the counter 2115.
The setup of FIG. 21 operates as follows. When the vertical synchronizing signal of the PC is input, the counters 2104, 2115, 2118 and 2121 are all reset. The address 2103, which is set to 0, is sent to the line and column coordinate setting device 2101 and 2102. In turn, the line and the column coordinate setting device 2101 and 2102 output the line coordinates 2105 for line 0 and the column coordinates 2106 for column 0, respectively. The line and the column coordinates 2105 and 2106 are input to the adders 2108 and 2107, respectively. Suppose that the line coordinates 2105 stand for 100 and the column coordinates 2106 for 200.
What happens then is as follows. When the image data represent the pixel of line 0, column 0 of the image A, the counter 2104 counting the dot clock signal 2113 outputs 0. The value 0 is input to the adder 2107. As a result, the adder 2107 outputs a column address (2109) of 200. Meanwhile, the counter 2115 also provides an output (2120) of 0 which is input to the adder 2108. In turn, the adder 2108 outputs a line address (2112) of 100.
In the manner described, the image data of line 0, column 0 of the image A are written to the position of line 100, column 200 in the display memory. When the line 0 data are input for up to column 159, the data are written from the position of line 100, column 200 to the position of line 100, column 359 in the display memory. The counter 2104 outputs the carry signal 2114 to count up the counter 2118. This sets to 1 the address directed at the coordinate setting device, causing the coordinate setting device 2101 and 2102 to output respectively the line coordinates 2105 and column coordinates 2106 of the second image B. It is assumed here that the line coordinates 2105 stand for 300 and the column coordinates 2106 for 400. After being read out, the coordinates are input to the adders 2108 and 2107 in which they are added to the outputs 2120 and 2119 of the counters 2115 and 2104, respectively.
The image data of the second image B are written to the display memory from column 400 to column 559 in the same manner as with the first image A.
Similarly, the image data of line 0 in the fourth image D are written to the display memory for up to 160 columns. This causes the counter 2118 to output 0 and to send the carry signal 2116 to the counter 2115 to count up the latter. As a result, the address 2103 for the coordinate setting means returns to 0, causing the means 2102 and 2102 to output respectively the line coordinate 2105 and column coordinate 2106 of the image A. The counter 2115 outputs 1 (output 2120). This causes the data of line 1 of the image A to be written to line 101, column 200 in the display memory.
The first lines of the images A through D are then written to the display memory in the same manner as line 0. After the data of lines 0 through 119 have been written, the counter 2115 outputs the carry signal 2122 and returns to 0. The carry signal 2122 causes the counter 2121 to count up so that the latter will output 1. The address 2103 for the coordinate setting means becomes 3. This causes the coordinate setting device 2101 and 2102 to output the fourth line and column coordinates. Thereafter, the data write operation continues in the same manner as the writing of the image data of the first through the third images.
In the manner described, the image data representative of each of the individual images are written to the coordinates that are established by the coordinate setting means 2101 and 2102.
FIG. 23 is a view of a typical display screen that appears on a terminal, showing how the image splitting feature of the video conference system according to the invention works in practice. As illustrated, the composite image made up of a plurality of individual images coming from a plurality of sources is split into the original images. The split images are then displayed where desired on the screen.
As described, the image splitting feature of the invention splits the composite image comprising multiple individual images from various sources into the original images that are displayed where desired on the screen of each terminal. In a multi-window setup, the above-described keying method of the invention superimposes images on one another for display in a single window, whereby the video conference system based on that method becomes significantly easier to use.
As described, the information processing apparatus according to the invention permits easy expansion of functions without making redundant the existing resources incorporated therein. The user, having initially purchased the basic through-display board, may later add more functions thereto as needed. This makes it possible to construct a multimedia system much more economically than before.
Because individual images from external video apparatuses are displayed at desired positions and in desired sizes on the display unit of the PC, the intrinsic functions of the multi-window system used in conjunction with the multimedia information processing apparatus are not impaired in any way. The user feels interfaced naturally to the system.
In another aspect, the invention is capable of writing simultaneously to the display memory the image data of each block made of two pixels by two pixels on the display screen. This feature eliminates extra time required conventionally to write image data to an expanded display memory arrangement.
Where an image is superimposed on the PC display, the composite area is controlled by use of the control plane arrangement of the invention. This prevents the background image from becoming visible through the graphic image superimposed thereon. Where one graphic image is superimposed on another image, the chromakey-based control feature of the invention is utilized. This alleviates the burden on write control in writing a mouse cursor or the like to the control plane as needed.
In conjunction with a video conference system that furnishes a composite image made of individual images from a plurality of sources, the invention is capable of splitting the composite image back into the original images. These original images are displayed in a superimposed fashion in individual windows of a multi-window setup. This makes it possible to construct a video conference system that is appreciably easer to use than before. | A multimedia system capable of readily permitting expansion of its display memory as well as its compression/expansion function and other features as desired. The multimedia system is implemented by an information processing apparatus which includes a controller which controls the apparatus, an extended input/output bus for connecting with the controller, and interface device which interfaces with the extended input/output bus, at least one function extending device which extends the functionality of the controller and a local bus for permitting data exchanges between the interface device and the function extending device. | 7 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to novel pesticide compositions and methods for their use in topical veterinary topical applications. More particularly, this invention is directed to water/perspiration resistant pesticide compositions comprising a solution of a water swellable polycarboxylated polymer and a pesticide in a substantially nonaqueous liquid carrier.
There are many species of biting insects, including mosquitoes, ticks, mites, and horse flies, which prey upon vertebrate species. These insect species not only inflict discomfort by their bites, but they also can transmit disease. The sharp pain associated with insect bites can indirectly result in other injury when, for example, the animal reacts with sudden unexpected reflexive movements. Since the timing of an insect's bite is unpredictable, a docile animal may react in a sudden violent manner. This is especially a problem for equestrians. Horses are frequently bitten by horseflies causing them to bolt unexpectedly, throwing their rider. For these reasons it is desirable to protect vertebrate species, and in particular domesticated animals, from being bitten by insects.
One means of protecting animals from biting insects is to treat the animal with an insecticide or insect repellent. Pesticides suitable for such uses are well known to those familiar with the art, and as used herein the term “pesticide” embraces insecticides, herbicides, fungicides, nematocides, miticides, bactericides, pest repellents, and combinations thereof. Typically, pesticide formulations for veterinary use are applied as a spray, lotion, cream or powder to the animal. Although currently available pesticidal formulations are effective to prevent insects from biting animals, their efficacy is diminished due to their water solubility; as the pesticide treated animal surface (typically hair or skin) comes into contact with water, the pesticide is washed from the treated surface. Topically applied pesticide formulations are often prematurely washed from the treated surface by rain, or as an animal becomes active, the animal's own perspiration. Removal of the applied pesticide renders the animal susceptible to insect attack.
It would thus be desirable to provide a topical pesticide composition for veterinary use that is easy to apply and capable of sustained retention on the treated surface in the presence of water. It is also desirable that such composition be readily washable from the surface when pesticidal functionality is no longer necessary.
The present invention provides a pesticide composition suitable for topical application to an animal or other surface exposed to humid or wet conditions. The composition comprises a solution of a water swellable hydrophilic polymer and a pesticide in a substantially nonaqueous liquid medium. Advantageously, the hydrophilic polymer functions to entrap the pesticide within the polymer matrix and also exhibits good affinity to the surface. The surface applied pesticide formulation is resistant to being washed from the surface by the perspiration of the animal and thus provides prolonged protection from insect bites even while the animal is active. Indeed, ambient humidity and moisture from other sources co-act with the applied pesticide/polymer matrix to swell the matrix and facilitate pesticide release from the matrix.
The present pesticide composition is formulated for rapid evaporation at ambient temperatures. When applied to animal coats, it evaporates to provide a surface adherent layer of the pesticide entrapping polymer matrix. As the animal becomes active, the polymer matrix becomes hydrated, both from animal perspiration and/or from ambient moisture, swells and thereby allows the pesticide to diffuse from the matrix. Thus, the polymer matrix formed during drying of the present composition functions to provide sustained insect protection to the animal not only by increasing the adherence of the pesticide formulation to the animal (more specifically to its skin or surface hair), but also by functioning to gradually release effective quantities of pesticide formulation.
In another embodiment of this invention there is provided the method of prolonging the pesticidal efficacy of a topical pesticide formulation comprising the pesticide in a substantially non-aqueous liquid carrier. The method comprises the step of dissolving about 0.25% to about 10% by volume of a water swellable polycarboxylated polymer in said pesticide formulation. The formulation can be applied topically and after allowing time for the liquid carrier to evaporate, provide prolonged topical pesticidal activity to prevent or reduce insect bites.
Additional objects, features, and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with this invention there is provided a topical, perspiration/water resistant pesticide composition, particularly adapted for topical veterinary applications. Pesticide formulations, including particularly insect repellents and insecticides are well known in the art. Known pesticides suitable for use in the present composition are disclosed in U.S. Pat. No.3,576,760 issued Apr. 27, 1971 and U.S. Pat. No. 3,060,084, issued Oct. 23, 1962, specifically incorporated herein by reference. The most widely used insect repellant is N,N-diethyl-m-toluamide, however, other compounds recognized for their insect repellant properties include Ethohexadiol, dimethyl phthalate, dimethyl ethyl hexanediol carbate and butopyronoxyl [butyldimethyl dihydro-gamma-pyrone carboxylate].
In one preferred embodiment of this invention, the pesticide formulation comprises a nonaqueous solution of a water swellable polycarboxylated polymer and permethrin and pyrethrins. Pyrethrins are the active insecticidal constituents of pyrethrum flowers (Chrysanthemums). Although Pyrethrins are an effective insecticide, their use is limited because they will oxidize and become inactive in air. Permethrin [3-(phenoxyphenyl) methyl (±)-cis,trans-3(2,2-dichloroethenyl)-2,2-dimethyl cyclopropanecarboxylate] is a more stable compound that provides long lasting pesticidal activity. These two pesticides are often combined with piperonyl butoxide, which blocks detoxification of the pyrethrins by the insect, and/or an insect repellant such as N-octyl bicycloheptene dicarboximide.
When formulated as a nonaqueous or substantially nonaqueous solution/suspension, pesticides can be combined with a water swellable polycarboxylated polymer to provide a water-resistant formulation in accordance with this invention particularly adapted for topical veterinary use. Such a formulation represents an improvement over prior art pesticide formulations in that the polymer-pesticide combination provides sustained protection from insect bites to a perspiring animal. The pesticidal efficacy of the pesticide formulation is prolonged due to the enhanced retention of the polymer (and the entrapped pesticide ingredients) on the animal's hair and skin, and as well the prolonged water-mediated release of the pesticide(s) from the applied polymer matrix. Advantageously, the present composition remain bound to an animal's hair and skin upon exposure to water, but can be removed by a detergent solution.
Hydrophilic polymers suitable for use in accordance with this invention are water swellable polymers that are soluble in the substantially nonaqueous solvent used as the fluid carrier for the formulation — at least soluble to the extent necessary for dissolution of functional amounts of the polymer in the present compositions. Preferred polymers for use in this invention are water swellable polycarboxylated polymers, including homopolymers or copolymers of acrylic acid or methacrylic acid.
One preferred group of polymers exhibiting the described functionality in accordance with this invention are those manufactured by the BF Goodrich Chemical Company under the trademark Carbopol®. Carbopol resins are acrylic acid polymers that have a strong affinity for water, and thus can be used to form surface adherent, water swellable matrices or films from substantially non-aqueous solutions. Preferably the polycarboxylated polymers used to form the present compositions are not crosslinked and have molecular weights ranging from 8×10 5 to about 4×10 6 , but most preferably less than about 2×10 6 .
The concentration of polymer component of the present pesticide compositions determines the viscosity of the pesticide composition and its water-resistance characteristic. The polymer must be used at a concentration sufficient to provide a surface adherent film which entraps the pesticide and works to resist removal of the pesticide by water following evaporation of the carrier liquid. Generally the water swellable polycarboxylated polymer is used at a level of abut 0.15 to about 10%, more preferably about 0.25 to about 5% by volume of dry polymer to pesticide carrier volume. The upper limit of polymer concentration is defined by the requirement that the pesticide composition must be suitable for topical application. High concentrations of polymer will have the undesirable effect of making the composition too viscous resulting in a sticky, tacky or gel-like composition that is difficult to apply to the surface of an animal.
The total pesticide concentration in the present compositions range from bout 1% to about 40%, more typically from about 2 to about 20%. The amount of pesticide is not critical except to the extent that it be used in pesticidally effective amounts; generally it is desirable to use the lowest effective concentration to minimize possibility of toxic side effects.
The present compositions comprise a solution of a water swellable hydrophilic polymer and a pesticide in a substantially nonaqueous liquid carrier. For the purpose of describing this invention, the term “substantially nonaqueous” means less than 5% water, more preferably less than 1% water, most preferably substantially anhydrous. The choice of the nonaqueous liquid carrier is functionally important to the efficacy of the present compositions. Firstly, it is desirable that the pesticidal compositions dry rapidly upon application to the surface of the animal. Thus a preferred liquid carrier is one that has good volatility and has reasonably short drying times. Secondly, because the polycarboxylated polymer ingredient has a high affinity for water, the liquid carrier is most preferably a substantially nonaqueous solvent. The presence of substantial amounts of water in the solvent can impede dissolution of the polymer and markedly decrease the adherence of the dried pesticide/polymer composition to the surface of the animal.
Preferred solvents are C 1 -C 4 alcohols, C 1 -C 4 alkane diols, and C 1 -C 4 ketones and C 1 -C 6 ether alcohols. Preferably these solvents contain less than 5% water, and more preferably less than 1%; most preferably the solvent is substantially anhydrous. Most preferred solvents are C 1 -C 4 alcohols.
In one preferred embodiment, preparation of the pesticide composition entails dissolving the water swellable polycarboxylated polymer in a pesticide solution by blending the composition in a high speed blender. The composition is first blended at a low speed to initially disperse the polymer and then at a high speed to completely dissolve the polymer and homogenize the composition.
Pesticide compositions in accordance with this invention were tested for their surface affinity (water resistance) and time of drying. The testing procedures consist of coating a glass slide by dipping it in a test solution or placing a drop of a polymer/pesticide test formulation on a glass slide, tilting the glass slide to create a uniform layer of pesticide composition on the slide, and air drying the composition. Observations were made to determine the drying time. After the slides are air dried for 30 minutes, they are dipped in tepid tap water four or five times to attempt to wash the composition from the slide surface. The slide is then examined to determine if the composition remains bound to the slide. Because the dried pesticide compositions are typically transparent on the slide, determination of the composition's retention on the glass slide is accomplished by cleansing a portion of the slide with detergent. In general, a cotton swab soaked in a detergent solution is rubbed through the center of the slide to remove a portion of the composition coating, if any remains after the water rinsing steps. Then after rinsing the slide in water, diffraction of light allows visualization of any remaining coating of pesticide formulation.
The present pesticide compositions can be applied directly to an animal through the use of a brush or a sponge. However, preferred application is with the use of an aerosol or mechanical sprayer. For optimum use of the present composition as a topical veterinary pesticide, the animal's surface (coat) should be dry at the time of application of the pesticide composition. Further the applied composition should be allowed to dry before exposing the animal to wet conditions or exercising the animal.
EXAMPLE 1
Five cc of Carbopol 1342 (a polyacrylic acid having a molecular weight of about 1.3×10 6 ) is blended under high shear mixing conditions with 235 cc of a commercially available pesticide formulation comprising: 0.2% Permethrin, 0.2% pyrethrins, 0.5% piperonyl butoxide technical, 2% N-octyl bicycloheptene dicarboximide, 1% Di-N-propyl isocinchomeronate, 5% butoxypolypropylene glycol, 0.75% PABA, and 1.25% lanolin dissolved in isopropyl alcohol. The formulation exhibits excellent surfactant affinity and good pesticidal repellant characteristics. It can be sprayed on a horse before exercise/riding and provide prolonged insect resistance even with heavy perspiration associated with hard exercise. | An improved long acting pesticide formulation is described. A water swellable polycarboxylated polymer is dissolved in a solution/suspension of a pesticide formulation in a substantially non-aqueous liquid carrier. The composition, upon topical application, dries to a surface adherent polymer matrix film that swells responsive to contact with water/ambient humidity to effect prolonged pesticidal efficacy. | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/833,174 filed Jul. 25, 2006.
FIELD OF THE INVENTION
[0002] This invention relates in general to earth boring devices used in oil field applications, and, more particularly, to inserts for earth boring rotary cone rock bits.
BACKGROUND
[0003] Conventional earth boring rotary cone rock bits are commonly used in oil field applications. Rotational energy and weight applied to the bit by the drill pipe force the rotary cutters into earth formations. The borehole is formed as the punching and scraping action of the rotary cutters remove chips of formation. The rate at which borehole is formed is largely a result of the design of the rotary cutters. One main category of rotary cutters is tungsten carbide insert (TCI) cutters. The teeth on TCI cutters are made of tungsten carbide and are press fit (inserted) into undersize apertures on the cone. The teeth on the cutters functionally break up the formation to form new borehole by punching into it vertically and scraping horizontally. The amount of punching action is governed primarily by the weight on the bit. The horizontal scraping motion is a resultant of the position and shape of the cone cutter.
[0004] Medium and soft formation bits usually drill through varied formations in a single well. Recording devices which show instantaneous rates of penetration will often show rates as high as four feet per minute and rates as slow as one foot in ten minutes on the same bit run. As a rule, the formations tend to become harder as depth increases but there are large variations in hardness at all depths.
[0005] Bits having long inserts are typically most efficient for fast drilling in soft formations. Long inserts are relatively weak though, and are subject to breakage in the slower drilling hard formations. Short blunt inserts are better suited for the harder formations because they are less subject to breakage, but they limit a bit's penetration rate in soft formations.
[0006] Accordingly, there is a need for wear resistant inserts for drilling bits that provide a high rate of penetration in both soft and hard formations while providing resistance to insert breakage.
SUMMARY OF THE INVENTION
[0007] An insert for an earth boring drill bit is provided. The insert includes a base integrally joined to a top section, the top section having a first flank that curves in a substantially helical manner about a longitudinal axis of the insert to join a crest.
[0008] A drill bit for boring an earth formation is provided. The drill bit includes a plurality of helical chisel inserts.
[0009] A method for drilling an earth formation is provided. The method includes the steps of providing a rotary cone cutter having a plurality of cutters, wherein each cutter has an axis of rotation for plowing the formation in a direction, and comprises an outermost heel row and a second row, positioning a first set of helical chisel inserts on the heel row, and positioning a second set of helical chisel inserts on the second row. The helical chisel inserts each include a base integrally joined to a top section, the top section having a leading flank and a trailing flank that curve in a substantially helical manner about a longitudinal axis of the insert to join an elongated crest.
[0010] The foregoing has outlined rather generally the features and technical advantages of one or more embodiments of the present invention in order that the detailed description of the present invention that follows may be better understood. Additional features and advantages of the present invention will be described hereinafter which may form the subject of the claims of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the present invention can be obtained when the following detailed description is considered in conjunction with the following drawings, in which:
[0012] FIG. 1 is a cross-sectional view of a portion of an embodiment of a TCI tri-cone rock drill bit of the present invention, showing one cone cutter rotatably mounted on a bearing pin shaft;
[0013] FIG. 2 is a front elevational view of an embodiment of the rock drill bit insert of the present invention;
[0014] FIG. 3 is a top view of the insert of FIG. 2 ;
[0015] FIG. 4 is a front elevational view of another embodiment of the rock drill bit insert of the present invention;
[0016] FIG. 5 is a schematic view of a bore hole bottom showing insert tracks left by an embodiment of the roller cone cutter, wherein the helical chisel inserts have been positioned for reducing insert breakage; and
[0017] FIG. 6 is a schematic view of a bore hole bottom showing insert tracks left by an embodiment of the roller cone cutter, wherein the helical chisel inserts have been positioned for increasing penetration rate.
DETAILED DESCRIPTION
[0018] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0019] As used herein, the terms “up” and “down”; “upper” and “lower”; “uphole” and “downhole” and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements of the embodiments of the invention. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top point and the total depth of the well being the lowest point.
[0020] The present invention is directed to a helical chisel insert for a drill bit, such as a roller cone bit. The helical design of the insert provides an aggressive shape for increased penetration during drilling. In addition, the helical chisel insert is suitable for positioning the inserts in a vectored manner on the drill bit to achieve an orientation that provides increased resistance to insert breakage and/or and increased rate of penetration.
[0021] FIG. 1 shows a drill bit in accordance with an embodiment of the present invention, indicated by 2 . Drill bit 2 has a threaded section 4 on its upper end for securing to the drill string (not shown). A frusto-conical roller cone cutter 8 is rotatably mounted and secured on the bearing pin shaft 16 which extends downward and inward, from the bottom of the journal segment arm 6 . Cone cutter 8 has a cutting structure consisting of helical chisel inserts 22 . Helical chisel inserts 22 are mounted on either heel row 10 , second row 12 , inner row 14 , or any combination thereof Helical chisel inserts 22 may be press fit into hole 9 or otherwise positioned on cone cutter 8 . Helical chisel inserts 22 may be made from any suitable material including tungsten carbide, diamond enhanced tungsten carbide, diamond or polycrystalline diamond compact (PDC). Cone cutter 8 may include conventional inserts on those rows where helical chisel inserts 22 are not mounted. The cone cutters 8 are rotatably mounted on journals with sliding bearing surfaces. The axis of rotation 18 of the cone cutter 8 extends inwardly through the center of the bearing pin shaft 16 toward and offset from the axis of rotation 20 of the drill bit 2 . Although FIG. 1 depicts drill bit 2 as a roller cone bit, it will be understood by those of ordinary skill in the art that the helical chisel insert of the present invention may be used in PDC bits and other types of drill bits.
[0022] FIGS. 2 and 3 show front and top views, respectively, of an embodiment of the helical chisel insert 22 a of the present invention. FIG. 4 shows the front view of another embodiment of helical chisel insert 22 b of the present invention. As shown in FIGS. 2-4 , helical chisel insert 22 has a cylindrical base 24 which may be inserted in hole 9 with its longitudinal axis 26 being normal to the surface 21 of cutter 8 (hole 9 and surface 21 shown in FIG. 1 ). A top portion 50 , which is connected to cylindrical base 24 , includes a cutting tip 28 and an elongated crest 36 having a length 52 along its broad side and a width 53 . Top portion 50 has two faces or flanks, leading flank 30 and trailing flank 32 . Flanks 30 and 32 commence at the joinder of the top portion 50 and cylindrical base 24 , shown as corners 42 and 44 , respectively, and curve upwards in a substantially helical manner about longitudinal axis 26 , to join crest 36 at corners 38 and 40 , respectively. Flanks 30 and 32 define substantially concave surfaces 46 and 48 . As is apparent from FIGS. 2-4 , flanks 30 and 32 define a contoured surface that is continuously twisted from the top of base 24 to the crest 36 such that iterative cross sections of top portion 50 will describe a helix at their outermost points.
[0023] The contoured surface of helical chisel insert 22 provides a more aggressive cutting surface than convention chisel inserts and may provide a greater rate of penetration than conventional chisel inserts. The shape of helical chisel insert 22 may allow insert 22 to plow through the formation, as opposed to merely striking the formation. As a result, helical chisel insert 22 may remove more rock for a given position in the drill bit than a conventional insert. For example, helical chisel inserts 22 may provide a more aggressive insert in soft formation drilling by orientating the elongated crest 36 of the cutting tip 28 preferentially with the cutting or plowing action of the drilled formation relative to the chisel rolling direction. The result may be faster rates of penetration for the drill bit 2 as a whole. Helical chisel inserts 22 may add improved plowing action to the insert over conventional inserts as helical chisel insert 22 describes its arc into, through and out of the formation being drilled.
[0024] Helical chisel insert 22 has a degree of twist θ, measured from the longest axis of the bottom cross section to the longest axis of the elongated crest 36 . The degree of twist θ may be selected based on the desired characteristics including, for example, penetration rate and resistance to breakage. The embodiment of helical chisel insert 22 a shown in FIGS. 2 and 3 has a degree of twist θ of about 90°, for example. The embodiment of helical chisel insert 22 b shown in FIG. 4 , has a degree of twist θ of about 15°, for example. Flanks 30 and 32 may curve either substantially clockwise or substantially counterclockwise. Flanks 30 and 32 may have a twist from about 90° clockwise to about 90° counterclockwise, thus describing the entire 360° radius. Flanks 30 and 32 may be selectively shaped to provide different crest 36 geometries that describe the degree of twist in variations of an “s” shape, but within the same insert diameter. Helical chisel insert 22 may incorporate timing mark 54 to assist a user with positioning helical chisel inserts 22 on drill bit 2 in a precise manner.
[0025] Although FIGS. 2-4 depict helical chisel bit 22 with two flanks, it will be understood by those of ordinary skill in the art that other embodiments of the helical chisel insert of the present invention may include only one flank, or may include more than two flanks. Similarly, while FIGS. 2-4 depict helical chisel bit 22 with an substantially elongated crest, it will be understood by those of ordinary skill in the art that other embodiments of the helical chisel insert of the present invention may include different crest formations depending on the number of flanks and the selected contour geometry, among other factors.
[0026] Helical chisel inserts 22 may be positioned on rolling cone cutter 8 in a vectored manner such that the elongated crests 36 are selectively oriented with respect to the direction of plowing action. By vectoring helical chisel inserts 22 in this manner, a drill bit 2 may be selectively configured to provide a greater rate of penetration, improved resistance to breakage, or a combination thereof. Embodiments of this vectored positioning are shown in FIGS. 5 and 6 .
[0027] FIG. 5 is a schematic view of a borehole bottom showing the impression left by helical chisel inserts 22 on the two outer rows of a cone cutter, selected and positioned thereon to reduce insert breakage. The direction of bit rotation is indicated by arrow 56 . By orienting (vectoring) the elongated crests 36 of the inserts 22 in line with the insert movement a helical chisel insert 22 presents a very small face to the formation. The insert 22 can withstand higher forces (or harder formations) in this situation. The helical chisel inserts 22 on the outermost heel row have a selected angle of twist θ such that crests 36 are oriented at an angle from about 30° to about 60° from the axis of rotation of the cone toward the leading side of the cone. The helical chisel inserts 22 on the second row have a selected angle of twist θ such that crests 36 are oriented at an angle from 30° to 60° from the axis of the cone toward the trailing side of the cone. Stated another way, the elongated crests on the heel row are oriented at an azimuth direction ranging from 300° to 330° from the axis of rotation of the cone with the axis being equal to 360°. The elongated crests on the second row are oriented at an azimuth direction of 30° to 60° from the axis of the cone.
[0028] With such an orientation, the insert 22 moves in formation in a direction in line with the elongated crest 36 so that a relatively small area, about width 53 of the insert 22 , contacts the formation and relatively small chips are formed. The relatively thick section of tungsten carbide, for example, along the length 54 of the crest 36 provides a very high resistance to insert breakages. This type of insert orientation provides a cone cutter with much higher resistance to breakage than a similar cutter with conventional insert orientation.
[0029] The direction of bit rotation is indicated by arrow 56 . The initial engagement of the elongated crests of the heel row inserts is indicated by 58 . The disengagement of the elongated crests of the heel row inserts is indicated by 66 with the direction of the plowing of formation represented by arrow 62 . The elongated crests of the second row inserts engage 60 and disengage 68 the formation in the direction indicated by arrow 64 .
[0030] Alternatively, the angle of twist θ may be selected to orient or vector the crest 36 so that the broad side 52 of the insert crest 36 faces the direction of the plowing action. In this case, each insert 22 removes more formation, resulting in a faster penetration rate. This configuration is illustrated in FIG. 6 , which is a schematic view of a borehole bottom showing insert tracks left by inserts 22 on the two outer rows of a cone cutter, where the inserts are oriented for increasing penetration rate. As shown in FIG. 6 , the elongated crests 36 of the helical chisel inserts 22 are relatively perpendicular to the direction of the plowing action, indicated by arrow 88 . The elongated crests 36 of the inserts 22 positioned on heel row 10 are oriented at an angle of 30° to 60° toward the trailing side of the cone. The elongated crests 36 of the inserts 22 on second row 12 are oriented at an angle of 30° to 60° toward the leading side of the cone. Stated another way, the elongated crests of the heel row inserts are oriented at an azimuth direction ranging from about 30° to 60° from the axis of rotation of the cone. The elongated crests of the second row inserts are oriented at an azimuth direction of 300° to 330° from the axis of rotation of the cone with the axis being equal to 360°. This orientation may break formation along a wider path, making more chips and larger chips than orientation of standard TCI bits, resulting in an increase penetration rate.
[0031] The direction of bit rotation is indicated by arrow 82 . The initial engagement of the elongated crests of the heel row inserts is indicated by 84 . The disengagement of the elongated crests of the heel row inserts is indicated by 86 with the direction of the plowing of formation represented by arrow 88 . The elongated crests of the second row inserts engage 90 and disengage 92 the formation in the direction indicated by arrow 94 .
[0032] The embodiments shown in FIGS. 5 and 6 show an angle of twist θ of about ±30°. Other embodiments of the helical chisel inserts of the present invention, however, may have a twist from about 90° clockwise to about 90° counterclockwise, thus describing a greater range. As a result, the helical chisel inserts allow for an increased degree of freedom in configuring the drill bit to improve resistance to insert breakage, rate of penetration, or a balance of both.
[0033] The helical chisel inserts of the present invention may provide a more aggressive cutting surface than convention chisel inserts and may provide a greater rate of penetration than conventional chisel inserts. The helical chisel inserts may add improved plowing action to the insert over conventional inserts as the helical chisel insert describes its arc into, through and out of the formation being drilled. If the insert life is given priority over the rate of penetration, the helical chisel insert may be described in reverse rotation. The helical chisel inserts also provide an insert designer with another degree of freedom to optimize chisel contour geometries to accommodate the particular stresses and wear patterns observed downhole.
[0034] From the foregoing detailed description of specific embodiments of the invention, it should be apparent that a helical chisel insert for rock bits that is novel has been disclosed. Although specific embodiments of the invention have been disclosed herein in some detail, this has been done solely for the purposes of describing various features and aspects of the invention, and is not intended to be limiting with respect to the scope of the invention. It is contemplated that various substitutions, alterations, and/or modifications, including but not limited to those implementation variations which may have been suggested herein, may be made to the disclosed embodiments without departing from the spirit and scope of the invention as defined by the appended claims which follow. | An insert for an earth boring drill bit, such as a PDC rock bit or a roller cone rock bit, is provided. The insert includes a base integrally joined to a top section, the top section having a first flank that curves in a substantially helical manner about a longitudinal axis of the insert to join a crest. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to seals, particularly seals in the nature of O-rings, X-rings e.g., four-lobed rings, gumdrop seals and compression seals of various custom designed cross sections, especially for applications in which the seal is exposed to severe temperature and/or chemical conditions.
BACKGROUND OF THE INVENTION
[0002] Where O-rings and similar sealing elements are exposed to relatively extreme conditions of temperature and/or chemical exposure, conventional elastomeric materials tend to deteriorate quickly and thus involve excessive maintenance. As a result, various attempts have been made to employ special high performance materials, such as perfluoroelastomers (FFKM) for such seals. While FFKM has outstanding chemical and temperature resistance, it is an expensive material and it is somewhat lacking in the level of resilience that is desired for many sealing applications.
[0003] Various attempts have been made to combine FFKM elastomers with less costly and/or more resilient materials. In the Tanaka et al U.S. Pat. No. 6,730,385, for example, a perfluoro rubber was combined with other rubber, using a polyfunctional adhesive coating between the two materials, preferentially “primarily” vulcanizing one of the materials before laminating to improve dimensional accuracy, and thereafter laminating and vulcanizing the combined materials.
[0004] In the Proper U.S. Pat. No. 6,918,595, a high pressure pump seal for gas chromatography applications is formed by wrapping the end of a cylindrical membrane, formed of an FFKM material about an O-ring of softer, more resilient elastomeric material, such that the only material contacting surfaces of the pump is the FFKM. This arrangement minimizes contamination of the chromatographic examination by the softer but less resistant material of the O-ring, while taking advantage of the elastic characteristics of the O-ring material.
[0005] In the Okoroafor international publication WO 2007/096664, there is shown an O-ring structure comprised of a central body of an elastomer such as FKM, formed over a reinforcing spring by compression or injection molding, after which, in a separate transfer molding operation, a thin (0.1-0.3 mm) coating of FFKM is formed about the central body.
[0006] In European Patent Application EP 1 852 902, for example, FFKM perfluoroelastomer is mixed with FKM, together with a cross linking agent in a range of 80-50% FFKM to 20-50% FKM, to achieve a homogeneous mixture taking properties from each of the primary components. Although the mixture had some of the advantages of each major component, it also had some of the disadvantages of the other component, and thus is a less than satisfactory compromise.
SUMMARY OF THE INVENTION
[0007] The present invention provides a simplified and economical co-molding procedure for the manufacture of high performance seals utilizing combinations of a perfluoroelastomer (FFKM) externally for temperature and chemical resistance and other, more resilient elastomers internally for improved sealing performance. Combining the materials can occur one of two ways. Either an outer jacket of the perfluoroelastomer is formed and is loaded with an inner core of the softer material, either as part of a co-extrusion process or in a subsequent operation; or the outer layer is calendered to a specified wall thickness then wrapped around an uncured inner core. The combined materials are then formed to the shape of the desired seal, placed in a compression mold, and cured under heat and pressure to form an integral unit. Use of a co-agent within both layers promotes the cross-linking between the two during vulcanization. Examples include triallyl isocyanurate (TAIC) and trimethylallyl isocyanurate. A lower cost product is realized, as compared to an all-FFKM seal, while improved performance is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a cross sectional view of one preferred form of seal material made in accordance with the procedures of the invention.
[0009] FIG. 2 is a longitudinal section as taken along line 2 - 2 of FIG. 1 .
[0010] FIG. 3 is a plan view of a typical O-ring formed with the seal material of FIGS. 1 and 2 .
[0011] FIG. 4 is a cross sectional view of a second preferred form of seal material used in the formation of a gumdrop seal.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The process of the invention is particularly useful in connection with the manufacture of various temperature- and chemical-resistant seals, such as O-rings, lobed rings, such as X-rings, gumdrop seals, and various customized forms of compression seals. The process is unique in providing for the co-molding of an FFKM outer layer together with a more resilient core, without the requirement of adhesives or special bonding agents, to realize a particularly advantageous combination material useful particularly in connection with the manufacture of sealing elements with excellent service life under severe conditions while having improved sealing characteristics. The process involves an initial encapsulation of a resilient elastomer within a sheath or jacket of an FFKM, configuring the encapsulation product to form the desired seal (e.g., an O-ring), and then curing (vulcanizing) the product under heat and pressure in a compression mold.
[0013] A wide variety of commercially available FFKM products are suitable for use in connection with the invention. Examples of such are “KALREZ”, a product of DuPont Performance Elastomers, “SIMRIZ”, a product of Freudenberg-NOK, “CHEMRAZ”, a product of Greene Tweed and “DYNEON”, a product of Dyneon LLC (3M). The named products are registered trademarks of their respective manufacturers. Likewise, a wide variety of elastomers are suitable for the encapsulated core material. By way of example, suitable core materials may be various fluoroelastomers (FKM), fluorosilicones, silicone, EPDM, nitrile, and neoprene. Importantly, the perfluoroelastomer and the core elastomer must have similar and compatible cure types and characteristics, including incorporation of a cross linking co-agent such as TAIC, for proper bonding during the compression molding process. Typically, the FFKM is subject to peroxide or free radical curing, in which case the core is selected from materials that are also subject to peroxide curing.
[0014] In the process according to the invention, the uncured FFKM component is either extruded in the form of an elongated tube 10 of suitable cross sectional contour—typically but not necessarily cylindrical, as shown in FIGS. 1 and 2 , or calendered to a specified thickness. For a typical form of O-ring seal, an extruded tube 10 of FFKM material may have a wall thickness of, for example, 0.020 inch and an inside diameter typically in the range of about 0.100 inch to 0.5 inch. The extruded tube 10 is packed with a selected core elastomer 11 , such as fluoroelastomer (FKM), fluorosilicone, silicone, EPDM, nitrile or neoprene. The core material can be selected for its desired characteristics, such as resiliency, cost, etc., but in all events must be of a cure type and have curing characteristics similar to those of the encapsulating perfluoroelastomer material. The core material 11 may be injected into the encapsulating tube 10 , completely filling it, or may, in appropriate cases, be co-extruded within the surrounding tube 10 . An outer layer 10 of calendered FFKM may also be wrapped around the uncured core material 11 . No adhesive or special bonding agent is required or used at the interface between the core material and the encapsulating tube.
[0015] To form a circular seal using the above-described material, a section of the combined encapsulating and core materials, as set forth above, with both components thereof still in the uncured state, is cut to a predetermined length and formed into a desired circular shape 12 , as shown in FIG. 3 , with opposite ends of the length being positioned in tightly abutted relation, as shown at 12 in FIG. 3 . The circular shape is then placed in a compression mold having a suitable circular cavity where it is subjected to heat and pressure sufficient to effect curing (vulcanization) of the materials while simultaneously bonding the FFKM tube with the core material at the interface thereof to form an integral unit.
[0016] Seals made in accordance with the invention can be of a wide variety of sizes and shapes. By way of example and not of limitation, FIG. 4 illustrates a gumdrop seal, in which the thin-walled tubular sheath 20 of FFKM material is extruded in a gumdrop configuration and packed with uncured core material 21 of a more resilient elastomer, such as referenced above, either by a co-extrusion procedure or a subsequent injection of the uncured core material into the tubular sheath.
[0017] Curing time and temperature is a function of the specific materials utilized and the size and cross section of the article. However, for a typical O-ring, a curing time of 20-45 minutes at about 320-350° F. is appropriate. For a given combination of materials, and a given size of article, it is a simple matter for one skilled in the art to determine optimum times and temperatures for effective curing. To advantage, the secondary or core material is completely encapsulated by its perfluoroelastomer jacket or casing prior to the curing process. When the co-molded article is in the form of a ring or other closed shape, complete encapsulation is provided by the closing and butting together of the opposite ends of the section of filled tubular sheath. For non-closed shapes, however, it is desired and preferred that opposite ends of the tubular sheath be sealed closed, such that the core material is fully encapsulated before curing takes place, with the item being cut to final length after curing.
[0018] It will be understood that the specific forms of the invention illustrated and described here are intended to be representative and not limiting of the invention. Accordingly, reference should be made to the appended claims in determining the full scope of the invention. | A method of making a high performance seal wherein an uncured elastomeric material is tightly encapsulated in a tubular section of uncured perfluoroelastomer, where the elastomeric material and the perfluoroelastomer are chosen to have similar cure characteristics. The uncured encapsulation is formed into a desired shape for the seal, and vulcanized under heat and pressure. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for decoding a lock of the wafer combination type such as that commonly marketed under the trademark SCHLAGE.
Such wafer combination lock is found primarily in apartment complexes because it is a master-keyed type of lock, that is, there is a master key which will open all of the locks in a particular complex. In such locks a plurality of wafers, which are essentially semi-circular discs having a radial protrusion or pin, are inserted into slots arranged from front to rear in columns of two in a keyway cylinder. The wafers are spring biased, and depending on the type of wafer, the pin either extends outwardly of the keyway cylinder or retracts under normal bias action of the springs. The purpose of the pins is to prevent the keyway cylinder from turning and thus opening the lock. Only when the proper key is inserted will all of the pins retract and allow the lock to open.
There are three types of wafers used in such locks: "series;" "combination;" and "master" wafers. For each wafer there are two possible orientations. "Series" wafers are either "S1" or "S2," and combination wafers are "odd" or "even." The single master wafer (if used) has an orientation opposite that of the series wafers. All series wafers have the same orientation.
All three types of wafers, "master," "series" and "combination," resemble generally the letter "C." Each is a semi-circular disc with two extending arms, and an outwardly radially-extending pin or protrusion, and a second protrusion or tooth on one arm of the wafer which acts as a seating member for springs which bias the wafers in a predetermined fashion. Both protrusions lie in the plane of the wafer.
The keyway cylinder comprises a frame portion in which is located the master wafer column and seven other wafer columns for the series and combination wafers. The series and combination wafers may be arranged according to the desire of the user; however, there will always be 4 combination wafers and at least one series wafer. If desired, there may be one or more columns left completely blank with no wafer at all.
The orientation of these types of wafers in the columns of the keyway cylinder determines the alpha-numeric code of the lock and provides all of the information necessary to cut a key that will open the lock.
Heretofore, it has not been possible to manufacture replacement keys for wafer combination locks without entirely removing the lock from its fixed surroundings, i.e., the door. This is because in order to make a replacement key, it is necessary to actually see the wafers that are used in the combination lock and visually observe the type and orientation of each wafer used in the combination. Only in this way could an alpha-numeric code, representing the orientation and position of cuts to be made on a key blank, be obtained.
Thus, if it were possible to determine for each wafer column the type of each wafer, that is, whether "combination" or "series," and its orientation, without disassembling the lock, it would be possible to determine the code for the lock and make a key corresponding to the code which would fit and open the lock.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for determining the code of a wafer combination type lock without disassembling the lock. According to the method of the invention, one may observe, through the keyway, by either visual or mechanical means, the type and orientation of each wafer at each position in the keyway cylinder and convert this information into the proper alpha-numeric code. A key may then be made according to that alpha-numeric code which will open the lock. Both the code and the method of making a key from the code are well-known in the art.
According to the invention "combination" wafers are distinguished from "series" wafers by the detection of a cut-off corner or chamfered portion on one arm of the wafer. Series wafers do not have a chamfered portion but have an essentially rectangular arm.
These different characteristics may be either visually observed or manually sensed through the use of a probe. The probe of the invention has an elongate base member of a shape adapted to slidably engage the keyway. Contained within the probe are at least two hollow and substantially parallel portions extending longitudinally. The probe may in fact be constructed of a plurality of long hollow tubes welded together into a shape that will fit within the keyway. Lying within two of these hollow portions are elongate rigid members which may be made of stiff wire or the like. Near one end of the probe is a notch cut into two of the hollow portions so as to expose the wire's ends. Each wire end comprises a relatively short portion bent at a 90° angle which forms a leg. The other end of the wire is bent to form a dial or pointer, or may be connected to any suitable indicating means to indicate the length of the arc of the leg in a plane perpendicular to the longitudinal direction of the probe. The wire lies relatively loosely within the hollow portion of the probe and thus can rotate about its longitudinal axis. Marked on the base of the probe are probe depth increment markings. As the probe is inserted into the keyway, the markings indicate the positon of the notch relative to a given wafer column. When positioned at a chosen wafer column, as indicated by the appropriate probe depth increment mark, the dial or pointer is manually rotated causing the leg end of the wire to describe an arc. The leg will rotate until it contacts one arm of the wafer lying within the particular column. Due to the aforementioned differences between the arms of the different types of wafers, the point of contact and, hence, the length of the arc will differ. Once contact is sensed between the leg and the wafer, a scale on the front of the probe, calibrated to the dial of the pointer, will indicate the type and orientation of the particular wafer encountered. If this process is repeated for every column position in the keyway frame, the alpha-numeric code of the key may be readily obtained.
The method of the invention may also be practiced without the use of the aforementioned probe. With the aid of a "zip scope" or other suitable illuminating device, capable of emitting a pencil beam of light, the interior of the lock may be examined from the outside. By viewing the interior of the key way unit slightly off-center from the longitudinal axis of the keyway, one may determine by visual inspection the type of wafer (series or combination) and its slot location. The chamfered portion of a combination wafer is easily visible with the aid of a zip scope, which distinguishes the combination wafer from the series wafer. Moreover, it is not necessary to actually see the master wafer since wafer combination locks are designed such that the master wafer is always oriented in a direction opposite that of the series wafers, and all series wafers are oriented in the same direction.
It is therefore an object of this invention to provide a method and apparatus for decoding a wafer combination lock without the necessity for removing the lock from its fixed surroundings.
It is a further object of this invention to provide an apparatus for sensing the type and orientation of wafers constituting the code of the combination wafer lock thereby enabling a key to be made without disassembling the lock.
It is a further object of this invention to provide a method for determining the code of a wafer combination lock by visual inspection of certain characteristics of the combination wafer in the interior of the lock without removing the lock from its fixed surroundings.
These and other objects of the invention will become apparent by reference to drawings and the detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a probe for manually decoding a combination wafer lock, shown in position preparatory to insertion into a lock oriented horizontally for sake of illustration.
FIG. 2 is an enlarged perspective view of the end portion of the probe taken along line 2--2 of FIG. 1.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a side view of a vertically-oriented keyway cylinder which is part of a wafer combination lock.
FIG. 5 is a partially sectional front view taken along line 5--5 of FIG. 4.
FIG. 6 is a front view of a series wafer showing the probe of FIG. 1 juxtaposed therewith.
FIG. 7 is a front view of a combination wafer showing the probe of FIG. 1 juxtaposed therewith.
FIG. 8 is a front view of the face cap of the keyway cylinder as it would appear inserted into a doorknob, showing the visible characteristic portions of combination and series wafers within the keyway.
FIG. 9 is a schematic representation of the spatial relationship between the face cap of FIG. 8 and a series wafer located at one column in the keyway.
FIG. 10 is a schematic representation of the spatial relationship between the face cap of FIG. 8 and a combination wafer located at one column in the keyway.
FIG. 11 is a schematic representation of the spatial relationship between the face cap of FIG. 8 and a master cylinder wafer located in the master wafer column in the keyway.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 shows a probe for decoding a combination wafer lock in accordance with the invention. An elongate probe 10 comprises a base 12 constructed of two pieces of elongate brass tubing 30 and two pieces of elongate brass rod 30a, all of essentially square cross-section as shown in FIG. 2. The four pieces of tubing are welded together to form a cross-sectional shape corresponding to the keyway frame style. In the embodiment shown in FIGS. 1, 2 and 3, the keyway frame style is a "W." For an "A" style keyway frame the tubing would be welded together to form an "A" so as to slideably engage the keyway.
The probe has an L-shaped mounting bracket or finger grip 14 for supporting the body of the probe 12 and providing a convenient grip for inserting and manipulating the probe. Connected to fingergrip 14 by welding or any other suitable method of attachment is a reader board 24 having markings thereon which indicate the type and orientation of the wafers to be tested inside the lock. The probe is intended to be slideably inserted into keyway cylinder 16 which has a face cap 34 and a keyhole of the "W" style 36. Brass tubing 30 is hollow and inserted through the tubing are two stiff wires 22a and 22b. Wires 22a and 22b have pointer portions 28a and 28b bent at right angles so as to form indicators for reader board 24. At the opposite end of the probe there is a notch 20. The opposite ends of stiff wires 22a and 22b terminate in legs 18a and 18b, respectively, which are bent at a 90 degree angle to the longitudinal direction of the wires in probe 12 which lie parallel to the longitudinal axis of the keyway, and are also bent inwardly toward the axis of the probe so as to lie flush within notch 20 when the pointers 28a and 28b of wires 22 are pointing straight up at the "start" indication as shown in FIG. 1. As shown in FIG. 2, legs 18a and 18b move in arcs generally designated at 32a and 32b, respectively, upon movement of pointers 28a and 28b.
Probe 12 has a series of increment depth marks such as those indicated at 26a and 26b. These marks consist of alternately colored light and dark bands. The purpose of these bands is to allow the user to position the probe such that notch 20, in which lie leg members 18a and 18b, may be aligned sequentially with the wafer columns of the keyway cylinder. These columns are indicated generally at 38 in FIG. 4. As the probe notch 20 is aligned with each one of the columns 38, legs 18a and 18b may test for the presence of particular types and particular orientations of wafers which may be located therein. When the probe is inserted to a depth indicated by probe increment mark 26a, for example, the probe tests for wafers in the wafer column nearest to the face cap 34. At probe increment mark 26b the probe is testing for a wafer located at the next deeper column. This same sequence obtains all the way to probe increment mark 26g at which point the user is testing for a wafer in the deepest column. The final test involves inserting the probe until it can go no farther, stopped by shoulder stop 27 the end-most point on fingergrip and L-shaped mounting bracket 14. When thus inserted all the way into key way unit, the probe is in a position to test for a wafer in the master wafer column.
The way in which the probe tests for the presence, type and orientation of wafers is shown generally in FIGS. 4, 5, 6 and 7. FIG. 4 shows a typical keyway cylinder 16 loaded with combination and series wafers. The front of the keyway cylinder has a cylindrical face cap 34 where keyway 36 is located. Connected to the face cap and forming the keyway frame style are a pair of frame members 50a and 50b (FIG. 5). These frame members extend longitudinally, terminating at a single cylinder support member 15. Cylinder support member 15 includes a plunger spring 19 and a keyway cam 17. Keyway cam 17 accuates the lock upon rotation of keyway cylinder 16 allowing the door to open. Located adjacent frame member 50a and 50b and extending in a longitudinal direction parallel to those members is a spring rack 40. Spring rack 40 is fixedly attached to face cap 34 and to cylinder support member 15. Spring rack 40 has a series of teeth on which are mounted springs 48. The springs are used to bias the wafers in a manner which will be described herein.
The way in which the wafers are mounted in the keyway cylinder can be seen in FIG. 5. Except for a single master wafer 42 as shown in FIG. 11, the wafers used in a combination wafer lock are either "series" wafers such as 44 shown in FIGS. 5 and 6, or "combination" wafers such as 46 shown in FIG. 7.
FIG. 5 illustrates the way in which a typical wafer is inserted and biased in the keyway unit. Series wafer 44 is an essentially semi-circular disk having a long arm 52 on which is located a tooth 56 to engage spring 48 which is mounted on spring rack 40. Long arm 52 also has a protrusion or pin 54 which extends between keyway frame members 50a and 50b outwardly radially of the keyway cylinder. This extension of pin 54 is caused by the normal bias action of spring 48 and will prevent the keyway cylinder from being turned unless the key inserted into the lock has a blank portion at the column in which the series wafer lies. For a key to have a blank portion means that no cut has been made in the body of the key. Such a blank would cause the wafer to move in the direction shown by the arrow in FIG. 5 and retract pin 54 in a radially inwardly direction, consequently allowing keyway cylinder unit 16 to rotate and open the lock.
For a combination wafer such as 46 shown in FIG. 7, the mechanics of opening the lock are just the opposite. In a combination wafer, the positions of the short arm and long arm are reversed such that the bias action of the spring holds pin 62 of combination wafer 46 in a normally retracted condition. Only an appropriate cut in the key blank at the location of each combination wafer will keep the combination wafer retracted. In the event that cut is not made, the key blank will force pin 62 in radially outward direction so as to resemble the normally outwardly protruding positon of pin 54 for series wafer 44. Like the series wafer, combination wafer 46 has a long arm 64 with a tooth 66 and a short arm 60. However, in the combination wafer, pin 62 is located on the short arm 60, not on the long arm as is the case with series wafers.
The most important distinguishing feature between combination wafer 46 and series wafer 44 is that the short arm of combination wafer 46 is chamfered. That is, where series wafer 44 has a normally rectangular short arm 58, short arm 60 of combination wafer 46 has its inside corner cut off at an approximately 45° angle so as to form a chamfered surface. This difference allows the probe to distinguish between series and combination wafers at each wafer column.
FIG. 4 illustrates the manner in which the plurality of series and combination wafers may be inserted into a keyway unit so as to form a combination for the lock. The keyway cylinder of FIG. 4 is similar to that shown in FIG. 1 except that in FIG. 4 the cylinder has been rotated about 90 degrees in a counter clockwise direction. FIG. 4 illustrates a wafer combination code consisting of 2 series wafers 44, 4 combination wafers 46 and a master cylinder wafer 42. The wafers have been inserted into columns 38 in the keyway frame members 50a and 50b. They are held in columns 38 and biased in the correct direction by the action of springs 48. Each of columns 38 has two slots 37. Although a wafer occupies an entire column, for purposes of forming the code for which a key may be cut, a wafer is considered to occupy only one slot within a column. The particular slot that is occupied will be the slot occupied by the short arm of the wafer. This slot will always be the slot opposite that adjacent the spring.
The way in which the probe decodes the lock is shown in FIGS. 6 and 7. FIG. 6 shows a series wafer 44 being tested by probe 10. The probe has been inserted such that notch 20 lies adjacent the first column of the keyway cylinder. This is accomplished by aligning probe depth increment marker 26a with face cap 34. Once this alignment has been accomplished, the user rotates pointer portions 28a and 28b of wires 22a and 22b until resistance is encountered. FIG. 6 demonstrates that resistance will be encountered when leg 18a of wire 22a makes contact with the short arm portion 58 of wafer 44. The reader board 24 has been calibrated such that for this particular orientation an "S1" reading is indicated by pointer 28a. Thus, from the test, it is known that an "S1" series wafer lies in column 1 of keyway cylinder 16.
In a similar manner, FIG. 7 shows how a combination wafer is detected. In this case, leg 18b makes contact with the chamfered short arm 60 of combination wafer 46. Because of the chamfered surface of short arm 60, the arc described by leg 18b is longer and consequently, reader board 24 indicates, by means of pointer 28b the existence of a "combination even" wafer at this point of contact.
The above process is repeated for each column in the keyway cylinder, as determined by the probe depth increment markings, and proceeding column by column. The user tests at each column position for the presence, type, and orientation of the wafers. In each case one of legs 18a or 18b will encounter resistance at a point along the arc 32a or 32b described by the rotation of the leg. One of the pointer portions will then indicate the type and orientation of the wafer encountered.
It is not necessary, however, for all wafer columns to have a wafer inserted therein. Some columns may be left blank. In such a case, no resistance is encountered by either leg, and thus the pointers 28a and 28b complete an arc of almost 180 degrees indicating that the particular column under test is blank.
It is not actually necessary to test the master wafer column because of certain conventions observed in the art when constructing the code. First, the wafer present in the master wafer column is always oriented in a direction opposite that of the series wafers, whose orientation are all the same. Thus, the detection of the first series wafer determines the orientation of all other series wafers and the wafer in the master column. FIG. 11 illustrates a master wafer 42 having a pin 45 oriented opposite that of series wafer 44. Second, although series wafers may be used in the master column, it is most often the case that a master wafer is used. Thus, one may assume when cutting a key that a master wafer is present. If desired, however, one may test the master column. A master wafer is distinguishable from a series wafer by the resistance encountered at approximately 115° from vertical on the wire opposite the wire yielding a series wafer reading. Thus, if no resistance is encountered by this wire in the master wafer slot, a series wafer, not a master wafer, is present.
Thus, the entire alpha-numeric code for the particular lock may be determined by inserting the probe and testing, at each column as indicated by the probe depth increment markings, for the presence of series or combination wafers and their particular orientation. Once this information is known, a key for the lock may be cut on a conventional key cutting machine which will open the lock.
The same information may be obtained without the use of a probe. Viewing the interior of the lock from the outside as shown in FIG. 8, reveals that wafers may be seen by visual inspection of the interior of the lock. In order to inspect the lock in such a manner, a pencil beam of light known generally in the art as a "zip scope" is used. With the aid of such a device, one may visually observe at each wafer column, and its corresponding slot positions, the presence or absence of a combination or series wafer. In order to view wafer columns within the interior of the keyway, the observer must shift his line of sight to a position slightly off center, that is skewed for the longitudinal axis of the keyway. For example, with the aid of a zip scope the user would observe that all of the combination wafers of the lock depicted in FIG. 4 are "combination even" wafers since the chamfered short arm portion 60 of the wafers 46 are on the top. At least one series wafer has a short arm 58 in the lower slot indicating an S1 orientation for all series wafers. Within the dotted small circles 68 and 70 in FIGS. 9 and 10, respectively, are shown the portions seen by the observer looking into the keyway. These portions indicate either series or combination wafer types in the lock viewed in the manner shown in FIG. 8. In FIG. 11 dotted circle 72 indicates that an observer will view the master column wafer as having an orientation opposite that of the series wafers.
All of the information necessary to derive the alpha-numeric code may be obtained by using either the probe of FIG. 1 or by visually inspecting the interior of the lock with a zip scope or the like as previously disclosed herein. With the code, a key may be made on any standard key cutting machine as is well known in the art and the door may then be opened without having to disassemble the lock.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | A probe for manually decoding a lock of the wafer combination type having an elongate body to slideably engage the keyway, the body comprising at least two hollow tubular members. Within the hollow members are rotatably disposed detecting members which detect, by means of physical contact, certain identifying portions of wafers therein which form the combination of the lock. An indicator on the outside of the probe, responsive to the detecting members, indicates the presence, type, and orientation of the wafers. The same method may be practiced without the use of the probe by viewing the interior of the lock slightly off center with a pencil beam of light to determine the same characteristic wafer portions. | 4 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to an apparatus for supporting a form member extending perpendicularly to the longitudinal axis of a form carrier. Such apparatus are generally called truss holders.
2. Description of Related Art
Such a truss holder is known, for example, from the preprint of the construction instructions "Truss form with wooden carriers (Unterzugschalung mit Holztragern)" (Status: March 1991) of the company Huennebeck-Roero GmbH. In this construction, the support member consists of a hollow profile with two blocks located thereon. The supporting frame is placed with these supporting blocks on the upper side of a profile transverse carrier of a truss form. A screw bolt is inserted through the hollow profile of the support member perpendicularly to the longitudinal axis of the profile transverse carrier, and a plate-shaped bracket is secured to the support member at its lower end. The bracket can be rotated between the hollow profile of the support member and the upper flange of the profile transverse carrier. Thus, by turning the bracket, its holding brackets can be engaged with the lower side of the upper flange of the profile transverse carrier. By tightening a wing-nut on the screw bolt, the truss holder can subsequently be tightened against the profile transverse carrier.
In tightening the truss holder against the profile transverse carrier, a clamping force is only applied in the direction parallel to the side face of the form skin. Consequently, there is no force component which can act directly against the concrete pressure on the side face. Therefore, it often arises that the side face of the form skin is pushed back a few millimeters in the direction of the profile transverse carrier when concreting the truss so that concrete escapes between the base plate and the form skin of the side face through the gap which has been created.
A truss holder is known from the Handbook 92 (Issue 1/92) of Peri GmbH by means of which clamping force components are applied in the direction parallel to as well as perpendicular to the side face of the form skin. On the supporting frame, a screw bolt is arranged in a direction inclined to the side face, a clamping hook being mounted to the lower end thereof. In this solution, two profile transverse carriers of the truss form are arranged in parallel directly adjacent one another and a perforated rail is inserted between both profile transverse carriers in the area beneath the base plate of the form skin. Respectively two truss holders arranged opposite one another on both side faces of the truss form are then braced by means of the clamping hooks hooked into the perforated rail.
In this construction, a further part in the form of the perforated rail is required in addition to the truss holder and a bracing of the truss holders can only ensue after both opposing truss holders as well as the perforated plate are mounted. Furthermore; respectively two profile transverse carriers must be arranged adjacent one another in order to be able to lay the truss holders and the perforated rail.
SUMMARY OF THE INVENTION
The invention is therefore based on the problem of providing a truss holder by means of which a prestressing can be applied to the side face of the form skin of a truss form in the direction perpendicular to the side face surface.
In the inventive truss holder, the knuckle joint arrangement of the clamping means and the gripping means have the effect that, in tightening the truss holder mounted, for example, to a wooden form carrier, the clamping means and the gripping means are moved out of their angular alignment in the prestressed state into a substantially coaxial arrangement. In this manner, a horizontal tightening path ensues, and thus also a biasing of the truss holder in the direction perpendicular to the side face. The truss holder can in this case itself be mounted and tightened without further parts being required for tightening thereof. The inventive truss holder is secured to a single carrier of the truss form, which can be different in terms of material and shape.
In accordance with the invention, it is favourable if a screw bolt is used as the clamping means of the truss holder which can be tightened against the support frame by means of a suitable screw nut. In order to ensure safe tightening of the truss carrier, for example by means of a hammer, the use of a star nut is suitable.
Furthermore, for the jointed connection of the tightening and gripping means, it is advantageous to shape the end of the screw bolt near the joint in the form of a bracket.
Furthermore, it is advantageous in accordance with the invention to provide two substantially similar clamping brackets as gripping means which can be connected with one another in a form- and force-locked manner. Usefully, the clamping brackets respectively have a straight leg as well as a bent section connected to this. The clamping brackets can then be placed on top of one another with their bent sections and in such a manner that the concave inner surfaces of the clamping brackets face one another. In order to achieve a good form-lock of the superimposed clamping brackets, it is favourable to select the outer radius of the bent section of the lower clamping bracket to be the same as the inner radius of the bent section of the upper clamping bracket. Furthermore, it is useful to form the straight leg of the upper clamping bracket that much longer that both free ends of the straight leg of the superimposed clamping brackets are flush with one another, i.e. that they end at the same level. If the clamping brackets are placed on one another in the described manner and inserted into the bracket at the end of the screw bolt near the joint, they can be displaced with respect to one another and can be folded laterally out of the plane defined by the support frame so that the clamping brackets can be placed around a carrier of the truss form.
Additionally, it is advantageous in accordance with the invention if the clamping brackets respectively have a through hole and if a bolt is respectively provided on the support member on both sides perpendicular to the longitudinal axis of the carrier, both bolts fitting through the through hole of the clamping bracket. In this case, it is useful to provide the free ends of the bolts respectively with a radially widening collar section which holds an axially displaceable stop disc on the bolt in such a manner that it cannot be lost, the outer diameter of the stop disc being greater than the diameter of the through hole of the clamping bracket. Thus, both clamping brackets remain mutually displaceable and openable with respect to one another on account of their freedom of movement relative to the respective bolt for mounting the truss holder, and are simulataneously held in their functional position by means of the stop discs and the collar sections of the bolts in a manner in which they cannot be lost. The inner diameter of the stop discs are in this case smaller than the outer diameter of the collar sections. In accordance with the invention, it is advantageous if the gripping means has two claws. Here it is preferred to form the claws to be respectively substantially plate-like and to arrange these at such an angle that when the truss holder is mounted and prestressed, the claws only lie with one edge extending perpendicularly to the carrier longitudinal axis on the contacting surface of the carrier of the truss form and the middle surface of the claws define an angle of a few degrees with the contacting surface of the carrier. In this manner, when securely tightening the truss holder, the support edge of the claw is pressed against the material of the carrier of the truss form and, on account of the coaxial alignment of both knuckle joint members which occurs upon tightening, the claws rotate about the contacting surface and in fact to a maximum until either the claw lies entirely against the support surface of the carrier of the truss form or until both knuckle joint members are coaxially aligned. On account of this rotational movement of the clamping brackets about the support edge of the claws on the carrier, the support frame of the truss holder moves parallel to the carrier longitudinal axis in the direction towards the side face of the form skin via the bolts mounted to the support member and engaged with the clamping brackets. On account of this tightening path, a corresponding bias occurs in the direction perpendicular to the side face and a sealing of the gap between the base plate and the side face is created.
In accordance with an advantageous embodiment of the invention, the claw is formed as a flat plate. In a preferred embodiment, the claw has over its entire contacting surface a toothing extending substantially perpendicular to the carrier longitudinal axis, on account of which a particularly good and secure contact of the claw is achieved. In further preferred embodiments, an elevation is provided on the contacting surface of the claw, the elevation extending across the width of the claw perpendicular to the carrier longitudinal axis and being arranged either in the middle of the contacting surface or on the edge of the contacting surface facing the side face. In a further preferred embodiment, the claw is formed as a plate which is bent up towards the contacting surface on the carrier at the end face facing in the direction of the side face. The embodiment of the claw in which an elevation is provided at the edge of the plate-like claw is particularly suited for mounting the truss holder on metal carriers, for example of aluminum or steel, which have a profile at the lower side of the upper flange of the carrier.
It is preferred in accordance with the invention to form the support member as a support rail which is formed either of two L-profiles or of an U-profile. The support rail guides the support frame along the form carrier as the side faces of the form carrier are also surrounded by the profile flanges. On account of this, the support frame is also guided particularly along the tightening path upon tightening the truss holder. Furthermore, it is favourable to form the support member as a substantially U-shaped profile with through holes arranged in a grid-like manner in the profile flanges.
It is preferable to apply an adjustable carrier, known in principle, on the support member which is displaceable parallel to the longitudinal axis of the support member. Such an adjustable carrier suitably consists of two parallel perforated plates and of a holding plate arranged perpendicular thereto, the perforated plates having through holes matching the through holes of the supporting member and being arranged in grids adapted to each other. The adjustable carrier can therefore be adapted in terms of its height adjustment to correspond to the required truss height and be fixed with respect to the support member by means of a holding bolt which is inserted through the through holes of the adjustable carrier and the support member.
The inventive truss holder is suitable for different types of form carriers in truss forms, for example for profiled wooden truss carriers, for square timber and for metal carriers of steel or aluminum. For using the inventive truss holder for square timber carriers, it is useful to form the straight legs of the clamping brackets appropriately longer in accordance with the thickness of the square timber.
The truss holder according to the invention is easily and quickly mountable and a flowing of concrete out of the form skin through the gap between the side face and the base plate is reliably prevented. The inventive truss holder can additionally be used for example for bracing side faces in ceiling forms.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is described in more detail by way of example with reference to the enclosed drawings, in which:
FIG. 1 shows a truss holder and adjustable carrier in a perspective view;
FIG. 2 shows a truss holder in side view;
FIG. 3 shows a truss holder in plan view;
FIG. 4a shows a truss holder with an adjustable carrier in side view during placement against the truss form;
FIG. 4b shows a truss holder with an adjustable carrier in side view prestressed on the truss form;
FIG. 4c shows a truss holder with an adjustable carrier in side view in the final tightened state on the truss form;
FIG. 5a shows a holding bracket leg with a claw according to a first embodiment in side view prestressed on the form carrier;
FIG. 5b shows a holding bracket leg with a claw according to a second embodiment in side view prestressed on the form carrier;
FIG. 5c shows a holding bracket leg with a claw according to a third embodiment in side view prestressed on the form carrier;
FIG. 5d shows a holding bracket leg with a claw according to a fourth embodiment in side view prestressed on the form carrier;
FIG. 5e shows a holding bracket leg with a claw according to a fifth embodiment in side view prestressed on the form carrier;
FIG. 5f shows a sectional view of the claw according to FIG. 5e;
FIG. 6 shows a truss holder with an adjustable carrier in side view finally tightened on a truss form with a square timber form carrier;
FIG. 7 shows a truss holder with an adjustable carrier in side view finally tightened on a truss form with a metal form carrier;
FIG. 8a shows a partial front view of a truss holder prestressed on a wooden form carrier;
FIG. 8b shows a partial front view of a truss holder upon placement against a wooden form carrier;
FIG. 9a shows a partial front view of a truss holder tightened on a metal form carrier; and
FIG. 9b shows a partial front view of a truss holder upon placement on a metal form carrier.
DESCRIPTION OF PREFERRED EMBODIMENT
As can be seen in FIG. 1, FIG. 2 and FIG. 3, the truss carrier 1 has a support frame which is formed by the support rail 6, the support strut 7 and the connecting strut 8. Here the support strut 7 is arranged perpendicular to the support rail 6 securely connected with this, and the support strut 7 and the support rail 6 are securely connected in the region of their free ends by the connecting strut 8 so that a substantially triangular structure of the support frame ensues. The support strut 7 is a substantially U-shaped profile, the flanges of which are formed as perforated plates with circular through holes 9 arranged in a grid-like manner. The support rail 6 is formed of two parallel spaced L-profiles. The width of the support rail is selected according to the type of form carrier used in such a manner that the flanges of the L-profiles surround the form carrier, and the support frame is thus guided along the support carrier. The support rail can also be formed as a U-profile. A support 24 is formed on the connecting strut 8 through which a screw bolt 2 is guided. The screw bolt 2 acts together with a star nut 4 which can be securely tightened against the support 24. A bracket 5 is mounted on the end of the screw bolt 2 inside the support frame. Two superimposed holding brackets 3 are arranged on both sides of the support rail and are connected by means of the bracket 5 in a hinged manner with the screw bolt 2. An oblong hole 11 is provided in the straight leg of each holding bracket 3.
It can be seen in FIG. 3 that a bolt 14, which for example can be a hollow bolt, is securely mounted to the side surfaces of the support rail 6 perpendicular to the plane defined by the support frame, the free ends of the bolts being expanded in a collar-like manner and on which a stop disc 13 is held by these collar sections 12 in a manner such that they cannot be lost. The bolts 14 are respectively inserted through the oblong holes 11 of the associated holding bracket 3, the stop disc 13 respectively being between the collar section 12 and the holding bracket 3. On account of the fact that the stop disc 13 has a greater outer diameter than the oblong hole 11 of the holding bracket 3, both holding brackets 3 are respectively secured against loss, as the stop disc itself is secured by the collar section 12. Furthermore, a claw 10 is mounted respectively in the area of the free end of the straight leg of the holding bracket 3, as FIG. 1 and FIG. 2 show. This claw 10 is substantially plate-like in shape and arranged perpendicular to the inner surface of the straight leg of the holding bracket 3.
FIG. 1 also shows an adjustable carrier 30 with two parallel perforated plates 31 having a U-profile which, in terms of their spacing, fit the width of the support strut 7 so that the adjustable carrier can be placed onto the support strut. A holding plate 32 is provided on the adjustable carrier which lies perpendicular to the perforated plates 31 and upon which a side carrier 52 of the truss form (cf. FIG. 4a) can be placed. In accordance with the desired truss height, the adjustable carrier 30 can be fixed with a holding bolt 34 in terms of its height on the support strut 7. The through holes 33 of the perforated plates 31 have the same diameter as the through holes 9 in the support strut 7 and the through holes of the perforated rail and the support strut are arranged in a grid which are matched with respect to one another. The holding bolt 34 is fastened to the adjustable carrier by means of a safety cord 35.
The necessary steps for mounting the truss holder 1 on the truss form are shown in FIG. 4a, 4b, and 4c. In this, the truss holder 1 is additionally provided with an adjustable carrier 30. As FIG. 4a shows, the truss holder 1 is placed on the upper flange 41 of a wooden form carrier 40 in the first step of assembly. Two side carriers 52 are inserted between the truss holder 1 with the adjustable carrier 30 and a side face 50 of the form skin, the first being placed directly on the wooden form carrier 40 and the second on the holding plate 32 of the adjustable carrier 30. The truss holder with the adjustable carrier is pushed with the side carriers and side face along the wooden form carrier 40, which serves as a transverse carrier, towards a base plate 51 of the form skin (see arrow) until the gap between the side face 50 and the base plate 51 is sealed. FIG. 4a shows how the screw bolt 2 is connected via the bracket 5 with both holding brackets 3 in a knuckle joint arrangement.
As FIG. 4b shows, the truss holder is prestressed in such a manner in a second assembling step that both claws 10 respectively lie with one edge 18 (cf. FIG. 5a) on the contacting surface 42 on the lower side of the upper flange 41 of the wooden form carrier 40. The claws 10 are respectively arranged at such an angle on the clamping bracket 3 that when respectively only one edge of the claws 10 lies against the contacting surface 42 after the prestressing of the truss holder, the middle surface of the claw respectively forms an angle of a few degrees with the contacting surface 42. FIG. 4b shows that the longitudinal axis of the screw bolt 2 and the longitudinal axes of the straight legs of the clamping brackets 3 are not arranged coaxially, but that they are respectively inclined to the plane of the side face 50. In this case, the longitudinal axis of the screw bolt 2 and the longitudinal axes of the holding brackets 3 are respectively parallel to the plane defined by the support frame and the ends of the straight legs of the holding brackets 3 remote from the joint are oriented more towards the side face 50 than the end of the screw bolt 2 near the joint.
As can be seen in FIG. 4c, the truss holder is tightened to such an extent after prestressing by means of tightening the star nut 4 (see upper arrow) that the longitudinal axis of the screw bolt 2 and the longitudinal axes of the straight legs of the clamping brackets 3 are substantially aligned coaxially and, correspondingly, the contacting surfaces of the claws 10 lie against the contacting surfaces 42 of the upper flange 41 on account of rotation about their contacting edges 18 (cf. FIG. 5a). Due to the rotation of the clamping brackets 3 about the contacting edges 18, the support rail 6 is displaced by means of the bolts 14 along a prestressed path, which in the depicted exemplified embodiment can amount to several millimeters in the direction towards the side face 50 (see lower arrow). On account of this prestressing perpendicular to the plane of the side face 50, it is ensured that the gap between the form skin of the side face 50 and the base plate 51 is maintained in a sealing manner even when the pressure of the concrete acts on the side face 50.
FIG. 5a to FIG. 5e show various embodiments of the claws on the holding brackets 3, the holding brackets respectively being shown in the prestressed state. The oblong hole 11 in the straight leg of the holding bracket 3 can also be clearly seen.
In FIG. 5a to 5c as well as in FIG. 5e, the claws are respectively prestressed on the contacting surface 42 on the lower side of the upper flange 41 of a wooden form carrier 40. In a first embodiment according to FIG. 5a, the claw 10 is a flat plate and it lies with the contacting edge 18 on the contacting surface 42. It can be recognized that the middle surface of the contacting claw 10 forms an angle of a few degrees with the contacting surface 42 in the prestressed state of the truss holder, as is the case in the embodiments according to FIG. 5b to 5e. In a second embodiment according to FIG. 5b, the claw 15 is formed of a flat plate in which the end face 19 facing the side face 50 is bent upwardly in the direction of the oblong hole 11. The claw 15 also lies only with one edge against the contacting surface 42.
As FIG. 5c shows, a third embodiment of the claw 16 consists in that an elevation in the form of a triangular prism 20 is formed on a flat plate, the elevation being arranged in the middle of the contacting surface on the side of the claw and extending perpendicularly across the plate. The contact of the claw 16 with the wooden form carrier 40 ensues by means of the edge which is formed by the elevation 20.
FIG. 5d shows a fourth embodiment of the claw 17 which can be used in connection with metal form carriers 60. The claw 16 is formed of a flat plate which in comparison to the embodiments according to FIG. 5a to 5c is shorter and has at its one edge an elevation 21 which extends perpendicularly to the plate. The elevation 21 fits exactly into the wave-shaped profile 62 on the lower side of the upper flange 61. As the elevation 21 has a round tip which acts together with the matching wave-shaped profile 62, the claw 17 is securely fixed in the axial direction of the metal form carrier 60 and the rotation of the holding bracket 3 about the contacting edge of the claw is possible without problems when tightening the truss holder.
A fifth embodiment of the claw 26 is shown in FIG. 5e in which the contacting surface of the claw is provided with a continuous toothing 27. As the enlarged depiction of the claw 26 in FIG. 5f shows, the toothing 27 extends across the entire length of the claw and the teeth rows extend perpendicular to the carrier longitudinal axis across the entire width of the claw.
In addition to the described embodiments, the claws can also have other geometrical forms, for example those which are not substantially plate-like are provided with a contacting edge and allow a rotation of the claw about this edge.
FIG. 6 shows a truss holder 1 with an adjustable carrier 30 which is finally tightened to a truss form, the transverse carrier of which is a square piece of timber 70. In order to be able to mount the truss holder to this, the straight legs of the holding brackets 3 are longer than in the embodiments of the truss holders which are provided for mounting to wooden form carriers or metal form carriers with a double T-profile or a T-profile. In the case of these form carriers, respecively one upper flange 41, 61 and one web 43, 63 are present, while a square timber form carrier 70 has a rectangular cross section. The claws 10 of the holding brackets 3 are therefore placed on the lower side 71 of the square timber form carrier 70.
The depiction in FIG. 7 corresponds to the situation in FIG. 6, but the truss holder is tightened on a metal form carrier 60 rather than a square timber form carrier. In this case, the lower side of the upper flange 61 has a wave-shaped profile 62, which is shown in FIG. 5d, in order to also guarantee a good and secure contact of the claw on the metal form carrier.
FIG. 8a and 8b respectively show the truss holder On a wooden form carrier with a double T-profile in a finally tightened state and in the case of placement on the upper flange 41 of the form carrier. In the clamped state according to FIG. 8a, the straight legs 23 of both holding brackets 3 are substantially parallel to one another. However, in order for the claws 10 to be able to grip beneath the upper flange 41 when mounting the truss holder, the superimposed holding brackets 3 can be displaced with respect to one another along their bent sections 22 and can therefore be spread apart perpendicularly to the plane clamped by the support frame. In order to achieve a good form-lock of both superimposed clamping brackets in the area of their bent sections 22, the outer radius of the bent section of the lower clamping bracket corresponds to the inner diameter of the bent section of the upper clamping bracket. The straight leg 23 of the upper clamping bracket is extended to such an extent that the free lower ends 25 of the superimposed holding brackets 3 and the claws 10 are at the same level. The holding brackets 3 have, for example, a flat rectangular section, but can also have other cross-sections which are connectable in a form- and force-locked manner. It is not necessary in this case that the cross-sections of both superimposed clamping brackets are geometrically similar. Furthermore, it is possible to arrange the clamping brackets to be behind one another instead of being superimposed.
FIG. 9a and 9b respectively correspond to FIG. 8a and 8b, but in this case the truss holder is placed on a metal form carrier. One can recognize how the claws 17 engage in the wave-shaped profiles 62 of the upper flange 61. | Apparatus for supporting a form member extending perpendicularly to the longitudinal axis of a form carrier, in particular for supporting the side face of a truss form for concrete. The apparatus has a support frame and a clamping device connected to the support frame. A tightening device and a holding member are arranged in such a manner in a knuckle joint arrangement that, upon tightening, a prestressing path for the apparatus along the form carrier, and, thus a prestressing force perpendicular to the plane of the side face, ensues so that the gap between the side face and the base plate remains sealed in a reliable manner despite the concrete pressure, which arises. In a preferred embodiment, the truss holder is provided with an adjustable carrier adjustable in height, and which can be adapted to the required truss height. | 4 |
The present application claims priority of Japanese Patent Application No. 62-163146 filed on June 30, 1987.
FIELD OF THE INVENTION AND RELATED ART STATEMENT
This invention relates to a magnetic recording medium, and more particularly to a magnetic recording medium capable of high-density recording and excellent in runnability and durability.
Generally, the magnetic recording medium is produced by applying a magnetic coating material containing a ferromagnetic powder and a resinous binder on a non-magnetic substrate such as of polyester thereby forming a magnetic layer thereon. Recording and reproducing is done while head is in sliding contact with the magnetic recording medium.
The state or degree of sliding contact between head and magnetic recording layer is different due to various application. In the case of a floppy disc drive, an audio deck, or a video deck, for example, the recording or replay is carried out with the state of sliding contact so adjusted that the dynamic frictional coefficient will fall approximately in the range of 0.04 to 0.4.
Recently, the promotion of OA and FA activities is gathering momentum. As a natural consequence, the demand for magnetic recording media, particularly those capable of high-density recording, is steadily growing in enthusiasm.
For realization of the high-density recording system from the standpoint of the magnetic recording medium, the improvement of magnetostatic properties, the enhancement of surface quality of the magnetic layer, etc. are believed to be effective measures. Then, for realization of highly desirable output and frequency properties, the enhancement of surface quality particularly of the magnetic layer constitutes itself an essential requirement.
In contrast, for realization of the high-density recording system from the standpoint of design of the deck, it is necessary to pay due consideration to the shape of the head and the magnetic property of the head and pay due respect to the stability of contact between the head and the recording medium. In the case of a floppy disc drive, for example, studies must be given to the shape of the slider and to the gimbal, the penetration, the head load, etc. as well. When the state of contact between the head and the recording medium is improved, the contact pressure is necessarily enhanced. As a result, the improvement of stable runnability and durability is required in addition to the improvement of magnetostatic property and surface property from the standpoint of the magnetic recording medium. Particularly in the case of a floppy disc medium, the reliability expected thereof is so exacting that the medium is rated as commercially valueless unless it exhibits durability enough to withstand not less than ten million passes of continuous sliding contact with one and the same track.
When the magnetic recording medium which has the surface quality thereof improved over the heretofore attainable level so much as to permit high-density recording was tested for durability and runnability with the aforementioned floppy disc drive, it was found to lose stability of runnability in one and the same track and durability with the elapse of the traveling time. To be more specific, when the head was caused to travel on the magnetic layer of the magnetic medium for a stated length of time, there was observed a phenomenon that the replay output could not be generated as required because the dynamic frictional coefficient between the head and the medium suddenly increased and the posture of the gimbal side head was impaired. When the surface of the magnetic recording medium was visually examined after the sudden increase of the dynamic frictional coefficient, it was found to have sustained scars of sliding on the test track.
For solution of this problem, various studies were made with various lubricants in search of a method capable of curbing the abrupt increase of the dynamic frictional coefficient. It was consequently found that a mere change in the kind and quantity of lubricant could not sufficiently prevent the sudden change in the dynamic frictional coefficient with the elapse of the traveling time.
Japanese Patent Disclosure SHO 60(1985)-111325 discloses an invention relating to a magnetic recording medium which has such qualities relating to a magnetic recording medium which has such qualities thereof as wear resistance, durability, ability to preclude particle falling, and tackiness improved by using as a resinous binder for the magnetic layer thereof a mixed resin consisting of two kinds of polyurethane resin different in tensile strength and elongation at fracture, a cellulosic resin, and a vinyl chloride type copolymer.
In the specification of Japanese Patent Application Disclosure SHO 60(1985)-111325, however, a technique for improving the surface quality of the magnetic recording medium and, at the same time, preventing degradation of durability and runnability for the purpose of imparting enhanced recording density to the magnetic recording medium is disclosed nowhere.
OBJECT AND SUMMARY OF THE INVENTION
A major object of the present invention, therefore, is to provide a magnetic recording medium possessing a highly desirable surface accuracy and enjoying improvement in durability and runnability.
Another object of this invention is to provide a magnetic recording medium capable of high-density recording and excellent in runnability and durability.
The other objects of this invention will become apparent from the following description of this invention.
The objects of this invention described above are accomplished by a magnetic recording medium which is produced by applying to a substrate a magnetic coating material containing a ferromagnetic powder and a resinous binder and whose magnetic layer formed of the magnetic coating material possesses a deformation ratio (exhibited under a load applied perpendicularly to the film surface on the magnetic layer side) not more than 1×10 -2 μm 3 /mgf, preferably in the range of 1×10 -2 to 1×10 -6 μm 3 /mgf.
The deformation ratio as reported in the present invention is measured with a probe type micro-displacement as follows. Otherwise, the deformation ratio may be measured with a commercially available surface roughness meter in the place of the micro-displacement detector.
To measure the deformation ratio of the magnetic recording medium, a given sample is attached fast to a thoroughly washed glass plate of amply high surface accuracy. Then, the pressure of the probe of the detector is increased stepwise and, under a varying probe pressure, the surface roughness of the sample is measured. In this case, the relative positions of the sample under measurement and the probe may be varied when the surface condition of the sample is sufficiently uniform. To ensure accurate comprehension of the viscoelastic deformation of the medium due to the phenomenon of creeping, the relative speed of the sample and the probe is desired to be as low as possible, preferably to be below 10 μm/sec. Though the pressure of the probe is fixed in relation to the shape of the tip of the probe, it is desired to fall in the range in which the deformation of the medium apparently occurs after the pattern of an elastic deformation.
The amount of the deformation to be measured must be fixed below 1/10 of the thickness of the magnetic layer. Generally, the thickness of the magnetic layer is in the range of 2 to 6 μm. The conditions for the measurement of the amount of this deformation, therefore, must be selected so that the amount of the deformation to be measured will be approximately 0.1 μm. These conditions are important because the effect of the substrate, namely the mechanical coupling of the magnetic layer and the substrate grows to a hardly negligible degree when the amount of the deformation is greater than the level mentioned above. In accordance with this method, the deformation of the medium which is balanced against the pressure of the probe increases in proportion as the load for measurement increases. The height at which the curve of measurement indicating the surface falls, therefore, the falls increase in proportion as the load fixed for the measurement. The width of this fall represents the amount of deformation. The deformation ratio is determined by measuring this amount of deformation. When the shape of the tip probe is known, then the area of contact of the tip of the probe on the medium is consequently known, it is possible to measure the deformation of the medium relative to the load per unit area.
When the device for this measurement is of the type marketed under the trademark designation of "Taylor-Hobson Talystep", the probe for measurement has a tip the shape of which has a radius of curvature falling in the range of 2.5 to 100 μm.
When the probe has a tip such that the radius of curvature is 2.5 μm, for example, the first profile of surface quality is obtained with the pressure of the probe varied in the range of 2 to 10 mgf and the relative speed of the probe and the sample in the range of 1 to 400 μm/sec, then the second profile of surface quality is obtained with the pressure of the probe varied in the range of 10 to 50 mgf and the relative speed of the probe and the sample in the range of 0 to 400 μm/sec, and the difference between the heights of these profiles is the amount of deformation.
Then, from the amount of this deformation, the deformation ratio is calculated as follows.
It is assumed that the surface profile level varies from r 1 to r 2 when the load exerted on the probe held in contact with the sample increases from w 1 to w 2 . Then, the area of contact is expressed by the formula, 2 π(r 2 -r 1 ) R (wherein R stands for effective radius of the probe).
Since the surface pressure (P) is expressed by the formula, ##EQU1## the deformation ratio per unit area per unit load is found as follows: ##EQU2##
The deformation ratio in this invention has little dependency on the thickness and material of the substrate and can be equally applied to magnetic layers of varying magnetic recording media ranging from tapes to discs.
Examples of the substrate which is used effectively in the present invention include flexible substrates formed of films of polyethylene terephthalate and polyolefin sulfide and rigid substrates of aluminum.
As examples of the ferromagnetic powder suitable for use in the present invention, hexagonal ferrites represented by the general formula, MO·n(Fe 2 O 3 ) (wherein M stands for one element selected from among Ba, Sr, Pb and Ca, and n for a number in the range of 5 to 6, providing that part of the Fe may be substituted with a metal such as Ti, Co, Zn, In, Mn, Cu, Ge, Nb, Zr, V, Al, or Sn), and possessing a coercive force in the range of 200 to 2,000 Oe may be cited.
As the resinous binder to be used in this invention, any one or the same combination of the flexible film-forming material possessing affinity for the material for the substrate and the magnetic powder can be used. As concrete example of such materials, such well-known materials as vinyl chloride-vinyl acetate type copolymer materials, NBR-polyvinyl acetate type materials, urethane-plasticized vinyl chloride-vinyl acetate type copolymer materials, polyurethane type materials, polyester type resins, and isocyanate type materials can be cited.
These resinous binder materials can be used either singly or in the form of a mixture of two or more members. The resinous binder is desired to be incorporated in an amount in the range of 2 to 30 parts by weight, based on 100 parts by weight of the fine ferromagnetic particles.
This range is fixed for the following reason. If the amount of the resinous binder is less than 2 parts by weight, the degree of dispersion of the fine ferromagnetic particles is lowered and the stability of the produced magnetic coating material during the dilution with a solvent or the orientation of magnetic field is possibly degraded. Conversely if the amount of the resinous binder exceeds 30 parts by weight, the produced magnetic recording medium possibly fails to acquire necessary magnetic properties. Further, the resinous binder is desired to be such that the deformation ratio of the produced magnetic recording medium will fall below 1×10 -2 μm 3 /mgf, preferably in the range of 1×10 -2 to 1×10 -6 μm 3 /mgf.
The limits of the deformation ratio are fixed for the following reason. If the deformation ratio exceeds 1×10 -2 μm 3 /mgf, the curing property is degraded and the produced magnetic recording medium possibly fails to acquire stable durability.
The amount of the curing agent to be used in the present invention is desired to be in the range of 2 to 50 parts by weight, based on 100 parts by weight of the aforementioned resin. If this amount is less than 2 parts by weight, the reaction for bonding resinous binder molecules to a three-dimensional reticular structure each other does not proceed sufficiently. If the amount exceeds 50 parts by weight, the excess curing agent which does not participate in the reaction with the resinous binder reacts with itself and the product of this reaction finds its into the reticular structure of the resinous binder and degrades the strength of the coating.
The magnetic recording medium of this invention is produced, for example, as follows. First, in a dispersing and mixing machine such as a sand grinder pot, the hexagonal ferromagnetic powder, the resinous binder, and a suitable solvent are placed in suitable amounts and are mixed by setting the machine operating, to the kind of prepare a magnetic coating material.
In this case, by adjusting the mixing ratio of the magnetic powder and the resinous binder and selecting the resinous binder, for example, the deformation ratio of the magnetic media is caused to fail below 1×10 -2 μm 3 /mgf.
Generally, the relation between the deformation ratio and the film composition can be adjusted by varying the mixing ratio of the pigment such as the magnetic powder to the resinous binder. Further, by selecting the resinous binder by sufficiency of rigidity or by controlling the amount of the curing agent to be added, the cross-link density of the resinous binder can be heightened and the deformation ratio decreased. The resinous binder of high rigidity under discussion is a resinous binder of the type such that when a film of this resinous binder is tested by the method described above, the amount of deformation is small.
The magnetic coating material, when necessary, may further incorporate therein various known additives such as antistatic conductor like carbon black, dispersant like lecithin, lubricant, abradant, and stabilizer. Then, magnetic coating material consequently obtained is applied by the conventional method using a reverse roll coater, a doctor blade coater, or a gravurecoater. The applied layer of this coating material is dried and subjected to a smoothening treatment, to produce the magnetic recording medium of this invention. The surface of the magnetic recording medium is desired to have a roughness (Ra) in the range of 0.003 to 0.1 μm. If the surface roughness exceeds 0.1 μm, the produced magnetic medium acquires a capacity for high density recording with difficulty. Conversely if the surface roughness is less than 0.003 μm, the runnability of the produced magnetic medium is unstable from the beginning.
When the smoothening treatment is carried out with a calender, the deformation ratio can be varied by the conditions of the calendering operation. Generally, the deformation ratio is decreased by exacting such conditions as pressure and temperature.
The mechanism which underlies the improvement of the traveling stability and the stabilization of durability in the magnetic recording medium of the present invention is not perfectly clear. Since the magnetic recording medium of this invention, for a fixed frictional force, exhibits a smaller amount of deformation and a smaller sliding surface change during the sliding than the conventional magnetic recording medium, it is inferred that this magnetic recording medium retains a high surface accuracy, maintains the runnability stably irrespectively of the number of passes of sliding even from the initial stage of operation, and consequently attains stabilization of the runnability and durability.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described more specifically below with reference to working examples.
EXAMPLE 1
A magnetic coating material was prepared by the conventional method, using the following components in the proportions indicated correspondingly.
______________________________________Ba-ferrite powder (Co--Ti substituted 100 parts by weightgrade, having an average particlediameter of 0.08 μm)Carbon black 3 parts by weightCr.sub.2 O.sub.3 (abradant) 3 parts by weightFluorocarbon (lubricant) 6 parts by weightPolyurethane resin (resinous binder) 25 parts by weightPolyisocyanate (product of Nippon 10 parts by weightUrethane Co., Ltd. and marketedunder trademark designation of"Coronate L")______________________________________
With a blade coater, this magnetic coating material was applied to both sides of a polyester film (substrate) 75 μm. in thickness. The applied layers of the magnetic coating material were dried. Then, the coated sample was given a calendering treatment at 80° C. to smoothen the surfaces of the magnetic layers. Discs 3.5 inches in diameter were punched out of the magnetic recording medium. Part of the discs were set in jackets. The magnetic layers in these discs had a thickness of 3 μm.
Then, a portion of a given disc was cut off, applied fast to a thoroughly washed glass plate of high surface quality, and subsequently tested for deformation by the following method. The measurement of the deformation was carried out with an instrument marketed under trademark designation of "Taylor-Hobson Talystep" using a probe with a diamond tip of which had a radius of curvature of 2.5 μm.
First, a profile indicating surface quality of the sample was obtained under a probe pressure of 2 mgf at a probe sample relative speed of 2.5 μm/sec. Then, with the sample held in the same state, the probe was returned to the original position and another surface profile was obtained under a probe pressure of 45 mgf. In this measurement, the difference in height between the surface profiles under probe pressures 2 mgf and 45 mgf, namely the deformation of the magnetic layer due to an increased load of 43 mgf, was 0.02 μm.
Incidentally, a coating formed solely of the same resinous binder incorporating therein 10 parts by weight of "Coronate L" and then cured was found, by the same test, to exhibit a deformation ratio of 3×10 -2 μm 3 /mgf.
Since the contact area was approximately 2 π(r 2 -r 1 )·R, the deformation ratio per unit area per unit load is found by calculation to have been ##EQU3##
The surface roughness (Ra) of the magnetic layer of the disc calculated from the profile under the probe pressure 2 mgf was 0.1 μm.
EXAMPLE 2
A magnetic coating material was prepared by the conventional method using the following components in the amounts indicated correspondingly.
______________________________________Ba-ferrite powder (Co--Ti substituted 100 parts by weightgrade, having an average particlediameter of 0.08 μm)Carbon black (antistatic agent) 6 parts by weightCr.sub.2 O.sub.3 (abradant) 3 parts by weightFluorocarbon (lubricant) 6 parts by weightPolyurethane resin 25 parts by weight(resinous binder)Polyisocyanate (product of Nippon 2 parts by weightUrethane Co., Ltd. and marketedunder trademark designation of"Coronate L")______________________________________
Discs of magnetic recording medium 3.5 inches in diameter were prepared by following the procedure of Example 1. Part of these discs were set in jackets.
The magnetic layers of the magnetic recording medium were found to have a thickness of 3 μm and a surface roughness of 0.1 μm. The magnetic recording medium was found to have a deformation ratio of 1×10 -2 μm 3 /mgf. A coating obtained solely of the same resinous binder incorporating 10 parts by weight of Coronate and subsequently curing the applied layer was found to exhibit a deformation ratio of 5×10 -2 μm 3 /mgf.
EXAMPLE 3
Discs of magnetic recording medium 3.5 inches in diameter were prepared by the same procedure of Example 1, excepting the calendering treatment was performed twice. Part of the discs were set in jackets.
The magnetic recording medium was found to have a deformation ratio of 4×10 -5 μm 3 /mgf and a surface roughness of 0.003 μm.
EXAMPLE 4
Discs of magnetic recording medium 3.5 inches in diameter were prepared by following the procedure of Example 3, excepting the magnetic coating material obtained in Example 2 was used instead. Part of the discs were set in jackets.
The magnetic recording medium had a magnetic layer thickness of 3 μm, a deformation ratio of 1×10 -3 μm 3 /mgf, and a surface roughness of 0.003 μm.
COMPARATIVE EXPERIMENT 1
A magnetic coating material was prepared by the conventional method using the following components in the amounts indicated correspondingly.
______________________________________Ba-ferrite powder (Co--Ti substituted 100 parts by weightgrade, having an average particlediameter of 0.08 μm)Carbon black (antistatic agent) 6 parts by weightCr.sub.2 O.sub.3 (abradant) 3 parts by weightFluorocarbon (lubricant) 0.8 part by weightPolyurethane resin (resinous binder) 25 parts by weightPolyisocyanate (product of Nippon 0.25 Part by weightUrethane Co., Ltd. and marketedunder trademark designation of"Coronate L")______________________________________
Discs magnetic recording medium 3.5 inches in diameter having magnetic layers 3 μm in thickness were produced by following the procedure of Example 1. Part of the discs were set in jackets.
COMPARATIVE EXPERIMENT 2
Discs of magnetic recording medium 3.5 inches in diameter possessing magnetic layers 3 μm in thickness were produced by following the procedure of Example 3, excepting the magnetic coating material of Comparative Experiment 1 was used instead. Part of the discs were set in jackets.
COMPARATIVE EXPERIMENT 3
Discs of magnetic recording medium 3.5 inches in diameter possessing magnetic layers 3 μm in thickness were produced by following the procedure of Example 1, excepting the magnetic coating material of Comparative Experiment 1 was used instead and calendering treatment was performed three times. Part of the discs were set in jackets.
COMPARATIVE EXPERIMENT 4
Discs of magnetic recording medium 3.5 inches in diameter possessing magnetic layers 3 μm in thickness were produced by following the procedure of Example 1, excepting the magnetic coating material of Comparative Experiment 2 was used instead and the calendering treatment was performed three times. Part of the discs were set in jackets.
COMPARATIVE EXPERIMENT 5
Discs of magnetic recording medium possessing magnetic layers 3 μm in thickness were produced by following the procedure of Example 1, excepting the surface smoothening treatment was carried out one-half degree. Part of the discs were set in jackets.
The properties of the magnetic recording media obtained in the working example and the comparative experiments are shown in the following table.
TABLE__________________________________________________________________________ Example Comparative Experiment 1 2 3 4 1 2 3 4 5__________________________________________________________________________Deformation ratio (μm.sup.2 /mgf) 1 × 1 × 4 × 1 × 1.3 × 1.2 × 7 × 8 × 1.2 × 10.sup.-4 10.sup.-2 10.sup.-5 10.sup.-2 10.sup.-2 10.sup.-2 10.sup.-3 10.sup.-3 10.sup.-2Surface roughness, Ra (um) 0.1 0.1 0.003 0.003 0.1 0.003 0.001 0.002 0.12Output (*1) 0 0 +1.5 +1.3 0 +1.5 +1.8 +1.7 -0.8D50 (bpi) 53 53 59 59 52 59 60 60 48Dynamic frictional coefficient (*2) 0.19 0.25 0.20 0.25 0.32 0.33 0.41 0.42 0.3Durability (× million passes) (*3) >10 >10 >10 >10 5 3 1 1 >1__________________________________________________________________________ (*1) Relative value based on the value of Example 1; conditions of measurement 40 KFRI and 0.33 um in head gap. (*2) Calculated from motor load current obtained by doubleface head drive under the conditions of 20 gf of head load and 300 rpm of rotational speed. (*3) In a continuous doubleface head drive around the periphery of a give 3.5 inch disc medium, the number of passes made by the time the fall of replay output from the initial value totalled 1 dB was reported as durability. | A magnetic recording medium is disclosed which is produced by applying to a non-magnetic substrate a magnetic coating material containing a ferromagnetic powder and a resinous binder. The coating formed of the magnetic coating material exhibits a deformation ratio (in the direction perpendicular to the film surface from the magnetic layer side) is not more than 1×10 -2 μm 3 /mgf. This magnetic recording medium possesses a high surface accuracy, retains a highly desirable runnability for a long period of time, and excels in durability. | 8 |
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