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FIELD OF THE INVENTION
This invention relates to the manufacture of refractory carbon material capable to be used as high-temperature thermal insulators in ovens operating at high temperatures and in a non-oxidizing atmosphere.
This invention relates more particularly to expanded graphite base cylindrical or tubular insulators, intended for high-temperature ovens.
PRIOR ART
Application FR 2 849 651 describes an insulating structure comprising at least one flexible layer with a “dense” compressed expanded graphite particle base, of which the density is at least equal to 400 kg/m 3 and at least one other layer, “sub-dense”, also with an expanded graphite base, having a density that is lower than that of the dense layer, typically less than 400 kg/m 3 .
The same patent application further describes the use of the insulating structure for manufacturing parts of cylindrical form, by coiling insulating structures in a spiral such as described hereinabove. The main disadvantage in this technique resides in the fact the layers become detached during the heat treatment to which is submitted the cylinder obtained after coiling.
This technique of coiling in spirals is also described in other patents or patent applications such as U.S. Pat. No. 6,143,601 and U.S. 2004/0076810.
On the other hand, application FR 2 849 651 describes a method of manufacturing comprising, in addition to a step of coiling, the use of a curving technique for the manufacture of portions of cylinders with the insulating structure such as described hereinabove.
PROBLEMS PUT FORTH
The invention aims to overcome several problems simultaneously, the method of manufacturing of tubular insulating devices according to the invention having to make possible all at the same time:
obtaining devices of high mechanical resistance across the entire range of high temperature of use, being able to exceed 1500° C., obtaining devices having a high “insulating power/mass ratio”, a method of manufacturing that is simple and economical as it makes use of a single and same technology, and furthermore easy to adapt to any form of tubular device.
OBJECT OF THE INVENTION
The applicant has now perfected a method of manufacturing tubular devices used in particular for the insulating of high-temperature ovens by curving insulating structures making it possible to obtain tubular wall elements, then gluing on edges of these elements and stacking of two layers of insulating structures with an offset of the glued edges forming a junction between two juxtaposed elements.
In this method of manufacturing a tubular insulating device comprising a lateral wall of thickness Ep, of axial length L, provided with an axial direction, is fed an insulating material with bi-dimensional structure of thickness E M <Ep, with for example E M at most equal to 0.5 Ep, and said insulating material is put into form by superposing a plurality of N layers C 1 of said insulating material, with i ranging from 2 to N, said tubular insulating device comprising at least two layers C 1 and C 2 of said insulating material.
This method is characterised in that:
a) for each layer C i , a plurality of n i precut axial insulating elements E i is formed in said insulating material in such a way that said n i , insulating elements E i can form said layer C i , after an edge-to-edge juxtaposition and thanks to an adapted deformation,
b) a rough form of said tubular insulating device is formed by:
b1) assembling, thanks to an adhesive, more preferably on an axial shaping mandrel, layer after layer, and by beginning with the first inside layer C 1 , the n i elements E i of each layer C i juxtaposed edge to edge according to a plurality of joining zones J i , the elements E i+1 of the layer C i+1 being offset in relation to the elements E i of the layer C i in such a way as to offset the plurality of joining zones J i+1 in relation to the plurality of joining zones J i , and as such obtain in fine a tubular insulating device of high mechanical strength,
b2) then by polymerizing said adhesive, in such a way as to rigidify said rough form,
c) said rough form of tubular element is subjected to a heat treatment, in such a way as to carbonize said adhesive, and as such obtain, where applicable after separation from said mandrel, said tubular insulating device.
This method makes it possible to overcome the problems put forth.
Indeed, the applicant has observed that the devices obtained via this method of manufacturing did indeed have the high mechanical strength required in particular for their use as an insulating sleeve for ovens in an industrial environment, and, thanks to an appropriate choice of the insulating material, an excellent “insulating power/mass” ratio.
Moreover, as it does not require coiling, the manufacture of these devices is simple as well as capable of being applied to any form of tubular device, since it comprises a preparation of insulating elements, for example by cutting in an insulating material in strips or in sheets, possibly followed by their forming, and followed by their assembly thanks to an adhesive, by forming at least two layers. This method calls upon only a limited number of pieces of industrial equipment in such a way that it is economical and also nevertheless of great flexibility in order to form devices of all sorts of forms or dimensions.
DESCRIPTION OF THE FIGURES
All of the figures relate to the invention.
FIGS. 1 a to 1 g diagrammatically show different steps of the manufacture of a tubular insulating device ( 1 ) according to the invention.
FIG. 1 a shows, as a partial section according to a transversal plane, the insulating material ( 2 ) with bi-dimensional structure of thickness E M used to form said insulating elements ( 4 ).
FIGS. 1 b and 1 c are views, as a transversal section, of the planar insulating elements ( 4 , 4 a ) formed by cutting in said material ( 2 ) in FIG. 1 a , and noted respectively E P1 and E P2 , the planar insulating element E P1 in FIG. 1 b , intended to form an insulating element of the first layer C 1 , having a width l 1 less than that l 2 of the planar insulating element E P2 in FIG. 1 c and intended to former an insulating element of the second layer C 2 .
FIGS. 1 d and 1 e , analogous to FIGS. 1 b and 1 c , show the curved insulating elements E C1 and E C2 formed by curving respectively the planar insulating elements E P1 and E P2 of FIGS. 1 b and 1 c.
FIG. 1 f is a view, as a transversal section in a plane perpendicular to its axial direction ( 11 ), of the rough form ( 5 ) formed by assembling, on two layers C 1 and C 2 , of the eight curved insulating elements E C1 and E C2 of FIGS. 1 d and 1 e (four insulating elements per layer C i ), this assembly being formed by a gluing on the edge ( 60 ) between curved elements ( 4 , 4 b ) of the same layer C i , and by so-called inter-layer gluing ( 61 ) between the layers C 1 and C 2 , the layers C 1 and C 2 being directed in such a way that the axial junctions J A1 ( 30 , 31 ) of the first layer C 1 ( 3 , 3 a ) are angularly offset in relation to the axial junctions J A2 ( 30 , 31 ) of the second layer C 2 ( 3 , 3 b ).
FIG. 1 g is a partial side view of the rough form ( 5 ) in FIG. 1 f.
FIG. 2 a is analogous to FIG. 1 f and shows another modality of rough form ( 5 ), and therefore tubular insulating device ( 1 ), further comprising two layers C 1 and C 2 , each layer C i comprising 3 insulating elements ( 4 , 4 b ) per layer C i .
FIG. 2 b , analogous to FIG. 2 a , shows another modality of rough form ( 5 ) and of device ( 1 ), wherein the number N of layers C i is equal to 3, each layer C i comprising two elements E i .
FIGS. 2 c and 2 d are enlarged views of the curved portions “c” and “d” in FIG. 2 b , which respectively show the gluing on edge ( 60 ) between curved elements ( 4 b ) of the same layer C i and the inter-layer gluing ( 61 ) between two adjacent layers C i and C i+1 , is between the layers C 1 and C 2 in FIG. 2 b.
FIGS. 3 a to 3 f show different forms of lateral walls ( 10 ) of the devices ( 1 ) and of the corresponding rough forms ( 5 ).
FIGS. 3 a to 3 c relate to tubes ( 1 a ) with lateral walls ( 10 ) with constant section, along their entire axial length L.
FIG. 3 a is a side view of the lateral wall ( 10 ), wherein the axial joining zones J i ( 30 ) have not been shown.
FIGS. 3 b and 3 c show two outside transversal sections of the lateral wall ( 10 ) in FIG. 3 a , the FIG. 3 b corresponding to a cylindrical wall of outside diameter D, and the FIG. 3 c corresponding to a 6-faced hexagonal wall of which the outside section is inscribed in a circle of diameter D.
FIGS. 3 d to 3 f , analogous respectively to FIGS. 3 a to 3 c , relate to tubes ( 1 b ) with variable section on their axial length L and of average outside diameter D M at mid-height.
FIG. 3 d shows the wall ( 10 ) of tapered form as a side view.
FIG. 3 e diagrams the case of a circular section, while the FIG. 3 f diagrams the case of a polygonal (hexagonal) section.
FIG. 4 a , analogous to the FIG. 1 g or 3 a , shows a device ( 1 ) or a rough form ( 5 ) said of great axial length L, of which each layer C i comprises at least one transversal junction zone J Ti ( 32 ) in order to join said curved elements ( 4 , 4 b ) according to said axial direction ( 11 ). The inside layer C 1 ( 3 a ) comprises two transversal junctions J T1 offset axially in relation to the single transversal junction J T2 of the outer layer C 2 ( 3 b ).
FIG. 4 b is a bottom view of the device ( 1 ) in FIG. 4 a.
FIG. 4 c is an axial cross-section of the wall ( 10 ) according to the plane B-B in FIG. 4 b passing through said axial direction ( 11 ).
FIGS. 4 d and 4 e show, as a partial transversal section, two modalities of material ( 2 ′) with an expanded graphite base constituting said insulating material ( 2 ) and forming a multilayer material ( 2 a ).
FIG. 4 d shows a multilayer material ( 2 a ) comprising two layers of expanded graphite: one layer referred to as “low density” ( 20 ) and a layer referred to as “high density” ( 21 ), the high-density layer ( 21 ) having for example a thickness at least two times less thick than that of the low-density layer ( 20 ).
FIG. 4 e , analogous to the FIG. 4 d , forms a three-layer material ( 2 ) comprising a central layer ( 23 ) forming a low-density layer ( 20 ), and two external layers ( 22 ) forming two high-density layers ( 21 ). FIG. 4 f is a partial transversal section of a wall ( 10 ) comprising two layers C 1 and C 2 formed using the material in FIG. 4 d and assembled with a layer of adhesive ( 61 ) between the layers C 1 and C 2 . As can be seen in FIG. 4 f , the high-density layers ( 21 ) form the outside and inside surfaces of said wall ( 10 ).
FIGS. 5 a to 5 e diagrammatically show different views of a modality of manufacturing a rough form ( 5 ) using a shaping mandrel ( 7 ) as well as a shaping mould ( 8 ).
FIG. 5 a shows, in perspective, two layers C 1 and C 2 of insulating material ( 2 , 2 ′) arranged on the mandrel ( 7 ).
FIG. 5 b shows a section, according to the axial direction ( 11 ), of the shaping mould ( 8 ) with two half-shells ( 80 ) containing the unit constituted of the elements in FIG. 5 a , in such a way as to compress said layers C i ( 3 ) between a rigid mandrel and the typically metal half-shells of the mould, and as such give predetermined dimensions to said rough form ( 5 ).
FIG. 5 c shows as a side view the unit, at the output of the cast, formed by the mandrel ( 7 ) plus the rough form ( 5 ) with predetermined dimensions, the FIG. 5 d showing the rough form ( 5 ) separated from the mandrel ( 7 ) shown in FIG. 5 e.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, and as shown in the FIGS. 1 g and 4 a , said joining zones J i ( 30 ) can include axial joining zones J Ai ( 31 ) of axial length at most equal to L.
However, as shown in FIGS. 4 a and 4 c , said joining zones J i ( 30 ) can include transversal joining zones J Ti ( 32 ) in such a way as to obtain a tubular insulating device ( 1 , 1 ′) said of great axial length L.
However, when it is not required to join the elements ( 4 ) according to said axial direction ( 11 ) as shown in the FIGS. 4 a and 4 c , said joining zones J i can be constituted of axial joining zones J Ai ( 31 ) of axial length equal to L.
Advantageously, said n i axial insulating elements E i precut ( 4 ) from the same layer C i can be identical, said plurality of junctions J i forming said plurality of axial junctions J Ai ( 31 ), the n i axial junctions J Ai ( 31 ) of said plurality being separated angularly in relation to said axial direction ( 11 ) by an angle of 360°/n i . However, in the case of the fabrication of a “customised” device of relatively complex configuration, it would be possible to juxtapose different insulating elements ( 4 ) by their form, in the way in which the different pieces of a puzzle are assembled, but on a surface deployed in the three-dimensional space.
As shown in the FIGS. 1 f , 2 a and 2 b , the number N of layers C i ( 3 ) can be at least equal to 2.
The number n i of insulating elements E i ( 4 ) can be a number n which remains the same for each layer C i ( 3 ) of said tubular insulating device ( 1 ), n varying typically with said average diameter D.
As such, for example:
n can have the value of 2 for D ranging from 286 mm to 573 mm, n can have the value of 3 for D greater than 573 mm and less than 907 mm, n can have the value of 4 for D at least equal to 907 mm.
As shown in the FIGS. 1 a to 1 f , before the step b) of the method, using said n i insulating elements ( 4 ), for example using n i planar insulating elements ( 4 a ), n i curved insulating elements ( 4 b ) can be formed, in such a way as to have a radius of curvature R i in a transversal plane perpendicular to said axial direction ( 11 ), corresponding to that of said corresponding layer C i , said radius R i increasing by a C i to the next layer C i+1 of greater average diameter D i+1 .
In the method according to the invention, and as shown in the FIGS. 5 a to 5 e , during said step b2), said rough form ( 5 ) can be placed in a shaping mould ( 8 ) comprising, for example, two half-shells ( 80 ), in such a way that, with the two half-shells ( 80 ) together and closed provide said rough form ( 5 ) and in fine said tubular insulating device ( 1 ) with predetermined and reproducible geometric dimensions.
According to the invention, said insulating material ( 2 ) can be a material ( 2 ′) with an expanded graphite base of thickness E M ranging from 2 to 30 mm, and ranging preferably from 5 to 20 mm.
More preferably, and as shown in the FIGS. 4 d and 4 e , said material with expanded graphite base ( 2 ′) can be a multilayer material ( 2 a ) comprising at least one layer referred to as “low” density ( 20 ), its density being less than 0.4 g/cm 3 (400 kg/m 3 ) and at least one layer referred to as “high” density ( 21 ), its density being at least equal to 0.4 g/cm 3 .
Said high-density layer ( 21 ) can have a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 and wherein said low-density layer ( 20 ) has a density ranging from 0.03 g/cm 3 to 0.2 g/cm 3 .
As shown in FIG. 4 e , said multilayer material ( 2 a ) can be a material referred to as “triple-layer” ( 2 b ) comprising two high density external layers ( 22 , 21 ) arranged on either side of a central low density layer ( 23 , 20 ).
Advantageously, in such a way as to obtain a high “insulating power/mass” ratio, the thickness E f of the low-density central layer ( 20 , 23 ) can be at least twice as high than the thickness E h of the high-density external layer ( 21 , 22 ), and more preferably at least three times higher.
According to the invention, said adhesive ( 6 ) can include a thermosetting resin, for example a phenolic resin, or a thermoplastic resin, said adhesive being in the form of powder or in liquid form, said adhesive being advantageously loaded with a black carbon or graphite electro-conductive powder.
Said heat treatment can include a baking at a temperature of at least 800° C., and more preferably of at least 1000° C.
Said heat treatment can include an additional methane pyrolysis flash treatment in such a way as to increase the rigidity of said insulating device.
Furthermore, said heat treatment can include a step of purifying of said insulating device wherein said insulating device is brought to 2000° C., in such a way as to remove any volatile element.
Finally, said heat treatment can be followed by a machining.
As shown in the FIGS. 3 a to 3 c , said tubular insulating device ( 1 ) can form a tube ( 1 a ) with constant section on its axial length L, said section being circular of diameter D or oval or polygonal.
However, as shown in the FIGS. 3 d to 3 f , said tubular insulating device ( 1 ) can form a tube ( 1 b ) with a uniformly variable section on its axial length L, said section being circular of average diameter D M or oval or polygonal.
For example, said axial length L can vary from 0.1 m to 3 m, and said thickness Ep can range from 5 mm to 80 mm, the L/D or L/D M ratio able to range from 0.5 to 5.
Another object of the invention is constituted by a tubular insulating device ( 1 ) typically obtained by the method according to the invention. This tubular insulating device ( 1 ) comprises a lateral wall ( 10 ) of thickness Ep ranging from 5 mm to 80 mm, of axial length L ranging from 0.1 m to 3 m, provided with an axial direction ( 11 ), said lateral wall ( 10 ) forming a superposition being constituted by a plurality of N layers C i ( 3 ) of an insulating material ( 2 ), with i ranging from 2 to N.
It is characterised in that:
a) each layer C i ( 3 ) comprises a plurality of n i axial insulating elements E i ( 4 ) constituted of said insulating material ( 2 ) in such a way that said axial insulating elements E i ( 4 ) are juxtaposed edge ( 40 ) to edge ( 40 ′) according to a plurality of joining zones J i ( 30 ),
b) two successive layers C i and C i+1 are assembled thanks to an adhesive ( 6 ), said successive layers C i and C i+1 being directed in relation to one another in such a way that the plurality of joining zones J i+1 of said layer C i+i is offset in relation to the plurality of joining zones J i and said layer C i , and that as well said tubular insulating device ( 1 ) obtained in fine has a high mechanical strength.
In this device, said insulating material ( 2 ) can be a material ( 2 ′) with expanded graphite base of thickness E M ranging from 2 to 30 mm, and ranging preferably from 5 to 20 mm.
Said material with expanded graphite base ( 2 ′) can be a multilayer material ( 2 a ) comprising at least one layer referred to as “low” density ( 20 ), its density being less than 0.4 g/cm 3 (400 kg/m 3 ) and at least one layer referred to as “high” density ( 21 ), its density being at least equal to 0.4 g/cm 3 .
Said high-density layer ( 21 ) can have a density ranging from 0.8 g/cm 3 to 1.2 g/cm3 and wherein said low-density layer ( 20 ) has a density ranging from 0.03 g/cm 3 to 0.2 g/cm 3 .
Said multilayer material ( 2 a ) can be a material referred to as “triple-layer” ( 2 b ) comprising two external high density layers ( 22 , 21 ) arranged on either side of a central low density layer ( 20 , 23 ).
Said low-density central layer ( 20 , 23 ) can have a thickness E f at least twice as high than the thickness E h of the high-density external layer ( 21 , 22 ), and more preferably at least three times higher.
EXAMPLES
FIGS. 1 a to 5 e constitute embodiments.
For the implementation of the method according to the invention, devices of complex form without rotation symmetry have as such also been manufactured, and in particularly in this case, computer means were used making it possible, using the precise geometric definition of said device ( 1 ) introduced into the computer memory, to define the plurality of insulating elements E i of each layer C i , in such a way that all of the joining zones ( 30 , 31 , 32 ) are offset.
In the case where the insulating elements ( 4 ) are not of simple form and do not result in an even and compact tiling, computer means were used to optimise the cutting of these elements and minimise the scrap and losses of insulating material.
However, this scrap was able to be recycled by homogenising them and by incorporating them at a low percentage (more preferably <10%) into the low-density layer ( 20 ).
Different types of mandrels were used. The mandrels were coated with sliding agents in such a way as to facilitate the separation between rough form ( 5 ) and mandrel ( 7 ). Mandrels with a retractable core were also used, in such a way as to further facilitate this separation.
ADVANTAGES OF THE INVENTION
The method according to the invention has major advantages. Indeed, in addition to overcoming the problems put forth, it can easily be automated and adapted to any configuration of device ( 1 ), even of complex form.
LIST OF MARKINGS
Tubular insulating device 1
Device 1 of great axial length 1 ′
Tube with constant section 1 a
Tube with variable section 1 b
Lateral wall 10
Axial direction 11
Insulating material with bi-dimensional structure 2
Material with expanded graphite base 2 ′
Multilayer material 2 a
Triple-layer material 2 b
“Low density” layer 20
“High density” layer 21
External layer 22
Central layer 23
Layer Ci of 1 3
Inside layer 3 a
Outer layer 3 b
Central layer 3 c
Joining zone J i of 3 30
Axial joining zone J Ai 31
Transversal joining zone J Ti 32
Axial insulating element E i 4
Planar insulating element E pi 4 a
Curved insulating element E ci 4 b
Juxtaposition edge 40 , 40 ′
Rough form of 1 5
Adhesive 6
Edge-to-edge gluing edge zone 60
Inter-layer gluing zone 61
Axial mandrel 7
Shaping mould 8
Half-shells of the mould 80 | An insulating material is fed in and shaped by superposing a plurality of N layers C i ( 3 ) of the insulating material. For each layer C i , a plurality of n i , axial insulating elements E i precut from the insulating material is formed, a rough form of the tubular insulating device is formed by using an adhesive to assemble the N i elements E i of each layer C i which are juxtaposed along a plurality of joining zones J i , so that the plurality of joining zones J i+1 of a layer C i+1 is offset relative to the plurality of joining zones J i , of the adjacent layer C i . Then, by the adhesive is polymerized, and the tubular element rough form is subjected to a heat treatment. The method is economical and makes it possible to obtain a device of high mechanical strength. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 09/436,676 filed on Nov. 9, 1999 and issued on Oct. 31, 2000 as U.S. Pat. No. 6,140,323, which is a Divisional of application Ser. No. 09/009,678 filed on Jan. 20, 1998, and issued on Apr. 11, 2000 as U.S. Pat. No. 6,048,857, which is a continuation-in-part of application Ser. No. 08/622,829 filed on Mar. 27, 1996 and issued on Apr. 14, 1998 as U.S. Pat. No. 5,739,136, which is a continuation-in-part of application Ser. No. 08/321,246 filed on Oct. 11, 1994 and issued on Apr. 2, 1996 as U.S. Pat. No. 5,504,086, which is a continuation-in-part of application Ser. No. 08/038,911 filed on Mar. 29, 1993 and issued on Oct. 11, 1994 as U.S. Pat. No. 5,354,780, which is a continuation-in-part of application Ser. No. 07/703,049 filed on May 17, 1991 and issued on Mar. 30, 1993 as U.S. Pat. No. 5,198,436, which is a continuation application of Ser. No. 07/422,992 filed on Oct. 17, 1989 and now abandoned.
Abbreviations
The following abbreviations are employed throughout
this application.
Definition
Abbreviation
area under the curve
AUC
benzodiazepine Type I
BZ 1
benzodiazepine Type II
BZ 2
carbon 11, radioactive
11 C
chlorimipramine
CL
N-desalkyl-3-hydroxy-halazepam
ND
N-desalkyl-2-oxoquazepam
DOQ
desmethylchlorimipramine
DMCL
gastrointestinal
GI
halazepam
HZ
levo-dihydroxyphenylalanine
levo-dopa
meta-chlorophenylpiperazine
mCPP
monoamine oxidase
MAO
nefazodone
NEF
peak plasma concentration
C max
per oral swallowed dose
PO
position emission tomography
PET
quazepam
Q
single sublingual dose
SL
standard deviation
SD
TECHNICAL FIELD
The present invention relates to a novel method of administering certain medicaments which surprisingly results in a maximization of the effect on the human body, including the central nervous system receptors, due to the desired medicament and results in minimization of the effect on the human body, including the central nervous system receptors, due to one or more unwanted metabolites from the medicament. Consequently, the invention maximizes therapeutic effects, such as antianxiety, anticonvulsant, anti-Alzheimer's disease, anti-Parkinson's disease, antidepression, antioxidant, and/or hypnotic effects, and minimizes unwanted side effects, such as ataxic, antianxiety, and incoordination effects, of the medicament, due to unwanted metabolites, which effects depend on the specific medicament.
More particularly, the additional information in connection with the instant continuation-in-part patent application involves irreversible enzyme inhibitors, especially the lipid soluble, MAO inhibitor drug deprenyl (which exists as a racemic mixture of levo-deprenyl and dextro-deprenyl), and even more particularly levo-deprenyl, the chemical name of which is L-(−)-N,2-dimethyl-N-2-propynyl phenethyl amine or L-(−)-phenylisopropyl methyl propynyl amine, and also the desired, wanted metabolite of levo-deprenyl, namely L-(−)-desmethyl deprenyl (also known as levo-desmethyl deprenyl and as levo-desmethyl selegiline). Levo-deprenyl is a MAO type B inhibitor, and when in the HCl salt form, is sold as tablets under the trade name selegiline and under the trademarks MOVERGAN®, JUMEX®, and ELDEPRYL®.
When certain medicaments that generate metabolites which are unwanted (the adversive metabolites are increased by gastrointestinal tract absorption and subsequent portal vein entry to the liver for instance when the medicament is orally swallowed), then, in accordance with the present invention, the intraoral administration via the mucous membrane of the mouth, i.e., buccal administration and/or sublingual administration, of such medicaments, i.e., levo-deprenyl and/or levo-desmethyl deprenyl, significantly reduces change of the medicaments into unwanted metabolites.
Also, then, in accordance with the present invention, inhalation administration of such medicaments, i.e., levo-deprenyl and/or levo-desmethyl deprenyl, would avoid the gastrointestinal tract absorption portal vein entry to the liver and thus, will significantly reduce change of the medicaments into unwanted metabolites.
BACKGROUND OF THE INVENTION
The disclosures of all patents mentioned are incorporated by reference.
With respect to intraoral administration, the most pertinent prior art reference known to applicants is U.S. Pat. No. 4,229,447 to Porter which discloses a method of administering certain benzodiazepines sublingually and buccally. Porter specifically mentions the sublingual or buccal administration of diazepam, lorazepam, oxazepam, temazepam and chlorodiazepoxide and describes two generic structures of benzodiazepines that may be administered sublingually or buccally.
The compound shown below is contemplated by the generic structures in Porter. All of the benzodiazepines disclosed and the generic structure described in Porter are BZ 1 -BZ 2 receptor non-specific since they lack the trifluoro ethyl group pendant at the N position of the “B” ring which confers BZ 1 specificity.
Porter's method is based on the rapid buccal or sublingual absorption of selected benzodiazepines to attain effective plasma concentration more rapidly than oral administration. In contrast, while parenteral administration provides a rapid rise of blood levels of the benzodiazepines, parenteral administration is frequently accompanied by pain and irritation at the injection site and may require sterilization of the preparatives and the hypodermic syringes.
Porter points out that the intraoral, i.e., buccal or sublingual administration, of lipid soluble benzodiazepines results in therapeutic levels resembling parenteral administration without some of the problems associated with parenteral administration. Porter's administration technique for benzodiazepines in general builds on a long established knowledge in pharmacology that a drug absorbed in the intraoral route gives rise to more rapid absorption than the same drug swallowed into the stomach. What is not recognized by Porter, however, are concerns with first-pass metabolism which can be avoided either with the sublingual or parenteral route of drug administration of certain benzodiazepines.
Porter does not recognize that first-pass metabolism designates the drug intestinal absorption with subsequent entry directly into the portal blood supply leading to the liver and that the liver in turn rapidly absorbs and metabolizes the drug with its first-pass high concentration through the liver. In addition, some first pass metabolism may occur during the absorption process into the intestine. Thus, large amounts of the drug may never be seen by the systemic circulation or drug effect site. Porter further does not recognize that the more rapid metabolism via the first-pass metabolism route can lead to accelerated desalkylation with formation of high plasma concentrations of an unwanted metabolite.
Thus, applicants' concern with avoiding the degradation of the parent compound and its desired positive effect and avoiding the metabolism of the parent compound to an undesired metabolite is neither recognized nor addressed by Porter, who only addresses the ability of the oral mucous membranes to absorb certain benzodiazepines fast and achieve high plasma levels of these benzodiazepines quickly.
The specific drug for which this phenomenon was demonstrated by Porter was lorazepam which has a simple metabolism that results in it not being metabolized to active compounds. Also, and very significantly, the issue of human nervous system receptor specificity and activation for BZ 1 and BZ 2 type receptors is not recognized by Porter either generally or with reference specifically to trifluorobenzodiazepines.
U.S. Pat. No. 3,694,552 to Hester discloses that 3-(5-phenyl-3H-1,4-benzodiazepine-2-yl)carbazic acid alkyl esters, which are useful as sedatives, hypnotics, tranquilizers, muscle relaxants, and anticonvulsants, can be administered sublingually. Subsequently issued U.S. Pat. No. 4,444,781 to Hester specifically teaches that 8-chloro-1-methanol-6-(o-chlorophenyl)-4H-s-triazolo[4,3-a][1,4]-benzodiazepine therapeutic compounds, which are useful as soporifics, can be suitably prepared for sublingual use.
Also, U.S. Pat. No. 4,009,271 to vonBebenburg et al. discloses that 6-aza-3H-1,4-benzodiazepines and 6-aza-1,2-dihydro-3H-1,4-benzodiazepines (which have pharmacodynamic properties including psychosedative and anxiolytic properties as well as antiphlogistic properties) can be administered enterally, parenterally, orally or perlingually.
The chemical formula of nefazodone is 2-(3-(4-(3-chlorophenyl)-1-piperazinyl)propyl-5-ethyl-2,4-dihydro-4-(2-phenoxyethyl)-3H-1,2,4-triazol-3-one hydrochloride and it is abbreviated as NEF.
Patients with obsessive compulsive disorder respond to meta-chlorophenylpiperazine (abbreviated as mCPP), an undesirable metabolite of NEF, by becoming much more anxious and obsessional, as reported by Zohar et al. in “Serotonergic Responsivity in Obsessive Compulsive Disorder: Comparison of Patients and Healthy Controls”, Arch. Gen. Psychiatry , Vol. 44, pp. 946-951 (1987). The peak in the anxiousness and obsessional behaviors is observed within 3 hours of mCPP administration and the duration of the worsening ranges from several hours to as much as 48 hours. Much more significantly, mCPP induced a high rate of emergence of entirely new obsessions or the reoccurrence of obsessions that had not been present in the patients for several months. Patients also reported being more depressed and dysphoric.
More specifically, Zohar et al. administered 0.5 mg/kg of mCPP orally to subjects in eliciting their obsessional symptoms. The peak plasma concentration in the control patients was 33.4±17.34 ng/ml, whereas, in the obsessional patients, the peak plasma concentration inducing the obsessional behavior was 26.9 ng/ml±12.33.
Furthermore, Hollander et al., in “Serotonergic Noradrenergic Sensitivity in Obsessive Compulsive Disorder: Behavioral Findings”, Am. J. Psychiatry , Vol. 1945, pp. 1015-1017, (1988), have reported many of these obsessional worsening effects in obsessive compulsive patients.
Additionally, Kahn et al., in “Behavioral Indications for Serotonin Receptor Hypersensitivity in Panic Disorder”, Psychiatry Res., Vol. 25, pp. 101-104 (1988), have reported mCPP induces anxiety in a group of panic disorder patients.
Moreover, Walsh et al., as reported in “Neuroendocrine and Temperature Effects of Nefazodone in Healthy Volunteers”, Biol. Psychiatry , Vol. 33, pp. 115-119 (1933), administered oral doses of 50 mg and 100 mg of NEF to normal subjects and measured NEF and its metabolite mCPP. For the 50 mg dose, the NEF/mCPP area under the curve (abbreviated as AUC) ratio was 1.58. For the 100 mg dose, the AUC ratio was 1.63, indicating that within the first 3 hours, NEF is substantially metabolized to MCPP at levels considerably above the mCPP levels that Zohar et al., supra, found to induce anxiety and obsessional states in susceptible individuals.
In studies in dogs, intravenous dosing of NEF reduced plasma mCPP Cmax by 50% from that found with oral dosing, as reported by Shukla et al., in “Pharmacokinetics, Absolute Bioavailability, and Disposition of [ 14 C] Nefazodone in the Dog”, Drug Metab. Disposition, Vol. 21, No. 3, pp. 502-507 (1993).
Also, a discussion of bupropion and its three major metabolites, erythrohydrobupropion, hydroxybupropion, and threohydrobupropion, as well as the strong relationship of higher hydroxybupropion metabolite concentrations in therapeutically non-responding patients in contrast to responders, can be seen in Posner et al., “The Disposition of Bupropion and Its Metabolites in Healthy Male Volunteers after Single and Multiple Doses”, Vol. 29, Eur. J. Clin. Pharmacol., pp. 97-103 (1985) and Bolden et al., “Bupropion in Depression”, Vol. 45 , Arch. Gen. Psychiatry , pp. 145-149 (Feburary 1988). Hydroxybupropion, therefore, represents an unwanted metabolite.
Background information with respect to skin administration of drugs is as follows.
Highly lipid soluble substances are absorbed through the skin and even are the basis for the toxicity for such lipid soluble drugs, for instance, insecticides and organic solvents. Absorption through the skin can be enhanced by suspending the drug in an oily vehicle and rubbing it onto the skin, a method known as inunction.
A variety of improvements in transdermal administration of drugs has transpired over the last few years.
For example, ultrasound mediated transdermal delivery, in which low frequency ultrasound application increases the permeability of the skin to many drugs including higher molecular weight drugs, was recently described by Mitragotri, Blankschtein, and Langer in “Ultrasound-Mediated Transdermal Protein Delivery”, Science, 269:850-853 (1995).
In addition, when ionizable drugs such as dexamethasone sodium phosphate or lidocane hydrochloride are used, the electro-transport system of iontophoresis can be used to drive the drugs through the skin such as in the use of the PHORESOR® made by IOMED. Also, Alza Corporation has also been active in developing electro-transport systems for drug delivery. (See, Alza U.S. Pat. Nos. D384,745 issued Oct. 7, 1997; D372,098 issued Jul. 23, 1996; U.S. Pat. Nos. 5,629,019 issued May 13, 1997; and 566,817 issued Sep. 16, 1997.
The advantages of skin administration to the systemic circulation include:
1) bypassing the gastrointestinal portal vein entry into the liver and its first-pass metabolism,
2) sustained blood levels without multiday dosing, and
3) blood concentrations of drug controllable within and between patients in a narrow range.
See, Shaw, J. E. and Chandrasekaran, S. K., “Skin as a Mode for Systemic Drug Administration”, Greaves, M. W. and Shuster, S. (eds.), Pharmacology of the Skin II , Springer-Verlag:New York, pp. 115-122 (1989).
Background information with respect to skin patches is described in U.S. Pat. No. 4,920,989 to Rose, Jarvik, and Rose, and in U.S. Pat. No. 5,016,652 to Rose and Jarvik, both of which involve administration of nicotine by way of a skin patch. See also, Southam, M. A., “Transdermal Fentanyl Therapy: System Design, Pharmacokinetics and Efficacy”, Anti - Cancer Drugs, 6 Suppl. 3:29-34, (1995) as another example of skin patches.
Of the rapid development of techniques for administering drugs by skin patches, one improvement is the development by Fuisz Technology LTD of a melt spinable carrier agent such as sugar which is combined with a medicament and then converted to a fiber for by melt-spinning. (See, U.S. Pat. No. 4,855,362, entitled “Rapidly Dissolvable Medicinal Dosage Unit and Method of Manufacture”.) This facilitates dissolving the medication onto any surface area when wetted such as with skin moisture. It is also readily applicable to sublingual or buccal administration.
These skin delivery systems are well known to those practiced in the art of clinical pharmacology.
More specifically in connection with the additional information in the instant continuation-in-part patent application vis-a-vis deprenyl are U.S. Pat. Nos. 4,868,218 and 4,861,800, both issued in 1989 to Buyske. The former discloses the MAO inhibitor type B drug levo-deprenyl being used in the treatment of mental depression in a formulation applied to the skin of a human patient. The latter discloses the MAO inhibitor type B drug levo-deprenyl being used for the treatment of Parkinson's disease or Alzheimer's disease in a formulation applied to the skin of a human patient.
Background information with respect to inhalation of drugs is as follows.
Inhalation techniques for administering drugs have been known for centuries. Witness the use of smoking to administer opiates and nicotine.
Also, inhalation of gases is a classical means of inducing surgical anesthesia and as well volatile drugs may be inhaled in this manner.
In another embodiment of the present invention, the focus is on inhalation administration of medicaments, particularly via inhalators, such as for dry powders or aerosols. Inhalation drug administration provides a means of bypassing the gastrointestinal portal vein entry first-pass metabolism and as well provides a means of rapid access to the general circulation. See, Benet, L. Z., Kroetz, D. L. and Sheiner, L. B., “Pharmacokinetics: The Dynamics of Drug Absorption, Distribution, and Elimination”, Hardman, L. G. et al. (eds), Goodman and Gilman's The Pharmacological Basis of Therapeutics, 9 th Ed, McGraw-Hill:New York, pp. 3-27, (1996).
Drugs delivered from inhalators are airborne fine particles. The particles may be aerosolized suspensions (admixed with a propellant gas, i.e., a chlorofluorocarbon) or may be dispersed powders (generally admixed with an excipient). These particles may be either liquids or solids and are defined by the mass median aerodynamic diameter (MMAD). Thus, solid particulate(s) and liquid droplet(s) with the same unit density have the same average rate of settling (e.g., in the lungs).
The size of the airborne particles is important. If they are larger than 10 micrometers diameter, they are unlikely to reach the lungs for deposit. If they are smaller than 0.5 micrometers diameter, they may be exhaled again.
One of the problems with inhalation delivery is that only approximately 10-20% of the drug is delivered to the lung alveoli. The rest is deposited into the oro-pharynx. If this were swallowed, it would go into a gastrointestinal absorption portal vein liver entry and metabolism pathway. Thus, mouth rinsing is frequently recommended.
In the present invention, this deposition into the oropharynx does not present the same type of problem. Since the airborne drug being inhaled is in a fine particle form with the appropriate formulation, it will be rapidly absorbed in the oral cavity if swallowing is delayed as it will with sublingual administration. Thus, inhalation administration presents a combined buccalingual pathway (as well as an oropharyngeal pathway) plus the lung absorption means of bypassing the gastrointestinal liver first-pass metabolism.
There are several inhalator delivery systems contemplated as useful in the present invention.
One is a traditional nebulizer which works via a mechanism similar to the familiar perfume atomizer. The airborne particles are generated by a jet of air from either a compressor or compressed gas cylinder passing through the device. In addition, newer forms utilize an ultrasonic nebulizer by vibrating the liquid at speeds of up to about 1 MHZ.
Another type of inhalator delivery system is the metered dose inhaler (MDI). This has been widely used because of its convenience and usually contains a suspension of the drug in a aerosol propellant. However, the MDI has fallen into disfavor recently due to problems with chlorofluorocarbon propellants causing depletion of the earth's ozone layer, which has led to increased use of still another type of inhalator delivery system, namely the dry powder inhaler.
The typical dry powder inhaler has the appropriate dose often placed in a capsule along with a flow aid or filler excipient, such as large lactose or glucose particles. Inside the device, the capsule is initially either pierced by needles (SPINHALER®) or sheered in half (ROTOHALER®). Propellers turning cause the capsule contents to enter the air stream and to be broken up into small particles. (See also, DISKHALER®, TURBUHALER®, plus numerous other dry powder inhalation delivery devices.) For a review, see Taburet, A. M. and Schmit, B., “Pharmacokinetic Optimisation of Asthma Treatment”, Clin. Pharmacokinet., 26(5):396-418 (1994).
More recently, Inhale Therapeutic Systems has created an inhalator delivery system that integrates customized formulation and proprietary fine powder processing and packaging technologies with their proprietary inhalation device for efficient reproducible deep-lung delivery. Their process of providing agglomerate composition compounds of units of aggregated fine particles and methods for manufacture and use of the units has recently been covered by a series of patents. The particle size containing the drug is in the optimum range for deep-lung delivery and has a suitable friability range. The U.S. Patents covering these methods include U.S. Pat. Nos. 5,458,135 issued Oct. 17, 1995, 5,607,915 issued Mar. 4, 1997 and 5,654,007 issued Aug. 5, 1997. (See also, U.S. Pat. No. 5,655,516 issued Aug. 12, 1997.)
Other potential improvements of pulmonary inhalation of drugs via an inhalator delivery system include the use of liposomes (microscopic phospholipid vesicles). The liposomal delivery of drugs slows the uptake of drug absorption from the lungs thus, providing a sustained drug release. (See, Hung, O. R., Whynot, S. C., Varvel, J. R., Shafer, S. L. and Mezel, M., “Pharmacokinetics of Inhaled Liposome-Encapsulated Fentanyl”, Anesthesiol., 82:277-284 (1995).
The key factor to be considered here is that most inhalation delivery devices are currently used for treatment of lung conditions in which it is important to supply the active drug to a site in the lungs where the drug acts for a period of time before being absorbed into the general circulation. Since the lungs have a surface area of at least the size of a tennis court and a series of thin cell sacks (alveoli) that are highly vascularized, the lungs provide a large surface area for absorption of drugs. However, in the present invention, the inhalation technique provides a means of not only administering drugs to the lungs, but also, because of the small particle size, a means of delivering highly absorbable small particles to multiple sites in the oropharyngeal pathway. Thus, the drug is dispersed to a topographically much larger mucosal absorption area than would occur from sublingual and/or buccal administration, and additionally, provided is the 10-20% absorption by lung administration.
Moreover, general background information with respect to dry powder inhalers can be seen in U. S. Pat. Nos. 2,642,063 to Brown; 3,807,400 to Cocozza; 3,906,950 to Cocozza; 3,991,761 to Cocozza; 3,992,144 to Jackson; 4,013,075 to Cocozza; 4,371,101 to Cane and Farneti; 4,601,897 to Saxton; 4,841,964 to Hurka and Hatschek; 4,955,945 to Weick; 5,173,298 to Meadows; 5,369,117 to Sallmann, Gschwind, and Francotte; 5,388,572 to Mulhauser, Karg, Foxen, and Brooks; 5,388,573 to Mulhauser and Karg; 5,394,869 to Covarrubias; 5,415,162 to Casper, Taylor, Leith, Leith, and Boundy; 5,503,869 to Van Oort; International Publication No. WO 92/00115 to Gupte, Hochrainer, Wittekind, Zierenberg, and Knecht; International Publication No. WO 94/20164 to Mulhauser and Karg; and International Publication No. WO 93/24166 to Wright, Seeney, Hughes, Revell, Paton, Cox, Rand, and Pritchard.
Background information specifically with respect to levo-deprenyl and levo-desmethyl deprenyl, the subject of the additional information in the instant continuation-in-part patent application is as follows.
U.S. Pat. No. 5,792,799 issued in 1998 to ShermanGold discloses the treatment of Parkinson's disease in a human patient by nasal administration, intrapulmonary administration, or parenteral administration of a MAO type A inhibitor, and optionally, the MAO type A inhibitor can be administered in conjunction with a MAO type B inhibitor, such as selegiline, i.e., deprenyl. See, for instance, the paragraph at lines 28-39 of column 4 of '799, especially, line 34 of this paragraph.
Additionally, U.S. Pat. No. 5,380,761 issued in 1995 to Szabo et al. discloses an anhydrous transdermal composition containing racemic N-methyl-N-(1-phenyl-2-propyl)-2-propynyl amine, another chemical name for racemic deprenyl, for treatment of a human patient.
As noted above, U.S. Pat. Nos. 4,868,218 and 4,861,800, both to Buyske, disclose levo-deprenyl in a formulation applied to the skin of a human patient.
Each of U.S. Pat. Nos. 5,792,799, 4,861,800, and 4,868,218 contains a discussion of the “cheese effect” of MAO type A inhibitors. More specifically, MAO type A inhibitors, when given orally to a human patient such as by swallowing, reduce the gut and liver MAO type A enzyme, resulting in a human patient hypertensive crisis following ingestion by the human patient of foods containing high levels of tyramine, such as cheese and red wine; that is, tyramine is not sufficiently metabolized by MAO type A enzyme, resulting in high hypertensive levels of tyramine. Moreover, these patents also recognize that MAO type B inhibitors, such as deprenyl, have only modest effects on tyramine metabolism in the gut and the liver as compared to MAO type A inhibitors.
Similarly, the researchers Lajtha et al. in “Metabolism of (−)-Deprenyl and pF-(−)-Deprenyl in Brain after Central and Peripheral Administration”, Vol. 21, No. 10 , Neurochemical Research, pp. 1155-1160 (1996) demonstrated in a study that when deprenyl was administered to rats by subcutaneous injection, then the unwanted metabolites of levo-amphetamine and levo-methamphetamine were significantly reduced, especially in comparison to the deprenyl level.
In other words, as reported by Oh et al. in “(−)-Deprenyl Alters the Survival of Adult Murine Facial Motoneurons After Axotomy: Increases in Vulnerable C 57 BL Strain but Decreases in Motor Neuron Degeneration Mutants”, Vol. 38, Journal of Neuroscience Research, pp. 64-74 (1994), oral dosing of mice with deprenyl, because of the nonspecific high first pass metabolism in the liver and the gut results in extremely high levels of the unwanted metabolites, levo-amphetamine and levo-methamphetamine, which themselves can result in neurotoxicity and can reduce the effectiveness of the neuronal protection by deprenyl.
A good discussion of the rapid rise of the unwanted metabolite, levo-methamphetamine, after first pass metabolism, can be seen in Rohatagi et al., “Pharmacokinetic Evaluation of a Pulsatile Oral Delivery System”, Vol. 18, No. 8 , Biopharmaceutics & Drug Disposition, pp. 665-680 (1997).
Nevertheless, a problem with skin patch administration of deprenyl to a patient is that skin patch administration induces a sustained low level of deprenyl since deprenyl is slowly absorbed from the skin patch. Because deprenyl is an irreversible inhibitor substrate for MAO type B, a high short period of brain levels of deprenyl is the most efficient and most effective means of administration as once deprenyl binds to the enzyme, MAO, deprenyl is irreversibly bound (i.e., inhibits the enzyme) and is not available for egress from the brain to the blood stream with subsequent availability for metabolism.
More specifically, Tarjanyi et al. in “Gas-Chromatographic Study on the Stereoselectivity of Deprenyl Metabolism”, Vol. 17 , Journal of Pharmaceutical and Biomedical Analysis, pp. 725-731 (1998) demonstrated with PET scanning in human subjects that 11 C-labeled deprenyl had a very fast penetration of levo-deprenyl into the brain, namely that deprenyl entered the brain within seconds and the radioactivity was found to be constant during a 90 minute PET examination. At the same time, the inactive stereoisomer, dextro-deprenyl, which does not have a comparable binding to the enzyme, MAO, was rapidly washed out of the brain. Thus, this irreversible inhibition of MAO type B is induced by the formation of a covalent bond between the flavine group of the enzyme and levo-deprenyl, which prevents levo-deprenyl from brain egress into the peripheral circulation and liver metabolism.
This rapid entry of levo-deprenyl into the brain, as noted by Heinonen et al. in “Pharmacokinetics and Clinical Pharmacology of Selegiline”, Chapter 10 , Inhibitors of Monoamine Oxidase B, Pharmacology and Clinical Use in Neurodegenerative Disorders , pp. 201-213, Edited by Szelenyi (1993), is due to the high lipophilicity of deprenyl. Heinonen et al. conclude that the bioavailability of levo-deprenyl after oral administration is only about 8%. Therefore, a significant percentage of levo-deprenyl, after oral administration, is rapidly metabolized into unwanted metabolites.
In such degenerative diseases as Parkinson's disease, dopamine neurons degenerate and they are replaced by glial cells possessing MAO type B activity, as reported by Tatton and Chalmers-Redman in “Modulation of Gene Expression Rather than Monoamine Oxidase Inhibition: (−)-Deprenyl Related Compounds in Controlling Neurodegeneration”, Vol. 47, No. 6, Supplement 3, Neurology, pp. 171S-183S (December, 1996). Consequently, dopamine modulation in the brain declines in Parkinson's disease and in senescence, and concurrently, an increase in MAO activity develops. The increase in MAO type B activity is thought to be responsible for the oxidative dopamine metabolites that injure neurons. As reported by Strolin-Bendetti and Dostert in “Monoamine Oxidase, Brain Aging and Degenerative Diseases”, Vol. 38, No. 4 , Biochemical Pharmacology , pp. 555-561 (1989), MAO type B increases with the age of a person, which leads to a rise in hydrogen peroxide that may well contribute to the neuronal damage.
Tatton and Chalmers-Redman, supra, also discuss that levo-deprenyl has been used in combination with levo-dopa therapy, in part to reduce the needed levo-dopa dosage (by reducing dopamine metabolism) and in part to decrease the response fluctuation. As also noted by Tatton and Chalmers-Redman, supra, another action of levo-deprenyl at low levels is that super oxide dismutase, a scavenger of neuronal oxygen radicals, is increased in the striata of rats treated with levo-deprenyl.
Use of levo-deprenyl in combination with levo-dopa therapy is also discussed in U.S. Pat. No. 5,844,003 to Tatton and Greenwood. In addition, this patent mentions several deprenyl analogues, i.e., desmethyl deprenyl, that may also be irreversible inhibitors of MAO type B, accompanied by formation, during metabolism, of unwanted metabolites.
Moreover, as reported by the Parkinson Study Group in “Effects of Tocopherol and Deprenyl on the Progression of Disability in Early Parkinson's Disease”, Vol. 328, No. 3 , The New England Journal of Medicine , pp. 176-183 (Jan. 21, 1993), levo-deprenyl, when used alone, can slow the time course of Parkinson's disease as judged by the time required for the disease to progress to the point where levo-dopa is required.
The capacity of levo-deprenyl to increase the time to the requirement for levo-dopa therapy in Parkinson's disease is highly statistically significant but appears to wane after a year of treatment. The waning may be due to the actual impairment effects of levo-amphetamine and levo-methamphetamine (or dextro-amphetamine and dextro-methamphetamine, if dextro-deprenyl or a racemic mixture is used), which as noted above can be neurotoxic, but in the case of Parkinson's disease, levo-amphetamine and levo-methamphetamine may actually exhaust the dopamine cells by driving dopamine metabolism to high levels.
Lastly, it is noted that unlike levo-amphetamine and levo-methamphetamine (which are unwanted metabolites of levo-deprenyl) , levo-desmethyl deprenyl is not an unwanted metabolite of levo-deprenyl. Rather, levo-desmethyl deprenyl protects dopamine neurons from N-methyl-D-aspartate receptor-mediated excitotoxic damage. See, Mytilineou et al., “L-(−)-Desmethylselegiline, a Metabolite of Selegeline [L-(−)-Deprenyl], Protects Mesencephalic Dopamine Neurons from Excitotoxicity in Vitro”, Vol. 68, No. 1 , Journal of Neurochemistry, pp. 434-436 (1997).
The disclosures of all of the cited patents are incorporated herein by reference.
SUMMARY AND OBJECTS OF THE INVENTION
It is well known by those practiced in the art that special distribution of enzymatic activity within the gastrointestinal tract and the liver leads to a metabolic zonation for metabolism of drugs. This zonation is noted not only in the GI tract, but also in peripheral midzonal and pericentral regions of the liver.
Thus, the relative distribution of two or more enzymes with respect to substrate entry point and the relative magnitudes of the enzymatic parameters will have a large impact on the metabolic pathway emphasized. When a drug is swallowed, each of the stomach and the small intestine absorbs it, presenting an opportunity for partial metabolism with subsequent flow to the portal vein entry to the liver.
Therefore, differential metabolic zonation is possible if the drug is absorbed by the gastrointestinal tract and distributed to the liver by the portal vein, rather than by the hepatic artery from the general circulation.
Even though this general background information is known to those persons practiced in the art, the specific findings that formation of unwanted metabolites is reduced by sublingual/buccal administration was not known until applicants' unexpected discovery. Also, that formation of unwanted metabolites will be reduced by inhalation administration was not anticipated until applicants' present invention.
Hence, in accordance with the present invention, provided is an improvement in a method for administering medicament to the human body, including the central nervous system, wherein a therapeutically effective amount of said medicament is administered to a human by inhalation administration. The improvement comprises selecting a medicament that is metabolized into an unwanted or adversive metabolite which is increased by gastrointestinal tract absorption and subsequent portal vein entry to the liver; and placing the medicament in a suitable inhalation formulation. Then, a therapeutically effective amount of the formulation is administered by way of inhalation administration so as to bypass the gastrointestinal tract absorption and subsequent portal vein entry to the liver and thereby to decrease formation of the unwanted metabolite. Next, the ratio is increased of medicament to the unwanted metabolite made available to the human body, including the central nervous system, and this method is utilized over a period of one or more doses to achieve sustained high levels of the medicament relative to the unwanted metabolite.
Also, the specific findings that trifluoro-benzodiazepine N-desalkylation is reduced by non-oral administration was not known until applicants' unexpected discovery with quazepam and halazepam.
Therefore, also in accordance with the present invention, applicants provide a novel method for maximizing the effect of selected trifluorobenzodiazepines including 7-chloro-1-(2,2,2-trifluoroethyl)-5-(o-fluorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine-2-thione (i.e., quazepam) and 7-chloro-1,3-dihydro-5-phenyl-1-1-(2,2,2-trifluoroethyl)-2H-1,4-benzodiazepine-2-one (i.e., halazepam) on benzodiazepine Type I (BZ 1 ) receptors and minimizing the unwanted potent effect of certain metabolites on benzodiazepine Type II (BZ 2 ) receptors of the human central nervous system so as to maximize the antianxiety and anticonvulsant and/or hypnotic effects and to minimize the ataxic and incoordination effects thereon. The method comprises selecting a suitable lipid soluble and BZ 1 specific trifluorobenzodiazepine, placing the trifluorobenzodiazepine in a suitable inhalation and/or skin formulation, and then administering a therapeutically effective amount of said formulation by inhalation administration and/or by skin administration so as to bypass the first pass metabolism of said selected trifluorobenzodiazepine in the liver.
The selected trifluorobenzodiazepines with BZ 1 specificity are represented by the following structural formula and include:
COMPOUND
R 1
R 2
R 3
R 4
1. HALAZEPAM
═O
H, H
H
Cl
2. 3-OH-HALAZEPAM
═O
OH, H
H
Cl
3. QUAZEPAM
═S
H, H
F
Cl
4. 2-OXO-Q
═O
H, H
F
Cl
5. 2-OXO-3-OH-Q
═O
OH, H
F
Cl
6. SCH 15698
H, H
H, H
F
Cl
7. SCH 16893
H, H
H, H
Cl
Cl
8. SCH 18449
H, H
H, H
F
Br
9. 3-OH-Q
═S
OH, H
F
Cl
1. 7-chloro-1-(2,2,2-trifluoroethyl)-5-phenyl-1,3-dihydro-2H-1,4-benzodiazepine-2-one.
2. 7-chloro-1-(2,2,2-trifluoroethyl)-5-phenyl-1,3-dihydro-3-hydroxy-2H-1,3-benzodiazepine-2-one.
3. 7-chloro-1-(2,2,2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine-2-thione.
4. 7-chloro-1-(2,2,2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine-2-one.
5. 7-chloro-1-(2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-3-hydroxy-2H-1,4-benzodiazepine-2-one.
6. 7-chloro-1-(2,2,2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine.
7. 7-chloro-1-(2,2,2-trifluoroethyl)-5-(2-chlorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine.
8. 7-bromo-1-(2,2,2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-2H-1,4-benzodiazepine.
9. 7-chloro-1-(2-trifluoroethyl)-5-(2-fluorophenyl)-1,3-dihydro-3-hydroxy-2H-1,4-benzodiazepine-2-thione.
The trifluorobenzodiazepines referenced above are also lipid soluble. All of the benzodiazepines reported to have BZ 1 specificity have a CH 2 CF 3 group on the nitrogen in the “B” ring. Metabolic loss of this CH 2 CF 3 group results in a benzodiazepine that is non-specific for the BZ 1 -BZ 2 receptors. Applicants' invention was made possible by the unexpected and surprising discovery from pharmacokinetic studies that sublingual dosing minimizes the desalkylation metabolic pathway leading to the formation of non-specific metabolites of the selected trifluorobenzodiazepine. It is well known by those practiced in the art of pharmacokinetics that inhalation and/or skin administration, like buccal and/or sublingual administration, also bypasses the gastrointestinal absorption and subsequent portal vein entry into the liver. Thus, the pharmacokinetic profile of dosing, by inhalation administration and/or skin administration, demonstrates that bypassing gastrointestinal absorption and portal vein liver entry will minimize the desalkylation metabolic pathway leading to the formation of non-specific metabolites of the selected trifluorobenzodiazepine.
An object of the present invention is to increase the effectiveness of certain selected trifluorobenzodiazepines on human subjects to reduce anxiety and convulsions.
Another object of the present invention is to provide a new administration method which increases the availability of certain selected trifluorobenzodiazepines to the human central nervous system and decreases the amount of undesirable metabolites available to the human central nervous system.
Still another object of the present invention is to maximize the effect of certain selected trifluorobenzodiazepines on BZ 1 receptors of the human central nervous system and to minimize their effect on BZ 2 receptors.
Yet another object, particularly in connection with irreversible enzyme inhibitors, such as levo-deprenyl and/or levo-desmethyl deprenyl, namely the additional matter with respect to the instant continuation-in-part application, is an increase in the ratio of wanted irreversible enzyme inhibitor:unwanted metabolite and thus an increase in the level of wanted irreversible enzyme inhibitor rapidly reaching the brain, which consequently reduces the dose needed and the egress from the brain. An advantage is that subsequent peripheral metabolism to unwanted metabolites is decreased, which could potentially reduce the waning effects of an irreversible enzyme inhibitor, such as levo-deprenyl, after a year or more of use.
Thus, a feature of the present invention, with levo-deprenyl and/or levo-desmethyl deprenyl, is that the high levels induced by the method of the present invention result in rapid brain extraction and irreversible binding to the enzyme, MAO type B, further reducing liver metabolism.
Hence, the present invention also provides a method for administering medicament to the human body, including the central nervous system, wherein a therapeutically effective amount of the medicament is administered to a human. The method comprises the steps of: (a) selecting an irreversible enzyme inhibitor as a medicament that is metabolized into an unwanted or adversive metabolite that is increased by gastrointestinal tract absorption and subsequent portal vein entry to the liver;(b) placing the irreversible enzyme inhibitor in a suitable formulation selected from the group consisting of an intraoral administration formulation, an inhalation administration formulation, and combinations thereof;(c) administering a therapeutically effective amount of the formulation from step (b) so as (i) to bypass the gastrointestinal tract absorption and subsequent portal vein entry to the liver and (ii) thereby to decrease formation of the unwanted metabolite; (d) increasing the ratio of the irreversible enzyme inhibitor to the unwanted metabolite made available to the human body, including the central nervous system; and (e) utilizing this method over a period of one or more doses to achieve sustained high levels of the irreversible enzyme inhibitor relative to the unwanted metabolite. Preferably, the irreversible enzyme inhibitor is a deprenyl drug selected from the group consisting of levo-deprenyl, levo-desmethyl deprenyl, and combinations thereof.
Additionally, the present invention also provides a method for facilitating irreversible enzyme inhibition, when administering a therapeutically effective amount of medicament to a human, the method comprising the steps of: (a) selecting an irreversible enzyme inhibitor as a medicament that is metabolized into an unwanted or adversive metabolite that is increased by oral administration of the irreversible enzyme inhibitor; (b) placing the irreversible enzyme inhibitor in a suitable formulation selected from the group consisting of an intraoral administration formulation, an inhalation administration formulation, and combinations thereof; (c) administering a therapeutically effective amount of the formulation from step (b) so as to achieve irreversible enzyme binding in the brain of the human; and (d) utilizing this method over a period of one or more doses to achieve sustained high levels of the bound irreversible enzyme inhibitor relative to the unwanted metabolite with a dose that is lower than a dose needed to achieve the same high levels when administering the same irreversible enzyme inhibitor orally, whereby the lower dose results in a decrease in metabolization into the unwanted metabolite. Preferably, the irreversible enzyme inhibitor is a deprenyl drug selected from the group consisting of levo-deprenyl, levo-desmethyl deprenyl, and combinations thereof.
Some of the objects of the invention having been stated above, other objects will become evident as the description proceeds, when taken in connection with the accompanying drawings as best described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating the concentration of quazepam (Q) and N-desalkyl-2-oxoquazepam (DOQ) in the blood plasma over 96 hours following a single sublingual dose (SL) or per oral swallowed dose (PO) of 15 mg of quazepam;
FIG. 2 is a graph illustrating the concentration of quazepam (Q) and N-desalkyl-2-oxoquazepam (DOQ) in the blood plasma over 210 hours following a single sublingual dose (SL) of 15 mg of quazepam or per oral swallowed dose (PO);
FIG. 3 is a graph of computer simulated concentration levels of Q and DOQ in the blood following sublingual and oral swallowed doses of 15 mg of Q once a day for a 15 day period illustrating the marked reduction in accumulated levels of DOQ with sublingual dosing;
FIG. 4 is a graph illustrating the concentration of halazepam (HZ) and N-desalkyl-3-hydroxy-halazepam (ND) in the blood over 96 hours following a single sublingual dose (SL) or per oral swallowed dose (PO) of 20 mg of halazepam;
FIG. 5 is a graph illustrating the concentration of halazepam (HZ) and N-desalkyl-3-hydroxy-halazepam (ND) in the blood over 240 hours following a single sublingual dose (SL) or per oral swallowed dose (PO) of 20 mg of halazepam;
FIG. 6 is a flow chart of the method of the present invention with respect to sublingual/buccal absorption;
FIG. 7 is a graph illustrating the concentration of propoxyphene and norpropoxyphene in the blood plasma over 8 hours following a single per oral swallowed dose of 65 mg of propoxyphene;
FIG. 8 is a graph illustrating the concentration of propoxyphene and norpropoxyphene in the blood plasma over 8 hours following a single sublingual dose of 65 mg of propoxyphene in the same subject as seen in FIG. 7;
FIG. 9 is a graph illustrating the ratio of propoxyphene concentration to norpropoxyphene concentration for both per oral swallowed and sublingual administration in the subject seen in FIGS. 7 and 8;
FIG. 10 is a graph illustrating the ratio of propoxyphene concentration to norpropoxyphene concentration for both per oral swallowed and sublingual administration in another subject in addition to that shown in FIGS. 7 and 8;
FIG. 11 is a graph illustrating the sublingual (SL) versus the oral (OR) dosing for m-chlorophenylpiperazine plasma; and
FIG. 12 is a graph illustrating the sublingual (SL) versus the oral (OR) dosing for nefazodone plasma.
DETAILED DESCRIPTION OF THE INVENTION
When certain medicaments that generate metabolites which are toxic and thus unwanted (the adversive metabolites are increased by gastrointestinal tract absorption and subsequent portal vein entry to the liver, for instance when the medicament is orally swallowed), then, in accordance with the present invention, the intraoral, i.e., buccal or sublingual administration, of such medicaments significantly reduces change of the medicaments into unwanted or toxic metabolites. Based on the well known bypass of gastrointestinal portal vein liver entry, the same reduction will also be true for inhalation administration of the medicament.
Suitable medicaments useful in accordance with the present invention are those that have the properties of:
(1) an unwanted metabolite, and
(2) the ratio of the unwanted metabolite to the therapeutic drug is substantially reduced by sublingual or buccal administration, in contrast to administration by swallowing, and likewise, the ratio of the unwanted metabolite to the therapeutic drug will be substantially reduced by inhalation administration, in contrast to administration by swallowing.
Examples of such suitable medicaments include, but are not limited to, a medicament selected from the group consisting of propoxyphene, trifluorobenzodiazepine, nefazodone, trazodone, chlorimipramine (also known as imipramine HCl), bupropion, and combinations thereof.
More particularly, in accordance with the additional matter in the instant continuation-in-part application, a suitable medicament is an irreversible enzyme inhibitor, preferably a deprenyl drug selected from the group consisting of levo-deprenyl, levo-desmethyl deprenyl, and combinations thereof. Levo-deprenyl has the unwanted or toxic metabolites, levo-amphetamine and levo-methamphetamine. Applicants submit that essentially the same results as discussed below for the intraoral administration and/or inhalation administration of trifluorobenzodiazepines, propoxyphene bupropion nefazodone, trazodone, and/or chlorimipramine (also known as clomipramine HCl) will be obtained for the intraoral administration and/or inhalation of an irreversible enzyme inhibitor, such as a deprenyl drug selected from the group consisting of levo-deprenyl, levo-desmethyl deprenyl, and combinations thereof.
Quazepam, a trifluoro-benzodiazepine, is selective for benzodiazepine Type I (BZ 1 ) receptors of the central human nervous system. Action at the BZ 1 receptors has been linked to antianxiety and anticonvulsant and/or hypnotic effects, whereas action at BZ 2 receptors of the human central nervous system has been linked to muscle relaxation and ataxic effects. N-desalkyl-2-oxoquazepam (DOQ), an active metabolite of quazepam (Q), is BZ 1 , BZ 2 receptor non-specific, and also has a much higher affinity or potency for both receptor types when compared to the BZ 1 specific affinity of quazepam (Q). Thus, the higher affinity metabolite (DOQ) of quazepam (Q) contributes substantially to the adverse ataxic and incoordination effects of quazepam (Q) on the human central nervous system.
In addition, because DOQ has a much longer elimination half-life than the parent compound Q, repeated dosing of Q leads to the gradual accumulation of the non-specific, unwanted metabolite, and a greater ratio of DOQ/Q attains over a period of days. Thus, after 2 or 3 hours subsequent to an acute dose of Q, the DOQ metabolite, both because of its increased gradual accumulation and its greater potency than the parent compound Q, can obviate the advantages of Q itself.
Applicants have unexpectedly and surprisingly discovered that sublingual dosing, in contrast to the usual clinical oral dosing of Q, increases the availability of Q about 60% while the DOQ drops to about ½ that of the oral Q administration levels. In other words, applicants have unexpectedly and surprisingly discovered that the aforementioned undesirable “first pass” augmentation of desalkylation to the DOQ metabolite can be markedly reduced or obviated by sublingual dosing of Q.
This change in concentrations for the two compounds can be seen with reference to FIG. 1 and FIG. 2 of the drawings where the differences in the parent compound Q and the metabolite DOQ for both the oral and sublingual dosing is shown.
In FIG. 3, by use of standard multiple Q dose simulations, the differences in accumulation of Q and DOQ for sublingual versus oral dosing over 15 days is shown. With chronic dosing it is readily apparent that after 15 days the DOQ level, following oral administration, has reached levels that are associated with the threshold for impairing ataxic and incoordination affects (especially if larger doses are given). With sublingual dosing the accumulated levels of DOQ are approximately M of the oral dosing and the levels of Q are over twice that of the oral levels.
In Table 1 and Table 2, set forth below, the average pharmacokinetic parameters for both Q and DOQ for both oral and sublingual routes of administration are reported:
TABLE I
AVERAGE PHARMACOKINETIC PARAMETERS OF
QUAZEPAM FOLLOWING SUBLINGUAL AND
ORAL ADMINISTRATION OF QUAZEPAM (15 mg)
Route of Administration
of Quazepam
Parameter
Sublingual
Oral
t ½ K a (hr)
0.27 ± 0.10 a
0.77 ± 0.23
t ½ λ1 (hr)
1.44 ± 0.45
1.73 ± 0.65
t ½ λ2 (hr)
27.72 ± 7.18
24.63 ± 8.35
Lag time (hr) b
0.18 ± 0.05
0.52 ± 0.28
C max (ng/ml) b
42.35 ± 10.43
26.74 ± 6.83
t max (hr) b
0.78 ± 0.31
2.57 ± 1.69
AUC (ng · hr/ml) b
1461.35 ± 298.67
472.79 ± 238.92
CL/F (1/hr) b
8.78 ± 5.25
37.56 ± 16.89
a Mean ± SD
b Differed significantly from oral dosing (P < 0.05)
Legend:
t ½ = Half-Life
K a = Absorption
λ1 = Rapid Distribution
λ2 = Terminal Elimination
C max = Peak Plasma Concentration
t max = Time to C max
AUC = Area Under Plasma Concentration Time-Curve
CL/F = Clearance
TABLE II
AVERAGE PHARMACOKINETIC PARAMETERS OF
N-DESALKYL-2-OXOQUAZEPAM FOLLOWING SUBLINGUAL
AND ORAL ADMINISTRATION OF QUAZEPAM (15 mg)
Route of Administration
of Quazepam
Parameter
Sublingual
Oral
t ½ K m (hr)
1.07 ± 0.31 a
1.24 ± 0.52
t ½ λ2 (hr)
69.30 ± 18.62
71.44 ± 21.56
Lag time (hr)
1.74 ± 0.86
0.66 ± 0.32
C max (ng/ml) b
8.18 ± 2.35
17.58 ± 4.17
t max (hr)
7.33 ± 4.15
6.17 ± 3.52
AUC (ng · hr/ml) b
949.02 ± 365.74
1966.70 ± 410.90
a Mean ± SD
b Differed significantly from oral dosing (P < 0.05)
Legend:
t ½ = Half-Life
K m = Formation
λ2 = Terminal Elimination
C max = Peak Plasma Concentration
t max = Time to C max
AUC = Area Under Plasma Concentration- Time Curve
The profile in FIGS. 1 and 2 of the drawings clearly shows that there is a first-pass metabolism for Q leading to the attenuated Q levels. On the basis of applicants' pharmacokinetic studies, applicants have discovered that sublingual dosing, which bypasses first-pass metabolism, minimizes the N-desalkylation metabolic pathway that leads to the formation of the unwanted metabolite, DOQ. This has led applicants to the sublingual dosing method of the invention which provides for maximization of the important therapeutic effects of the drug. Thus, applicants have discovered the means by which quazepam can be administered such that one can maximize the BZ 1 effect and reduce the BZ 2 effect of its metabolite DOQ and thereby enhance the efficacy in use on humans of this therapeutic drug.
In summary, applicants have discovered the following: (1) the use of sublingual dosing of Q to reduce markedly the first-pass metabolism of the Q structure and thereby to enhance the BZ 1 effect of the drug; and (2) the use of sublingual dosing to increase the BZ 1 to BZ 2 ratio with acute dosing and repeated dosing over days (since the dosing regimen is reducing the DOQ levels and thus attenuating the many impairing effects of the high affinity slowly metabolized Q metabolite). These phenomena resulting from sublingual dosing provide for an unexpected and surprising enhancement of the efficacy and reduction of toxicity of the drug in reducing anxiety and convulsions in humans.
Applicants believe that essentially the same results as discussed above for the sublingual administration of Q should be obtained for the inhalation administration and/or skin administration of Q (i.e., marked reduction in the first-pass metabolism of Q and increase in the BZ 1 to BZ 2 ratio), as compared to the oral administration of Q.
With reference now to FIGS. 4 and 5, applicants have also tested the high BZ 1 specific drug halazepam and discovered similar results obtained by sublingual administration of this drug. More particularly, the availability of halazepam was significantly increased thus maximizing the BZ 1 effect while reducing the BZ 2 metabolite N-desalkyl-hydroxy-halazepam.
Based on the pharmacokinetic knowledge well known to those skilled in the art, essentially the same results as discussed above for the sublingual administration of HZ will be obtained for the inhalation administration and/or skin administration of HZ (i.e., marked reduction in the first-pass metabolism of HZ and increase in the BZ 1 to BZ 2 ratio), as compared to the oral administration of HZ.
Intraoral administration, either buccal or sublingual, and likewise inhalation administration and/or skin administration, of selected trifluorobenzodiazepines can substantially enhance their therapeutic effect for the reasons set forth.
Applicants' novel method can be better appreciated with reference to FIG. 6 of the drawings which depicts a flow chart of the steps of the novel therapeutic method for sublingual/buccal administration, and applicants believe essentially the same results will be obtained for inhalation administration and/or skin administration.
Applicants have shown above that the manner in which the original blood borne trifluorobenzodiazepine drug enters into the liver has a profound effect on directing the vector of metabolism for this given species of drugs. This class of benzodiazepines has an unwanted desalkylation metabolite.
Applicants' findings of the alteration of metabolism by sublingual administration led to the novel discovery that one could alter the steady state metabolic profile of this class of benzodiazepine drugs by bypassing the profound early stage unwanted desalkylation metabolism that occurred when the swallowed drug entry was via the gastrointestinal absorption and portal vein metabolic pathway. This discovery required projection of acute dosing pharmacokinetics to understand fully and to project steady state pharmacokinetics that document the robust advantages of the sublingual administration route in: (1) shifting to a reduced desalkylation metabolic profile; (2) reducing the production of unwanted non-specific metabolites; and (3) thereby, enhancing an advantageous ratio BZ 1 specific to the non-specific BZ 1 , BZ 2 metabolites.
Since the original discovery described above that N-desalkylation of trifluorobenzodiazepines could be markedly reduced by sublingual administration, applicants have now discovered that desalkylation of other drugs can be reduced by sublingual or buccal administration. Applicants likewise submit that essentially the same results will be obtained for inhalation administration and/or skin administration of these other drugs. These other drugs also have unwanted or toxic desalkylation metabolites.
For example, propoxyphene (the formula of which is (+)-α-4-(dimethylamino)-3-methyl-1,2-diphenyl-2-butanol propionate hydrochloride), is a widely used, prescribed, oral analgesic that is frequently associated with poisonings and death. A major concern is that accumulating levels of the non-analgesic metabolite norpropoxyphene has cardiac conduction depressing effects that are a source of cardiotoxicity. The wanted analgesic effects of propoxyphene are limited by its short half-life, whereas, the unwanted norpropoxyphene metabolite has a half-life of 2 to 3 times that of the propoxyphene. With multiple dosing, the norpropoxyphene metabolite half-life may increase to 39 hours, thus accumulating over days of use.
Propoxyphene is N-desalkylated similarly to the trifluorobenzodiazepines. Since its desalkylated metabolite norpropoxyphene has the potential to induce cardiac conduction delay with toxic consequences at accumulated doses, applicants explored the sublingual route of administration. Two normal subjects were given 65 mg of propoxyphene both by per oral swallowed and sublingual administration.
FIGS. 7 and 8 demonstrate the propoxyphene and norpropoxyphene plasma concentrations for (1) per oral swallowed and (2) sublingual administration, respectively, in a single subject over a respective 8 hour period for each type of administration. FIG. 9 illustrates the propoxyphene/norpropoxyphene ratios for sublingual and oral dosing over time for the subject of FIGS. 7 and 8. FIG. 10 illustrates the same ratios for a second subject under the same test conditions. The increase in wanted parent compound to unwanted metabolite for sublingual dosing is readily apparent. Thus, sublingual dosing reduces propoxyphene desalkylation metabolism thereby increasing the therapeutic to toxic ratio.
Applicants submit that essentially the same results as discussed above for the sublingual administration of propoxyphene will be obtained for the inhalation administration and/or skin administration of propoxyphene.
As a further example, another drug that has N-desalkylation to an unwanted metabolite is chlorimipramine (CL) (also known as imipramine HCl) which is metabolized to desmethylchlorimipramine (DMCL).
CL is a tricyclic antidepressant which is desirable in the treatment of obsessive compulsive disorders, whereas DMCL is a potent inhibitor of norepinephrine. Therefore, the DMCL metabolite in many individuals accumulates to levels much greater than CL, and thus qualitatively changes the biochemical effect during treatment. In addition, the accumulation of DMCL poses additional potential toxicity from its cardiac conduction slowing properties similar to that of norproxyphene.
Applicants administered 25 mg of CL to normal subjects per orally and sublingually. In subjects who had a high desalkylation level, sublingual administration markedly reduced the unwanted metabolite DMCL thereby increasing the wanted parent compound CL to unwanted metabolite DMCL ratio. Other subjects did not demonstrate this effect. Therefore, the sublingual administration would be important only for certain individual patients who were shown to have unfavorable ratios.
Applicants submit that essentially the same results as discussed above for the sublingual administration of CL will be obtained for the inhalation administration and/or skin administration of CL.
In a study of mCPP plasma levels that were achieved by oral dosing of human subjects with nefazodone (mCPP is an unwanted metabolite of nefazodone, abbreviated as NEF), the area under the curve from 1 hour to 6 hours for two subjects revealed a NEF/mCPP ratio of 1.93, slightly higher than the ratio described by Walsh et al., supra. In contrast, sublingual administration of NEF (which included an incidental amount of buccal administration) to human subjects resulted in a NEF/mCPP ratio from 1 hour to 6 hours of 3.82.
Thus, approximately a 100% increase in the ratio of wanted to unwanted metabolites was achieved with sublingual administration of NEF, as compared to oral administration of NEF, and the same magnitude of increase should also be achieved with buccal administration of NEF. Because NEF and mCPP have a short half-life, values after 6 hours have little contribution to the plasma levels. The plasma levels before 1 hour were variably below the detection level and/or highly variable so they were not included in the values reported.
More importantly, the peak mCPP plasma levels (hereinafter, abbreviated C max ) were considerably more elevated from the oral dosing versus the sublingual dosing. One subject had a peak level of 51 ng/ml for sublingual dosing compared to 145 ng/ml for oral dosing. The other subject had a 21 ng/ml C max mCPP level for sublingual dosing versus a 48 ng/ml mCPP for oral dosing. Thus, the C max levels for mCPP were approximately 3 times greater for the oral dosing than for the sublingual dosing. These values are significant in that Zohar et al., supra, reported that levels of 26-35 ng/ml induced obsessional and anxiolytic effects, in obsessional patients.
To compare sublingual to oral administration, the mean average values for the two subjects for mCPP for sublingual administration (SL) and for oral administration (PO) at 1 to 6 hours, are reported below in Table III.
TABLE III
PHARMACOKINETICS OF NEFAZODONE (NEF) AND
mCPP AFTER 50 mg SUBLINGUAL AND ORAL DOSES OF NEF
Means for Both
Subject 1
Subjects
NEF
mCPP
NEF
mCPP
Parameters
SL
PO
SL
PO
SL
PO
SL
PO
C max (ng/ml)
200
291
21
48
174
226
33
97
AUC 6hr
568
420.3
44
84.3
435.5
521
114
270
(ng · hr/ml)
The abbreviations used in Table III are the same as those used in Tables I and II above.
At 1 hour, there was a 5 times greater ratio from oral as compared to sublingual administration for mCPP, which decreased to a 3 times greater ratio at 1 and ½ hours, and gradually reduced after that. (Also, see FIG. 11.) In contrast, the NEF levels were comparable in the ratios for oral as compared to sublingual administration. (Also, see FIG. 12.) Thus, the sublingual/oral ratio of NEF appeared slightly above 1.
Conditions such as obsessive compulsive syndrome and panic disorder, which have a large overlap with anxiety disorders, are susceptible to precipitation and worsening with mCPP. The present discovery indicates that mCPP, an unwanted metabolite of NEF, and especially the early peak mCPP levels, can be reduced by sublingual administration of NEF, and also should be reduced by buccal administration of NEF.
It has been demonstrated that mCPP, an unwanted metabolite, induces a rapid onset of adverse consequences and at times long-lasting adverse consequences, including obsessional ruminations and anxiety as reported by Zohar et al., supra. With the present invention, it has been demonstrated that the rapid onset of mCPP maximal peak levels can be remarkably reduced by sublingual administration of NEF, and should also be reduced by buccal administration of NEF. This demonstration of changes with the mCPP metabolite of NEF is to be compared with the above data for trifluorobenzodiazepines and chlorimipramine, in which the accumulation of unwanted metabolites may require hours or days to manifest its effect, and with the rapid rise in plasma level of certain unwanted metabolites from oral administration mCPP that is associated with an intense, rapid induction of unwanted effects, the mCPP peak effects occurring within 3 hours, as reported by Zohar et al., supra. Once precipitated, the adverse effects can last for hours.
Applicants submit that essentially the same results as discussed above for the sublingual administration of NEF will be obtained for the inhalation administration and/or skin administration of NEF.
In summary, the discovery that the sublingual method of administration for trifluorobenzodiazepines and propoxyphene reduced the adverse effects of unwanted metabolites was based on the reduction of the gradual accumulation of the unwanted metabolites to adverse cumulative concentration levels. Essentially the same results will occur for the inhalation method of administration and/or the skin method of administration for trifluorobenzodiazepines and propoxyphene.
On the other hand, in the case of mCPP, the unwanted metabolite levels measured after the oral administration of NEF far exceeded the 25 to 35 ng/ml of mCPP that manifests onset of adverse precipitous symptoms in susceptible panic disorder patients as reported by Zohar et al., supra. More importantly, the ratio of peak oral to peak sublingual mCPP blood levels was found to be approximately 3 times that reported by Zohar et al., supra. In contrast, the ratio of the parent compound, NEF, levels for the oral to sublingual ratio was found to be near 1 to 1.3 times that reported by Walsh et al., supra. Essentially the same results will occur for the inhalation method of administration and/or the skin method of administration of NEF.
Also, trazodone, an antidepressant with a very close molecular structure to NEF, is similarly metabolized to the mCPP unwanted metabolite and is a candidate for sublingual or buccal administration to reduce the unwanted metabolite to parent drug ratio. In other words, sublingual or buccal administration of trazodone should increase the ratio of parent medicament to unwanted metabolite made available to the human body, including the central nervous system. Applicants submit that essentially the same results as discussed above for the sublingual administration of trazodone will be obtained for the inhalation administration and/or skin administration of trazodone.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A method of therapeutically administering certain medicaments, for instance levo-deprenyl and/or levo-desmethyl deprenyl, in order to maximize the desired effects and minimize the unwanted metabolite effects on the human body, including the central nervous system, in order to maximize therapeutic effects, such as antianxiety, anticonvulsant, antidepression, antioxidant, anti-Parkinson's disease, anti-Alzheimer's disease, and hypnotic effects, and minimize unwanted side effects, such as ataxic, anxiety, and incoordination effects, of the medicament, for instance by intraoral administration and/or inhalation administration | 0 |
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional patent application S. No. 60/299,859 filed Jun. 21, 2001, titled “I/Q Imbalance Compensation” which is hereby expressly incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to communications systems and, more particularly, to methods and apparatus for in-phase (I) and quadrature phase (Q) imbalance compensation in a communication network.
BACKGROUND
[0003] In many communication systems, data is often converted into a passband signal, e.g., centered around a carrier frequency, before transmission. One reason for converting the original signal into a passband signal is that the conversion allows multiple channels of data to be transferred over a single transmission medium, e.g., by using several different carrier signals. A common example of this is radio broadcasts.
[0004] Since the transmitted signal is a passband signal, the received signal is also passband. In many systems, the passband signal is first converted to its baseband, i.e., is centered around zero frequency as opposed to the carrier frequency, before further signal processing takes place. The generation of the baseband signal is in many cases done with analog devices before any analog-to-digital conversion takes place. The baseband signal normally comprises an in-phase (I) component and a quadrature (Q) component.
[0005] The baseband signal may be any one of several different signal formats which are possible. Many transmitted signals are used to transmit values known as symbols. Various symbol transmission systems are designed so that symbols will be distributed in an I/Q plane relatively symmetrically about the origin over a period of time.
[0006] The I and Q components of a baseband signal are often processed separately, e.g., in parallel. As part of the steps to obtaining a baseband signal, the passband signal is copied and multiplied by a cos (2πf c t) signal to generate the I component and the same passband signal is copied and multiplied by a sin (2πf c t) signal to generate the Q component. In principle, the in-phase cos (2πf c t) and quadrature sin (2πf c t) components should have exactly π/2 phase shift and the same amplitude. However, in reality it is very difficult and costly to achieve a highly accurate π/2 phase shift and equal amplitude using analog devices. Consequently, the resultant in-phase and quadrature components generally have imbalance in amplitude and/or phase, i.e., I/Q imbalance, which causes signal quality degradation in the subsequent receiver signal processing.
[0007] [0007]FIG. 1 illustrates an exemplary 16 -QAM (quadrature amplitude modulation) constellation 10 , which is an example of a modulation scheme used to transmit data. Each symbol in the constellation is denoted by an “x”. In known 16 -QAM the permissible nominal symbol values for both the x and y coordinates is (±1, ±3) with the nominal squared magnitude being approximately 2, 10 and 18. The rings are included in FIG. 1 to show how the symbols are distributed symmetrically around the original of the I/Q plane. As a result of phase imbalance, received symbols might appear to be distributed along an oval centered at the origin as opposed to around a circular ring centered at the origin. Amplitude imbalance may case the radius of the rings on which the symbols are located to deviate from the ring's intended radius. Such errors can complicate the process of accurate symbol interpretation.
[0008] In-Phase and Quadrature phase (I/Q) signal imbalance is a well-known problem in the receiver design of many communication systems. Therefore, many I/Q imbalance some of these devices can be very complex in their design. Complex designs are often harder to implement in hardware, take more physical space to implement and have higher processing overhead than simple designs. Many known I/Q imbalance compensation devices only work with a particular type of received signal. Such devices use the specific structure and/or the nature of the received signal to compensate for I/Q imbalance. Unfortunately, those types of compensation devices are often limited in utility to the received signal for which they were designed. Using such devices for other types of received signals may cause more I/Q imbalance rather than compensate for it.
[0009] Accordingly, there is a need for new and improved methods and apparatus that can be used to compensate for, reduce, and/or eliminate I/Q imbalance. In addition, the methods and apparatus should be relatively independent of the received signal's structure, thereby making the methods and apparatus applicable to a greater diversity of communication systems than some of the known designs.
BRIEF DESCRIPTION OF THE FIGURES
[0010] [0010]FIG. 1 illustrates a known 16 -QAM symbol constellation.
[0011] [0011]FIG. 2 illustrates a communication device implemented with an exemplary embodiment of an I/Q imbalance correction device of the present invention.
[0012] [0012]FIG. 3 illustrates a detailed view of the I/Q imbalance compensation device of FIG. 2
[0013] [0013]FIG. 4 illustrates an exemplary implementation of a coefficient K updating component of the coefficient updating device of FIG. 2, in accordance with the invention.
[0014] [0014]FIG. 5 illustrates an exemplary implementation of a coefficient x updating component of the coefficient updating device of FIG. 2, in accordance with the invention.
SUMMARY OF INVENTION
[0015] The present invention is directed to methods and apparatus for performing I and Q signal imbalance detection and correction operations.
[0016] In some embodiments, the imbalance correction operation is limited to phase error correction. However, in other embodiments both phase and amplitude imbalance compensation operations are performed.
[0017] Phase and amplitude correction coefficients are generated using a relatively simple feedback mechanism. Thus, in accordance with the invention the in-phase and quadrature phase signals resulting from phase and amplitude imbalance correction processing are used to update the correction coefficients.
[0018] Phase imbalance correction coefficient generation in-phase and quadrature phase signals. These signals may be viewed as separate components of a single complex signal. The phase imbalance correction coefficient generation technique of the invention relies on the symmetric nature of most transmitted symbol constellations. Over time, the phase imbalance correction coefficient will average to zero assuming that received symbols are distributed symmetrically around the I/Q origin over time. If phase imbalance exists, the phase imbalance coefficients will cause the processed signals to tend to values which will have the expected symmetry.
[0019] To obtain the desired symbol averaging effect in generation of the phase imbalance correction coefficient, in some embodiments the phase imbalance correction coefficient is generated in a manner that depends on the symbol values received in multiple symbol time periods. This averaging effect is achieved in one embodiment of the invention by low pass filtering the inverse of the product of the processed in-phase and quadrature phase signals.
[0020] The amplitude imbalance correction coefficient may be generated based on the difference between squared in-phase and quadrature phase values that is detected over some period of time, e.g., multiple symbol periods.
[0021] Phase and amplitude correction operations may be performed on input signals I 1 , and Q 1 to generate processed signals I 2 and Q 2 as follows:
I 2 =I 1 +Kx×Q 1 ;
[0022] and
Q 2 =xI 1 +KQ 1 ;
[0023] where x is the phase correction coefficient and K is the amplitude correction coefficient generated in accordance with the invention.
[0024] Numerous additional features, benefits and details of the methods and apparatus of the present invention are described in the detailed description which follows.
DETAILED DESCRIPTION OF INVENTION
[0025] As mentioned earlier, the present invention describes methods and apparatus for correcting for I and Q phase imbalance in a received signal. As will be discussed below, this is done by adaptively compensating for I/Q imbalance using simple feedback in accordance with the present invention.
[0026] [0026]FIG. 2 illustrates an exemplary communication apparatus 100 implemented in accordance with one exemplary embodiment of the present invention. The apparatus may be, e.g., part of a receiver. The communication apparatus 100 includes an input line 104 , local oscillator 106 , π/2 phase shifting device 108 , two multipliers 110 , 112 , two analog filters 114 , 116 , two analog to digital converters 118 , 120 , two digital filters 122 , 124 and an I/Q imbalance correction module 102 coupled together as illustrated in FIG. 2.
[0027] An exemplary description of an I/Q imbalance compensation operation will now be described with reference to communication apparatus 100 . The description will include a discussion of exemplary operations performed by the aforementioned components. The received signal, which serves as input to the apparatus 100 , is generally a passband signal centered on a carrier frequency. The signal enters apparatus 100 through input 104 . The input 104 is split into two paths, sending the received input signal to an in-phase path and to a quadrature path. The two paths are used to produce the in-phase and quadrature signal components as part of the process of converting the received passband signal into a baseband signal.
[0028] The local oscillator 106 drives the multiplier 110 included in the in-phase path with a generated signal of cos (2πf c t). In addition, the local oscillator 106 also drives the multiplier 112 in the quadrature path after being shifted by π/2 by phase shifting device 108 . Thus, phase shifting device 108 generates the signal sin (2πf c t) used by multiplier 112 . In the preceding locally generated signals, t is the time variable and f c is a down conversion frequency, e.g., the carrier frequency. Note that ideally generated cos (2πf c t) and sin (2πf c t) components have an exact π/2 phase shift. However, in various exemplary embodiments the phase shifting operation is implemented with analog devices which may not be as accurate as desired. This can lead to I/Q imbalance, i.e., mismatch between the phase of the in-phase and the quadrature signal components. Amplitude errors may also be introduced, e.g., due to slight differences between multipliers 110 and 112 . Unless corrected, I/Q imbalance tends to corrupt the baseband signal and degrade the receiver performance.
[0029] In the in-phase path, multiplier 110 multiples the local oscillator signal, i.e., cos (2πf c t), with the received signal. The resulting in-phase (I) signal is filtered by analog filter 114 , and then converted from analog to digital by A/D converter 118 . The digital I signal is then filtered by digital filter 122 and then supplied to the input of the I/Q imbalance correction module 102 of the present invention.
[0030] The quadrature signal path, which includes multiplier 112 , filter 116 , A/D converter 120 , and digital filter 124 are coupled in the same manner as the in-phase path. The filtered Q signal output by digital filter 124 is supplied to the second input of I/Q imbalance correction module 102 . The I/Q imbalance correction module 102 simultaneously compensates for amplitude and phase imbalance between the I and Q input signals and outputs a corrected in-phase (I) signal and a corrected quadrature (Q) signal. The outputs of the correction module 102 are the balanced in-phase and quadrature baseband signals. The balanced I and Q baseband signals are supplied to other communication device components (not shown) for further signal processing, e.g., signal decoding. The I/Q imbalance correction module 102 is suitable for use in a plurality of different receiver designs that suffer from I/Q imbalance and is not overly dependant on signal characteristics.
[0031] The I/Q imbalance correction module 102 includes an I/Q imbalance compensation module 126 , and a coefficient updating module 128 . The I/Q imbalance compensation module 126 corrects the I/Q imbalance between its two input signals as a function of a phase compensation correction coefficient, x and an amplitude correction coefficient K. As will be discussed below, x coefficient is used for phase compensation, and the K coefficient is used for amplitude compensation. One constraint of the compensation coefficients is that the value of the amplitude correction coefficent should be non-negative. The I/Q imbalance compensation module 126 adjusts to changes in I/Q imbalance through the use of coefficient updating module 128 , which is responsible for generating the correction coefficients.
[0032] [0032]FIG. 3 illustrates a detailed view of an exemplary I/Q imbalance compensation module 126 . In-phase and quadrature signal components, I 1 and Q 1 , respectively, are inputs to the compensation module 126 , as well as coefficients K and x. In accordance with the invention, and as shown in FIG. 3, the outputs of the compensation module 126 , I 2 and Q 2 , are given by
[ I 2 Q 2 ] = [ 1 Kx x K ] · [ I 1 Q 1 ]
[0033] Thus,
I 2 =I 1 +Kx×Q 1 ;
[0034] and
Q
2
=xI
1
+KQ
1
[0035] Initial values may be set as follows:
[0036] I 2 =I 1
[0037] Q 2 =Q 1
[0038] K=1
[0039] x=0.
[0040] Initial amplitude correction factor K=1 corresponds to the case where no correction, e.g., alteration, of the I and Q signal's amplitude is to occur. Similarly, x=0 corresponds to the case where no phase correction is to be applied to the I and Q signals. Over time, the initial values for K and x are adjusted based on the detected phase and amplitude errors.
[0041] In accordance with the present invention, phase correction may be used independent of amplitude correction, in such a case, amplitude correction factor K is treated as 1 resulting in the following:
I
2
=I
1
+xQ
1
Q
2
=xI
1
+Q
1
[0042] where x is the phase correction coefficient.
[0043] As mentioned earlier, K and x represent the compensation coefficients for amplitude and phase imbalance, respectively.
[0044] The amplitude and phase correction coefficients K and x in the compensation module 126 are updated periodically by coefficient updating module 128 , in a feedback manner, as a function of the corrected I and Q signals I 2 and Q 2 . Coefficient updating circuit 128 is part of a feedback loop that uses the current I and Q corrected signals to determine the current received signal imbalance. Updating of the values K and x can, and in the illustrated embodiment is, done separately, e.g., using separate circuits to generate the K and x coefficient values from the I 2 and Q 2 signals. FIGS. 4 and 5 illustrate exemplary embodiments of circuits which can be used to implement the coefficient updating module 128 .
[0045] [0045]FIG. 4 illustrates an exemplary coefficient K updating circuit 300 implemented in accordance with the invention. The coefficient K updating circuit 300 includes two squarers 302 , 304 , an adder 306 , a low pass filter 308 , and memory 310 to store the value of K. In accordance with the invention and as shown in FIG. 4, an error term, e K , used to adjust the value of the K amplitude correction coefficient, is calculated as follows:
e K =( I 2 ) 2 −( Q 2 ) 2
[0046] The inputs, I 2 and Q 2 , are independently squared by squarers 302 , 304 and the squared quadrature component is subtracted from the squared in-phase component. Next, the obtained error term, e K , is passed through a low pass filter 308 to update K. For example, in a discrete first-order low pass filter implementation,
K new =K old +α K ·e K ,
[0047] where K new and K old are values after and before updating respectively, and α K is a filter coefficient that acts as a step size used to control the rate at which the value K is adjusted. In one exemplary embodiment, α K is set to equal a value in the range of 0<α≦1. By selecting α to be small, e.g., α≦0.25, transient noise or other short term signal changes will not significantly effect the imbalance compensation operation since the transient noise's brief signal effect will be moderated by the low pass filtering effect achieved through the use a small α.
[0048] The updated amplitude correction value of K is stored in memory unit 310 and updated in the I/Q imbalance correction module 126 at the next periodic update, e.g., on the next clock cycle.
[0049] [0049]FIG. 5 illustrates an exemplary phase correction coefficient (x) updating circuit 400 implemented in accordance with the invention. The coefficient x updating circuit 400 includes a multiplier 402 , an inverting gain amplifier 406 , a low pass filter 408 , and memory 410 to store the value of x, which are coupled together as shown in FIG. 5. In accordance with the invention, an error term, e x , used to adjust the value of the x coefficient, is calculated by
e x =−( I 2 ) ( Q 2 )
[0050] Thus, the present invention performs phase corrections as a function of the negative of the product of the I 2 and Q 2 signals being processed. For a phase balanced in the I/Q plane around the I/Q origin, statistically I 2 Q 2 will equal 0. In other words, whenever I 2 Q 2 is not equal to zero, the feedback compensation loop will try to adjust X in a direction that tends to force I 2 Q 2 to zero. In this manner, over time, phase compensation is performed.
[0051] To generate the value e x , the inputs, I 2 and Q 2, are multiplied by multiplier 402 and the calculated value is negated by inverting gain amplifier 406 . Next, the obtained value, ex, is passed through a low pass filter 408 to update x. For example, in a discrete first-order low pass filter implementation,
x new =x old +α x ·e x ,
[0052] where x new and x old are values after and before updating respectively, and α x is a filter coefficient. As noted above, x old may be initialized to 0. α x may be the same as α k and is used, in various embodiments, to achieve low pass filtering in the same manner as α k was used in regard to the amplitude correction coefficient generation. Thus, α k will normally be selected to be a value in the range of 0<α≦1. While in some embodiments where low pass filtering is implemented, α x ≦0.25. The updated value of x is stored in memory unit 410 and updated in the I/Q imbalance correction module 126 on the next periodic update, e.g., at the next clock cycle.
[0053] The steps of the various methods of the invention discussed above may be implemented in a variety of ways, e.g., using software, hardware or a combination of software and hardware to perform each individual step or combination of steps discussed. Various embodiments of the present invention include means for performing the steps of the various methods. Each means may be implemented using software, hardware, e.g., circuits, or a combination of software and hardware. When software is used, the means for performing a step may also include circuitry such as a processor for executing the software. Accordingly, the present invention is directed to, among other things, computer executable instructions such as software for controlling a machine or circuit to perform one or more of the steps or signal processing operations discussed above. | Methods and apparatus for performing amplitude and phase imbalance correction operations on in-phase and quadrature phase signal components corresponding to a received signal are described. The imbalance correction operations relay on the use of relatively simple to implement feedback loops. The phase imbalance feedback loop relies on the tendency of transmitted symbols to be distributed uniformly around the origin of the I/Q plane if proper phase balance is present in the processed signal. Phase correction coefficients are generated over time as a function of the negated product of the processed in-phase and quadrature phase signal components. Amplitude correction coefficients are generated over time as a function of the difference in the squared values of the I and Q processed signal components. | 7 |
TECHNICAL FIELD
The present disclosure relates to friction drive belts.
BACKGROUND ART
V-ribbed belts having a large number of pores on their pulley contact surfaces are known.
For example, Patent Document 1 describes a V-ribbed belt in which a portion including a pulley contact surface is at least partially made of a porous rubber composition having an air content of 5-20%.
Patent Document 2 describes a V-ribbed belt having a two-layer structure including an outer adhesion rubber layer and an inner compression rubber layer. In this V-ribbed belt, hollow particles are blended into a rubber composition forming the compression rubber layer, and part of the hollow particles exposed at the pulley contact surface is partially cut away to form a large number of cellular pores.
CITATION LIST
Patent Document
PATENT DOCUMENT 1: Japanese Patent Publication No 2007-255635
PATENT DOCUMENT 2: International Patent Publication No. WO2008/007647
SUMMARY OF THE INVENTION
The present disclosure relates to a friction drive belt including a compression rubber layer which is provided on an inner periphery of a belt body and transmits power between pulleys upon coming into contact with the pulleys, wherein the compression rubber layer includes a surface rubber layer including numerous pores on a pulley contact surface, and an inner rubber layer which is provided toward an inside of the belt relative to the surface rubber layer and whose storage modulus at 25° C. in a belt length direction is higher than that of the surface rubber layer and is in the range from 30 to 50 MPa.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a V-ribbed belt according to an embodiment.
FIG. 2( a ) is an enlarged cross-sectional view of a principal portion of the V-ribbed belt of the embodiment in which hollow particles are used. FIG. 2( b ) is an enlarged cross-sectional view of a principal portion of a V-ribbed belt of the embodiment in which a foaming agent is used.
FIG. 3 is a longitudinal cross-sectional view of a belt forming mold.
FIG. 4 is an enlarged longitudinal cross-sectional view of a portion of the belt forming mold.
FIG. 5 is an illustration showing a step of forming a multilayer member.
FIG. 6 is an illustration showing a step of setting the multilayer member in an outer mold.
FIG. 7 is an illustration showing a step of setting the outer mold outside an inner mold.
FIG. 8 is an illustration showing a step of forming a belt slab.
FIG. 9 is a diagram showing a layout of pulleys in an accessory drive belt transmission system for an automobile according to the embodiment.
FIG. 10 is a diagram showing a layout of pulleys in a multi-axis bending belt running test machine used to evaluate resistance to bending fatigue.
FIG. 11 is a diagram showing a layout of pulleys in a belt running test machine for a measurement of slip noise.
DESCRIPTION OF EMBODIMENTS
An embodiment will be described below in detail with reference to the drawings.
FIG. 1 shows a V-ribbed belt B (a friction drive belt) according to the embodiment. The V-ribbed belt B of this embodiment is used in, for example, an accessory drive belt transmission system provided in an engine room of an automobile. The V-ribbed belt B of this embodiment has a belt total length of 700-3000 mm, a belt width of 10-36 mm and a belt thickness of 4.0-5.0 mm.
The V-ribbed belt B of this embodiment includes a V-ribbed belt body 10 having a three-layer structure made of a compression rubber layer 11 provided on the inner periphery of the belt, an intermediate adhesion rubber layer 12 , and a backing rubber layer 13 provided on the outer periphery of the belt. The adhesion rubber layer 12 of the V-ribbed belt body 10 includes a cord 14 embedded therein in a spiral having pitches adjacent to each other along the belt width.
The compression rubber layer 11 has a plurality of V-ribs 15 rising inward relative to the inner periphery of the belt. The V-ribs 15 are each formed into a rib extending along the belt length and having a cross section in a substantially inverted triangular shape, and are arranged adjacent to each other along the belt width. Each of the V-ribs 15 has, for example, a rib height of 2.0-3.0 mm and a width of 1.0-3.6 mm at its root. The number of the V-ribs is, for example, from three to six (six in FIG. 1 ).
The compression rubber layer 11 includes a surface rubber layer 11 a formed into a layer shape extending along the entire pulley contact surface, and an inner rubber layer 11 b provided toward the inside of the belt relative to the surface rubber layer 11 a . The surface rubber layer 11 a has a thickness of 50-500 μm, for example.
Each of the surface rubber layer 11 a and the inner rubber layer 11 b included in the compression rubber layer 11 is made of a rubber composition which is cross-linked with a cross-linker by application of heat and pressure to a non-crosslinked rubber composition produced by blending various compounding ingredients into a base material rubber.
Examples of the base material rubber for the rubber composition forming each of the surface rubber layer 11 a and the inner rubber layer 11 b of the compression rubber layer 11 include: ethylene-α-olefin elastomers such as ethylene propylene copolymer (EPR), ethylene-propylene-diene terpolymer (EPDM), ethylene-octene copolymer, and ethylene-butene copolymer; chloroprene-rubber (CR); chlorosulfonated polyethylene rubber (CSM); and hydrogenated acrylonitrile rubber (H-NBR). Among the examples, an ethylene-α-olefin elastomer is preferably used as the base material rubber. The base material rubber may include either a single species or a mixture of two or more species. The rubber composition forming the surface rubber layer 11 a and that forming the inner rubber layer 11 b may be either the same or different from each other.
Examples of the compounding ingredients include reinforcing agents such as carbon blacks, softeners, processing aids, vulcanization aids, cross-linkers, vulcanization accelerators, resins for rubber compounding, and antioxidants.
Examples of the carbon blacks used as the reinforcing agents include: channel black; furnace black such as SAF, ISAF, N-339, HAF, N-351, MAF, FEF, SRF, GPF, ECF, and N-234; thermal black such as FT and MT; and acetylene black. Silica may also be used as the reinforcing agent. The reinforcing agent may include either a single species or two or more species. In order that resistance to wear and resistance to bending fatigue will be well balanced, 30-80 parts by mass of the reinforcing agent is preferably blended into 100 parts by mass of the base material rubber.
Examples of the softeners include: petroleum softeners; mineral oil-based softeners such as paraffin wax; and vegetable oil based-softeners such as castor oil, cottonseed oil, linseed oil, rapeseed oil, soybean oil, palm oil, coconut oil, peanut oil, Japan wax, rosin, and pine oil. The softener may be made of either a single species or two or more species. For example, 2-30 parts by mass of the softener is blended into 100 parts by mass of the base material rubber.
Examples of the processing aids include stearic acids. The processing aid may include either a single species or two or more species. For example, 0.5-5 parts by mass of the processing aid is blended into 100 parts by mass of the base material rubber.
Examples of the vulcanization aids include metal oxides such as magnesium oxide and zinc oxide (zinc white). The vulcanization aid may include either a single species or two or more species. For example, 1-10 parts by mass of the vulcanization aid is blended into 100 parts by mass of the base material rubber.
Examples of the cross-linkers include sulfur and organic peroxides. Sulfur or an organic peroxide may be used alone as the cross-linker. Both of sulfur and the organic peroxide may also be used in combination. For example, 0.5-4.0 parts by mass of sulfur as the cross-linker is blended into 100 parts by mass of the base material rubber. For example, 0.5-8 parts by mass of the organic peroxide as the cross-linker is blended into 100 parts by mass of the base material rubber.
Examples of the vulcanization accelerators include metal oxides, metal carbonates, fatty acids and the derivatives thereof. The vulcanization accelerator may include either a single species or two or more species. For example, 0.5-8 parts by mass of the vulcanization accelerator is blended into 100 parts by mass of the base material rubber.
Examples of the resins for rubber compounding include phenolic resin. The resin for rubber compounding may include either a single species or two or more species. For example, 0-20 parts by mass of the resin for rubber compounding is blended into 100 parts by mass of the base material rubber.
Examples of the antioxidants include amine-based agents, quinoline-based agents, hydroquinone derivatives, phenolic agents, phosphite-based agents. The antioxidant may include either a single species or two or more species. For example, 0-8 parts by mass of the antioxidant is blended into 100 parts by mass of the base material rubber.
Numerous pores 16 are formed on the pulley contact surface of the surface rubber layer 11 a , i.e. on the surfaces of the V-ribs 15 . The average pore size of the pores 16 is preferably 40-150 μm and more preferably 80-120 μm. The average pore size of the pores 16 is calculated based on a number-average pore size of 50-100 pores measured by means of a surface image.
As shown in FIG. 2( a ) , the numerous pores 16 on the pulley contact surface of the surface rubber layer 11 a may be made of partially cut away hollow particles 17 blended into the rubber composition forming the surface rubber layer 11 a . Examples of the hollow particles 17 include EXPANCEL 092-120 (manufacturer: Japan Fillite Co., Ltd, particle size: 28-38 μm), EXPANCEL 009-80 (manufacturer: Japan Fillite Co., Ltd, particle size: 18-24 μm), ADVANCELL EMH204 (manufacturer: Sekisui Chemical Co., Ltd., particle size: 23-29 μm), ADVANCELL EMS-026 (manufacturer: Sekisui Chemical Co., Ltd., particle size: 25-35 μm), MATSUMOTO MICROSPHERE F-80S (manufacturer: Matsumoto Yushi-Seiyaku Co., Ltd., particle size: 20-30 μm), and MATSUMOTO MICROSPHERE F-190D (manufacturer: Matsumoto Yushi-Seiyaku Co., Ltd., particle size: 30-40 μm). The particle size of the hollow particles 17 is preferably 10-45 μm and more preferably 18-40 μm. The hollow particles 17 are blended preferably in an amount of 0.5-10 parts by mass and more preferably in an amount of 1-5 parts by mass into 100 parts by mass of the base material rubber.
As shown in FIG. 2( b ) , the numerous pores 16 on the pulley contact surface of the surface rubber layer 11 a may be formed by partially cut away hollows produced by a foaming agent blended into the rubber composition forming the surface rubber layer 11 a . Examples of the foaming agent include CELLMIC CAP-500 (manufacturer: Sankyo Kasei Co., Ltd.). The foaming agent is blended preferably in an amount of 1-15 parts by mass and more preferably in an amount of 3-8 parts by mass into 100 parts by mass of the base material rubber.
The rubber composition forming the surface rubber layer 11 a may contain short fibers. The short fibers are preferably oriented in the belt width direction. Part of the short fibers exposed at the pulley contact surface preferably has their ends protruding from the pulley contact surface. Examples of the short fibers include nylon short fibers, aramid short fibers, polyester short fibers, and cotton short fibers. For example, the short fibers may be manufactured through an adhesion treatment in which the fibers are soaked in a resorcinol formaldehyde latex aqueous solution (an RFL aqueous solution) and then heated. The short fibers have a length of 0.2-3.0 mm, for example. For example, 3-30 parts by mass of the short fibers are blended into 100 parts by mass of the base material rubber. The rubber composition forming the surface rubber layer 11 a may not contain short fibers.
The surface rubber layer 11 a has a storage modulus (E′) at 25° C. in the belt length direction ranging preferably 20-45 MPa, and more preferably 35-40 MPa. The storage modulus (E′) at 25° C. is measured in accordance with Japanese Industrial Standards (JIS) K6394.
The rubber composition forming the inner rubber layer 11 b does not contain the hollow particles 17 and the foaming agent. Accordingly, the inner rubber layer 11 b does not contain hollows similar to the ones that the surface rubber layer 11 a contains. The rubber composition forming the inner rubber layer 11 b preferably contains no short fibers. The storage modulus (E′) at 25° C. in the belt length direction of the inner rubber layer 11 b is preferably higher than that of the surface rubber layer 11 a , and is preferably 30-50 MPa and more preferably 35-45 MPa.
The adhesion rubber layer 12 is formed into a band shape with a rectangular cross section and has a thickness of 1.0-2.5 mm, for example. The backing rubber layer 13 is also formed into a band shape with a rectangular cross section and has a thickness of 0.4-0.8 mm, for example. In order to reduce noise produced between the belt back face and a flat pulley in contact with the belt back face, the surface of the backing rubber layer 13 preferably has a transferred weave pattern of woven fabric.
Each of the adhesion rubber layer 12 and the backing rubber layer 13 is preferably made of a crosslinked rubber composition which is cross-linked with a cross-linker by application of heat and pressure to a non-crosslinked rubber composition produced by blending various compounding ingredients into base material rubber. In order to reduce adhesion produced by contact between the belt back face and the flat pulley, the backing rubber layer 13 is preferably made of a rubber composition which is slightly harder than that of the adhesion rubber layer 12 .
Examples of the base material rubber for the rubber composition forming the adhesion rubber layer 12 and the backing rubber layer 13 include ethylene-α-olefin elastomers, chloroprene-rubber (CR), chlorosulfonated polyethylene rubber (CSM) and hydrogenated acrylonitrile rubber (H-NBR). The base material rubber of the adhesion rubber layer 12 and the backing rubber layer 13 is preferably the same as that of the compression rubber layer 11 .
In a manner similar to the compression rubber layer 11 , examples of the compounding ingredients include reinforcing agents such as carbon blacks, softeners, processing aids, vulcanization aids, cross-linkers, vulcanization accelerators, resins for rubber compounding, and antioxidants.
The rubber compositions forming the inner rubber layer 11 b of the compression rubber layer 11 , the adhesion rubber layer 12 , and the backing rubber layer 13 may be either different from each other or the same in constitution.
The cord 14 is made of twisted yarn of polyester fibers (PET), polyethylene naphthalate fibers (PEN), aramid fibers, vinylon fibers, etc. In order that the cord 14 has adhesion to the V-ribbed belt body 10 , the cord 14 is subjected to an adhesion treatment in which the cord is soaked in an RFL aqueous solution and then heated and/or an adhesion treatment in which the cord is soaked in rubber cement and then dried, prior to molding the V-ribbed belt.
Meanwhile, there is a growing need for alleviation of noise produced in traveling automobiles. Such a need has created demands for a V-ribbed belt running in an engine room to reduce slip noise generated in running of the V-ribbed belt in a wet state and to alleviate reduction of power transmission capacity in running of the V-ribbed belt in a wet state. To meet the demands, in the V-ribbed belt B having the structure described in the embodiment, the compression rubber layer 11 includes the surface rubber layer 11 a and the inner rubber layer 11 b , the numerous pores 16 are formed on the pulley contact surface of the surface rubber layer 11 a , the storage modulus (E′) at 25° C. in the belt length direction of the inner rubber layer 11 b is higher than that of the surface rubber layer 11 a and is 30-50 MPa. This structure can reduce slip noise generated in running of the V-ribbed belt in a wet state and alleviate reduction of power transmission capacity in running of the V-ribbed belt in a wet state.
A method for fabricating the V-ribbed belt B of the embodiment will be described next.
A belt forming mold 20 is used to fabricate the V-ribbed belt B of the embodiment. As shown in FIGS. 3 and 4 , the belt forming mold 20 includes a cylindrical inner mold 21 and a cylindrical outer mold 22 , which are provided concentrically.
In this belt forming mold 20 , the inner mold 21 is made of a flexible material such as rubber. The outer mold 22 is made of a rigid material such as a metal. The inner periphery surface of the outer mold 22 serves as a molding surface, and grooves 23 for forming the V-ribs are provided in the axial direction at regular intervals on the inner periphery surface of the outer mold 22 . The outer mold 22 is provided with a temperature control mechanism which allows a heating medium such as water vapor or a cooling medium such as water to flow. This belt forming mold 20 is provided with a pressurizing means for pressurizing and expanding the inner mold 21 from the inside.
In fabrication of the V-ribbed belt B of this embodiment, non-crosslinked rubber sheets 11 a ′ and 11 b ′ for the surface rubber layer and the inner rubber layer of the compression rubber layer 11 are first produced by blending the compounding agents into the base material rubber, kneading the resultant blend with a kneading machine such as a kneader and a Banbury mixer, and molding the resultant non-crosslinked rubber composition into a sheet shape by calender molding and the like. Non-crosslinked rubber sheets 12 ′ and 13 ′ for the adhesion rubber layer and the backing rubber layer are also produced in a similar manner. Twisted yarn 14 ′ for forming the cord is subjected to the adhesion treatment in which the yarn is soaked in an RFL aqueous solution and then heated, and thereafter to the adhesion treatment in which the yarn is soaked in rubber cement and then dried.
Then, as shown in FIG. 5 , a rubber sleeve 25 is placed on the outer periphery of a cylindrical drum 24 having a smooth surface. Thereafter, the non-crosslinked rubber sheet 13 ′ for the backing rubber layer and the non-crosslinked rubber sheet 12 ′ for the adhesion rubber layer are wrapped around the rubber sleeve 25 in this order to form layers. The twisted yarn 14 ′ for the cord is winded around the resultant layers in a helical manner with respect to the cylindrical inner mold 21 . Further, the non-crosslinked rubber sheet 12 ′ for the adhesion rubber layer, the non-crosslinked rubber sheet 11 b ′ for the inner rubber layer of the compression rubber layer 11 , and the non-crosslinked rubber sheet 11 a ′ for the surface rubber layer of the compression rubber layer 11 are wrapped around over the twisted yarn 14 ′ in this order, thereby producing a multilayer member 10 ′.
The rubber sleeve 25 on which the multilayer member 10 ′ is formed is subsequently removed from the cylindrical drum 24 , and then put inside the outer mold 22 , as shown in FIG. 6 .
Next, as shown in FIG. 7 , the inner mold 21 is positioned inside the rubber sleeve 25 set in the outer mold 22 , and then, hermetically sealed.
The outer mold 22 is heated and the inner mold 21 is pressurized by introducing, for example, high-pressure air into its hermetically-sealed inner space. In this step, as shown in FIG. 8 , the inner mold 21 expands and the non-crosslinked rubber sheets 11 a ′, 11 b ′, 12 ′ and 13 ′ for molding belt of the multilayer member 10 ′ are compressed on the molding surface of the outer mold 22 . At the same time, cross-linking is promoted in the sheets, and the sheets are integrated and combined with the twisted yarn 14 ′. Further, the hollow particles 17 or the foaming agent contained in the non-crosslinked rubber sheet 11 a ′ forms numerous hollows in the portion corresponding to the surface rubber 11 a . Through these steps, a belt slab S in a cylindrical shape is formed. The molding temperature of the belt slab S is, for example, 100-180° C., the molding pressure thereof is, for example, 0.5-2.0 MPa, and the molding time is, for example, 10-60 minutes.
The inner space of the inner mold 21 is reduced in pressure to be released from the hermetically sealed state, and the belt slab S formed between the inner mold 21 and the outer mold 22 with the rubber sleeve 25 interposed therebetween is removed. The belt slab S is cut into rings having a predetermined width, and each ring is turned inside out, thereby obtaining the V-ribbed belt B. The outer periphery of the belt slab S, i.e., the surface having the V-ribs 15 may be grinded, if necessary. This grinding partially cuts away the hollow particles 17 contained in the rubber composition forming the surface rubber layer 11 a or the hollows formed by the foaming agent blended in the rubber composition forming the surface rubber layer 11 a , thereby ensuring exposure of the pores 16 at the surface having the V-ribs 15 .
FIG. 9 shows a layout of pulleys of an accessory drive belt transmission system 30 for an automobile using the V-ribbed belt B of this embodiment. This accessory drive belt transmission system 30 is a serpentine drive type system in which the V-ribbed belt B is allowed to run around six pulleys including four ribbed pulleys and two flat pulleys to transmit power.
The accessory drive belt transmission system 30 includes: a power steering pulley 31 which is an uppermost ribbed pulley; an AC generator pulley 32 which is a ribbed pulley disposed below the power steering pulley 31 ; a tensioner pulley 33 which is a flat pulley disposed downwardly leftward of the power steering pulley 31 ; a water-pump pulley 34 which is a flat pulley disposed below the tensioner pulley 33 ; a crankshaft pulley 35 which is a ribbed pulley disposed downwardly leftward of the tensioner pulley 33 ; and an air-conditioner pulley 36 which is a ribbed pulley disposed downwardly rightward of the crankshaft pulley 35 . These pulleys are made of, for example, a pressed metal product, a casting product, or a resin molding product made of a nylon resin or phenolic resin, and their pulley diameters are 50-150 mm.
In the accessory drive belt transmission system 30 , the V-ribbed belt B is allowed to run sequentially around the following components: the power steering pulley 31 with the surface having the V-ribs 15 in contact with the power steering pulley 31 ; the tensioner pulley 33 with the belt back face in contact with the tensioner pulley 33 ; the crankshaft pulley 35 and then the air-conditioner pulley 36 with the surface having the V-ribs 15 in contact with the pulleys 35 and 36 ; the water-pump pulley 34 with the belt back face in contact with the water-pump pulley 34 ; the AC generator pulley 32 with the surface having the V-ribs 15 in contact with the AC generator pulley 32 ; and then the power steering pulley 31 again. Belt span lengths which are the lengths of the parts of the V-ribbed belt B between the pulleys are 50-300 mm, for example. Misalignment produced between the pulleys is 0-2°.
Though the V-ribbed belt B is applied as the friction drive belt in this embodiment, the present disclosure is not particularly limited to this embodiment. A raw-edge type V-belt may be applicable to the present disclosure.
Though the V-ribbed belt body 10 of this embodiment is constituted by the compression rubber layer 11 , the adhesion rubber layer 12 , and the backing rubber layer 13 , the present disclosure is not particularly limited to this embodiment. The V-ribbed belt body 10 may be constituted by the compression rubber layer 11 , the adhesion rubber layer 12 , and reinforcement fabric, which is provided in place of the backing rubber layer 13 . This reinforcement fabric is made of, for example, woven fabric, knitted fabric, or unwoven fabric made of fibers such as cotton fibers, polyamide fibers, polyester fibers, and aramid fibers.
Though the accessory drive belt transmission system 30 is described as the belt transmission system in this embodiment, the present disclosure is not particularly limited to this embodiment. The present disclosure is applicable to belt transmission systems for general industries, for example.
EXAMPLES
Preparation of Materials for Belt
<Rubber Compositions for Surface Rubber Layer of Compression Rubber Layer>
Each of surface rubbers 1-10, as will be described below, was prepared as the rubber composition for the surface rubber layer of the compression rubber layer. The constitution of each of surface rubbers 1-10 is also shown in Table 1 or 2.
—Surface Rubber 1—
First, 100 parts by mass of EPDM (manufacturer: JSR Corporation, trade name: EP22) used as the base material rubber was blended with 80 parts by mass of an HAF carbon black (manufacturer: Tokai Carbon Co., Ltd., trade name: SEAST 3), 8 parts by mass of paraffinic oil (manufacturer: Sun Oil Company, trade name: SUNPAR 2280), 1 part by mass of a processing aid (manufacturer: NOF Corporation, trade name: STEARIC ACID CAMELLIA), 5 parts by mass of a vulcanization aid (manufacturer: Sakai Chemical Industry Co., Ltd., trade name: Zinc White No. 1), 2.3 parts by mass of a vulcanizer (manufacturer: Hosoi Chemical Industry Co., Ltd., trade name OIL SULFUR), 4 parts by mass of a vulcanization accelerator (manufacturer: Ouchi Shinko Chemical Industrial Co., Ltd., trade name: EP-150), 3 parts by mass of a resin for rubber compounding (manufacturer: Sumitomo Bakelite Co., Ltd., trade name: SUMILITERESIN PR-13355), and 5 parts by mass of hollow particles (manufacturer: Sekisui Chemical Co., Ltd., trade name: ADVANCELL EMS-026). The resultant blend was kneaded with a Banbury mixer and the kneaded blend was then rolled with calender rolls, thereby producing a non-crosslinked rubber sheet as surface rubber 1.
—Surface Rubber 2—
A non-crosslinked rubber sheet as surface rubber 2 was produced by the same method as that of surface rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the paraffinic oil to 4 parts by mass, the vulcanization accelerator to 6 parts by mass, and the resin for rubber compounding to 10 parts by mass.
—Surface Rubber 3—
A non-crosslinked rubber sheet as surface rubber 3 was produced by the same method as that of surface rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 70 parts by mass, the paraffinic oil to 5 parts by mass, and the resin for rubber compounding to 5 parts by mass, and blending 5 parts by mass of a foaming agent (manufacturer: Sankyo Kasei Co., Ltd., trade name: CELLMIC CAP-500) as a substitute for the hollow particles into 100 parts by mass of the base material rubber.
—Surface Rubber 4—
A non-crosslinked rubber sheet as surface rubber 4 was produced by the same method as that of surface rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 70 parts by mass.
—Surface Rubber 5—
A non-crosslinked rubber sheet as surface rubber 5 was produced by the same method as that of surface rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 90 parts by mass, the paraffinic oil to 5 parts by mass, and the resin for rubber compounding to 5 parts by mass.
—Surface Rubber 6—
A non-crosslinked rubber sheet as surface rubber 6 was produced by the same method as that of surface rubber 2 except that no hollow particles were blended into the base material rubber.
—Surface Rubber 7—
A non-crosslinked rubber sheet as surface rubber 7 was produced by the same method as that of surface rubber 2 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the hollow particles to 0.5 parts by mass.
—Surface Rubber 8—
A non-crosslinked rubber sheet as surface rubber 8 was produced by the same method as that of surface rubber 2 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the hollow particles to 10 parts by mass.
—Surface Rubber 9—
A non-crosslinked rubber sheet as surface rubber 9 was produced by the same method as that of surface rubber 2 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the hollow particles to 12 parts by mass and the resin for rubber compounding to 13 parts by mass.
—Surface Rubber 10—
A non-crosslinked rubber sheet as surface rubber 10 was produced by the same method as that of surface rubber 1 except that 25 parts by mass of nylon short fibers (manufacturer: Asahi Kasei Corporation, trade name: LEONA 66, fiber length: 1 mm) were blended into 100 parts by mass of the base material rubber, in addition to the ingredients contained in surface rubber 1.
TABLE 1
Surface rubber
—
Manufacturer/Trade name
1
2
3
4
5
EPDM
JSR Corporation/EP22
100
100
100
100
100
HAF carbon black
Tokai Carbon Co., Ltd./SEAST 3
80
80
70
70
90
Paraffinic oil
Sun Oil Company/SUNPAR 2280
8
4
5
8
5
Processing aid
NOF Corporation/
1
1
1
1
1
STEARIC ACID CAMELLIA
Vulcanization aid
Sakai Chemical Industry Co., Ltd./
5
5
5
5
5
Zinc White No. 1
Vulcanizer
Hosoi Chemical Industry Co., Ltd./
2.3
2.3
2.3
2.3
2.3
OIL SULFUR
Vulcanization
Ouchi Shinko Chemical Industrial
4
6
4
4
4
accelerator
Co., Ltd./EP-150
Resin for rubber
Sumitomo Bakelite Co., Ltd./
3
10
5
3
5
compounding
SUMILITERESIN PR-13355
Hollow particles
Sekisui Chemical Co., Ltd./
5
5
5
5
ADVANCELL EMS-026
Foaming agent
Sankyo Kasei Co., Ltd./
5
CELLMIC CAP-500
Total
—
208.3
213.3
197.3
198.3
217.3
Storage modulus E′ (MPa)
28.6
43.6
33.6
26.4
36.5
Average pore size (μm)
86
82
85
89
95
TABLE 2
Surface rubber
—
Manufacturer/Trade name
6
7
8
9
10
EPDM
JSR Corporation/EP22
100
100
100
100
100
HAF carbon black
Tokai Carbon Co., Ltd./SEAST 3
80
80
80
80
80
Paraffinic oil
Sun Oil Company/SUNPAR 2280
4
4
4
4
8
Processing aid
NOF Corporation/
1
1
1
1
1
STEARIC ACID CAMELLIA
Vulcanization aid
Sakai Chemical Industry Co., Ltd./
5
5
5
5
5
Zinc White No. 1
Vulcanizer
Hosoi Chemical Industry Co., Ltd./
2.3
2.3
2.3
2.3
2.3
OIL SULFUR
Vulcanization
Ouchi Shinko Chemical Industrial
6
6
6
6
4
accelerator
Co., Ltd./EP-150
Resin for rubber
Sumitomo Bakelite Co., Ltd./
10
10
10
13
3
compounding
SUMILITERESIN PR-13355
Hollow particles
Sekisui Chemical Co., Ltd./
0.5
10
12
5
ADVANCELL EMS-026
Nylon short fibers
Asahi Kasei Corporation/
25
LEONA 66, Fiber length 1 mm
Total
—
208.3
208.8
218.3
223.3
233.3
Storage modulus E′ (MPa)
47.7
44.3
35.7
27.4
35.2
Average pore size (μm)
—
92
84
92
89
<Rubber Compositions for Inner Rubber Layer of Compression Rubber Layer>
Each of inner rubbers 1-6, as will be described below, was prepared as the rubber composition for the inner rubber layer of the compression rubber layer. The constitution of each of inner rubbers 1-6 is also shown in Table 3.
Inner Rubber 1—
First, 100 parts by mass of EPDM (manufacturer: JSR Corporation, trade name: EP22) used as the base material rubber was blended with 70 parts by mass of an HAF carbon black (manufacturer: Tokai Carbon Co., Ltd., trade name: SEAST 3), 5 parts by mass of paraffinic oil (manufacturer: Sun Oil Company, trade name: SUNPAR 2280), 1 part by mass of a processing aid (manufacturer: NOF Corporation, trade name: STEARIC ACID CAMELLIA), 5 parts by mass of a vulcanization aid (manufacturer: Sakai Chemical Industry Co., Ltd., trade name: Zinc White No. 1), 2.3 parts by mass of a vulcanizer (manufacturer: Hosoi Chemical Industry Co., Ltd., trade name OIL SULFUR), 4 parts by mass of a vulcanization accelerator (manufacturer: Ouchi Shinko Chemical Industrial Co., Ltd., trade name: EP-150), and 1.7 parts by mass of a resin for rubber compounding (manufacturer: Sumitomo Bakelite Co., Ltd., trade name: SUMILITERESIN PR-13355). The resultant blend was kneaded with a Banbury mixer and the kneaded blend was then rolled with calender rolls, thereby producing a non-crosslinked rubber sheet as inner rubber 1.
—Inner Rubber 2—
A non-crosslinked rubber sheet as inner rubber 2 was produced by the same method as that of inner rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 80 parts by mass, the paraffinic oil to 4 parts by mass, the vulcanization accelerator to 6 parts by mass, and the resin for rubber compounding to 10 parts by mass.
—Inner Rubber 3—
A non-crosslinked rubber sheet as inner rubber 3 was produced by the same method as that of inner rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the resin for rubber compounding to 5 parts by mass.
—Inner Rubber 4—
A non-crosslinked rubber sheet as inner rubber 4 was produced by the same method as that of inner rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the resin for rubber compounding to 5 parts by mass, and further adding 5 parts by mass of hollow particles (manufacturer: Sekisui Chemical Co., Ltd., trade name: ADVANCELL EMS-026) with respect to 100 parts by mass of the base material rubber.
—Inner rubber 5—
A non-crosslinked rubber sheet as inner rubber 5 was produced by the same method as that of inner rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 60 parts by mass and the paraffinic oil to 10 parts by mass.
—Inner rubber 6—
A non-crosslinked rubber sheet as inner rubber 6 was produced by the same method as that of inner rubber 1 except for changing the amount (with respect to 100 parts by mass of the base material rubber) of the HAF carbon black to 90 parts by mass, the paraffinic oil to 4 parts by mass, the vulcanizer to 2.5 parts by mass, the vulcanization accelerator to 6 parts by mass of, and the resin for rubber compounding to 10 parts by mass.
TABLE 3
Inner rubber
—
Manufacturer/Trade name
1
2
3
4
5
6
EPDM
JSR Corporation/EP22
100
100
100
100
100
100
HAF carbon black
Tokai Carbon Co., Ltd./SEAST 3
70
80
70
70
60
90
Paraffinic oil
Sun Oil Company/SUNPAR 2280
5
4
5
5
10
4
Processing aid
NOF Corporation/
1
1
1
1
1
1
STEARIC ACID CAMELLIA
Vulcanization aid
Sakai Chemical Industry Co., Ltd./
5
5
5
5
5
5
Zinc White No. 1
Vulcanizer
Hosoi Chemical Industry Co., Ltd./
2.3
2.3
2.3
2.3
2.3
2.5
OIL SULFUR
Vulcanization
Ouchi Shinko Chemical Industrial
4
6
4
4
4
6
accelerator
Co., Ltd./EP-150
Resin for rubber
Sumitomo Bakelite Co., Ltd./
1.7
10
5
5
1.7
10
compounding
SUMILITERESIN PR-13355
Hollow particles
Sekisui Chemical Co., Ltd./
5
ADVANCELL EMS-026
Total
—
189.0
208.3
192.3
197.3
184.0
218.5
Storage modulus E′ (MPa)
32.6
47.7
36.1
35.5
27.8
51.3
Average pore size (μm)
—
—
—
94
—
—
<Rubber Compositions for Adhesion Rubber Layer and Backing Rubber Layer, and Twisted Yarn for Cord>
A non-crosslinked rubber sheet made of an EPDM rubber composition was produced as a rubber composition for the adhesion rubber layer, and a non-crosslinked rubber sheet made of an EPDM rubber composition was produced as a rubber composition for the backing rubber layer.
Twisted yarn made of polyester fibers with the structure of 1,100 dtex/2×3 (the number of second twists: 9.5 T/10 cm (Z), the number of first twists: 2.19 T/10 cm, manufacturer: Teijin Limited) was used for the cord. The twisted yarn was sequentially subjected to: a treatment in which the twisted yarn was soaked in a toluene solution containing 20% by mass (solid content concentration) of isocyanate and then heat-dried at 240° C. for 40 seconds; a treatment in which the twisted yarn was soaked in an RFL aqueous solution and then heat-dried at 200° C. for 80 seconds; and a treatment in which the twisted yarn was soaked in rubber cement prepared by dissolving the rubber composition for the adhesion rubber layer in toluene and then heat-dried at 60° C. for 40 seconds.
(V-Ribbed Belt)
V-ribbed belts of Examples 1-15 and Comparative Examples 1-6, as will be described below, were fabricated for test evaluation. The configurations of the V-ribbed belts are shown in Tables 4-9.
Example 1
The V-ribbed belt of Example 1 was fabricated by a method similar to the fabrication method of the embodiment, using surface rubber 1 as the rubber composition for the surface rubber layer of the compression rubber layer, inner rubber 1 as the rubber composition for the inner rubber layer of the compression rubber layer, the rubber composition for the adhesion rubber layer, the rubber composition for the backing rubber layer, and the twisted yarn for the cord.
The V-ribbed belt of Example 1 had a belt total length of 1117 mm, a belt thickness of 4.3 mm, a V-rib height of 2.0 mm, and three V-ribs (belt width: 10.68 mm). The surface rubber layer of the V-ribbed belt of Example 1 had a thickness of 400 μm.
Example 2
The V-ribbed belt of Example 2 was fabricated by the same method as that of Example 1 except that surface rubber 2 was used as the rubber composition for the surface rubber layer of the compression rubber layer and inner rubber 2 was used as the rubber composition for the inner rubber layer of the compression rubber layer.
Example 3
The V-ribbed belt of Example 3 was fabricated by the same method as that of Example 1 except that surface rubber 3 was used as the rubber composition for the surface rubber layer of the compression rubber layer and inner rubber 3 was used as the rubber composition for the inner rubber layer of the compression rubber layer.
Example 4
The V-ribbed belt of Example 4 was fabricated by the same method as that of Example 1 except that the surface rubber layer had a thickness of 40 μm.
Example 5
The V-ribbed belt of Example 5 was fabricated by the same method as that of Example 1 except that the surface rubber layer had a thickness of 60 μm.
Example 6
The V-ribbed belt of Example 6 was fabricated by the same method as that of Example 1 except that the surface rubber layer had a thickness of 450 μm.
Example 7
The V-ribbed belt of Example 7 was fabricated by the same method as that of Example 1 except that the surface rubber layer had a thickness of 550 μm.
Example 8
The V-ribbed belt of Example 8 was fabricated by the same method as that of Example 1 except that surface rubber 1 was used as the rubber composition for the surface rubber layer of the compression rubber layer, inner rubber 3 was used as the rubber composition for the inner rubber layer of the compression rubber layer, and the storage modulus E′ in the belt length direction of the surface rubber layer, which will be described later, and the average pore size of the pores were set at 35.7 MPa and 44 μm, respectively, by regulating the molding pressure.
Example 9
The V-ribbed belt of Example 9 was fabricated by the same method as that of Example 8 except that the storage modulus E′ in the belt length direction of the surface rubber layer and the average pore size of the pores were set at 25.4 MPa and 147 μm, respectively, by regulating the molding pressure.
Example 10
The V-ribbed belt of Example 10 was fabricated by the same method as that of Example 8 except that the storage modulus E′ in the belt length direction of the surface rubber layer and the average pore size of the pores were set at 23.4 MPa and 169 μm, respectively, by regulating the molding pressure.
Example 11
The V-ribbed belt of Example 11 was fabricated by the same method as that of Example 2 except that surface rubber 7 was used as the rubber composition for the surface rubber layer of the compression rubber layer.
Example 12
The V-ribbed belt of Example 12 was fabricated by the same method as that of Example 2 except that surface rubber 8 was used as the rubber composition for the surface rubber layer of the compression rubber layer.
Example 13
The V-ribbed belt of Example 13 was fabricated by the same method as that of Example 2 except that surface rubber 9 was used as the rubber composition for the surface rubber layer of the compression rubber layer.
Comparative Example 1
The V-ribbed belt of Comparative Example 1 was fabricated by the same method as that of Example 1 except that inner rubber 3 was used as the rubber composition for the surface rubber layer of the compression rubber layer and as the rubber composition for the inner rubber layer of the compression rubber layer. The compression rubber layer of Comparative Example 1 had a single layer structure made of inner rubber 3.
Comparative Example 2
The V-ribbed belt of Comparative Example 2 was fabricated by the same method as that of Example 1 except that inner rubber 4 was used as the rubber composition for the surface rubber layer of the compression rubber layer and as the rubber composition for the inner rubber layer of the compression rubber layer. The compression rubber layer of Comparative Example 2 had a single layer structure made of inner rubber 4.
Comparative Example 3
The V-ribbed belt of Comparative Example 3 was fabricated by the same method as that of Example 1 except that surface rubber 4 was used as the rubber composition for the surface rubber layer of the compression rubber layer and inner rubber 5 was used as the rubber composition for the inner rubber layer of the compression rubber layer.
Comparative Example 4
The V-ribbed belt of Comparative Example 4 was fabricated by the same method as that of Example 1 except that surface rubber 2 was used as the rubber composition for the surface rubber layer of the compression rubber layer and inner rubber 6 was used as the rubber composition for the inner rubber layer of the compression rubber layer.
Comparative Example 5
The V-ribbed belt of Comparative Example 5 was fabricated by the same method as that of Example 1 except that surface rubber 5 was used as the rubber composition for the surface rubber layer of the compression rubber layer and inner rubber 1 was used as the rubber composition for the inner rubber layer of the compression rubber layer.
Comparative Example 6
The V-ribbed belt of Comparative Example 6 was fabricated by the same method as that of Example 8 except that the storage modulus E′ in the belt length direction of the surface rubber layer and the average pore size of the pores were set at 41.2 MPa and 35 μm, respectively, by regulating the molding pressure.
Comparative Example 7
The V-ribbed belt of Comparative Example 7 was fabricated by the same method as that of Example 2 except that surface rubber 6 was used as the rubber composition for the surface rubber layer of the compression rubber layer.
Comparative Example 8
The V-ribbed belt of Comparative Example 8 was fabricated by the same method as that of Example 1 except that surface rubber 10 was used as the rubber composition for the surface rubber layer of the compression rubber layer.
TABLE 4
Example 1
Example 2
Example 3
Surface rubber layer
Surface
Surface
Surface
rubber 1
rubber 2
rubber 3
Thickness of surface rubber
400
400
400
layer (μm)
E′ (MPa) of surface rubber layer
28.6
43.6
33.6
Inner rubber layer
Inner
Inner
Inner
rubber 1
rubber 2
rubber 3
E′ (MPa) of inner rubber layer
32.6
47.7
36.1
Means for forming pores
Hollow
Hollow
Foaming
particles
particles
agent
Average pore size (μm)
86
82
85
Bending fatigue lifetime
1000 or
960
1000 or
(hours)
more
more
Slip noise evaluation
None
None
Low
TABLE 5
Comparative
Comparative
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 4
Example 5
Surface rubber layer
Inner rubber 3
Inner rubber 4
Surface rubber 4
Surface rubber 2
Surface rubber 5
Thickness of surface rubber
400
400
400
400
400
layer (μm)
E′ (MPa) of surface rubber
36.1
35.5
26.4
43.6
36.5
layer
Inner rubber layer
Inner rubber 3
Inner rubber 4
Inner rubber 5
Inner rubber 6
Inner rubber 1
E′ (MPa) of inner rubber layer
36.1
35.5
27.8
51.3
32.6
Means for forming pores
—
Hollow
Hollow
Hollow
Hollow
particles
particles
particles
particles
Average pore size (μm)
—
94
89
82
95
Bending fatigue lifetime
1000 or more
648
1000 or more
600
720
(hours)
Slip noise evaluation
Loud
None
Loud
None
None
TABLE 6
Example 4
Example 5
Example 1
Example 6
Example 7
Surface rubber layer
Surface rubber 1
Surface rubber 1
Surface rubber 1
Surface rubber 1
Surface rubber 1
Thickness of surface rubber
40
60
400
450
550
layer (μm)
E′ (MPa) of surface rubber
28.6
28.6
28.6
28.6
28.6
layer
Inner rubber layer
Inner rubber 1
Inner rubber 1
Inner rubber 1
Inner rubber 1
Inner rubber 1
E′ (MPa) of inner rubber layer
32.6
32.6
32.6
32.6
32.6
Means for forming pores
Hollow
Hollow
Hollow
Hollow
Hollow
particles
particles
particles
particles
particles
Average pore size (μm)
86
86
86
86
86
Bending fatigue lifetime
1000 or more
1000 or more
1000 or more
1000 or more
856
(hours)
Slip noise evaluation
Medium
Low
None
None
None
TABLE 7
Comparative
Exam-
Exam-
Exam-
Example 6
ple 8
ple 9
ple 10
Surface rubber layer
Surface
Surface
Surface
Surface
rubber 1
rubber 1
rubber 1
rubber 1
Thickness of surface rubber
400
400
400
400
layer (μm)
E′ (MPa) of surface rubber
41.2
35.7
25.4
23.4
layer
Inner rubber layer
Inner
Inner
Inner
Inner
rubber 3
rubber 3
rubber 3
rubber 3
E′ (MPa) of inner rubber layer
36.1
36.1
36.1
36.1
Means for forming pores
Hollow
Hollow
Hollow
Hollow
particles
particles
particles
particles
Average pore size (μm)
35
44
147
169
Bending fatigue lifetime
1000 or
1000 or
921
836
(hours)
more
more
Slip noise evaluation
Loud
Medium
None
None
TABLE 8
Comparative
Example 7
Example 11
Example 2
Example 12
Example 13
Surface rubber layer
Surface
Surface
Surface
Surface
Surface
rubber 6
rubber 7
rubber 2
rubber 8
rubber 9
Thickness of surface rubber
400
400
400
400
400
layer (μm)
E′ (MPa) of surface rubber
47.7
44.3
43.6
35.7
27.4
layer
Inner rubber layer
Inner rubber 2
Inner rubber 2
Inner rubber 2
Inner rubber 2
Inner rubber 2
E′ (MPa) of inner rubber layer
47.7
47.7
47.7
47.7
47.7
Means for forming pores
—
Hollow
Hollow
Hollow
Hollow
particles
particles
particles
particles
Average pore size (μm)
—
92
82
84
92
Bending fatigue lifetime
1000 or more
1000 or more
960
824
755
(hours)
Slip noise evaluation
Loud
Low
None
None
None
TABLE 9
Comparative
Example 1
Example 8
Surface rubber layer
Surface rubber 1
Surface rubber
10
Thickness of surface rubber
400
400
layer (μm)
E′ (MPa) of surface rubber
28.6
35.2
layer
Inner rubber layer
Inner rubber 1
Inner rubber 1
E′ (MPa) of inner rubber layer
32.6
32.6
Means for forming pores
Hollow
Hollow
particles
particles
Average pore size (μm)
86
89
Bending fatigue lifetime
1000 or more
537
(hours)
Slip noise evaluation
None
None
(Test Evaluation Method)
<Storage Modulus E′ at 25° C. in Belt Length Direction>
In conformity with JIS K6394, each of surface rubbers 1-10 and inner rubbers 1-6 was molded into a rubber sheet, and a predetermined test peace which was cut out from each rubber sheet was subjected to a measurement of the storage modulus E′ at 25° C. in the drawing direction corresponding to the belt length direction. The molding pressures applied to the rubber sheets were made to correspond to those of the belt molding condition of Examples 1-7 and 11-13 and Comparative Examples 1-5 and 7-8, exclusive of Examples 8-10 and Comparative Example 6.
<Average Pore Size of Pores>
For each of surface rubber 1-5 and 7-10 and the inner rubber 2, an image for observation of the cut surface of the molded rubber sheet was obtained at 175-fold magnification by using a digital microscope (manufacturer: Keyence Corporation, model number: VHX-200). Pore sizes of an arbitrary number of the pores showed in each obtained image for observation were measured by means of a measurement mode of the digital microscope, and the average pore sizes of the pores were calculated.
<Test for Bending Fatigue>
FIG. 10 shows a layout of pulleys in a multi-axis bending belt running test machine 40 used to evaluate the resistance to bending fatigue of the V-ribbed belt B.
The multi-axis bending belt running test machine 40 has a structure including: a first driven pulley 41 and a drive pulley 42 which are ribbed pulleys with a pulley diameter of 45 mm and disposed at upper and lower positions, respectively; a pair of idler pulleys 43 which are flat pulleys with a pulley diameter of 50 mm and disposed to the right of the vertical midway between the pulleys 41 and 42 ; and a second driven pulley 44 which is a ribbed pulley with a pulley diameter of 45 mm and disposed to the right of the vertical midway between the pulleys 43 .
Each V-ribbed belt of Examples 1-13 and Comparative Examples 1-8 was set in the multi-axis bending belt running test machine 40 in the following manner. Each V-ribbed belt was wrapped around the first and second driven pulleys 41 and 44 and the drive pulley 42 with the V-ribs in contact with the pulleys 41 , 44 and 42 , and around the pair of the idler pulleys 43 with the belt back face in contact with the pulleys 43 . A deadweight of 588.4 N was imposed on the first driven pulley 41 by setting the first driven pulley 41 in an upwardly pulled state. Each V-ribbed belt B was allowed to run by rotating the drive pulley 42 at 5100 rpm. Then, the period of time before a crack was observed in any of the V-ribs on each V-ribbed belt B was measured as a bending fatigue lifetime.
<Slip Noise Test>
FIG. 11 shows a layout of pulleys in a belt running test machine 50 for measurement of slip noise produced by the V-ribbed belt B.
The belt running test machine 50 has a structure including: a first driven pulley 51 and a drive pulley 52 which are ribbed pulleys with a pulley diameter of 120 mm and disposed at upper and lower positions, respectively; an idler pulley 53 which has a pulley diameter of 70 mm and is disposed vertically midway between the pulleys 51 and 52 ; and a second driven pulley 54 which is a ribbed pulley with a pulley diameter of 55 mm and disposed to the right of the idler pulley 53 . The idler pulley 53 and the second driven pulley 54 are arranged in such a manner that the wrap-around angle of the V-ribbed belt on each of the pulleys 53 and 54 is 90°.
Each V-ribbed belt of Examples 1-13 and Comparative Examples 1-8 was set in the belt running test machine 50 for measurement of slip noise in the following manner. Each V-ribbed belt was wrapped around the first and second driven pulleys 51 and 54 and the drive pulley 52 with the V-ribs in contact with the pulleys 51 , 54 and 52 and around the idler pulley 53 with the belt back face in contact with the pulley 53 , torque loads of 2.5 kW per V-rib were applied to the first driven pulley 51 , and the second driven pulley 54 was set in a sideways-pulled state such that a set weight of 277 N was imposed per V-rib. The V-ribbed belt B was allowed to run by rotating the drive pulley 52 at 4900 rpm, and water was poured on the drive pulley 52 at a rate of 200 ml/min. Then, the slip noise produced in running of the V-ribbed belt B was evaluated by means of a sensory evaluation and graded from “loud” to “none.”
(Test Evaluation Results)
The results of the test evaluations are shown in Tables 1-9.
The storage modulus E′ at 25° C. in the belt length direction was as follows: surface rubber 1, 28.6 MPa; surface rubber 2, 43.6 MPa; surface rubber 3, 33.6 MPa; surface rubber 4, 26.4 MPa; surface rubber 5, 36.5 MPa; surface rubber 6, 47.7 MPa; surface rubber 7, 44.3 MPa; surface rubber 8, 35.7 MPa; surface rubber 9, 27.4 MPa; surface rubber 10, 35.2 MPa; inner rubber 1, 32.6 MPa; inner rubber 2, 47.7 MPa; inner rubber 3, 36.1 MPa; inner rubber 4, 35.5 MPa; inner rubber 5, 27.8 MPa; and inner rubber 6, 51.3 MPa.
The average pore size of the pores was as follows: surface rubber 1, 86 μm; surface rubber 2, 82 μm, surface rubber 3, 85 μm; surface rubber 4, 89 μm; surface rubber 5, 95 μm; surface rubber 7, 92 μm; surface rubber 8, 84 μm; surface rubber 9, 92 μm; surface rubber 10, 89 μm; and inner rubber 2, 94 μm.
The bending fatigue lifetime was as follows: Example 1, 1000 hours or more; Example 2, 960 hours; Example 3, 1000 hours or more; Example 4, 1000 hours or more; Example 5, 1000 hours or more; Example 6, 1000 hours or more; Example 7, 856 hours; Example 8, 1000 hours or more; Example 9, 921 hours; Example 10, 836 hours; Example 11, 1000 hours or more, Example 12, 824 hours; Example 13, 755 hours; Comparative Example 1, 1000 hours or more; Comparative Example 2, 648 hours; Comparative Example 3, 1000 hours or more; Comparative Example 4, 600 hours; Comparative Example 5, 720 hours; Comparative Example 6, 1000 hours or more; Comparative Example 7, 1000 hours or more; and Comparative Example 8, 537 hours.
The evaluation of the slip noise was as follows: Example 1, “none”; Example 2, “none”; Example 3, “low”; Example 4, “medium”; Example 5, “low”; Example 6, “none”; Example 7, “none”; Example 8, “medium”; Example 9, “none”, Example 10, “none”; Example 11, “low”; Example 12, “none”; Example 13, “none”, Comparative Example 1, “loud”; Comparative Example 2, “none”; Comparative Example 3, “loud”; Comparative Example 4, “none”; Comparative Example 5, “none”; Comparative Example 6, “loud”; Comparative Example 7, “loud”; and Comparative Example 8, “none”.
INDUSTRIAL APPLICABILITY
The present disclosure is useful for friction drive belts.
DESCRIPTION OF REFERENCE CHARACTERS
B V-ribbed belt (friction drive belt)
10 V-ribbed belt body
11 Compression rubber layer
11 a Surface rubber layer
11 b Inner rubber layer
16 Pores
17 Hollow particles | A vehicle periphery monitoring system is provided, in which by matching a behavior of a semitransparent tire image with an operation from a driver's viewpoint, a feeling of strangeness is reduced, an intuitive space perception is assisted and also a moving direction and a behavior of a vehicle can be easily perceived. In a side-view monitor system an image processing controller converts a real camera image including a blind spot into an image to be viewed from a driver's viewpoint to generate a blind spot image, and superimposes a semitransparent vehicle image which is obtained by making a vehicle viewed from the driver's viewpoint semitransparent and a semitransparent tire image which is obtained by making a tire semitransparent and displaying a behavior following a handle operation viewed from the driver's viewpoint on the blind spot image. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to polymeric polyamines and a method for stabilizing Ag nanoparticles by employing the same. The produced Ag nanoparticles are in the form of silver slurry, silver gel or solid, and suitable for composite material or antimicrobial material. Fields of the present invention include electric industries, for example, conductive silver nanowires, parts and sensors, and biomedicine or medicinal industries. In addition, the Ag nanoparticles have both hydrophilic and hydrophobic properties and therefore can be dissolved in water and organic solvents, and are compatible with many kinds of polymers. Therefore, the product of the present invention is a good polymeric surfactant or dispersant suitable for dispersing nanoscale particles, for example, pigments and silver particles.
[0003] 2. Related Prior Arts
[0004] The application of Ag nanoparticles is one of the most important technologies in this century. The traditional methods for producing water solutions of Ag nanoparticles are primarily to reduce silver nitrate or other silver salts with organic surfactants, dispersants or stabilizers for stabilizing the Ag nanoparticles. To exhibit good effects in antimicrobial, pharmaceutical, biomedicine and electrical applications, the Ag particles have to keep in the nanoscale and large surface areas without aggregation. Therefore, it's very important to control size of the Ag particles in the nanoscale and maintain thermal stability thereof.
[0005] In processes for producing Ag nanoparticles, organic surfactants or stabilizers are an important operation factor. In addition, most silver slats, for example, silver nitrate, is more easily dissolved in water than organic solutions, and therefore the product is usually prepared in water solution. That is, the existing conditions will restrict applications of the Ag nanoparticles.
[0006] The above problems have been discussed in some reports. In J. Phys. Chem. B 1998, 102, 10663-10666, the Ag particles are prepared in water solution and stabilized with molecular chains of sodium polyacrylate or polyacrylamide. In Chem. Mater. 2005, 17, 4630-4635, thioalkylated poly(ethylene glycol) is used as a stabilizer for stabilizing Ag particles in water. In Langmuir 1999, 15, 948-951, 3-aminopropyltrimethoxysilane (APS) is used as a stabilizer and N,N-dimethylformamide is used to reduce silver ions in water. In J. Phys. Chem. B 1999, 103, 9533-9539, sodium citrate is used to prevent the Ag particles from aggregation or agglomeration which results in larger particle size, wider size distribution or multiple-peak distribution. In Langmuir 1996, 12, 3585-3589, some nonionic surfactants (polyethylene oxide or ethoxylated block) are used to stabilize Ag nanoparticles which are in the form of gel-type particles covered with molecular chains of the surfactant, the examples include poly-(10)-oxyethylene oleyl ether and Tween 80 (polyoxyethylene-(20)-sorbitan monooleate) (available from Sigma). In Langmuir 1997, 13, 1481-1485, NaBH 4 is used as a reducing agent, and the reaction equation is:
[0000] 2AgNO 3 +2NaBH 4 +6H 2 O→2Ag+2NaNO 3 +2H 3 BO 3 +7H 2
[0000] In this reaction, the stabilizers are cetyltrimethylammonium bromide (CTAB) as a cationic surfactant, sodium dodecyl sulfate (SDS) as an anionic surfactant and poly(oxyethylene) isooctylphenyl ether-TX-100 as a nonionic surfactant.
[0007] As described in the above, the traditional method for stabilizing Ag particles is to add surfactants or stabilizers. However, the solutions of such Ag particles have solid contents less than 10% and can not be in the form of silver slurry, or have a higher solid content with aggregation.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide a polymeric polyamine and a method for producing the same, wherein polymeric polyamine can be applied to producing Ag nanoparticles for stabilizing and dispersing.
[0009] Another object of the present invention is to provide a method for stabilizing Ag nanoparticles with polymeric polyamine, so that the produced silver slurry, silver gel or solid silver has a high solid content and good stability, even after processing treatment or preservation.
[0010] To achieve the above objects, polymeric polyamine of the present invention includes polyoxyalkylene-amine and a linker linking with an amino end thereof. The polyoxyalkylene-amine is preferably monoamine, diamine or triamine having a molecular weight about 200˜10,000, and the linker can be anhydride, carboxylic acid, epoxy, isocyanate or poly(styrene-co-maleic anhydride) copolymers (polystyrene-maleic anhydride polymers, SMA).
[0011] The proper linker includes: (1) anhydride, for example, maleic anhydride, succinic acid anhydride, trimellitic anhydride (TMA), benzene tetracarboxylic dianhydride (PMDA), phthalic anhydride, tetrahydromethyl-1,3-isobenzofurandione and poly(styrene-co-maleic anhydride) copolymers; (2) carboxylic acid, for example, dicarboxylic acid, adipic acid, succinic acid, p-phthalic, isophthalic acid; (3) glycidyl or epoxide, for example, diglycidyl ether of bisphenol-A (DGEBA), 3,4-epoxycyclohexyl-methyl-3,4-epoxy cyclohexane carboxylate; (4) isocyanate or diisocyanate, for example, toluene diisocyanate, methylen-biphenyldiisocyanate, 1,6-cyclohexamethylene-diisocyanate, methyl isopropyl ketone diisocyanate; and (5) maleic anhydride or maleated polystyrene, for example, SMA. The preferred linker includes benzene tetracarboxylic dianhydride (PMDA), trimellitic anhydride (TMA) and adipic acid.
[0012] The polymeric polyamine can have a structural formula: Linker-HN—R—NH-Linker, H 2 N—R—NH-Linker, H 2 N—R—NH-Linker, H 2 N—R—NH-Linker-NH—R—NH 2 , Linker-(HN—R—NH-Linker)x or H 2 N—R—NH-(Linker-HN—R—NH)x-H; wherein x=1˜5, H 2 N—R—NH and HN—R—NH are polyoxyalkylene-amine, R can be dianhydride, diacid, epoxy, diisocyanate or poly(styrene-co-maleic anhydride) copolymers (SMA).
[0013] The method for producing polymeric polyamine is to react polyoxyalkylene-amine with a linker having a reactive functional group. Segments of polymeric polyamine may chelate silver nanoparticles, and disperse in both water phase and an organic solvent. Accordingly, the Ag nanoparticles can be prepared as a stable concentrated gel, slurry or powders having a concentration more than 10 wt %. The polyoxyalkylene-amine and the linker are defined as the above.
[0014] For the process, molar ratio of the polyamine to the linker can be changed to synthesize Linker-(HN—R—NH-Linker)x or H 2 N—R—NH-(Linker-HN—R—NH)x-H, having different end functional groups.
[0015] After reaction of polyoxyalkylene-amine and the linker, the linker provides additional functional groups to enhance stability of silver in water or the organic solvent by chelating with silver. The solution will be more stable and the nanoparticles will not aggregate together.
[0016] The molar ratio of the linker to polyoxyalkylene-amine is preferably (n+1): n, n=1˜5, the reaction temperature is preferably about 25˜150° C., and the reaction time is preferably about 1˜12 hours.
[0017] In the present invention, the method for stabilizing Ag nanoparticles with polymeric polyamine includes steps of: (a) mixing polymeric polyamine and a water solution of silver salt; (b) reducing the Ag + ions with a reducer to form a solution of Ag nanoparticles. The polymeric polyamine serves as a stabilizer or a dispersant and comprises polyoxyalkylene-amine and a linker linking with an amino end of polyoxyalkylene-amine.
[0018] The polyoxyalkylene-amine has a molecular weight about 200˜10,000, and the linker is selected from the group consisting of anhydride, carboxylic acid, glycidyl, epoxide, isocyanate, diisocyanate, maleic anhydride and maleated polystyrene.
[0019] The reducer can be NaBH 4 , methanol, ethanol, glycerin, ethylene glycol, dodecanol, H 2 N—NH 2 , formaldehyde, PVA or DMF. The weight ratio of polymeric polyamine to the silver salt is preferably about 1:10˜10:1. The silver salt can be AgNO 3 , AgI, AgBr, AgCl or silver pentafluoropropionate.
[0020] The solution of Ag nanoparticles can be further dewatered to increase solid content thereof. An organic solvent can be also added to transfer the particles into the organic solvent.
[0021] The solution of Ag nanoparticles can further comprise sodium hydroxide with a molar ratio to the Ag salt more than 1, so that water solubility of the solution will be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows stable distribution of the Ag nanoparticles in the TEM picture;
[0023] FIG. 2 shows the size distribution of the Ag nanoparticles in the AFM picture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Materials used in the preferred embodiments of the present invention include:
1. Polyoxyalkylene-amine
[0026] product of Huntsman Chemical Co., Jeffamine® Amines series, including:
[0027] a. Jeffamine ED-2001: poly(oxypropylene-oxyethylene-oxypropylene)-bis-amines, polyoxyalkylene-amine with two functional groups, molecular weight=2000 (a.k.a. POE-2000), white color, hydrophilic, wax-like solid, mp. 35° C., amino content=0.95 mequiv./g, average oxyethylene/oxypropylene unit=39.5/5, structural formula:
[0000]
[0028] wherein a+c=6, b=38.7;
[0029] b. Jeffamine M-2070: poly(oxypropylene-oxyethylene)-monoamine, polyoxyalkylene-amine with single functional group, molecular weight=2000 (a.k.a. POP-2000), hydrophobic, structural formula:
[0000]
[0000] wherein a=10, b =31.
2. Trimellitic anhydride (TMA)
[0031] product of Aldrich Chemical Co., purified with sublimation before using, structural formula:
[0000]
3. Benzene tetracarboxylic dianhydride (PMDA)
[0033] product of Aldrich Chemical Co. or Sino-Japan chemical Co.
4. Poly(styrene-co-maleic anhydride) copolymers (SMA)
[0035] product of Aldrich Chemical Co. or Sino-Japan chemical Co., ratio of styrene/maleic anhydride or maleated polystyrene can be 1/1, 3/1, 6/1 or 11/1, average molecular weight=6,000 (SMA1000), 6,000 (SMA3000), 120,000 (SMA6000) and 140,000 (SMA 11000).
5. 4,4′-methylenebis(phenyl isocyanate) (MDI) 6. Silver nitrate
[0038] AgNO 3 (99.8%), product of Aldrich.
7. Tetrahydrofuran (THF) 8. NaBH 4
[0041] a reducing agent.
9. NaOH
[0043] In the present invention, the method for producing polymeric polyamine is to polymerize hydrophilic or hydrophobic polyoxyalkylene-amine with the linker. The product could be hydrophilic or hydrophobic.
[0044] The reaction is exemplified with schemes. When the linker is TMA, polyoxyalkylene-amine is hydrophilic POE2000 or hydrophobic POP2000, and sodium hydroxide is added for modifying the ions after the reaction, the reaction equations are as follows:
[0000]
[0045] When the linker is PMDA, polyoxyalkylene-amine is hydrophobic POP2000, and sodium hydroxide is added for modifying the ions after reaction, the reaction equations are as follows:
[0000]
[0046] When the linker is SMA and polyoxyalkylene-amine is various, comb-like polymers can be obtained as follows:
[0000]
[0047] When the linker is MDI and polyoxyalkylene-amine is various, the reaction equations are as follows:
[0000]
EXAMPLE 1
Step (A): Preparing a Stabilizer POE2000-TMA/4COOH
[0048] First, hydrophilic POE2000 (Jeffamine® ED-2001) is purified with sublimation. THF is dewatered with calcium hydride and then preserved with molecular sieves. Next, to a three-necked bottle (500 ml), POE2000 (100 g, 0.05 mol) is added and dissolved in THF (150 ml), and then anhydride linker TMA (19.2 g, 0.10 mol, previously dissolved in THF (50 ml)) is added drop by drop, so that molar ratio of POE2000 to TMA is 1:2. The reactant is mechanically stirred and filled with nitrogen during the whole reaction. The reaction is performed at 30° C. for 2 hours or longer. FT-IR spectrum is used for monitoring progress of the reaction by sampling every period of time until the anhydride functional groups disappear. After the reaction is completed, THF is removed by decompression to obtain creamy glue product, amido acid POE2000-TMA/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0049] To a three-necked bottle, the stabilizer POE2000/4COOH (0.069 g) is dissolved in water (50 g) which is stirred with a magnetic stirrer. AgNO 3 (0.045 g) is then added later. After 2 hours, a NaBH 4 solution (0.015 g, previously dissolved in water (50 g)) is added incontinuously and vigorously agitated. The solution immediately becomes black. The reactor is filled with nitrogen during whole reaction.
EXAMPLE 2
Step (A): Preparing a Stabilizer POE2000-TMA/2COOH
[0050] The product POE2000/4COOH of Example 1 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying imido functional groups. The product is imido acid POE2000/2COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0051] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000/2COOH.
EXAMPLE 3
Step (A): Preparing Stabilizer POP2000-TMA/4COOH
[0052] Repeat Step (A) of Example 1, but hydrophilic POE2000 is replaced with hydrophobic POP2000 to obtain product imido acid POP2000/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0053] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000/4COOH.
EXAMPLE 4
Step (A): Preparing Stabilizer POP2000-TMA/2COOH
[0054] The product POP2000/4COOH of Example 3 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying imido functional groups. The product is imido acid POP2000/2COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0055] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000/2COOH.
EXAMPLE 5
Step (A): Preparing Stabilizer POP2000-PMDA/8COONa
[0056] To a three-necked bottle (500 ml), POP2000 (40 g, 0.02 mol) is added and dissolved in THF (100 ml), and then the dianhydride linker TMA (6.54 g, 0.03 mol, previously dissolved in THF (100 ml)) is added drop by drop, so that molar ratio of POP2000 to PMDA is 2:3. The reactant is mechanically stirred and filled with nitrogen during the whole reaction. The reaction is performed below 30° C. for 3 hours. FT-IR spectrum is used for monitoring progress of the reaction by sampling every period of time until the anhydride functional groups disappear. After the reaction is completed, THF is removed by decompression to obtain creamy glue product, amido acid POP2000-PMDA/8COOH. Into the product POP2000-PMDA/8COOH (3.2 g, 0.08 mol), NaOH is added to form a water-soluble polymeric sodium compound.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0057] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000-PMDA/8COOH.
EXAMPLE 6
Step (A): Preparing Stabilizer POE2000-PMDA/4COOH
[0058] The product POE2000-PMDA/8COOH of Example 5 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying amido functional groups. The product is amido acid POE2000-PMDA/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0059] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000-PMDA/4COOH.
EXAMPLE 7
Step (A): Preparing Stabilizer POP2000-SMA/COOH
[0060] SMA and POP2000 are previously dewatered in vacuum at 120° C. for 6 hours. SMA3000 (10.0 g, 24.4 mmol of MA) and POP2000 (97.6 g, 48.8 mmol) are respectively dissolved in THF (50 mL). Next, SMA is incontinuously added into POP2000. To prevent cross-linking, the molar ratio of POP2000 to SMA is more than 1. Progress of the reaction is monitored with GPC and IR to confirm no cross-linking between the synthesized comb-like polymers. The excess POP2000 is isolated with a solvent mixture of water (or toluene) and ethanol due to different solubilities of the comb-like polymer and the straight-chain polyoxyalkylene-amine. The unreacted POP2000 can be dissolved in the solvent mixture and POP2000-SMA/COOH precipitates.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0061] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000-SMA/COOH.
EXAMPLE 8
Step (A): Preparing Stabilizer POE2000-POP2000-MDI
[0062] Jeffamine® ED-2001 and M2070 are first dewatered in a vacuum oven at 100° C. for 6 hours, and MDI is purified with decompressing distillation. To a three-necked bottle (100 ml), the linker MDI (1.5 g, 6 mmol, previously dissolved in toluene (15 g)) is added, and then ED-2001 (5.99 g, 3 mmol, previously dissolved in toluene (10 g)) is added drop by drop. The solution is continuously mixed with a magnetic stirrer. Next, M2070 (11.99 g, 6 mmol, previously dissolved in toluene (20 g)) is added into the solution. The molar ratio of MDI: ED-2001: M2070 is 2:1:2. The reactor is filled with nitrogen during the whole reaction. Progress of the reaction is monitored with FT-IR until the characteristic functional groups of MDI disappear. The solvent is removed from the solution by heating in a vacuum oven at 80° C. for 12 hours. The product is creamy glue.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0063] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000-POP2000-MDI.
COMPARATIVE EXAMPLE 1
[0064] Repeat the procedures of Example 1, but the stabilizer POE2000-TMA/4COOH is replaced with POE2000. After the reaction, a lot of silver particles precipitate on the bottom of the bottle, which shows that the stabilizer synthesized by the method of the present invention is required.
Analysis of the Product
[0065] Properties and features of the product of Example 1 are analyzed with instruments and results are as follows:
1. Formation of the Ag Nanoparticles
[0066] The Ag nanoparticles are identified by UV absorbance at wave length 400 nm.
2. Stability of the Ag Nanoparticles
[0067] FIG. 1 shows TEM pictures of the products concentrated with a rotary evaporator or a drier to have concentrations of 0.01 wt. % (picture a), 0.3 wt. % (picture b), 0.01 wt. % (picture c, diluted from the slurry of 0.3 wt. %), and 0.01 wt. % (picture d, diluted after evaporated). As shown in FIG. 1 , the Ag nanoparticles uniformly distribute and have diameters less than 30 nm after heating at 80° C. for 1 hour. That is, the solution containing Ag nanoparticles of the present invention is highly stable.
3. Diameter Distribution
[0068] FIG. 2 shows AFM pictures and distribution of the Ag nanoparticles, in which diameters of the Ag particles range about 33˜25 nm.
Concentrating Process
[0069] The Ag nanoparticles of the present invention can be concentrated to 10 wt % or higher with an evaporator or a drier, for example, decompression at 80° C. or freezing at 0° C. The highly concentrated solution can be also diluted and the dilution also exhibits good dispersibility and thermal stability.
[0070] The traditional silver solution has a concentration limit of 5 wt % and easily forms participate or aggregation. Contractively, by means of the present invention, solid content of the solution containing Ag nanoparticles can be promoted to 10 wt % or even higher. The most important factor is that a novel stabilizer, polymeric polyamine, is provided in the reduction reaction of silver salt into Ag nanoparticles. Molecular weight of the Ag nanoparticles is about 500˜10,000 mol/g, and the functional groups may include anhydride, carboxylic acid, epoxy and isocyanate.
[0071] According to the above, features or advantages of the present invention at least include:
[0072] 1. Different sizes of Ag nanoparticles can be obtained by using a synthesized polymeric dispersant and controlling the ratio of polymeric polyamine to silver.
[0073] 2. The prepared silver dispersion can be concentrated as a silver slurry which can be also diluted as a stable dispersion. The dispersing media can be water or other suitable organic solvents, for example, methanol, ethanol, IPA, acetone, ethylene glycol, dimethylformamide, N,N-dimethylacetamide N-methyl-2-pyrrolidinone, THF, MEK, etc.
[0074] 3. The Ag nanoparticles of the present invention are both hydrophilic and hydrophobic and thus are compatible with polymer in nanoscale. The highly concentrated solution of Ag nanoparticles can be applied to blending with organic polymer (for example, PI, Epoxy, Nylon, PP, ABS, PS, etc.), so as to improve conductivity, antimicrobial (properties) thereof. | The present invention discloses a polymeric polyamine which can be produced by polymerizing polyoxyalkylene-amine and a linker. The linker can be anhydride, carboxylic acid, epoxy, isocyanate or poly(styrene-co-maleic anhydride) copolymers (SMA). The present invention also discloses a method for stabilizing the Ag nanoparticles with polymeric polyamine. The polymeric polyamine serving as a stabilizer or dispersant is mixed with a water solution of silver salt and then a reducer is provided to reduce the silver ions and form an organic or a water solution of Ag nanoparticles. Water or solvent of this solution can be further removed through a heating, freezing or decompression process, and thus solid content of the solution can be increased. The concentrated solution also can be diluted to obtain a stable dispersion without aggregation. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for detecting a power loss to an appliance and storage of current operation settings of the appliance when the power loss occurs.
Some appliances such as washing machines and dryers include a feature that allow the appliance to retain current operation settings in the event of a power outage. This is accomplished by monitoring the AC power input to the appliance, detecting when the AC power is lost and saving the current operation settings in a memory device such as a EEPROM so that when power is restored the washing machine cycle or dryer cycle will resume at the point in the cycle when power was lost. The period of time between loss of AC power and saving of the operation settings is critical since during this time a microprocessor or controller within the appliance is powered by a charged capacitor. Hence, the quicker that the current operation settings can be saved the more likely that the settings will actually be stored within the EEPROM.
In order to ensure that there is sufficient charge on the capacitor during power outage to store the current operation settings, an approach has been to increase the size of the capacitor so as to store more charge. However, larger capacitors are more expensive.
Additionally, appliances such as a washing machine or a dryer typically have a motor that turns a washing drum or a drying chamber, respectively. Other appliances, such as dishwashers, include motors which drive pumps. Microwave ovens often times include motors which drive rotating turntables. Most other domestic appliances also include motors and/or heating elements. During the power outage, the motor within the appliance continues to rotate for a short time, especially given a large washing or drying load, which increases the mass and, hence, the momentum of the washing drum or the drying chamber. This continued rotation of the motor after power outage causes transient voltages to be generated from the motor on the incoming line, that, in turn, cause noise to be present in the supply to a control microprocessor that is supplied with power by the incoming line through a power supply circuit. This noise creates a problem in that the microprocessor senses this noise and, thus, does not quickly recognize that power on the incoming AC line has been lost. Furthermore, by the time that the microprocessor recognizes power loss, the capacitor used to store the current operation settings of the appliance has been partially discharged due to continued operation of other loads such as a relay coil driving a contact to the motor or a heater element. The partial discharge of the capacitor during the time that the microprocessor does not recognize power loss leads to the inability of the microprocessor to save current operation settings since enough charge on the capacitor does not remain to effect this storage.
SUMMARY OF THE INVENTION
There is therefore a need for an apparatus and method for more quickly recognizing loss of input power to a device, such as an appliance, so that operation settings will not be lost in the event of transient noise generated from an electromechanical device within the device. Additionally, the need exists for faster recognition of AC power loss in order to reduce the discharge time of a capacitor and, hence, allowing the capacitor to have a smaller value.
These and other needs are met by the present invention including a method for monitoring power input to a device where at least a voltage signal on an incoming line to the device is monitored. Variations of a frequency of at least the monitored voltage signal from a prescribed frequency are sensed and a power loss signal is issued when a variation of the frequency from the prescribed frequency exceeds a first predetermined amount. The power loss signal indicates a detected loss of power input on the incoming line. By sensing variations of the frequency of the monitored voltage signal, the present method is able to take into account transient noise generated by a motor after power loss more quickly than the known art.
According to another aspect of the present invention, a method for monitoring power input to an appliance and storing current operation settings of the appliance when the power input is lost includes monitoring at least a voltage signal on an incoming line to the device and sensing variations of a frequency of at least the monitored voltage signal from a prescribed frequency. When a variation of the frequency from the prescribed frequency exceeds a first predetermined amount a power loss signal is issued. The power loss signal indicates that a loss of power input on the incoming line has been detected. Relay coils that control power input to at least one of an electromechanical device and heating device within the appliance are pulsed at a predetermined duty cycle in response to the power loss signal in order to increase a discharge time of an electric charge on a capacitor connected to the input line and also connected to the relay coil. Finally, current operation settings of the appliance are simultaneously stored in a memory using the charge of the capacitor. The pulsing of the relay coils allows the relay coils to still maintain closed contacts in order to avoid an unnecessary opening of the contacts in a situation such as a brown out, thereby mitigating deleterious effects to the relay coils in these situations. Additionally, since the relay coils are driven by capacitor power, the pulsing at a predetermined duty cycle conserves charge on the capacitor that is later or simultaneously used for storing the current operation settings. Hence, enough capacitor charge will be present to ensure proper storing of the current operation settings. A further advantage is that a smaller capacitor can be utilized since the pulsing of the relay coils affords conservation of capacitor charge, and, thereby, a minimization of capacitor cost.
According to yet another aspect of the present invention an apparatus is provided for monitoring power input to an appliance and saving current operation settings of the appliance in the event of a power input loss. The apparatus includes a power input line for supplying a power input to the appliance. In addition, a power supply circuit for converting a voltage of the power input into a plurality of supply voltages is included. A capacitor within the power supply circuit is connected between the first supply voltage and a ground. A voltage sensing circuit is connected to the second supply voltage and outputs a sensing signal having a frequency that corresponds to a power input frequency of the power input line. One or more relay coils that control power input from the power input line to at least one of an electromechanical device and a heating device within the appliance are included. Current operation settings of the appliance are stored by a provided memory device. A controller is included that is configured to detect the frequency of the sensing signal, control the relay coils and store current operation settings of the appliance in the memory device. The controller pulses the relay coils using an electric charge from the capacitor at a prescribed duty cycle and also stores current operation settings of the appliance in the memory device using the same electric charge from the same capacitor when the controller detects a change in the frequency of the sensing signal after a predetermined number of cycles of the sensing signal.
Additional advantages and novel features of the invention will be set forth, in part, in the description that follows and, in part, will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the attached drawings wherein:
FIG. 1 is a partly cutaway perspective view of a clothes dryer employing the power input monitoring and current operation setting memory storage of the present invention; and
FIG. 2 is a circuit diagram of the monitoring and control circuit according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is applicable to various appliances or devices that have the capability of storing current operation or cycle settings in the event of a loss of power input and, in particular, to appliances and devices also having an electromechanical device such as a motor that may potentially present transient voltages during the time period immediately following loss of a power input. The present invention, for purposes of explanation, will be described in the context of an automatic clothes dryer. However, the present invention is, as mentioned above, applicable to various appliances and devices.
In FIG. 1 of the drawings, an automatic clothes dryer 10 is illustrated that is controlled, in part, by the control apparatus 200 shown in FIG. 2 . Specifically in FIG. 1, the mechanical components of the clothes dryer are well known in the art and are, thus, not shown in great detail. The clothes dryer 10 has a cabinet 12 including a control console 14 . Within the cabinet 12 is rotatably mounted a drum 16 that is rotatably driven about a horizontal axis by a motor 18 through a drive system 20 , typically including a belt 21 . A front door 22 formed in the front of the cabinet 12 provides selective access to the clothes treatment chamber 24 defined by the interior of the drum 16 .
The drum 16 is provided with an inlet aperture 26 and an outlet exhaust aperture 28 having a removable lint screen 30 . A supply of air is circulated by a fan 32 driven by the motor 18 . A heating element 34 is selectively energized by a relay coil 220 , shown in FIG. 2, that is controlled by a controller 216 located within the control console 14 , for example. As is well known in the art, supply of the temperature controlled air is circulated by the fan 32 past the heating element 34 through the inlet aperture 26 into the clothes treatment chamber 24 within the drum 16 and subsequently output through the outlet exhaust aperture 28 including the lint screen 30 .
The control console 14 includes a user interface 37 having, for example, a start button 38 , a dryness selector 40 and a temperature selector 42 to permit a user to start a drying cycle, as well as select other operation settings and parameters of the drying cycle. Further, the user interface 37 may also include means to allow a user to set time settings (not shown) such as a period of time in which the dryer is allowed to operate.
It is noted that the control circuitry of FIG. 2 may be located within the control console 14 . However, other locations within the appliance 10 for the control circuitry could be utilized. Typically, input power for the dryer 10 is supplied from a 208 V.A.C. or 240 V.A.C. power source by means of an input power supply 36 , such as via a three-wire pigtail. In the present embodiment shown in FIG. 2, a single phase line L 1 is input to the power supply and control circuitry 200 . This voltage typically is 120 V.A.C.
As shown in FIG. 2, an input voltage to the control circuit 200 is derived from line L 1 and a neutral, shown delivered to terminals 202 and 204 , respectively. The input power is delivered to a power supply circuit 203 within the control circuit 200 to a primary coil 206 of a transformer 205 . The line voltage L 1 is transformed down to approximately 5 volts in a preferred embodiment across the secondary coil 208 , although other voltages could be used. This voltage is rectified via diodes D 1 and D 2 to supply a full wave rectified alternating voltage V.A.C. In addition, a capacitor C 1 is connected from the output of the full wave rectifier (i.e., diodes D 1 and D 2 ) to a potential VSS connected to ground. The voltage VUNR at node 209 is also delivered to voltage regulator 210 , which outputs a steady state 5 volt signal. This 5 volts is split into a +5 volts source and a VDD source.
The control circuit 200 also includes a voltage sense circuit 212 comprised of a transistor T 1 diode D 5 and filtering capacitors C 4 and C 5 . The voltage V.A.C. from node 207 is input to the base of transistor T 1 via diode D 5 . Thus, this AC signal, which is typically 60 Hertz, turns on transistor T 1 during every other half cycle since diode D 5 acts as a half wave rectifier. When transistor T 1 is in an “on” state allowing conduction of the 5 volt source through resistance R 1 to ground potential VSS, the output 214 of the voltage sense circuit 212 is at a low state. During the next half cycle of the AC voltage V.A.C., the transistor T 1 is in an “off state preventing conduction through the transistor. At this point, the resistor R 1 pulls up the voltage on line 214 to 5 volts until the next half cycle of voltage source V AC. At that time, T 1 again becomes conductive and the voltage on line 214 is again brought to ground or zero potential. Accordingly, the output of the voltage sense circuit 212 is a square wave signal which is delivered to the V AC sense input of controller 216 . Since, during normal operation, the incoming line is operating at 60 Hertz frequency, the square wave signal out of voltage sense circuit 212 also has a frequency of 60 Hertz with a cycle of 16.66 milliseconds. Thus, a typical half cycle of the square wave is 8.33 milliseconds.
With the voltage sense circuit 212 , any change in the cycle length or, more particularly, the time between zero crossings of the square wave signal output from the voltage sense circuit, varying from a time period of 8.33 milliseconds can be sensed and such variation can be used to indicate that the incoming line voltage has either been lost or is undergoing a brown-out situation. Since capacitor C 1 maintains a charge even after line voltage L 1 is lost, the 5 volt signal is supplied to the voltage sense circuit 212 for a short period. As described previously, the motor 18 may continue to rotate for a short time after the line voltage L 1 is lost and, therefore, acts as a generator presenting transient voltages on the line L 1 . These transient noise signals are, in turn, transformed in the power supply circuit 203 and are present at the node 207 for voltage V.A.C. The motor 18 immediately begins to lose momentum as power on line L 1 is lost and causes the voltage V.A.C. to vary from the normal 60 Hertz or, in other words, the normal 8.33 millisecond half cycle period. Recognizing that this occurs, detection of variations in the zero crossing of the square wave signal output from the voltage sense circuit 212 may be used to quickly recognize either a power loss or a brown out on line L 1 .
The controller 216 contains internal software that is programmed to sense the period of the incoming square wave signal on line 214 and initiate an internal power loss signal when the half cycle period varies from 8.33 milliseconds. This controller is powered by voltage source VDD in normal operation. In the situation of a power loss or brown out, the capacitor C 1 provides energy to the controller for a short time period. The controller 216 also controls transistors T 2 and T 3 that drive relay coils 220 and 222 , respectively. Normally, the outputs OUT 1 and OUT 2 are a steady state voltage that holds transistors T 2 and T 3 in an “on” state. Relay coil 220 is supplied with the voltage VUNR and closes switch 224 to cause the heating element 34 to energize. Similarly, relay coil 222 is used to control the operation of motor 18 which is switched to line L 1 directly via switch 226 driven by relay coil 222 .
The controller 216 also has a third output OUT 3 that is used to save current operation settings of the appliance in an EEPROM 218 , which is also supplied by voltage source VDD. The EEPROM is used to store the current operation settings in the event of a power outage on line L 1 .
In the event of a power loss or brown out on line L 1 , the voltage sense circuit 212 begins to output a square wave signal having a time between voltage zero crosses of greater than 8.33 milliseconds. Furthermore, if the motor 18 is operating at the time of power loss or brown out, transient noise voltages will be generated on line L 1 . As the motor slows, the time between zero crossings of the voltage of the output of voltage sense 212 will begin to increase to times of 9 milliseconds, 10 milliseconds, etc. In the present invention, the controller is programmed to sense any variation from a voltage zero-cross time of 8.33 milliseconds. After the first half cycle that varies from this time, the controller initiates pulsing of the output signals OUT 1 and OUT 2 at a prescribed duty cycle that is less than 100% or, in other words, less than a steady state voltage. This pulsing is performed in order to protect the relay coils 220 and 222 from excessive wear and damage that can be caused by simply allowing them to turn off. In the event of a complete power loss or a brown out where the line voltage L 1 drops below 120 volts, the charge on capacitor C 1 is used to supply the voltage VDD to the controller and also the voltage VUNR to drive the relay coils C 1 and C 2 . Additionally, the controller needs only pulse transistor T 2 or T 3 when either the heating element 34 or the motor 18 was required to be run at that particular point in the drying cycle. Pulsing of the relay coils is preferably accomplished with a 50% duty cycle, which enables the coils to still operate, yet consumes less of the capacitor energy of the capacitor C 1 . Furthermore, in the event of a brown out, pulsing the relay coils maintains the connection via switches 224 and 226 to the heater 34 or motor 18 , respectively during the dip in voltage occurring during the brown out such that when the voltage again rises to normal operating voltage, no disruption in the settings of these switches occurs.
In the event of a complete power loss, pulsing of the transistors T 2 and T 3 conserves the charge energy in capacitor C 1 for a longer period of time. In a preferred embodiment, the controller 216 waits for four detected cycles of the output of voltage sense circuit 212 before storing the current operation settings to the EEPROM 218 , the storage operation also using the charge energy of capacitor C 1 to perform this operation. Preferably, the controller is programmed to wait for four cycles of the square wave output (i.e., approximately 64 msec) from the voltage sense circuit 212 before storing the current operation settings in the EEPROM 218 . This time delay allows the controller 216 to accurately determine whether a loss of power on line L 1 has occurred or merely a brown out before saving the current settings. Hence, unnecessary storage of current operation settings is avoided. Greater or lesser numbers of detected longer periods could be used, depending on the appliance, typical motor loads and other power demands. However, the number should preferably not be so low that unnecessary storage operations are frequently performed nor should the number be so high that the capacitor charge is frequently discharged prior to the saving of the operation settings.
The pulsing of the relay coils is advantageous in conserving energy from capacitor C 1 which is used to supply power to the relay coils 220 and 222 , the controller 216 , the voltage sense circuit 212 and the EEPROM 218 . Preferably, the capacitor C 1 is of sufficient size to afford enough charge to both pulse the relay coils and to effect storage of current operation settings in the EEPROM 218 . In order to provide sufficient charge, the capacitor C 1 is set at a value of approximately 2200 μF to provide about 300 milliseconds of available charge, which is sufficient to effect operation of the above mentioned devices. It is noted, however, the value of the capacitor C 1 is set in conjunction with the effective resistance of the circuit in which the capacitor C 1 is contained in order to achieve an RC time constant to allow sufficient time to store the operation settings in the BEPROM 218 . The capacitor C 1 value however, is nonetheless much smaller than would be required absent the pulsing operation of the coils and the quick voltage sensing afforded by voltage sense circuit 212 . Thus, the capacitor C 1 is a “smaller value” than would otherwise be required, which also reduces the cost of the control circuit 200 . The above provides a detailed description of the best mode contemplated for carrying out the present invention at the time of filing the present application by the inventors thereof. It will be appreciated, however, by those skilled in the art that many modifications and variations, which are included within the intended scope of the claims, may be made without departing from the spirit of the invention. | A method and apparatus for monitoring voltage input to an appliance, such as a dryer, sensing when power input to the appliance is lost. In addition, a controller in the appliance pulses relay coils controlling motors and/or heating devices within the appliance to conserve energy on a backup capacitor that supplies the control circuit of the appliance in the event of power loss. Further, a voltage sense circuit outputting a square wave effects monitoring of the input voltage to the appliance by outputting the square wave signal whose cycle period is monitored to determine power outage. The controller stores current operation settings at the time of power outage in a memory device and ensures proper storage through the extra energy conserved from the capacitor by the pulsing of the relay coils. | 3 |
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for increasing the thrust applied to coiled tubing over that applied by its injector alone during its injection into and withdrawal from a well bore. The apparatus of the invention is mounted in series with an injector and is used in situations where additional thrusting force is required to cause the tubing in the well bore to overcome high resisting forces due to obstructions, the annulus being sanded up, or the like. The apparatus provides a short, repeatable reciprocating stroke in either direction.
BACKGROUND OF THE INVENTION
Devices and methods for injecting coiled tubing into and retrieving it from wells are well known. Prior art injection systems include U.S. Pat. Nos. 6,142,406; 5,842,530; 5,839,514; 5,553,668; 5,309,990; 5,244,046; 5,234,053; 5,188,174; 5,094,340; 4,899,823; 4,673,035; 4,655,291; 4,585,061; and many other similar disclosures. In the prior art an injector at the wellhead is used to grip and control the injection and withdrawal of the tubing.
Conventional track injectors utilize gripper blocks mounted on two continuous parallel and opposed conveyor chains which are urged or pushed against the outer surface of the tubing. The interface forces between the gripper blocks and the tubing permit developing frictional forces which are used to transfer tangential loads from the conveyor chains to the tubing and vice versa. If insufficient interface force is applied to the tubing by the gripper blocks, slippage with attendant loss of control and wear occurs between the blocks and tubing. If excessive interface force is applied to the tubing by the gripper blocks, the tubing wall may be distorted and damaged or the injector may be damaged. A problem with such tracks results when the track is rotated into or out of engagement with the tubing from the sprockets at the ends of the track mounting assembly. This rotation can cause differential movement between the track and the tubing in the direction of the tubing axis so that rubbing occurs. This rubbing will cause undesirable wear of both the tubing and the gripper blocks.
Historically, the approach used to increase the injection forces with conventional track injectors has been to lengthen the injector while maintaining a sufficiently safe interface force between the individual gripper blocks and the tubing. U.S. Pat. No. 5,842,530 for example shows provision of substantially more gripper blocks along the length of its injector.
Other injectors utilizing two continuous, parallel, and opposing track injectors having grooved shoes or blocks mounted thereon are known in the art. These opposing track units have facing portions where the multiplicity of gripping blocks run parallel for gripping the tubing therebetween and are typically positioned in line, directly adjacent and above the wellhead.
Another approach has been to utilize a large diameter driven wheel with an annularly is grooved outer diameter to conform to and support the tubing. Relatively small-diameter hold-down idler rollers radially press the tubing against the wheel to provide extra interface force between the tubing and the wheel so that high tangential frictional forces can be imparted to the tubing by the wheel without maintaining large back tensions. These hold-down rollers have arcuate faces to match the tubing. One such wheel type injector is disclosed in U.S. Pat. No. 5,839,514.
A more recent injector system known in the art is a linear injector, which pulls on only one side of the tubing. For this type of device, coiled tubing is driven along a single linear section of an endless chain conveyor with normal forces being applied by an opposing linear array of small-diameter arcuate face hold-down idler rollers. These hold-down rollers are sized to conform to the tubing. Such a linear or one-track injector eliminates the necessity of synchronizing the two opposed sides of a conventional track type injector and is less damaging to the surface of the coiled tubing, but it requires a much longer unit, which of necessity extends much higher and requires additional overhead clearance. Additionally, such an injector is more expensive because it requires a considerable number of gripper blocks and rollers and a longer support track.
Copending U.S. Provisional Patent Application “Coiled Tubing Injector Utilizing Opposed Drive Modules and Having an Integral Bender”, Ser. No. 60/304,681, filed Jul. 11, 2001, utilizes a novel approach to imparting tangential injection forces to the tubing. That invention provides support over a larger portion of the tubing circumference by positioning the driving means around the circumference of the tubing. By using a plurality of sets of opposed individually driven annularly grooved rollers which closely conform to the tubing and alternating the orientations of adjacent roller sets so that they are 90° apart about the through axis of the injector, excellent tubing support is provided. That invention is economical and efficient, as well as being lightweight, compact, easy to service and adapt for different tubing sizes.
A major problem with tubing injectors of all types is providing sufficient injection force on the tubing so that not only normal, smoothly operating injection loads are provided, but also sufficient injection force is available to overcome temporary, abnormally high resistances to tubing movement. Such abnormally high loads normally would be the result of a buildup of sand around the tubing, hanging up on a shoulder within the well, or other similar unexpected problems. Generally, such abnormally high loads only occur over a short section of a given well bore, if at all. The conventional means for overcoming such abnormally high injection forces is to use an injector which is able to provide the maximum push/pull required. Generally, the result of such an approach is that the injector is oversized for conventional non-problematic operation. Resulting in an injector that is larger, heavier, and more expensive to build and operate than is necessary for routine operations.
There exist a need for a simple and efficient method to provide an injection force in excess of that required for routine, non-problematic operation without having to provide an injector built to supply the maximum force predicted to be needed in the field.
SUMMARY OF THE INVENTION
The present invention utilizes a novel means and method for improving the system of injecting of coiled tubing into and from a well by providing a secondary injection device for supplementing the primary injector means. The secondary injection device is used to increase the axial forces in the tubing over the force provided by the primary injector alone. The selectably operable thrust enhancement device of this invention provides a short, repeatable stroke in either direction. The thrust enhancement device operates by gripping the tubing with a reciprocably moveable means in a first position, moving the moveable means to a second position thereby moving the tubing, then gripping the tubing with a static means at its new position, releasing the tubing from the moveable means, and returning the moveable means to its first position. When the thrust enhancement device is not needed for the injection operation, it is disengaged from the tubing.
One aspect of the invention is a coiled tubing injection system for moving coiled tubing into or out of a wellbore comprising a coiled tubing injector; a static tubing gripper having a closed and an open position; and a moveable tubing gripper having a closed and an open position, said movable tubing gripper being coaxially reciprocable between a first and a second position; wherein the coiled tubing injector, the static tubing gripper and the moveable tubing gripper are positioned coaxially along a length of coiled tubing and are independently selectively operable.
Another aspect of the invention is a coiled tubing injection system for moving coiled tubing into or out of a wellbore comprising a coiled tubing injector; a tubular body having a static transverse deck and a moveable transverse deck with the moveable transverse deck is coaxially reciprocable between a first and a second position; a first tubing gripper attached to the static transverse deck and a second tubing gripper attached to the moveable transverse deck. The first tubing gripper has a first and a second side, each having a back end, a central portion and a front end. The first and second sides are connected at the back ends and have a circularly arcuate groove in the central portion, where the interior surface of the groove serves as a tubing gripping surface when the first tubing gripper is in a closed position. When the first tubing gripper is in an open position the front ends of the first and second sides are separated and when it is in a closed position the front ends of the first and second sides are urged together. Similarly, the second tubing gripper has a first and a second side, each side having a back end, a central portion and a front end. The first and second sides are connected together on the back ends and have a circularly arcuate groove in the central portion, where an interior surface of the groove serves as a tubing gripping surface when the second tubing gripper is in a closed position. The second tubing gripper is in an open position when the front ends of the first and second sides are separated and in a closed position when the front ends of the first and second sides are urged together. The second tubing gripper reciprocates between a first location and a second location in tandem with the reciprocation of said moveable transverse deck between the first position and second position. The coiled tubing injector, the opening and closing of the first tubing gripper, the opening and closing of the second tubing gripper and the reciprocation of the moveable transverse deck are independently selectively operable.
Yet another aspect of the invention is a method for moving coiled tubing into or out of a wellbore using a coiled tubing injector and a thrust enhancer where the thrust enhancer comprises: (i) a tubular body having a static transverse deck and a moveable transverse deck, with the moveable transverse deck coaxially reciprocable between a first and a second position within the tubular body; (ii) a first tubing gripper attached to the static transverse deck, the first tubing gripper having a closed and an open position and an interior surface that serves as a tubing gripping surface when the first tubing gripper is in a closed position; and (iii) a second tubing gripper attached to the moveable transverse deck and reciprocating in tandem with the moveable transverse deck, where the second tubing gripper has a closed and an open position and an interior surface that serves as a tubing gripping surface when the second tubing gripper is in a closed position. The method comprising the steps of: (1) coaxially attaching the thrust enhancer to the coiled tubing injector, (b) feeding a coiled tubing through the functional path of the coiled tubing injector and the first and second tubing grippers; (c) engaging the coiled tubing injector to move tubing into or out of a wellbore; (d) closing the second tubing gripper so that its interior surface will grasp the surface of the coiled tubing; (e) moving the moveable transverse deck from the first position to the second position; (f) closing the first tubing gripper such that it grasps the surface of the coiled tubing; (g) disengaging the second tubing gripper; and (h) moving the moveable transverse deck from the second position back to its first position. Thus, the thrust applied to the coiled tubing is greater than the thrust applied by the coiled tubing injector or the thrust enhancer alone.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features which are believed to be characteristic of the invention, both as to its organization and methods of operation, together with the objects and advantages thereof, will be better understood from the following description taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an oblique view of an opened manually operated tubing clamp;
FIG. 2 is an oblique view of the clamp of FIG. 1 shown mounted to a support surface and gripping a section of tubing;
FIG. 3 is a plan view of the clamp of FIG. 1 showing the clamp in open position, but with a section of tubing within its throat;
FIG. 4 is a plan view corresponding to that of FIG. 3, but with the clamp closed and gripping the tubing;
FIG. 5 is an oblique view of a hydraulically operated powered tubing clamp mounted to a support surface, and having a closing latch wedge shifted downwardly along its axis of travel;
FIG. 6 is a bottom view of the hydraulically operated powered tubing clamp of FIG. 5 clamped on a section of tubing within its throat;
FIG. 7 is a longitudinal vertical sectional view of the closed hydraulically operated powered tubing clamp of FIG. 5;
FIG. 8 is a transverse vertical sectional view of the wedging mechanism of the closed hydraulic clamp of FIG. 7;
FIG. 9 is an oblique view showing the wedging closure block used with the hydraulic clamp of FIG. 5;
FIG. 10 is an oblique view of one embodiment of the thrust enhancement device of this invention, which utilizes the hydraulic clamp of FIG. 5;
FIG. 11 is a vertical longitudinal partially sectioned view of the thrust enhancement device of FIG. 10, in a first operational position;
FIG. 12 is a vertical transverse partially sectioned view of the thrust enhancement device of FIG. 11 in its first operational position;
FIG. 13 is a vertical transverse partially sectioned view of the thrust enhancement device corresponding to the view shown in FIG. 12, but with the device in a second operational position;
FIG. 14 is a vertical transverse partially sectioned view of another embodiment of the thrust enhancement device, which utilizes the manual clamp of FIG. 1, in a first operational position;
FIG. 15 is a vertical transverse partially sectioned view of the embodiment of the thrust enhancement device corresponding to that of FIG. 14, but with the device in its second operational position;
FIG. 16 is an exploded oblique view of the gripping elements of the hydraulically operated powered tubing clamp of FIG. 5; and
FIG. 17 is a side profile view of the thrust enhancement device of this invention showing its relationship with the other elements of a coiled tubing injection system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and initially to FIG. 1, it is pointed out that like reference characters designate like or similar parts throughout the drawings. The Figures, or drawings, are not intended to be to scale. For example, purely for the sake of greater clarity in the drawings, wall thickness and spacing are not dimensioned as they actually exist in the assembled embodiment. The materials of construction can be varied, but are preferably either mild or high-strength low-alloy steel.
Referring to FIGS. 1 through 4, the manual tubing clamp 170 used in a manually operated embodiment of this invention is shown in both an exploded and an assembled, closed oblique view and also assembled in both open and closed views down the tubing axis. Manual tubing clamp 170 consists of right-hand gripper 171 , left-hand gripper 181 , a hinge shaft 188 with hinge nuts 189 , and a pair of clamp bolts 192 with associated clamp nuts 193 . Right-hand gripper 171 has a flat vertical interior face with a vertical axis circularly arcuate groove, which serves as a tubing gripping, face 172 positioned in the middle portion of the vertical interior face. The axis of the arcuate groove is spaced slightly away from and outside the vertical interior face so that the arc of the vertical arcuate groove is less than 180°, and the diameter of the gripping face 172 corresponds to that of the tubing with which the gripper will be used. At one side of the vertical interior face two spaced apart hinge eyes 173 a,b are formed, with eye 173 a at the top and eye 173 b just below midheight. Hinge eyes 173 a,b are short cylindrical elements with coaxial vertical axes which are spaced slightly away from and outside the flat vertical interior face. The outer cylindrical faces of hinge eyes 173 a,b are tangent to the exterior vertical face of right-hand gripper 171 . The wall thickness of right-hand gripper 171 is thickened adjacent tubing gripping face 172 to support high bending stresses in that region. Vertical hinge bolt hole 174 is bored coaxially with the hinge eyes 173 a,b and passes through both those eyes. Clamping ear 175 is formed on the opposite side of right-hand gripper 171 from the hinge eyes 173 a,b and has its outer face parallel to the vertical interior face. The horizontal top and bottom surfaces and the outer transverse side of clamping ear 175 are flat. Through clamping bolt holes 176 are located in clamping ear 175 normal to the vertical interior face and symmetrically spaced about the horizontal midplane of right-hand gripper 171 .
Left-hand gripper 181 is substantially identical to right-band gripper 171 , except for the provision of an antirotation pocket for boltheads on its outer face. Left-hand gripper 181 has a flat vertical interior face with a vertical axis circularly arcuate groove, which serves as a tubing gripping, face 182 positioned in the middle portion of its vertical interior face. The axis of the arcuate groove is spaced slightly away from and outside the vertical interior face so that the arc of the vertical arcuate groove is less than 180°, and the diameter of the gripping face 182 corresponds to that of the tubing with which the gripper will be used. At one side of the vertical interior face two spaced apart hinge eyes 183 a,b are formed, with eye 183 b at the bottom and eye 183 b just below midheight. Hinge eyes 183 a,b are short cylindrical elements with coaxial vertical axes which are spaced slightly away from and outside the flat vertical interior face. The outer cylindrical faces of hinge eyes 183 a,b are tangent to the exterior vertical face of left-hand gripper 181 . The wall thickness of left-hand gripper 181 is thickened adjacent tubing gripping face 182 to support high bending stresses in that region. Vertical hinge bolt hole 174 is bored coaxially with the hinge eyes 183 a,b and passes through both those eyes. Clamping ear 185 is formed on the opposite side of left-hand gripper 181 from the hinge eyes 183 a,b and has its outer face parallel to the vertical interior face. The horizontal top and bottom surfaces and the outer transverse side of clamping ear 185 are flat. Through clamping bolt holes 186 are located in clamping ear 185 normal to the vertical interior face and symmetrically spaced about the horizontal midplane of left-hand gripper 181 . Identical extensions of the exterior flat external face of clamping ear 185 extend into the thickened wall of left-hand gripper to accommodate the enlarged heads of clamp bolts 192 . These extensions have inboard vertical edges normal to the exterior flat external face of clamping ear 185 which are offset laterally from the centerline of clamping bolt holes 186 by a distance equal to or slightly more than the eccentricity of the bolt head flats from the clamp bolt axis.
Left-hand gripper 181 has its hinge eyes 183 a,b coaxial with the hinge eyes 173 a,b of right-hand gripper 171 and is mounted inverted relative to the right-hand gripper. The length and position of hinge eyes 173 a,b and 183 a,b are such that they intermesh closely when right-band gripper 171 and left-hand gripper 181 are positioned together. Hinge shaft 188 is a long cylindrical round shaft with male threads at both ends. Hinge shaft 188 has a close sliding fit into the hinge bolt hole 174 and serves as a pivot and mounting shaft for the right-hand and left-hand grippers. Hinge shaft 188 is made sufficiently long so that it can be inserted through a supporting base for the manual tubing clamp 170 and thereby support the clamp. Internally threaded clamp nuts 189 are mounted on the top and bottom threaded portions of hinge shaft 188 to cause the components of the clamp assembly to fit closely to themselves and to their mounting base. In particular, the hinge eyes 173 a,b and 183 a,b interleave with a close fit to minimize axial play of the grippers on hinge shaft 188 . Clamp bolts 192 are inserted through clamping bolt holes 186 and 176 of, respectively, the left-hand gripper 181 and the right-band gripper 171 so that a flat on the head of each of the clamp bolts will abut the vertical transverse face of the exterior flat face extensions when the bolts are torqued. A clamp nut 193 is threaded onto the end of each of clamp bolt 192 . Approximately round coiled tubing 198 may be deployed within the arcuate tubing gripping faces 172 and 182 as shown in FIG. 2 .
Powered tubing clamp 40 , shown in FIGS. 5 , 6 , 7 , and 8 , is similar in many respects to manual tubing clamp 170 , but uses a selectably operable hydraulically driven wedge tightening system instead of clamp bolts. Power tubing clamp 40 consists of right-hand gripper 41 , left-hand gripper 51 , a hinge shaft 58 with hinge nuts 60 , two Belleville spring washers 61 , an operator cylinder support 64 , an operator cylinder assembly 69 , and wedge block 80 .
Right-hand gripper 41 has a flat vertical interior face with a vertical axis circularly arcuate groove, which serves as a tubing gripping, face 42 positioned in the central portion of the vertical interior face. The axis of the arcuate groove is spaced slightly away from and outside the vertical interior face so that the arc of the vertical arcuate groove is less than 180°, and the diameter of the gripping face 42 corresponds to that of the tubing 90 with which the gripper will be used. At one side of the vertical interior face two spaced apart hinge eyes 43 a,b are formed, with eye 43 a at the top and eye 43 b just below midheight. Hinge eyes 43 a,b are short cylindrical elements with coaxial vertical axes which are spaced slightly away from and outside the flat vertical interior face. The outer cylindrical faces of hinge eyes 43 a,b are tangent to the exterior vertical face of right-hand gripper 41 . The wall thickness of right-hand gripper 41 is thickened adjacent tubing gripping face 42 to support high bending stresses in that region. Vertical hinge bolt hole 44 is bored coaxially with the hinge eyes 43 a,b and passes through both those eyes. Clamping ear 45 is formed on the opposite side of right-hand gripper 41 from the hinge eyes 43 a,b . The horizontal top and bottom surfaces and the outer transverse side of clamping ear 45 are flat. The wedging outer surface 46 of clamping ear 45 is obverse to the vertical interior face and is flat and inclined from the vertical by an angle of approximately 6.5° so that the thickness of clamping ear 45 decreases downwardly. The taper angle of wedging outer surface 46 is chosen to be a “non-slipping angle”. A wedge with such an angle has the property that due to friction it will not slip when the wedge is under transverse load without the application of sufficient external force substantially parallel to the wedging surfaces. Located on wedging outer surface 46 parallel to and spaced away from the outer transverse side of clamping ear 45 is a rectangular guide groove of constant cross-section.
Left-hand gripper 51 is in several respects similar to right-hand gripper 41 . Left-hand gripper 51 has a flat vertical interior face with a vertical axis circularly arcuate groove, which serves as a tubing gripping, face 52 positioned in the central portion of its vertical interior face. The axis of the arcuate groove 52 is spaced slightly away from and outside the vertical interior face so that the arc of the vertical arcuate groove is less than 180°, and the diameter of the gripping face 52 corresponds to that of the tubing with which the gripper will be used. At one side of the vertical interior face two spaced apart hinge eyes 53 a,b are formed, with eye 53 b at the bottom and eye 53 b just below midheight. Hinge eyes 53 a,b are short cylindrical elements with coaxial vertical axes which arc spaced slightly away from and outside the flat vertical interior face. The outer cylindrical faces of hinge eyes 53 a,b are tangent to the exterior vertical face of left-hand gripper 51 . The wall thickness of left-hand gripper 51 is thickened adjacent tubing gripping face 52 to support high bending stresses in that region. Vertical hinge bolt hole 44 is bored coaxially with the hinge eyes 53 a,b and passes through both those eyes. Clamping ear 55 is formed on the opposite side of left-hand gripper 51 from the hinge eyes 53 a,b and has its outer face parallel to the vertical interior face. The horizontal top and bottom surfaces and the outer transverse side of clamping ear 55 are flat. The wedging outer surface 56 of clamping ear 55 is obverse to the vertical interior face and is flat and inclined from the vertical by the same angle as that of wedging outer surface 46 of right-hand gripper 41 so that the thickness of clamping ear 55 decreases downwardly. Located on wedging outer surface 56 parallel to and spaced away from the outer transverse side of clamping ear 55 is a rectangular guide groove of constant cross-section. Two shallow, flat-bottomed circular spring pockets 57 are located symmetrically about the horizontal midplane of left-hand gripper 51 on the vertical interior face of clamping ear 55 .
Left-band gripper 51 has its hinge eyes 53 a,b coaxial with the hinge eyes 43 a,b of right-hand gripper 41 and is mounted so that the wedging outer surfaces 46 and 56 of the grippers both taper downwardly. The length and position of hinge eyes 43 a,b and 53 a,b are such that they intermesh closely when right-hand gripper 41 and left-hand gripper 51 are positioned together. Hinge shaft 58 is a long cylindrical round shaft with male threads at both ends and a coaxial cylindrical intermediate shaft upset section 59 with transverse upper and lower sides located nearly at the upper end of the shaft. Hinge shaft 58 has a close sliding fit into the hinge bolt hole 44 and serves as a pivot and mounting shaft for the right-hand and left-hand grippers. The lower transverse side of intermediate shaft upset 59 bears on the upper transverse face of hinge eye 43 a . Hinge shaft 58 is made sufficiently long so that it can be inserted through a supporting base for the power tubing clamp 40 and thereby support the clamp. Internally threaded clamp nuts 60 are mounted on the top and bottom threaded portions of hinge shaft 58 to cause the components of the clamp assembly to fit closely to themselves and to their mounting base. In particular, the hinge eyes 43 a,b and 53 a,b interleave with a close fit to minimize axial play of the grippers on hinge shaft 58 . A Belleville spring washer 61 is fined within each of the spring pockets 57 of clamp ear 55 so that it protrudes beyond the vertical interior face of left-hand gripper when uncompressed. The Belleville spring protrusion beyond the vertical interior face is such that the spring exerts substantial force on clamping car 45 of right-hand gripper 41 when the tubing is tightly gripped by power tubing clamp 40 .
Operator cylinder support 64 is a steel plate approximately two inches thick and having a lozenge shape with rounded corners. Threaded cylinder mount hole 65 is located at the first end of operator cylinder support 64 , tubing clearance hole 66 is located in the middle, and hinge shaft hole 67 is at the second end. Tubing clearance hole 66 is fairly large to provide ample clearance for passage of tubing through the power tubing clamp 40 . Hinge shaft hole 67 is a close fit to hinge shaft 58 . Operator cylinder support 64 is positioned horizontally with the upper end of hinge shaft 58 through hinge shaft hole 67 and the lower face of support 64 bearing on the upper transverse shoulder of intermediate shaft upset 59 of hinge shaft 58 . A hinge shaft nut 60 is torqued down onto the upper threads of hinge shaft 58 on the upper side of operator cylinder support 64 to firmly clamp the support to the hinge shaft 58 .
Double-acting operator hydraulic cylinder assembly 69 consists of cylinder body 70 , piston 71 , and rod 72 , along with associated elbow fittings 73 and hydraulic tubing 74 . Cylinder body 70 is of conventional tubular construction with a cylindrical male threaded front nose mount, an elastomeric rod seal in the front nose, and both a rod extension and a rod retraction port at opposed ends of the cylinder interior. Piston 71 is a short circular cylindrical disk with an annular elastomeric seal in its annular groove and integral cylindrical rod 72 attached to its lower side. The lower end of rod 72 is provided with a conventional wrench flat and male threads. The threaded front nose of the cylinder assembly 69 is screwed into the threaded cylinder mount hole 65 of operator cylinder support 64 . A hydraulic elbow fitting 73 is screwed into each of the ports of cylinder assembly 69 , and hydraulic tubing 74 is sealingly attached to the elbow fitting by the conventional compression nut of the fitting. Hydraulic pressure from a conventional hydraulic power system is applied by means of a selectably controlled hydraulic valve to one or the other hydraulic tubing 74 and thence to the operator hydraulic cylinder assembly 69 . This hydraulic power system is not shown herein, but is well understood by those skilled in the art.
Wedge block 80 is a rectangular block approximately 12 inches high by 7 inches wide and 3 inches thick. Wedge cavity 81 , located on one of the largest faces of wedge block 80 , has a constant depth trapezoidal shape symmetrical about the vertical perpendicular midplane of that face of the block. Wedge cavity 81 decreases in width downwardly with side tapers matching those of the wedging outer surfaces 46 and 56 of, respectively, right-hand gripper 41 and left-hand gripper 51 . On each tapered side of wedge cavity 81 is rectangular cross-section retainer land 82 parallel to and spaced apart from the face of wedge block 80 which contains wedge cavity 81 . Retainer lands 82 of wedge block 80 comate and interact with the rectangular guide grooves in the clamping outer faces 46 and 56 of, respectively, right-hand gripper 41 and left-hand gripper 51 when these elements are assembled so that the clamping ears 45 and 55 of the grippers are positioned in wedge cavity 81 . Retainer lands 82 thus retain and provide guidance to wedge block 80 . In the middle of the upper transverse face of wedge block 80 is a female threaded blind hole which has threads which are comated with the rod end threads of the rod 72 of operator cylinder assembly 69 so that wedge block 80 can be reciprocated vertically. Approximately round coiled tubing 90 may be deployed within the arcuate tubing gripping faces 42 and 52 .
Another embodiment of the thrust enhancement device for coiled tubing injectors, shown in FIGS. 10 through 13, is based upon the powered tubing clamp 40 , shown in FIGS. 5-9 and 16 . Remotely controlled thrust enhancement device 1 consists of a structural tube body 2 , multiple hydraulic thrust cylinders 20 , a moveable transverse deck 30 , and two powered tubing clamps 40 . Square structural tube body 2 is a commercially available steel section which is approximately 18 inches by 18 inches square and with 0.625 inch wall thickness by 61.25 inches long. The corners of the tube are radiused due to its manner of fabrication. Identical bottom 3 and top transverse flanges 4 are made of plate steel cut into a hollow square pattern and welded to the tubular body 2 . Transverse through mounting holes are provided on the outer corners of each of the flanges 3 and 4 to facilitate mounting the thrust enhancement device to the blowout preventers of the coiled tubing rig and/or the separate conventional coiled tubing injector system. Rectangular windows with rounded corners to provide reductions of stress concentrations are cut into each of the side walls of tubular body 2 to provide access and visibility for the tubing and the other hardware mounted therein. The four upper windows 8 are identical, approximately square cutouts with each positioned symmetrically about the centerline of its respective face of body 2 close to the top transverse flange 4 . The four lower windows 9 are identical and higher than they are wide. The lower windows are each positioned symmetrically about the centerline of their respective faces of body 2 close to the bottom transverse flange 3 .
Static transverse deck 12 is a horizontal square piece of plate approximately 2 inches thick with radiused corners on the vertical corners of the square to closely fit inside tubular body 2 . Static transverse deck 12 is welded into place inside tubular body 2 normal to the through axis of the body between the upper windows 8 and the lower windows 9 . A round through hole for powered tubing clamp mounting 13 is positioned on a first vertical midplane but offset to one side of the second, transverse vertical midplane of static transverse deck 12 . The through hole for powered tubing clamp mounting 13 provides a snug fit to the lower end of clamp hinge shaft 58 , which is mounted in the hole and retained by a hinge shaft nut 60 on the lower side of static transverse deck 12 . The offset of through hole 13 from the second vertical midplane is chosen so that the tubing 90 will be on the vertical centerline axis of body 2 when held by a powered tubing clamp 40 mounted by means of hole 13 . A rectangular through hole for tubing clearance 14 with rounded corners is symmetrical about the first vertical midplane but offset to the opposite side of the other, second transverse vertical midplane of static transverse deck 12 from through hole 13 for powered tubing clamp mounting. The through hole for tubing clearance 14 permits the tubing to pass through thrust enhancement device 1 on the vertical centerline of body 2 . Tubing clearance hole 14 is oversized to also permit ample clearance for downward unlatching movement of the wedge block 80 of powered tubing clamp 40 . Additionally, static transverse deck 12 also has a doubly symmetric pattern of four female threaded blind holes 15 on its lower side for attachment of the rod ends of hydraulic thrust cylinders 20 .
Hydraulic thrust cylinder 20 is a conventional double-acting cylinder with a single rod and a coaxial rear bolt mounting. Although the individual parts of the hydraulic thrust cylinder are not shown, it has a conventional construction and is well known in the art. Cylinder body has a rod gland with an elastomeric rod seal on its upper end with a coaxial female threaded mounting hole on the lower transverse blind end of the cylinder. Cylinder body has a radial rod return port near its upper end and a radial rod extend port near its lower end. Cylinder piston is a short circular cylindrical disk with an annular elastomeric seal in its annular groove and integral cylindrical cylinder rod 25 attached to its upper side. The upper end of rod 25 is provided with a conventional wrench flat and male threads which are comated with the female threads of the threaded blind holes for cylinder rod attachment 15 located on the bottom side of static transverse deck 12 of body 2 . Hex-headed cylinder mounting screw 28 comates with the female thread on the bottom side of cylinder body to mount the cylinder 20 to moveable transverse deck 30 . An elbow hydraulic fitting is screwed into each of the ports of the thrust cylinder, and hydraulic tubing is sealingly attached to the elbow fitting by the conventional compression nut of the fitting. Hydraulic pressure from a conventional hydraulic power system is applied by means of a selectably controlled hydraulic valve to one or the other hydraulic tubing and thence to the hydraulic thrust cylinder. This hydraulic power system is not shown herein, but is well understood by those skilled in the art. Four identical hydraulic thrust cylinders 20 are used in a doubly symmetrical mounting pattern when viewed in plan view to provide direct thrust loading without attendant bending to the tubing.
Moveable transverse deck 30 is a horizontal square piece of plate approximately 3 inches thick having large chamfers on the vertical corners of the square for clearance to fit inside tubular body 2 . Moveable transverse deck 30 is sized to be a close slip fit within tubular body 2 when it is reciprocated along the axis of the body. Moveable transverse deck 30 has the same pattern for its four through holes for cylinder mounting 33 as is used for the threaded blind holes for cylinder rod attachments 15 on the static transverse deck 12 of tubular body 2 . Likewise, the pattern for its through hole for powered tubing clamp mounting 32 and its through hole for tubing clearance 33 are the same as the corresponding holes 13 and 14 of static transverse deck 12 of tubular body 2 . Moveable transverse deck 30 is installed below static transverse deck 12 with its clamp mounting hole 32 coaxial with that of clamp mounting hole 13 of static transverse deck 12 . The bottom end of each of the four cylinders 20 is clamped to the top surface of moveable transverse deck 30 by means of cylinder mounting screws 28 engaged in through holes for cylinder mounting bolts 34 and the female threaded holes on the bottom end of cylinders 20 .
One powered tubing clamp 40 (described previously) is mounted on the upper surface of static transverse deck 12 by means of its hinge shaft 58 and a hinge shaft nut 60 coaxial with through hole 13 in the static transverse deck of body 2 . The vertical plane of symmetry of tubing clamp 40 is coplanar with the aforementioned first vertical plane of symmetry of the static transverse deck 12 of body 2 . A second powered tubing clamp 40 is mounted on the upper surface of moveable transverse deck 30 by means of its hinge shaft 58 and a hinge shaft nut 60 coaxial with through hole 32 in the moveable transverse deck 30 . The vertical plane of symmetry of tubing clamp 40 is coplanar with the aforementioned first vertical plane of symmetry of the moveable transverse deck 30 .
Another embodiment of the thrust enhancement device for coiled tubing injectors, shown in FIGS. 14 and 15, is based upon the manual tubing clamp 170 , shown in FIGS. 1-4. Manually controlled thrust enhancement device 101 consists of a structural tube body 102 , multiple hydraulic thrust cylinders 120 , a moveable transverse deck 130 , and two manual tubing clamps 170 . With the exception of the types of tubing clamps used, the manually controlled 101 and remotely controlled 1 thrust enhancement devices are identical. The part numbers 2 through 34 of thrust enhancer device 1 correspond to part numbers 101 - 134 of thrust enhancement device 101 and arc not necessarily discussed individually herein.
Square structural tube body 102 is a commercially available steel section which is approximately 18 inches by 18 inches square and with 0.625 inch wall thickness by 61.25 inches long. The corners of the tube are radiused due to its manner of fabrication. Identical bottom 103 and top transverse flanges 104 are made of plate steel cut into a hollow square pattern and welded to the tubular body 102 . Transverse through mounting holes are provided on the outer corners of each of the flanges 103 and 104 to facilitate mounting the thrust enhancement device to the blowout preventers of the coiled tubing rig and/or the separate conventional coiled tubing injector system. Rectangular windows with rounded corners to provide reductions of stress concentrations are cut into each of the side walls of tubular body 102 to provide access and visibility for the tubing and the other hardware mounted therein. The four upper windows 108 are identical, approximately square cutouts with each positioned symmetrically about the centerline of its respective face of body 102 close to the top transverse flange 104 . The four lower windows 109 are identical and higher than they are wide. The lower windows are each positioned symmetrically about the centerline of their respective faces of body 102 close to the bottom transverse flange 103 .
Static transverse deck 112 is a horizontal square piece of plate approximately 2 inches thick with radiused corners on the vertical corners of the square to closely fit inside tubular body 102 . Static transverse deck 112 is welded into place inside tubular body 102 normal to the through axis of the body between the upper windows 108 and the lower windows 109 . A round through hole for manual tubing clamp mounting 113 is positioned on a first vertical midplane but offset to one side of the second, transverse vertical midplane of static transverse deck 112 . The through hole for powered tubing clamp mounting 113 provides a snug fit to the lower end of clamp hinge shaft 188 , which is mounted in the hole and retained by a hinge shaft nut 189 on the lower side of static transverse deck 112 . The offset of through hole 113 from the second vertical midplane is chosen so that the tubing 198 will be on the vertical centerline axis of body 102 when held by a manual tubing clamp 170 mounted by means of hole 113 . A rectangular through hole for tubing clearance 114 with rounded corners is symmetrical about the first vertical midplane but offset to the opposite side of the other, second transverse vertical midplane of static transverse deck 112 from through hole 113 for manual tubing clamp mounting. The through hole for tubing clearance 114 permits the tubing 198 to pass through thrust enhancement device 101 on the vertical centerline of body 102 . Additionally, static transverse deck 112 also has a doubly symmetric pattern of four female threaded blind holes 115 on its lower side for attachment of the rod ends of hydraulic thrust cylinders 120 .
Hydraulic thrust cylinder 120 is a conventional double-acting cylinder with a single rod and a coaxial rear bolt mounting. Cylinder body 121 has a rod gland with an elastomeric rod seal on its upper end with a coaxial female threaded mounting hole on the lower transverse blind end of the cylinder. Cylinder body 121 has a radial rod return port 122 near its upper end and a radial rod extend port 123 near its lower end. Cylinder piston 124 , which is not shown but is of conventional construction, is a short circular cylindrical disk with an annular elastomeric seal in its annular groove and integral cylindrical cylinder rod 125 attached to its upper side. The upper end of rod 125 is provided with a conventional wrench flat and male threads which are comated with the female threads of the threaded blind holes for cylinder rod attachment 115 located on the bottom side of static transverse deck 112 of body 102 . Hex-headed cylinder mounting screw 128 comates with the female thread on the bottom side of cylinder body 121 to mount the cylinder 120 to moveable transverse deck 130 . An elbow hydraulic fitting 126 is screwed into each of the ports 122 and 123 of thrust cylinder 120 , and hydraulic tubing 127 is sealingly attached to the elbow fitting by the conventional compression nut of the fitting. Hydraulic pressure from a conventional hydraulic power system is applied by means of a selectably controlled hydraulic valve to one or the other hydraulic tubing 127 and thence to the hydraulic thrust cylinder 120 . This hydraulic power system is not shown herein, but is well understood by those skilled in the art. Four identical hydraulic thrust cylinders 120 are used in a doubly symmetrical mounting pattern when viewed in plan view to provide direct thrust loading without attendant bending to the tubing.
Moveable transverse deck 130 is a horizontal square piece of plate approximately 3 inches thick having large chamfers on the vertical corners of the square for clearance to fit inside tubular body 12 . Moveable transverse deck 130 is sized to be a close slip fit within tubular body 102 when it is reciprocated along the axis of die body. Moveable transverse deck 130 has the same pattern for its four through holes for cylinder mounting 133 as is used for the threaded blind holes for cylinder rod attachments 115 on the static transverse deck 112 of tubular body 102 . Likewise, the pattern for its through hole for powered tubing clamp mounting 132 and its through hole for tubing clearance 133 are the same as the corresponding holes 113 and 114 of static transverse deck 112 of tubular body 102 . Moveable transverse deck 130 is installed below static transverse deck 112 with its clamp mounting hole 132 coaxial with that of clamp mounting hole 113 of static transverse deck 112 . The bottom end of each of the four cylinders 120 is clamped to the top surface of moveable transverse deck 130 by means of cylinder mounting screws 128 engaged in through holes for cylinder mounting bolts 134 and the female threaded holes on the bottom end of cylinders 120 .
One manual tubing clamp 170 (described previously) is mounted on the upper surface of static transverse deck 112 by means of its hinge shaft 188 and a hinge shaft nut 189 coaxial with through hole 113 in the static transverse deck of body 102 . The vertical plane of symmetry of tubing clamp 170 is coplanar with the aforementioned first vertical plane of symmetry of the static transverse deck 112 of body 102 . A second manual tubing clamp 170 is mounted on the upper surface of moveable transverse deck 130 by means of its hinge shaft 188 and a hinge shaft nut 189 coaxial with through hole 132 in the moveable transverse deck 130 . The vertical plane of symmetry of tubing clamp 170 is coplanar with the aforementioned first vertical plane of symmetry of the moveable transverse deck 130 .
FIG. 17 shows the relationship of the thrust enhancement device of this invention to the other components of a coiled tubing injection system and a typical onshore wellhead of a well used for the production of petroleum products. The rigged up coiled tubing rig 200 on the wellhead 201 consists of the blowout preventors 202 , the thrust enhancement device 1 or 101 , the coiled tubing injector 203 , the gooseneck 204 , the storage reel 205 , and the coiled tubing 206 . Wellhead 201 is attached to the top end of the outer, initial casing of a well and provides physical support and flow isolation for the other various casing strings and tubing of the well, as well as valving and fluid connections for hooking the well up to the surface facilities for the well. The blowout preventors 202 for the coiled tubing rig are a modular assembly which can either seal on the exterior of the coiled tubing 206 or shear it and then seal across the upward looking end of the sheared coiled tubing. The blowout preventors 202 arc attached to the flange on the top of the wellhead by a similar, comating flange on the bottom of the blowout preventor assembly. A flange at the top of the blowout preventor assembly is attached to either the bottom flange 3 of the remotely controlled thrust enhancement device 1 or the bottom flange 103 of the manually controlled thrust enhancement device 101 , depending on which embodiment of the invention is used. A coiled tubing injector 203 is attached to either the top flange 4 of thrust enhancement device 1 or the top flange 104 of thrust enhancement device 101 , as appropriate. The coiled tubing injector 203 could be any one of a variety of designs, including that shown in copending U.S. Provisional Patent Application “Coiled Tubing Injector Utilizing Opposed Drive Modules and Having an Integral Bender”, filed Jul. 11, 2001, a conventional opposed track type, or a single-side track type with hold-down rollers. A gooseneck 204 of conventional construction is mounted on the top of injector 203 . The tubing 206 is stored on reel 205 and passes from the reel, over the gooseneck 204 , through the injector 203 , through the thrust enhancement device ( 1 or 101 ), and into the wellhead 201 and, thence, the well. These coiled tubing rig components are standard equipment items well known in the oilfield industry.
Operation of the Invention
The operation of both of the clamps 40 and 170 and of the thrust enhancement device embodiments 1 and 101 described herein is simple and straightforward. The thrust enhancement device embodiments are used in conjunction with the other hardware of a typical coiled tubing rig as shown in FIG. 17 . As may understood by those familiar with this equipment the thrust enhancement device could be positioned between the injector and the gooseneck, rather than as shown in FIG. 17 . Likewise, the thrust enhancement device could be used with a wheel type injector, rather than a single or double tracked injector or the device of the aforementioned copending injector.
The operation of manual tubing clamp 170 is best understood from referring to FIGS. 3 and 4. In FIG. 3, manual tubing clamp 170 is shown with the right-hand gripper 171 and the left-hand gripper 181 pivoted relative to each other about hinge shaft 188 to the open position of the clamp. This opening is possible because a manually operated wrench (not shown) has been used to loosen clamp nuts 193 so the clamp halves can separate and normally will not grip the tubing tightly. The position of the clamp 170 corresponds to the position, which is required for initially passing the tubing through the axis of the manually controlled thrust enhancement device 101 . This same position is used for both manual clamps in a manually controlled thrust enhancement device. In the event that the tubing binds in the grooves 172 and 182 of the grippers 171 and 181 , a prying device can be used to separate the grippers and a hammer or other suitable device can be used to separate a binding gripper from the tubing. This operation is not problematic, since generally only very short axial travels of the tubing equivalent to a very small number of thrust enhancement device strokes are required to overcome and excessive resistance to tubing injection which might necessitate use of the devices of this invention. The manual tubing clamp 170 is caused to grip the tubing by tightening the clamp nuts 193 manually with a wrench until the torque applied is sufficient to cause the gripper 171 and 181 to tightly hold the tubing 198 . The heads of clamp bolts 192 are restrained from rotating during the torqueing of clamp nuts 193 by the inboard vertical edges of the extensions of the external flat transverse face of clamping ear 185 .
The operation of powered tubing clamp 40 is best understood from FIGS. 6, 7 , and 8 . When wedge block 80 is caused to move downwardly by selectably applying hydraulic pressure to the rod extend port of the operator hydraulic cylinder assembly 69 , the wedging faces of wedge cavity 81 are caused to tend to separate from the wedging outer surfaces 46 and 56 of the right-hand and left-hand grippers 41 and 51 , respectively. When the wedging action is thus released by the downward shifting of wedge block 80 , the Belleville spring washers 61 force the interior faces of the grippers apart through rotation about hinge shaft 58 , thereby opening the clamp and causing the tubing 90 to be released by the clamp 40 . The open position of the clamp 40 is also the position of the clamp during initial loading of the clamp or when the thrust enhancement device is inactive. In order to close the clamp 40 so that it will grip the tubing 90 , hydraulic pressure is selectably applied to the rod return port of operator cylinder assembly 69 so that the rod 72 retracts, thereby raising wedge block 80 so that the wedging surfaces of wedge cavity 81 forcibly urge the grippers 41 and 51 to rotate together about hinge shaft 58 due to pressure on the wedging outer surfaces 46 and 56 of the clamping ears 45 and 55 . When the grippers 41 and 51 have moved sufficiently together, then the tubing 90 will be tightly gripped in grooves 42 and 52 .
The operation of the remotely controlled thrust enhancement device 1 proceeds as follows. Here it is assumed that the thrust enhancement device 1 is aiding in withdrawing the tubing 90 from the well. Hydraulic pressure is applied to the rod extend ports of selectably operable hydraulic thrust cylinders 20 so that moveable transverse deck 30 is caused to shift to its lowest position. During this initial downward reciprocation of the device 1 , both the upper and lower tubing clamps 40 are open. After moveable transverse deck 30 has reached its lowest position, the lower clamp 40 is selectably engaged to grip the tubing 90 . Hydraulic pressure is then applied to the retract the rods of thrust cylinders 20 , thereby both raising the moveable transverse deck 30 and pulling the tubing 90 upwardly. When moveable transverse deck 30 reaches its upper position, upper clamp 40 is engaged and then lower clamp 40 is released from the tubing 90 . Upper clamp 40 serves to hold the tubing 90 against moving downwardly back into the well. At this point, moveable transverse deck 30 is again selectable stroked downwardly for another stroke, if required. The next upward reciprocation stroke can begin when the lower clamp grips the tubing and the upper clamp then releases the tubing. When the pulling of the tubing from the well by means of reciprocating the thrust enhancement device 1 is complete, both clamps 40 are then released from the tubing. However, if the tubing must be held, then both clamps 40 can be used to grip the tubing tightly and the thrust cylinders 20 hydraulically locked in position to prevent movement. In order to force tubing into the well, the lower tubing clamp 40 on the moveable transverse deck 30 first grips the tubing at the upper position of the moveable deck 30 , the grip of the upper clamp 40 is released, and the moveable is stroked downwardly. At the end of the downward reciprocation, the upper clamp 40 grips the tubing and the lower clamp releases the tubing to permit reciprocating the moveable deck upwardly for another downstroke, similarly to the procedures used for the withdrawal of tubing from the well.
The operation of the manually controlled thrust enhancement device is identical in all respects to that of the remotely controlled thrust enhancement device, with the exception of the need to manually open and close the upper and lower tubing clamps 170 . The operation of the manually controlled thrust enhancement device 101 proceeds as follows. Here it is assumed that the thrust enhancement device 101 is aiding in withdrawing the tubing 198 from the well. Hydraulic pressure is applied to the rod extend ports 123 of selectably operable hydraulic thrust cylinders 120 so that moveable transverse deck 130 is caused to shift to its lowest position. During this initial downward reciprocation of the device 101 , both the upper and lower tubing clamps 170 are open. After moveable transverse deck 130 has reached its lowest position, the lower clamp 170 is selectably engaged to grip the tubing 198 . Hydraulic pressure is then applied to the retract the rods of thrust cylinders 120 , thereby both raising the moveable transverse deck 130 and pulling the tubing 198 upwardly. When moveable transverse deck 130 reaches its upper position, upper clamp 170 is engaged and then lower clamp 170 is released from the tubing 198 . Upper clamp 170 serves to hold the tubing 198 against moving downwardly back into the well. At this point, moveable transverse deck 130 is again selectable stroked downwardly for another stroke, if required. The next upward reciprocation stroke can begin when the lower clamp grips the tubing and the upper clamp then releases the tubing. When the pulling of the tubing from the well by means of reciprocating the thrust enhancement device 101 is complete, both clamps 170 are then released from the tubing. However, if the tubing must be held, then both clamps 170 can be used to grip the tubing tightly and the thrust cylinders 120 hydraulically locked in position to prevent movement. In order to force tubing into the well, the lower tubing clamp 170 on the moveable transverse deck 130 first grips the tubing at the upper position of the moveable deck 130 , the grip of the upper clamp 170 is released, and the moveable deck 130 is stroked downwardly, forcing the tubing downwardly. At the end of the downward reciprocation of moveable deck 130 , the upper clamp 170 grips the tubing and the lower clamp releases the tubing to permit reciprocating the moveable deck upwardly for another downstroke, similarly to the procedures used for withdrawing tubing from the well.
Advantages of the Invention
The novel thrust enhancement device for use with conventional coiled tubing injectors based on using the mechanisms of this invention offers several important advantages over using a conventional coiled tubing injector alone. Coiled tubing injectors are normally sized for a maximum service thrust based upon a certain tubing weight and well pressure plus a substantial extra allowance for the tubing motion in the well being obstructed by a shoulder, being sanded in, or the like. When the novel thrust enhancement device of this invention is used to provide the extra allowance for overcoming the obstructions to tubing motion, then the injector can be sized based its routine service requirements only. This permits the very significant advantage of using a more economical injector of smaller size and weight. The weight and cost of the thrust enhancement device of this invention are relatively small compared to the thrust delivered, so that the combination of the thrust enhancement device with a smaller injector is lighter and less expensive when compared to a large injector of equivalent thrust. This reduction in system weight is important for areas where significant weight limits are placed on transportation vehicles.
The thrust enhancement device of this invention can be used very effectively in either insertion or withdrawal of the coiled tubing in the well. Thrust capability is directly related to the piston areas of the thrust cylinders. Since use of larger thrust cylinders adds system cost and weight at a rate much less than proportional to the thrust increase ratio, a higher margin of safety can be obtained very economically for ensuring that the tubing can be withdrawn from the well. Additionally, the tubing clamping means of either of the embodiments of this invention can passively grip and hold the tubing against movement in either direction when the coiled tubing injector is not being operated, even with a leaky hydraulic system.
These and other advantages will be obvious to those skilled in the art. It may be understood readily that certain detail changes from the design herein arc still within the scope of this invention. For instance, another type of spring could be substituted for the Belleville springs used to passively release the powered tubing clamp. The wedging angles used in the powered tubing clamp could also be modified from those shown. Similarly, several variations can be made in the supporting body construction or the means for mounting the hydraulic cylinders without changing the basic principles of this invention. Likewise, power screws could be used to cause reciprocation of the moveable transverse deck holding the lower tubing clamp for the system without departing from the spirit of this invention. | A means and method for improving the injection of coiled tubing into and from a well by providing a secondary injection device for supplementing the thrust forces of the primary injector means. Use of the secondary injection device coacting in tandem with the coiled tubing injector permits developing significantly higher axial forces in the tubing than can be provided by the primary injector alone. The selectably operable thrust enhancement device of this invention provides a short, repeatable stroke in either direction. The thrust enhancement device operates by selectably gripping the tubing with a reciprocably moveable means in a first position, shifting the moveable means to a second position thereby moving the tubing, gripping the tubing with a static means at its new position, releasing the tubing from the moveable means, and returning the moveable means to its first position. When the thrust enhancement device is not needed for the injection operation, its gripping means are disengaged from the tubing. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cosmetic compositions for the skin or the exoskeleton containing a dispersion of solid particles whose surface is coated by means of an amphoteric polymer.
2. Background Information
Various make-up products, such as loose or compact powders, make-up foundations, blushers, eyeshadows and also lipsticks, are known to be presented in the form of compositions comprising a dispersion of solid inorganic particles in a fatty binding agent. The products in question can be anhydrous compositions or alternatively oil-in-water or water-in-oil emulsions.
Depending on the type of composition, the solid particles are exclusively pigments (white and/or coloured) intended to impart a certain coloration to the skin of the face or lips, or particles, generally referred to as "fillers", which have diverse functions which vary with the nature of the particles.
In compositions for application to the skin, use is often made of fillers intended to provide a covering power, that is to say to mask skin imperfections (differences in coloration, minor unevenness), either as a result of their opacity (this applies, in particular, to titanium oxide, zinc oxide and kaolin), or through their properties of reflection of light (this applies, in particular, to lamellar fillers such as talc and micas). Fillers are also used which are capable of absorbing the aqueous and oily secretions of the skin, in order to avoid a glistening appearance of the skin and the migration of colorants: kaolin, starch, precipitated calcium carbonate, bentonite and the like, are, for example, employed for this purpose.
Use is also made, in compositions intended for protection against UV radiation, of particles, micronized or otherwise, of TiO 2 and of ZnO as ultraviolet-absorbing agents.
In lipsticks, the solid particles dispersed in a suitable fatty binding agent are mostly coloured pigments, optionally in combination with white pigments (for example fine particles of titanium dioxide) which enable the shades of the colours provided by the coloured pigments to be varied.
Such white and/or coloured pigments are also used in nail varnish compositions, which consist essentially of a dispersion of these pigments in a solution of a film-forming polymer and a plasticizer in a suitable organic solvent.
The preparation and use of cosmetic compositions containing dispersions of solid particles create several kinds of problem. One problem common to the production of all the compositions just mentioned lies in the difficulty of obtaining homogeneous and stable dispersions, so as to apply, for example to the skin, an even make-up whose application is uniform and which retains good homogeneity. This requirement has led the experts to perform surface treatments on the powders used, in particular in order to modify the interfacial properties participating in the phenomena of wetting and dispersion. The aim of these treatments is often to make the powder hydrophobic in order to promote its incorporation in the formulation binding agents and oils, and to increase the stability of the dispersion by decreasing flocculation and aggregation phenomena; see, for example, European Patent 279,319, which describes the coating of pigments with silicone polymers.
Dispersion of the solid particles in aqueous media also gives rise to difficulties and, in order to overcome these, dispersing agents which are introduced into the dispersion medium are used in particular. Thus, for example, Patent FR 2,655,875 relates to the use of amphoteric copolymers as dispersing agents, especially in the papermaking field, and Patent FR 2,550,795 describes a pigment composition for paints containing an amphoteric dispersing resin. These various treatments hence enable the problems of stability of the dispersion to be resolved by limiting the flocculation phenomena. However, they do not resolve another major problem, namely the poor properties of adhesion of the solid particles to the skin. In effect, it is known that the solid particles used, in particular, in compositions in powder form have only poor properties of adhesion to the skin. The surface treatments intended to improve the stability of the dispersions in the fatty binding agents do not provide a substantial improvement as regards the adhesion properties.
SUMMARY OF THE INVENTION
It has now been discovered that it is possible to obtain cosmetic compositions comprising a dispersion of solid particles in a binding agent, having good properties of stability and adhesion to the skin or to the exoskeleton, by introducing into the said compositions solid particles whose surface has been coated with an amphoteric polymer. It was found, surprisingly, that the coating of solid particles with amphoteric polymers, which constitute, however, a hydrophilic coating, does not prevent a good dispersibility of the particles in fatty binding agents from being obtained. Moreover, the compositions thereby obtained have good properties of adhesion to the skin after application. The adhesion to the skin is not excessive, and hence permits a distribution on the skin and a make-up result which are especially homogeneous.
In addition, the coating of solid particles with an amphoteric polymer is compatible with the use of cationic polymers in cosmetic compositions containing such coated particles.
Moreover, the coated particles according to the invention retain their amphoteric character even after application to the skin, and irrespective of the nature of the particle thus coated.
The optimal quantitative ratio of cationic groups to anionic groups ranges from 40:60 to 90:10.
DETAILED DESCRIPTION OF THE INVENTION
The subject of the present invention is hence a cosmetic composition for the skin or the exoskeleton comprising a dispersion of solid particles in a binding agent, characterized in that at least a part of the said particles is introduced into the said composition in the form of particles whose surface is coated with at least one amphoteric polymer.
In the compositions of the invention, solid particles are surface-coated with an amphoteric polymer. This means that, after coating, there is neither a change in morphology nor a significant modification of the sizes of the particles, as may be verified by electron-microscopy.
In the present application, the term "amphoteric polymer" denotes a polymer containing both cationic and anionic groups and/or groups which can ionize to cationic and anionic groups, respectively.
The amphoteric polymers are known products.
Preferred cationic groups are chosen from those which contain primary, secondary, tertiary and/or quaternary amine groups, which can either form part of the polymer chain or be carried by a side-chain substituent.
The cationic group is preferably chosen from primary, secondary, tertiary and/or quaternary amino groups. The anionic groups can, for example, be COO - , SO 3 - , PO 4 3- or SO 4 2- groups.
These two types of charged groups (anionic and cationic) are each preferably carried by a side-chain substituent and are more or less well separated from one another.
Preferably, the cationic groups are quaternary ammonium groups, which may be obtained by quaternization of amino groups by means of traditional quaternizing agents such as alkyl or aralkyl halides (for example methyl iodide, ethyl bromide, benzyl chloride, and the like) or alkyl sulphates (for example dimethyl sulphate).
The amphoteric polymers used can have a molecular mass generally of between 10 3 and 10 9 approximately, and most often between 10 3 and 10 6 .
Preferably, the coated particles used in the compositions of the invention are coated exclusively with one (or more) amphoteric polymer(s).
When the amphoteric polymer carries cationic and anionic groups on side-chain substituents, the polymer chain is, for example an acrylic, vinyl, silicone, fluorinated or saccharide chain. It is preferable to use amphoteric polymers not containing silicon, that is to say polymers other than silicones.
The amounts of polymer deposited on the particles vary with the procedure used for obtaining the coating. Generally, the weight proportion of amphoteric polymer relative to the total weight of the coated particles is equal to at least 0.1%; the upper limit to the amount of amphoteric polymer is sufficiently low for the particles to keep their individual identity and their shape. In other words, the amphoteric polymer forms, at most, a thin layer (possibly lacunate) on the coated particles. More often than not, the weight proportion of amphoteric polymer in the coated particles is less than 10%, and preferably less than 8%, relative to the total weight of the coated particles. In fact, more often than not, an optimal result is obtained with a coating not exceeding 2% by weight. The risk of obtaining coated pigments whose colour becomes drab after coating is avoided in this way.
The compositions of the invention are, in particular, those which contain a dispersion of solid particles whose surface is coated with at least one amphoteric polymer containing units A and B distributed statistically in the polymer chain, where A denotes a unit derived from a monomer containing at least one cationic group as defined above, and B denotes a unit derived from a monomer containing one or more anionic groups, in particular carboxyl or sulphonic groups, or alternatively A and B, which may be identical or different, represent a group derived from a carboxybetaine zwitterionic monomer; A and B can also denote a polymer chain containing secondary, tertiary or quaternary amine groups, in which chain at least one of the amine groups carries a carboxyl or sulphonic substituent attached via a hydrocarbon arm, or alternatively A and B form part of a polymer chain containing ethylene-alpha, beta-dicarboxyl units in which one of the carboxyl groups has reacted with a polyamine containing one or more primary or secondary amine groups.
The amphoteric polymers corresponding to the definition stated above are chosen, in particular, from the following polymers:
(1) polymers resulting from the copolymerization of a monomer derived from a vinyl compound carrying a carboxyl group, such as acrylic acid, methacrylic acid, maleic acid and alpha-chloroacrylic acid, and a basic monomer derived from a substituted vinyl compound containing at least one basic nitrogen atom, such as dialkylaminoalkyl methacrylates and acrylates and dialkylaminoalkylmethacrylamides and-acrylamides. Such compounds are described in U.S. Pat. No. 3,836,537.
(2) polymers containing units derived from:
a) at least one monomer chosen from acrylamides or methacrylamides substituted on the nitrogen with an alkyl radical,
b) at least one acidic comonomer containing one or more reactive carboxyl groups, and
c) at least one basic comonomer such as an ester containing primary, secondary, tertiary and quaternary amine substituents of acrylic and methacrylic acids, or the product of quaternization of dimethylaminoethyl methacrylate with dimethyl or diethyl sulphate.
More especially preferred N-substituted acrylamide or methacrylamide monomers for the polymers mentioned above are, in particular, those in which the alkyl groups contain from 2 to 12 carbon atoms, and more especially N-ethylacrylamide, N-tert-butylacrylamide, N-tert-octylacrylamide, N-octylacrylamide, N-decylacrylamide, N-dodecylacrylamide or the corresponding methacrylamides. The acidic comonomers are chosen more especially from acrylic, methacrylic, crotonic, itaconic, maleic and fumaric acids, as well as the C 1 -C 4 alkyl monoesters of maleic acid or fumaric acid.
The basic comonomers are, for example, aminoethyl, butylaminoethyl, N,N-dimethylaminoethyl or N-tert-butylaminoethyl methacrylates.
Among these copolymers, the products sold by the company National Starch under the name Amphomer may be mentioned.
(3) polyaminoamides, optionally partially or completely crosslinked and/or alkylated, derived from polyaminoamides containing units of general formula:
--[--OC--R--CO--Z--]-- (I)
in which R represents a bivalent radical derived from a saturated dicarboxylic acid, from a mono- or dicarboxylic aliphatic acid containing an ethylenic double bond, from an ester of these acids with a lower alkanol having 1 to 6 carbon atoms or from a radical derived from the addition of any one of the said acids with a bis-primary or bis-secondary amine, and Z denotes a radical of a polyalkylenepoly(bis-primary or mono- or bis-secondary amine). In particular, in the said copolymers, Z can represent:
a) in a proportion of 60 to 100 mol % relative to the collective units containing Z, the radical
--NH--[--(CH.sub.2).sub.x --NH--]--.sub.n (II)
where x=2 and n=2 or 3, or alternatively x=3 and n=2
(this radical hence being derived from diethylenetriamine, triethylenetetramine or dipropylenetriamine),
b) in a proportion of 0 to 40 mol %, the above radical (II) in which x=2 and n=1 (hence derived from ethylenediamine) or the radical ##STR1## (derived from piperazine), c) in a proportion of 0 to 20 mol %, the radical --NH--(CH 2 ) 6 --NH-- (derived from hexamethylenediamine),
these polyaminoamides being optionally cross-linked by the addition of a bifunctional crosslinking agent chosen from epihalohydrins, diepoxides, dianhydrides and bis-unsaturated derivatives, for example by means of 0.025 to 0.35 mol of crosslinking agent per amine group of the polyaminoamide, and/or it being possible for them to be alkylated by the action of acrylic acid, chloroacetic acid, an alkanesultone or their salts.
The saturated carboxylic acids are preferably chosen from acids having 6 to 10 carbon atoms, such as adipic and 2,2,4-and 2,4,4-trimethyladipic acids, terephthalic acid and acids containing an ethylenic double bond such as, for example, acrylic, methacrylic or itaconic acid.
The alkanesultones which can be used in the alkylation of the polyaminoamides are, for example, propane- or butanesultone, the salts of the said alkylating agents being, in particular, the sodium or potassium salts.
(4) polymers containing zwitterionic units derived from a monomer of formula: ##STR2## in which R 1 denotes a polymerizable unsaturated group such as an acrylate, methacrylate, acrylamide or methacrylamide group,
x and y independently represent an integer from 1 to 3,
R 2 and R 3 represent hydrogen, methyl, ethyl or propyl,
R 4 and R 5 represent a hydrogen atom or an alkyl radical,
R 4 and R 5 being such that the sum of the carbon atoms they contain does not exceed 10.
The polymers comprising such units can also contain, in addition, units derived from non-zwitterionic monomers such as vinylpyrrolidone, dimethyl- or diethylaminoethyl acrylate or methacrylate, or alkyl acrylates or methacrylates, acrylamide, methacrylamide or vinyl acetate.
Among the polymers, there may be mentioned those containing units derived from carboxylic betaines, and in particular:
methyl methacrylate/ethyldimethylcarboxymethylammonium methacrylate copolymers, such as the products sold by Chimex under the name Mexomer PX (CTFA name: "polyquaternium-30") of formula: ##STR3## m≅60 p≅40,
or similar polymers containing different proportions of the said units,
the methacryloylethylbetaine/methacrylate copolymer sold by Sandoz under the name Diaformer,
or the methacryloylethylbetaine/methacrylate copolymer sold by Amerchol under the name Amersette.
Among the amphoteric polymers, there may also be mentioned polysiloxane betaines, such as the polysiloxane polyorganobetaine copolymers sold by Goldschmidt under the name Abil B 9950 (CTFA Name: "Dimethicone PropylPG-Betaine") of formula: ##STR4## or the polydimethylsiloxane containing alkylphosphobetaine groups sold by Siltech under the name Pecosil SPB-1240,
or the oxyethyleneoxypropylene organobetaine/siloxane copolymer sold by Goldschmidt under the name BC 1610.
(5) polymers derived from chitosan containing monomer units corresponding to the following formulae: ##STR5## in which the units (1) are present in proportions of between 0 and 30%, the units (2) in proportions of between 5 and 50% and the units (3) in proportions of between 30 and 90%. In the formula (3), R' represents a radical of formula:
--CR.sub.6 (R.sub.7)--(O).sub.n --CH (R.sub.8)--
in which n is a number equal to 0 or 1, if n=0, R 6 , R 7 and R 8 each independently represent a hydrogen atom, a methyl, hydroxyl, acetoxy, amino, monoalkylamine or dialkylamine residue (optionally interrupted by one or more nitrogen atoms and/or optionally substituted with one or more amine, hydroxyl, carboxyl, alkylthio or sulphonic groups) or an alkylthio residue in which the alkyl group carries an amino substituent, at least one of the radicals R 6 , R 7 and R 8 in this case being a hydrogen atom,
or n is equal to 1, in which case R 6 , R 7 and R 8 each represent a hydrogen atom,
as well as the salts formed by these compounds with bases or acids.
Among these polymers, there may be mentioned the polymers derived from chitosan by succinylation of a certain percentage of the amino groups, such as the products sold by Chimex under the name Mexomer PAD (CTFA name: "Chitosan Succinamide").
(6) polymers containing units of general formula (IV): ##STR6## in which R represents a hydrogen atom or a CH 3 O--, CH 3 CH 2 O--or phenyl radical, R 1 and R 2 independently represent a hydrogen or a lower alkyl radical such as methyl or ethyl, and R 3 denotes a lower alkyl radical such as methyl or ethyl or a group --R 4 --N(R 2 ) 2 , R 4 representing an alkylene group containing from 2 to 6 carbon atoms and R 2 being defined as above.
Such polymers are described in French Patent 1,400,366.
(7) amphoteric polymers chosen from:
the polymers obtained by the action of chloroacetic acid or sodium chloroacetate on compounds containing at least one unit of formula
--A--Z--A--Z--A-- (V)
where A denotes a ##STR7## radical and the groups Z independently represent an alkylene radical containing up to 7 carbon atoms in the main chain, optionally substituted with one or more hydroxyl groups and which can contain, in addition, oxygen, nitrogen and/or sulphur atoms and/or 1 to 3 aromatic and/or heterocyclic rings, it being possible for the said oxygen, nitrogen and sulphur atoms to be present in the form of an ether, thioether, sulphoxide, sulphone, sulphonium, alkylamine, alkenylamine, hydroxyl, benzylamine, amine oxide, quaternary ammonium, amide, imide, alcohol, ester and/or urethane group;
polymers containing units of formula
--A'Z--A'--Z-- (VI)
where A' denotes a ##STR8## radical and where at least one of the groups Z is as defined above and at least one of the groups Z represents an alkylene radical having up to 7 carbon atoms in the main chain, optionally substituted with one or more hydroxyl radicals and containing one or more nitrogen atoms substituted with an alkyl chain optionally interrupted by an oxygen atom, and necessarily containing one or more hydroxyl and/or carboxyl functions, as well as the quaternary ammonium salts resulting from the reaction of chloroacetic acid or sodium chloroacetate with the polymers (V).
Among the amphoteric acrylic and/or methacrylic copolymers, there may also be mentioned the copolymers of ammonium chloride and acrylic acid, such as the product sold by Calgon under the name Polyquaternum-22, the acrylic block copolymer sold by Kingston under the name Hypan SS 430E or the acrylic acid/dimethyldiallylammonium chloride/acrylamide copolymer sold by Merck under the name Merquat Plus 3330, or alternatively the copolymer of dimethyldiallylammonium chloride and acrylic acid sold by Merck under the name Merquat 280.
The coated particles present in the composition of the invention are, in particular, inorganic fillers or pigments, or alternatively organic particles.
The natural or synthetic inorganic fillers are, for example, chosen from: calcium carbonates, silicates such as, for example, aluminium silicate or kaolin, calcium silicates, sodium aluminosilicate, magnesium silicate or talc, potassium aluminosilicates or micas and hydrated magnesium aluminosilicate; sulphates such as, for example, barium sulphate, calcium sulphate; and precipitated or pyrogenic silicon dioxides, as well as silica hydrogels and aerogels.
The pigments are chosen, for example, from white pigments such as titanium dioxide or zinc oxide, and coloured pigments such as: coloured iron oxides (natural or synthetic), black, red and yellow in colour; green chromium oxides, hydrated or otherwise; Prussian blue; sodium aluminosulphosilicates and their different variants known by the name of "ultramarine" pigments; cobalt aluminate or cobalt blue and manganese violet.
The pigments can also be:
either pearlescent pigments such as titanium-coated micas (mica coated with particles of titanium dioxide) and bismuth oxychloride;
or micronized pigments of metal oxides chosen from titanium, zinc, cerium and zirconium oxides or mixtures thereof.
The pigments intended to be coated according to the invention can optionally be pigments which have undergone one or more prior surface treatments of a chemical, electronic and/or mechanical nature. They can also be composite pigments with an organic coating, such as those described below.
The organic particles intended to be coated with an amphoteric polymer, according to the invention, comprise, for example:
carmine lake,
carbon black,
organic lakes or insoluble sodium, potassium, calcium, barium, aluminium, zirconium or strontium salts of acid dyes such as halo acid, azo, anthraquinone, and the like, dyes. Among these lakes, special mention may be made of those known by the following names:
______________________________________D & C Red No. 2 Aluminium lakeD & C Red No. 3 Aluminium lakeD & C Red No. 4 Aluminium lakeD & C Red No. 6 Aluminium lakeD & C Red No. 6 Barium lakeD & C Red No. 6 Barium/strontium lakeD & C Red No. 6 Strontium lakeD & C Red No. 6 Potassium lakeD & C Red No. 7 Aluminium lakeD & C Red No. 7 Barium lakeD & C Red No. 7 Calcium lakeD & C Red No. 7 Calcium/strontium lakeD & C Red No. 7 Zirconium lakeD & C Red No. 8 Sodium lakeD & C Red No. 9 Aluminium lakeD & C Red No. 9 Barium lakeD & C Red No. 9 Barium/strontium lakeD & C Red No. 9 Zirconium lakeD & C Red No. 10 Sodium lakeD & C Red No. 19 Aluminium lakeD & C Red No. 19 Barium lakeD & C Red No. 19 Zirconium lakeD & C Red No. 21 Aluminium lakeD & C Red No. 21 Zirconium lakeD & C Red No. 27 Aluminium lakeD & C Red No. 27 Barium lakeD & C Red No. 27 Calcium lakeD & C Red No. 27 Zirconium lakeD & C Red No. 30 LakeD & C Red No. 31 Calcium lakeD & C Red No. 33 Aluminium lakeD & C Red No. 34 Calcium lakeD & C Red No. 36 LakeD & C Red No. 40 Aluminium lakeD & C Blue No. 1 Aluminium lakeD & C Green No. 3 Aluminium lakeD & C Orange No. 4 Aluminium lakeD & C Orange No. 5 Aluminium lakeD & C Orange No. 5 Zirconium lakeD & C Orange No. 10 Aluminium lakeD & C Orange No. 17 Barium lakeD & C Yellow No. 5 Aluminium lakeD & C Yellow No. 5 Zirconium lakeD & C Yellow No. 6 Aluminium lakeD & C Yellow No. 7 Zirconium lakeD & C Yellow No. 10 Aluminium lake______________________________________
melanin pigments derived from natural or synthetic sources and which may be obtained: (A) by oxidation of at least one indole compound, or (B) by oxidative or enzymatic polymerization of melanin precursors, or (C) by extraction of melanin from substances containing it, or (D) by culturing microorganisms.
(A) Melanin pigments can, in the first case, be obtained by oxidation of at least one indole compound chosen, in particular, from those corresponding to the formula: ##STR9## in which: R 1 and R 3 represent, independently of one another, a hydrogen atom or a C 1 -C 4 alkyl group;
R 2 represents a hydrogen atom, a C 1 -C 4 alkyl group, a carboxyl group or a (C 1 -C 4 alkoxy)carbonyl group;
the substituents R 4 to R 7 represent a hydrogen atom, a C 1 -C 4 alkyl group, a group --NHR° or --OZ,
R° denoting a hydrogen atom or a C 2 -C 4 acyl or C 2 -C 4 hydroxyalkyl group, and the radical Z denoting a hydrogen atom, a C 2 -C 14 acyl group, a C 1 -C 4 alkyl group or a trimethylsilyl group,
on the understanding that R 5 can, in addition, represent a halogen atom, and on the understanding that:
at least one of the radicals R 4 to R 7 represents a group OZ or NHR°, at most one of the radicals R 4 to R 7 representing NHR° and at most two of the radicals R 4 to R 7 representing OZ, and, in the case where Z represents a hydrogen atom, the two OH groups are at positions 5 and 6; and at least one of the radicals R 4 to R 7 represents a hydrogen atom and, in the case where only one of these radicals represents a hydrogen atom, only one radical among the radicals R 4 to R 7 then represents NHR° or OZ, the other radicals representing a C 1 -C 4 alkyl group, or alternatively, where appropriate, for R 5 , a halogen atom; and their alkali metal, alkaline-earth metal, ammonium and amine salts, as well as the hydrochlorides, hydrobromides, sulphates and methanesulphonates.
The indole compounds of formula (IX) above are preferably chosen from 4-hydroxyindole, 5-hydroxyindole, 6-hydroxyindole, 7-hydroxyindole, 4-hydroxy-5-methoxyindole, 4-hydroxy-5-ethoxyindole, 2-carboxy-5-hydroxyindole, 5-hydroxy-6-methoxyindole, 6-hydroxy-7-methoxyindole, 5-methoxy-6-hydroxyindole, 5,6-dihydroxyindole, N-methyl-5,6-dihydroxyindole, 2-methyl-5,6-dihydroxyindole, 3-methyl-5,6-dihydroxyindole, 2,3-dimethyl-5,6-dihydroxyindole, 2-carboxy-5,6-dihydroxyindole, 4-hydroxy-5-methylindole, 2-carboxy-hydroxyindole, 6-hydroxy-N-methylindole, 2-ethoxycarbonyl-5,6-dihydroxyindole, 4-hydroxy-7-methoxy-2,3-dimethylindole, 4-hydroxy-5-ethoxy-N-methylindole, 6-hydroxy-5-methoxy-2-methylindole, 6-hydroxy-5-methoxy-2,3-dimethylindole, 6-hydroxy-2-ethoxycarbonylindole, 7-(β-hydroxy)-3-methylindole 5-hydroxy-6-methoxy-2,3-dimethylindole, 5-hydroxy-3-methylindole, 5-acetoxy-6-hydroxyindole, 5-hydroxy-2-ethoxycarbonylindole, 6-hydroxy-2-carboxy-5-methylindole, 6-hydroxy-2-ethoxycarbonyl-5-methoxyindole, 6-[N-(β-hydroxyethyl)amino]indole, 4-aminoindole, 5-aminoindole, 6-aminoindole, 7-aminoindole, N-methyl-6-hydroxyethylaminoindole, 6-amino-2,3-dimethylindole, 6-amino-2,3,4,5-tetramethylindole, 6-amino-2,3,4-trimethylindole, 6-amino-2,3,5-trimethylindole, 6-amino-2,3,6-trimethylindole, 5,6-diacetoxyindole, 5-methoxy-6-acetoxyindole, 5,6-dimethoxyindole, 5,6-methylene-dioxyindole, 5,6-trimethylsilyloxyindole, 5,6-dihydroxy-indolephosphoric ester, 5,6-dibenzyloxyindole and the addition salts of these compounds.
5,6-Dihydroxyindole is one of the preferred compounds.
The oxidation of the indole compound of formula (IX) may be performed in an aqueous or water/solvent(s) medium, in the air, in the presence or absence of an alkaline agent and/or of a metallic oxidation catalyst such as, for example, cupric ion.
The reaction medium preferably consists of water and can, where appropriate, consist of a mixture of water and at least one solvent chosen in such a way that it rapidly solubilizes the indole compound of formula (IX). Among the solvents, there may be mentioned, as examples, C 1 -C 4 lower alcohols such as ethyl alcohol, propyl or isopropyl alcohol, tert-butyl alcohol, alkylene glycols such as ethylene glycol and propylene glycol, alkylene glycol alkyl ethers such as ethylene glycol monomethyl, monoethyl and monobutyl ethers, propylene glycol and dipropylene glycol monomethyl ethers, and methyl lactate.
The oxidation may also be performed using hydrogen peroxide in the presence of an alkaline agent such as, preferably, ammonia solution, or in the presence of an iodide ion, the iodide preferably being an alkali metal or alkaline-earth metal iodide or ammonium iodide.
It is also possible to perform the oxidation using periodic acid and its derivatives and water-soluble salts, permanganates and dichromates, for example sodium or potassium permanganates and dichromates, sodium hypochlorite, potassium ferricyanide, ammonium persulphate, silver oxide, lead oxide, ferric chloride, sodium nitrite, rare-earth salts including, in particular, those of cerium, and organic oxidizing agents chosen from Ortho-and parabenzoquinones, ortho-and para-benzoquinone mono- or diimines, 1,2- and 1,4-naphthoquinones and 1,2- and 1,4-naphthoquinone mono- or diimines as are defined in Application EP-A-O0,376,776. The preferred periodic acid salt is sodium periodate.
It is possible to activate the oxidizing agents with a pH modifier.
It is also possible to perform an enzymatic oxidation.
The insoluble product is isolated by filtration, centrifugation, lyophilization or atomization; it is then ground or micronized to achieve the desired particle size.
(B) Melanin pigments can also originate from the oxidative or enzymatic polymerization of melanin precursors such as L-tyrosine, L-dopa, catechol and their derivatives.
(C) melanin pigments can, also, originate from the extraction of melanin from natural substances such as human hair or the ink of cephalopods (cuttlefish, octopus), which is also known by the name of sepiomelanin, in which case the pigment is ground and purified before use.
(D) Melanin pigments may be obtained by culturing microorganisms. These microorganisms produce melanin either naturally, or by genetic modification or mutagenesis. Methods of preparation of these melanins are described, for example, in Patent Application WO 90/04029.
The melanin pigment may be present at the surface, or incorporated in a lamellar or non-lamellar, inorganic or organic particulate filler, coloured or otherwise. Composite melanin pigments are thereby obtained.
In this case, the melanin pigment can result from the oxidation of at least one indole compound of formula (IX) as defined above, mixed with the particulate filler, in a medium which is essentially a non-solvent for the said filler, at a temperature which can range from room temperature to approximately 100° C., or can alternatively result from the oxidative polymerization of melanin precursor on the filler.
The non-lamellar inorganic particles used in this process are, in particular, inert inorganic particles having a particle size of less than 20 micrometers. Such particles are, in particular, particles of calcium carbonate, silica or titanium oxide.
Such composite melanin pigments deposited on inorganic fillers are described, together with their preparation, in Patent Application FR-2,618,069.
By a similar process, composite melanin pigments with coloured inorganic particles may be prepared.
The term "coloured inorganic particles" denotes non-white particles consisting of metal salts which are insoluble in the cosmetic medium and usable in cosmetics, such as those listed in the Colour Index under the heading "Inorganic Colouring Matters" and bearing the numbers 77000 to 77947, excluding white pigments and particles occurring in lamellar form such as lamellar iron oxide. These coloured inorganic particles can consist of a single pigment or a mixture of pigments, and can thus take the form of pearlescent or interferential pigments.
The coloured inorganic particles are, in particular, non-white particles, preferably chosen from iron oxides excluding lamellar iron oxide, ultramarine blue (which is a complex sulphosilicate), chromium oxides, manganese violet (which is an ammonium manganese pyrophosphate) and Prussian Blue (which is an iron ferrocyanide).
Such composite melanin pigments, deposited on a coloured inorganic filler, are described in French Patent Application 92/0415 filed on 16th Jan. 1992.
The lamellar particles are inorganic or organic particles which take the form of lamellae, where appropriate stratified. These lamellae are characterized by a thickness which is smaller than the largest dimension of the particle. Preferably, the ratio of the largest dimension to the thickness is between 2 and 100. The largest dimension is generally less than 50 micrometers. Such composite melanin pigments deposited on a lamellar filler are described, together with their preparation, in European Patent Application No. 467,767.
The non-lamellar organic particles are particles of inert polymers chosen from natural or synthetic organic or inorganic polymers having a crystalline or amorphous crosslinked lattice and, for example, a molecular weight of between 5,000 and 5,000,000. Composite melanin pigments on a polymeric filler, together with their preparation, are described in European Patent Application No. 379,409;
the particles obtained by oxidative polymerization of at least one indolene compound of formula: ##STR10## in which formula: R 10 and R 8 represent, independently of one another, a hydrogen atom or a C 1 -C 4 alkyl radical;
R 9 represents a hydrogen atom, a C 1 -C 4 alkyl radical or a carboxyl or (C 1 -C 4 alkoxy ) carbonyl group;
R 12 denotes a hydrogen atom, a C 1 -C 4 alkyl, hydroxyl, C 1 -C 4 alkoxy, amino or C 1 -C 10 alkylamino radical or halogen;
R 11 denotes a hydrogen atom or a hydroxyl, C 1 -C 4 alkoxy or amino group; with the proviso that at least one of the radicals R 11 or R 12 denotes a hydroxyl, alkoxy or amino group; and with the proviso that, when R 11 denotes an amino group, R 12 cannot denote an alkylamino radical;
it also being possible for R 11 and R 12 to form a C 1 -C 2 alkylenedioxy group when they are at positions 5 and 6; and their salts.
The compounds corresponding to the formula (X) are chosen, in particular, from the group consisting of 5,6-dihydroxyindoline, 6-hydroxyindoline, 5,6-methylene-dioxyindoline, 7-methoxy-6-hydroxyindoline, 6,7-di-hydroxyindoline, 5-hydroxy-4-methoxyindoline, 4,5-di-hydroxyindoline, 5-methoxy-6-hydroxyindoline, 4-hydroxy-5-methoxyindoline, 5-hydroxy-6-methoxyindoline, 4,7-dihydroxyindoline, 6-aminoindoline, N-ethyl-4-hydroxyindoline, 1-ethyl-6-aminoindoline, 5-6-diaminoindoline, 1-methyl-6-aminoindoline, 2-methyl-6-aminoindoline, 3-methyl-6-aminoindoline, 2-methyl-5,6-diaminoindoline, 5-chloro-7-aminoindoline, 3-methyl-5,7-diaminoindoline, 5,7-diaminoindoline, 2-methyl-5,7-diaminoindoline, 7-aminoindoline, 2-methyl-7-aminoindoline, 4-aminoindoline, 4-amino-6-chloroindoline, 4-amino-6-iodoindoline, 4-amino-5-bromoindoline, 4-amino-5-hydroxyindoline, 4-amino-5-hydroxyindoline, 4-amino-5-methoxyindoline, 4-amino-7-methoxyindoline, 5-aminoindoline, 2,3-dimethyl-5-aminoindoline, 1-methyl-5-aminoindoline, 2-methyl-5-aminoindoline, 5-[-N-(1-methylhexyl)amino]-indoline, 5,6-dimethoxyindoline and 5,6-dihydroxy-2-carboxyindoline.
In the compounds of formula (X), C 1 -C 4 alkyl radicals preferably denote methyl, ethyl, propyl, isopropyl, butyl, isobutyl; C 1 -C 10 radicals preferably denote methyl, ethyl, propyl, isopropyl, butyl, isobutyl, 1-methylhexyl, 1-methylheptyl, 1-methyloctyl; the alkoxy radicals preferably denote methoxy, ethoxy, propoxy and butoxy; halogen preferably denotes bromine, chlorine or iodine.
The salts of the compounds of formula (X) are, in particular, hydrochlorides, hydrobromides, sulphates, methanesulphonates or alkali metal, alkaline-earth metal, ammonium or amine salts.
the particles obtained by co-oxidation of at least one indoline compound of formula (X) and at least one indole derivative. The latter may be chosen from mono- and dihydroxyindoles or aminoindoles, as are described, more especially, in Patent EP-A-2,398,826 and Patent Applications EP-A-425,345 and GB-A-2,224,754.
These indoles correspond more especially to the formula (IX). During the co-oxidation, it is possible to use up to 50% mol % of indole derivatives relative to the total number of moles of derivatives to be oxidized. The oxidation conditions are identical to those of the melanin pigments described above.
Just as in the case of the melanin pigments, the products originating from the oxidative polymerization of at least one indoline compound of formula (X) can be present at the surface of a particulate filler, or incorporated in the said lamellar or non-lamellar, inorganic or organic particulate filler, coloured or otherwise. They are then composite pigments.
The inorganic particulate fillers are those mentioned above for the composite melanin pigments.
The non-lamellar organic fillers are chosen from particles of:
a) polymers derived from keratin, which are optionally modified;
b) silk fibroins;
c) polymers derived from chitin, which are optionally deacetylated;
d) cellulose polymers;
e) synthetic polymers chosen from:
(i) polyethylene, polypropylene, polystyrene, poly(methyl methacrylate), optionally crosslinked;
(ii) crosslinked poly-β-alanine;
(iii) crosslinked styrene/divinylbenzene, methyl methacrylate/ethylene glycol dimethacrylate or vinyl stearate/divinylbenzene polymers;
(iv) hollow microspheres of copolymers of vinylidene chloride and acrylonitrile;
(v) porous microspheres of polyamide-12, polyamide-6 or copolyamide-6/12;
(vi) silicone powders consisting, in particular, of organosiloxane elastomers, gums or resins.
Such non-lamellar organic fillers are mentioned, in particular, in European Patent Application No. 379,409.
The lamellar fillers are chosen from L-lauroyl-lysine, microparticles of ceramic, optionally coated with zirconium powder, lamellar titanium dioxide, lamellar talc, boron nitride, lamellar mica, bismuth oxychloride and transparent red iron oxide.
Such lamellar fillers are mentioned, in particular, in European Patent Application No. 467,767.
Such composite pigments, together with their preparation, are described, in particular, in French Patent Application No. 92/00417 filed on 16th Jan. 1992.
In the compositions of the invention, the proportions of the coated particles dispersed in the binding agent depend on the type of composition; these proportions are the usual ones for the type of composition in question.
To coat the particles, a known method may be used, for example one of the following methods:
1) A solution of the polymer in one of its good solvents is prepared. The powder to be coated is dispersed in this solution with vigorous stirring, and a poor solvent for the polymer is added without going to the point of precipitation of the polymer in the solution, but to the point of initial cloudiness. The suspension is then left stirring vigorously, for example for 4 hours. The suspension is allowed to settle, and the product is separated, rinsed with a non-solvent for the polymer and dried, for example at 80° C. under reduced pressure.
2) A solution of the polymer is prepared, in which the powder to be coated is dispersed. The system is left stirring vigorously, and a precipitant for the polymer is added slowly so as to cause the polymer to precipitate gently at the surface of the powder. The suspension is allowed to settle, and the powder is separated, rinsed with a non-solvent for the polymer and dried.
3) A solution is prepared with a good solvent for the polymer, and the powder to be coated is dispersed therein. A poor solvent for the polymer is chosen, the boiling point of which is above that of the good solvent, and a slow evaporation of the system is carried out. This leads to the formation of a coacervate which gradually coats the powder, and the powder is then dried.
4) The so-called air-fluidized bed technique is used; a dilute solution of the polymer is sprayed in the heated state into a cyclone, in which the powder is kept buoyant.
5) A solution of the polymer is prepared, in which the powder to be coated is dispersed. The system is left stirring vigorously, and the solvent is evaporated slowly so as to cause the polymer to precipitate gently at the surface of the powder. The suspension is allowed to settle, and the powder is separated, rinsed with a non-solvent for the polymer and dried.
6) The technique of coating by atomization is used. A suspension of particles in water is prepared; when the suspension is homogenized, an aqueous solution of the polymer is introduced into it. The mixture is left stirring for 2 hours and the suspension is atomized in an atomizing apparatus. During the atomization, the mixture is preferably kept stirring magnetically.
7) The technique of coating by lyophilization is used. To this end, the polymer is solubilized in water, and an aqueous suspension of particles is then incorporated therein with magnetic stirring. The suspension is left stirring magnetically for 6 to 8 hours, and the mixture is then placed in the lyophilizer for at least 18 hours. A pulverulent product is recovered and sieved.
In the compositions of the invention, the binding agent in which the coated particles are dispersed is a standard binding agent. The binding agents are chosen, for example, from fats (oils and/or waxes) or film-forming polymers.
The compositions of the invention can be anhydrous compositions. The anhydrous compositions take the form, in particular, of a compact powder, a loose powder, a lipstick or a nail varnish.
The compositions of the invention can also take the form of water-in-oil or oil-in-water type emulsions.
These compositions are prepared according to standard methods.
In the make-up compositions, the binding agent is a standard fatty binding agent consisting of an oil, a mixture of oils or a mixture of oil and wax(es).
In the lipsticks, the binding agent is also a fatty binding agent generally consisting of a mixture of high-melting point waxes (natural or synthetic), of oils (synthetic, mineral or vegetable) and of low-melting point waxes (natural or synthetic).
In the nail varnishes, the binding agent consists of the solution of a film-forming polymer and a plasticizer in the chosen organic solvent.
In the emulsions, the binding agent is a standard fatty binding agent consisting of an oil or a mixture of oils.
When the composition contains a micronized pigment of metal oxides chosen from titanium, zinc, cerium or zirconium oxides or mixtures thereof, it can constitute a composition for protecting the skin or hair against ultraviolet rays.
The invention also relates to the use, in the preparation of a cosmetic composition for the skin and the exoskeleton containing a dispersion of solid particles in a binding agent, of particles whose surface is coated with at least one amphoteric polymer. In this use, the composition, and in particular the particles, the amphoteric polymer and also the binding agent, are, in particular, as defined above.
The examples which follow illustrate the invention without, however, limiting it.
EXAMPLE 1
0.5 g of a methyl methacrylate/ethyldimethylcarboxymethylammonium methacrylate copolymer (Mexomer PX of Chimex) is introduced into 200 ml of water, and is allowed to dissolve completely.
Concomitantly, 50 g of talc are dispersed in 550 ml of water and, when the suspension is homogeneous, the above preparation is added with stirring.
The suspension is kept stirring for 24 hours. The talc is then recovered by centrifugation, dried, ground and sieved through a sieve of mesh 0.160 μm.
Elemental analysis of the organic residue indicates the presence of 0.92% of polymer deposited on the talc (percentage by weight relative to the talc).
Particles of the following were also coated according to the same procedure:
manganese dioxide,
titanium dioxide,
chromium oxide.
EXAMPLE 2
7.15 g of copolymer of acrylic acid and dimethyldiallylammonium chloride (Merquat 280 of Merck) are introduced into 200 ml of water, and the mixture is stirred until dissolution is complete.
A homogeneous suspension of 50 g of talc in 550 ml of water is added thereto, and the mixture is left stirring for 24 hours. The liquid/solid separation is carried out by centrifugation. The pellet is then dried, ground and sieved.
The talc obtained possesses a coating of 1.65% (weight %) of amphoteric polymer.
EXAMPLE 3
2.25 g of octylacrylamide/acrylate/butylaminoethyl methacrylate (Amphomer of National Starch) are introduced into 200 ml of water in the presence of 0.0915 g of (aminomethyl)propanol.
When the polymer has dissolved completely, a homogeneous suspension of 50 g of talc in 550 ml of water is added thereto. The mixture is kept stirring for 4 hours.
A non-solvent, namely 10 ml of 0.1 M HCl solution, is then introduced into the mixture, and stirring is continued for a further 20 hours. The coated talc is separated by centrifugation, drying, grinding and sieving. A powder possessing 0.68% of polymer (weight %) at its surface is thereby recovered.
In a similar manner, a talc coated with 1% of the same polymer was prepared.
EXAMPLE 4
A suspension of 10 g of talc in 100 ml of water is prepared. When this suspension is homogenized, a solution containing 0.2 g of methyl methacrylate/ethyldimethylcarboxymethylammonium methacrylate copolymer (Mexomer PX of Chimex) dissolved in 50 ml of water is introduced into it. The suspension is left stirring for 12 hours.
This suspension is atomized with a laboratory atomizer (Buchi 190 and Roucaire Atomizer) under the following conditions:
entry: 135° C.
exit: 70° C.
pump: 7 bars
suction: 7 bars
flow rate: 700 liters/hour
Atomization time: 45 minutes
A coated dry powder containing 2.08% (weight %) of polymer is obtained.
The powder obtained is very light and of fluffy appearance.
EXAMPLE 5
3.18 g of methyl methacrylate/ethyldimethylcarboxymethylammonium methacrylate copolymer (Mexomer PX of Chimex) are introduced into 10 ml of water.
When the polymer has dissolved, this solution is added to a suspension of 10 g of talc in 40 ml of water.
The mixture is left stirring magnetically for 7 hours and then lyophilized for 18 hours.
The product recovered is sieved through a sieve of mesh 0.160 μm. A coated, very pulverulent powder is obtained, containing, on the basis of the results of elemental analysis, 6.94% of polymers (% by weight).
EXAMPLE 6
Coating of particles with an amphoteric silicone (Abil B 9950)
0.5 g of Abil B 9950 (Goldschmidt) is introduced into 200 ml of water, and is allowed to dissolve completely. The procedure followed thereafter is as described in Example 1.
COMPOSITION EXAMPLES
In these examples:
Sinnowax AO is the tradename of a mixture of cetyl/stearyl alcohol and polyoxyethylenated cetyl/stearyl alcohol (Henkel)
Geleol is the tradename of a mixture of glyceryl mono- and distearates (Gattefosse)
Veegum R is the tradename of a magnesium aluminium silicate (Vanderbilt)
Oramix L30 is the tradename of sodium lauroylsarcosinate (Seppic)
Blanose is the tradename of carboxymethylcellulose (sodium salt) sold by Aqualon
Miglyol 812 is a mixture of caprylic/capric acid triglycerides (Henkel)
Imwitor 780K is a mixture of isosteric acid mono- and diglycerides esterified with succinic acid (marketed by Huls-France).
______________________________________Talc coated with 1% of Amphomer (Ex. 3) 22.9%Mica 22.0%Bismuth oxychloride 8.0%Titanium dioxide 2.0%Zinc stearate 3.0%Nylon-12 20.0%Iron oxides 15.6%Binding agent 6.5%______________________________________
The binding agent contains (% by weight):
oleyl alcohol 11%
petroleum jelly 11%
liquid paraffin 67%
isopropyl myristate 11%
To prepare this eyeshadow, the procedure is as follows.
The particulate fillers other than iron oxides are homogenized using a Baker-Perkin type decaking stirrer. The iron oxides are then added, followed by the binding agent.
In the same manner, eyeshadows were prepared containing a talc coated, respectively, with:
1% of Mexomer PX
5% of Merquat 280.
A similar control eyeshadow, but containing uncoated talc, was also prepared.
On these eyeshadows, a sensory appraisal test was carried out using a jury of 10 people, with evaluation of the following features:
adhesion of the eyeshadow at the time of application to the eyelid,
covering power of the eyeshadow immediately after making up,
staying power of the eyeshadow four hours after making up. This involves evaluating the possible presence and the extent of streaking on the eyelids, corresponding to migration of the product towards preferential areas of the eyelid.
The results of the test are as follows:
The formulae employing the coated talc were judged superior to the control, on the three criteria listed, by 7 people out of 10.
It should be noted that the best results on these three criteria were obtained with the amphoteric polymers which carry their negative and positive charges on two different side-chain substituents (e.g. Amphomer and Merquat 280).
EXAMPLE C2
Oil/water emulsion into which 5% of manganese violet coated with Mexomer PX has been introduced.
This example demonstrates the ease of dispersion of manganese violet coated with an amphoteric polymer in an emulsion. Formulation used:
______________________________________Fatty phaseSinnowax AO 7%Geleol 2%Cetyl alcohol 1.5%Polydimethylsiloxane 1.5%Butyl p-hydroxybenzoate 0.2%Liquid petrolatum 15%PigmentManganese violet coated with 1% of 5%Mexomer PXAqueous phaseGlycerol 20%Water 47.6%Imidazolidinylurea (preservative) 0.2%______________________________________
The polydimethylsiloxane is the compound sold under the name Silbione Oils 70047 V300 (Rhone-Poulenc).
The emulsion is prepared according to a traditional procedure: the pigments are introduced into the aqueous phase and the emulsion is prepared by introducing the fatty phase into the aqueous phase.
By comparison with a control emulsion containing the same percentage of uncoated manganese violet, the use of the emulsion containing the coated manganese violet is easier. This pigment disperses better. Observation of the emulsion under the microscope shows a more homogeneous dispersion of the coated pigment than in the case of the same pigment uncoated.
EXAMPLE C3
Make-up foundation containing 10.7% of titanium dioxide coated with Mexomer PX.
Formula used:
______________________________________PHASE A:Water 30.34%Methyl p-hydroxybenzoate 0.1%Propylene glycol 2%Black iron oxide 0.5%Titanium dioxide coated 10.2%with 1% of Mexomer PXVeegum R 1% + 10 g of waterBlanose 0.16% + 10 g of waterOramix L30 0.6%Triethanolamine 1%PHASE B:Stearic acid 2.2%Geleol 2.2%Miglyol 812 15%Propyl p-hydroxybenzoate 0.1%Cyclopentadimethylsiloxane 12%(Dow Corning 24 S Fluid)PHASE CWater 1%Imidazolidinylurea 0.3%Glycerol 3%______________________________________
Phase A is prepared in the heated state (80° C.) with stirring, Phase B is introduced into it with stirring and Phase C is added thereto. The mixture is cooled. A pinkish, fluid make-up foundation is obtained.
Observation of this emulsion under the microscope, compared to the control composition (similar but containing uncoated titanium dioxide), shows a much more even dispersion.
EXAMPLE C4
Formulation of a silicone-containing make-up foundation in which all the pigments are coated with an amphoteric silicone: Abil B 9950 of Goldschmidt.
______________________________________Aluminium flakes coated with a 5%coloured epoxy varnish(Kingston Avocado M.I.Synthecolor)Cyclopentadimethylsiloxane 15%(Volatile Silicone 7158,Union Carbide)Miglyol 812 4%Imwitor 780K 2%Yellow iron oxide coated 1.43%with 1% of Abil B 9950Red iron oxide coated 0.55%with 0.5% of Abil B 9950Black iron oxide coated 0.23%with 1% of Abil B 9950Titanium dioxide coated 4.80%with 0.5% of Abil B 9950Water 34.50%Blanose 7 LF (Aqualon) 0.50%Glycerol 15%Methyl p-hydroxybenzoate 0.2%Water 6%Water 5.8%Hydrated magnesium sulphate, 0.7%7H.sub.2 OWater 7%Imidazolidinylurea 0.3%(Biopur 100, Biophil)Mixture of polydimethylsiloxanol 4%and cyclopentadimethylsiloxane,Dow Corning QC F2-1671(Dow Corning)______________________________________
By comparison with the same formula containing the pigments coated with 5% of PDMS (polydimethylsiloxane marketed by Wackherr), the above make-up foundation possesses a creamier and smoother texture and a more intense colour. The dispersion of the pigments is good, and the emulsion is fine, even and stable after centrifugation. The make-up obtained is very homogeneous. | Cosmetic composition for the skin or skin appendages comprising a dispersion of solid particles in a binder and characterized in that at least a part of said particles is introduced into the composition in the form of particles having their surface coated with at least one amphoteric polymer. The coated particles are easily dispersible, even in fatty binders, and the cosmetic compositions have good stability properties and show good adhesion to the skin and skin appendages. | 0 |
THE FIELD OF THE INVENTION
The present invention relates to trash collection vehicles, and more particularly to those having a large hose, for example eight inches in diameter, which is manipulated by the operator to pick up debris, litter and the like. The invention is more particularly related to the boom which supports and balances the hose to make it easier for the vehicle operator to use it.
The prior art shows various methods of supporting or counterbalancing the hose. Charky U.S. Pat. No. 5,058,235 uses a coil spring and in a later patent, U.S. Pat. No. 5,138,742, replaced the coil spring with a hydraulic cylinder. Holowell U.S. Pat. No. 3,710,412 made the boom support out of spring steel so that it was essentially a long leaf spring which had the ability to flex up and down. This was later refined in Holowell U.S. Pat. No. 5,519,915 in which a screw crank was added to the mounting bracket at the base of the leaf spring support arm to provide for adjustment of the pickup nozzle.
The present invention is a distinct improvement upon what is shown in the prior art in that a pair of pivotally mounted support arms comprise the boom. The rear support arm is pivotally connected to the frame of the vehicle for movement about a vertical axis. The front support arm is pivotally mounted to the rear support arm for movement about a horizontal axis. One or a pair of gas springs are pivotally connected between the two support arms and provide a lifting force to counterbalance the weight of the hose. The pivotal connection between the gas spring(s) and the front support arm includes a lever and there is an adjustment device on the lever which changes the effective moment arm through which the gas springs push on the front arm to exert more or less lifting force.
SUMMARY OF THE INVENTION
The present invention relates to trash collection vehicles of the type having a large diameter hose for use by the operator and more particularly to such a vehicle having an improved support structure for the hose.
A primary purpose of the invention is to provide a trash collection vehicle of the type described in which the hose support arm includes an adjustment handle which is advantageously located relative to the driver's seat.
Another purpose is an improved boom support system for the hose of a trash collection vehicle in which the lifting force applied to the boom is provided by one or more gas springs pivotally connected between two support arms which form the main structure of the boom.
Another purpose of the invention is a support structure as shown which includes a lever connected to the gas springs and pivotally connected to one of the support arms. The lever is adjustable in its relative position to the forward support arm which varies the effective moment arm through which the gas springs apply an upward or lifting force to the boom to thereby adjust the height of the pickup nozzle.
Other purposes will appear in the ensuing specification, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is a side view of a trash collection vehicle of the type disclosed herein;
FIG. 2 is an enlarged partial side view of the support boom;
FIG. 3 is a section along plane 3--3 of FIG. 2;
FIG. 4 is a bottom view of the boom support lever;
FIG. 5 is a section along plane 5--5 of FIG. 2;
FIG. 6 is an enlarged view of the connection between the telescopic control rod and the support element of FIG. 5;
FIG. 7 is an enlarged side view of the operator control assembly and its connection to the hose;
FIG. 8 is a top view of the operator handle;
FIG. 9 is a section along plane 9--9 of FIG. 8;
FIG. 10 is a top view showing the connection between the hose support ring and the hose yoke;
FIG. 11 is a partial enlarged side view of the vehicle showing the pickup head and its connection to the vehicle frame and front axle;
FIG. 12 is a top view of the pickup head and its connection to the vehicle front axle;
FIG. 13 is a front view of the pickup head and its connection to the vehicle frame;
FIG. 14 is a side view, on an enlarged scale, showing the debris canister and the mounting thereof on the vehicle frame;
FIG. 15 is a section along plane 15--15 of FIG. 14;
FIG. 16 is a side view of the deflector plate mounted in the debris collection plenum chamber;
FIG. 17 is an exploded view illustrating the trash collection canister and the rigid liners used therein;
FIG. 18 is a side view, in part section, of the debris canister;
FIG. 19 is an enlarged partial side view of the pivotal connection between the debris canister and the vehicle frame;
FIG. 20 is a top view of the connection of FIG. 19;
FIG. 21 is an enlarged side view, similar to FIG. 19, but showing the debris canister in a second position; and
FIG. 22 is a side view, similar to FIGS. 19 and 21, but illustrating the debris canister in a third position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The litter collection vehicle of the present invention includes a body 10 mounted on rear wheels 12 and front wheels 14. The body may support a driver's seat 16 and there will be the typical controls for the driver to use in operating the vehicle. These may include foot pedals 18 and 20 and a steering wheel 22, as well as other conventional devices found on vehicles of this type.
The vehicle includes both a pickup hose with supporting control elements and what is described as a pickup head. The hose is indicated at 24 and the pickup head is indicated at 26. The hose may be supported by a counterbalance system indicated generally at 28 and, in the FIG. 1 position, provides the vacuum to the pickup head 26 by being mounted thereon. The opposite end of hose 24 is connected to a cover 30 within which is housed a vacuum fan 32 indicated in dotted lines in FIG. 14. Thus, suction will be applied to the end of the hose 24 connected to the vacuum fan, with the free end of the hose, when it is not mounted on the pickup head 26, being used by the operator to pick up litter.
The hose counterbalance support system 28 is detailed in FIGS. 2-4 and includes a U-shaped roll bar 34, the upper end of which mounts a generally U-shaped bracket 36. Bracket 36 pivotally mounts a rod 38 which in turn is attached to one end of a rear support arm 40. The support arm will be seated on the upper flange 42 of bracket 36 and will pivotally move to either side relative to roll bar 34 by means of the pivotal connection comprising pin 38 and bracket 36.
Rear support arm 40 carries a mounting bracket 44 which in turn mounts a hose support 46 which is one of several such hose supports used to hold the hose 24 up above the body 10, as shown in FIG. 1. Rear support arm 40 is pivotally connected, as at 48, to a front support arm 50 which mounts a series, in this case three, hose supports 52.
Pivotally mounted to rear support arm 40, as at 56, are a pair of spaced gas springs 54. Each of the springs 54 has a forwardly extending piston rod 58, with the two springs being pivotally mounted to opposite sides 60 of an intermediate lever 62 illustrated in side view in FIG. 2 and in bottom view in FIG. 4. As shown in FIGS. 2 and 4, the leftwardly-extending portions of the sides 60 will pivotally mount the two gas spring piston rods 58. It will be understood that the gas springs could alternatively be installed with their piston rods and cylinders in opposite locations. Lever 62 is pivotally mounted, as at 64, to the forward support arm 50 and its forward extensions 66 pivotally mount a pin 68 which threadedly mounts a screw 70, as particularly shown in FIG. 3. The screw 70 has a handle 72 which rotates the screw. The upper end of the screw is mounted loosely in a pin 74 by a pair of lock nuts 76, with the pin 74 being rotatably or pivotally mounted within the interior of the forward support arm 50. Rotation of the handle 72 has the effect of raising and lowering the pivotal connection of the front end of lever 62 relative to the support arm 50, which in turn lowers or raises the pivotal connection between the gas springs and the rear end of lever 62. The raised and lowered positions of the lever 62 are illustrated in FIG. 2, with the raised position being in solid lines and the lowered position being in broken lines. Changing the height of the connection between the gas springs and lever 62 varies the effective moment arm through which the springs are pushing so they exert more or less lifting force on the front support arm 50. This has the effect of floating the hose pickup nozzle higher above or closer to the ground. Gas springs require less operator manipulative force for hose movement than prior art leaf springs.
The support arms 50 and 40, as their names imply, support the hose 24 in the position of FIG. 1 so that the operator may manipulate the hose, as described hereinafter. The height of the pickup end of the hose above the surface being cleaned is controlled by the handle 72, easily accessible to the operator while in the seat 16, again as shown in FIG. 1.
Movement of the hose 24 is controlled by a telescopic arm assembly 80, shown in FIG. 1, and illustrated in detail in FIGS. 5-10. It is comprised of upper tube 82, sleeve 100, handle 106 and fork 104. Focusing first on the upper mounting for the arm assembly, the top of the arm assembly 80, an upper tube 82, is pivotally mounted for movement about a horizontal axis on a pin 84 extending through opposite sides of a bracket 86. The bracket 86 is pivotally bolted to an anchor bracket 88, which in turn is bolted to the rear support arm 40 by bolts 90, particularly shown in FIG. 5. The bolts 90 also secure hose supports 92 which extend upwardly and outwardly from opposite sides of the rear support arm 40. The anchor bracket 88 may be mounted to extend to either the left side or the right side of the hose support, depending upon the preference of the machine operator or depending upon whether more debris will be picked up on the left or right side of the machine. This provides an advantage to the operator in terms of the ease of use of the hose for picking up litter. As clearly shown in FIG. 6, the upper end 82 of the telescopic support rod is pivoted about a horizontal axis, as shown by arrows 94, and is pivotal about a vertical axis, as shown by arrows 96. Thus, the control for the operator to manipulate the hose is essentially universally movable about its upper support assembly.
The telescopic arm assembly 80 includes the upper tube 82, the end of which is mounted as described. The tube 82 extends within a sleeve 100, shown in FIG. 7, with these elements being telescopically movable to vary the length of the support assembly. At the lower end of assembly 80 there is a stub shaft 102 which also extends into and is pinned to the sleeve 100 at 98, with the stub shaft 102 being connected to and forming part of a fork 104, which is indirectly connected to and carries the lower end of the hose 24.
The handle for use by the operator in manipulating the hose is indicated generally at 106 and will be located along sleeve 100 by two collet-type clamp collars indicated at 108 and 110 located at opposite ends of the handle 106. The handle 106 may be moved along sleeve 100 by loosening, moving and then tightening the collars 108 and 110. The handle 106 includes a tubular portion 112 and three separate hand gripping areas which are all joined together. There is a vertical hand gripping area 114 and left and right hand gripping areas 116 and 118. The hand gripping areas are tubular, as indicated by the cross section of FIG. 9. The operator may grip either the left side, the right side or the vertical portion of the handle which provides both ease in controlling movement of the hose and substantially lessens fatigue on the part of the operator by allowing use of either hand and shifting of the hand to different positions when manipulating the hose.
Of particular advantage in the handle shown and described herein is that it fits loosely over the telescopic tube assembly 80 and swivels freely relative thereto. Thus, when the operator holds the handle to move the hose around, it always stays aligned with the operator's body or arm, regardless of how the tube is swung about.
The fork 104 which forms the lower connection point for the telescopic tube assembly 80 is pivotally connected to a ring 120 as particularly shown in FIGS. 7 and 10. There are stub pivot shafts 122 attached to and extending outwardly from the ring with the fork 104 being pivotally attached thereto.
The ring 120 loosely surrounds a pickup nozzle 124, as shown in the partial section of FIG. 7, with the nozzle 124 extending inside of the hose 24 as at 126. A hose clamp 128 secures the lower end of hose 24 to the upper end 126 of the nozzle, again as particularly shown in FIG. 7. Ring 120 is loosely retained between a shoulder 127 formed in nozzle 124 and a flanged collar 129 fitted inside the end of hose 124. This type of pivotal connection between the hose and its control eliminates twisting of the hose, which has considerable torsional stiffness, and thus allows the operator to manipulate or control the hose with substantially less fatigue than prior art devices of a similar type. The nozzle 124 has a guard ring 111 spaced from its open end by mounting brackets 113. which provides an air gap 115. The air gap 115 allows the operator to drag the hose along a surface to be cleaned without vacuum causing it to stick to the ground. The ring 111 also dislodges flattened-out wet debris.
FIGS. 11, 12 and 13 illustrate the mounting of the pickup head 26 on the front axle 131. Brackets 130 are mounted to the top 132 of the pickup head and rearwardly extending arms 134 are pivotally mounted to each of the brackets 130. The arms 134, as particularly shown in FIGS. 11 and 12, are pivotally attached to a support assembly 136 which includes a pair of torsion springs 138 mounted on bolts 140 to permit yielding movement of the pickup head 26. The assembly 136 includes an upwardly extending flange 142 which will be attached by bolts 144 to the axle 131 of the front wheels 14. Thus, the pickup head 26 may be responsive to contact with large debris in that it has up, down and twisting yielding movement due to the presence of the torsion springs 138.
At one side of the top 132 of the pickup head 26 there is a stub tube 133 which will support the hose 24 on top of the pickup head as illustrated in FIG. 1. In this position, the hose is not used as an independent litter pickup device, but rather provides the suction to the pickup head so that it may sweep a wide area for litter. The pickup head has a peripheral skirt, as is customary, with the skirt comprising an upper retainer 135 and a depending flexible for example rubber skirt 137. The skirt 137 is peripheral, but has an opening on the left side, that being the side away from the stub tube 133, with the opening being indicated at 139. The skirt is also open across the front of the machine, as at 141, so that it may pass over debris to be sucked up by the pickup head. The advantage in having the opening 139 at the side of the pickup head opposite the point of suction, that being the stub tube 133, is that the air flow will be completely across the front of the pickup head which may be either 40" or as much as 48" in width. By drawing air across the full width of the pickup head a high air velocity is obtained, and the debris which is accessible at the front of the pickup head will be moved across its width into the stub tube 133, through the hose and into the debris containers. This provides a more efficient pattern for movement of picked up debris and litter. Also, by positioning the vacuum connection to one side of the pickup head, the area of maximum suction power may be located along a curb or fence where debris is more heavily concentrated.
The pickup head can be raised or lowered depending upon whether it is to be used as the means for picking up litter or whether it is to be unused and litter is to be picked up by the hose 24. A pair of cables 146, as shown in FIG. 13, are attached to the top 132 of the pickup head 126 with brackets 127, with the cables each extending around a pulley 148 and being dead-ended in a bracket 150. The pulleys 148 may be raised and lowered, which moves the pickup head away from or toward the surface to be cleaned. Each pulley is mounted on a pivotal arm 152 with the arms being connected by a lost motion link 154. The two arms 152 are connected together by a spring 156 and there is an actuating lever 158 which is connected to the left arm 152 and to link 154 and has, at its lower end, a spring 160 which is fixed to the vehicle frame. The upper end of actuating lever 158 is connected by a cable 162 to an actuator 164 shown in FIG. 11. The actuator is mounted on the vehicle frame and will either pull in or let out the cable 162, which will have the end result of raising or lowering the pulleys 148, which in turn raises or lowers the pickup head. The movement of the lever 158 is illustrated in FIG. 13 by the arrows 166 with such movement being effective to raise or lower the pulleys through the combination of the arms 152, the springs 160 and 156, the lost motion link 154 and a stop 168, the position of which is controlled by a manual control knob 170. By using this knob, the operator may control the height above the ground to which the pickup head can be raised or lowered. The actual raising and lowering of the pickup head is done by the actuator 164 which also will be controlled by the operator from one of the dashboard mounted controls.
FIGS. 14 through 22 illustrate the trash containers, the cover over them, the vacuum system and the mechanism which permits variable tilting of the trash containers for convenient disposal of the collected debris by the machine operator. In FIG. 14, the vacuum fan is illustrated generally at 32 and is located within the cover 30 and the vacuum fan is driven by a motor 172. Air is exhausted to atmosphere through an outlet 173. The hose inlet for the cover 30 where suction hose 24 connects is shown at 174 and there is a further inlet 176 which will be used with a wand pickup, the wand being illustrated generally at 178 in FIG. 1. The wand will be used when the machine operator dismounts and moves to pick up debris from an area that is not accessible while riding on or driving the machine.
The hose inlet 174 will direct debris into a plenum which is defined within the cover in the area 180 and located directly above a debris canister 182. The debris canister 182, shown in FIG. 17, will contain two side-by-side debris containers, such as plastic bags, which will be maintained in an open position for collection of debris by identical rigid inserts 184 and 186 shown in FIG. 17. The inserts, which may have open bottoms, will be placed inside of the plastic bags or other suitable debris containers and then the plastic bags will be placed side-by-side within the debris canister 182. The debris containers may each be on the order of 50 gals. in volume and will be seated side-by-side within the debris canister so that both will be filled as debris is sucked up by either the hose 24 or the vacuum head 26 or the wand 178. Thus, the present invention provides essentially double the normal capacity of prior art machines of this type.
In order to insure that the debris containers are relatively evenly filled, there is a deflector plate 188, shown in FIGS. 15 and 16, which is mounted longitudinally in the lateral center and near the top of the debris canister and which has deflecting flanges 190 which will cause the debris which is sucked in generally centrally of the debris canister to be directed to both of the debris containers. The plate 188 extends longitudinally completely across the top of the debris canister so that it will deflect the incoming litter laterally into the two plastic bags.
The cover 30 is attached by a hinge 192 to a hinge mount 194 which permits the cover to be raised up, as shown by dotted line 30A, so that the debris canister may be pivoted rearwardly as indicated by the two dotted line positions 208 and 210 in FIG. 14. The hinge mount 194 is fixed on the top of a post 196 and there is a gas spring 198 mounted to the hinge 192 and to the post 196 with the gas spring balancing the cover 30 and the vacuum fan when the cover is lifted. There is a cable 200 which is fastened to the debris canister at 202, as shown in FIG. 14 and to the post 196 at its opposite end, which cable will limit the pivotal movement of the debris canister as it is moved between the closed position of FIG. 14 and the lower broken line tilted position 210 of this same figure. The canister pivotal mounting is indicated at 204 and the canister will rest upon a front mount 206 when it is in the closed position shown in FIG. 14.
The debris canister may be moved first to a partially open position as shown by the broken lines indicated at 208 in FIG. 14 and finally to a full open position shown by the broken lines 210 in FIG. 14. In the first position, the trash bags may be tied at the top and at the second position the trash bags may be removed. The second position 210 provides for removal of the trash bags with less vertical lifting than if they were in the position 208, which assists the operator and provides trash removal with much less effort.
FIGS. 18 through 22 illustrate the mechanism for controlling movement of the debris canister through the various positions described above. The bottom of the canister has a stop 208 bolted thereto with the stop having a stiffening gusset 210. A portion of the vehicle frame is indicated at 212 and the pivot 204 will be attached to this portion of the frame. The frame mounts a bracket 214 which carries two forward flanges 216 pivotally mounting a block 218. Bracket 214 also has a floor 215 which serves as a motion stop for block 218, as shown in FIGS. 19 and 21. The block 218 has a forwardly curved nose 220 connected by two springs 222 to the bracket 214. The springs 222 urge the block to rotate in a counter clockwise direction about its pivot point 223.
FIG. 19 illustrates the closed position of the debris container with the block 218 being held firmly against bracket floor 215 by springs 222. FIG. 21 illustrates the position 208 of the debris canister. The debris canister has been moved rearwardly about its pivot 204 until the curved area 224 of the block 218 has encircled a stop pin 226 carried near the bottom of stop 208. The debris canister will be held in this position because the springs 222 hold the block in the described position against bracket floor 215.
When it is desired to move the debris canister to the fully tilted position illustrated at 210, a back and down movement by the machine operator on the debris canister is effective to push the block 218 up, fully releasing the debris canister from the FIG. 21 position and permitting its full movement to the FIG. 22 position. It is held in this position by the cable 200 and can move no further. Springs 222 go over center and hold block 218 against bracket 214. When it is desired to move the debris hopper back to its upright position, pin 210 will rotate downward about pivot 204, and will strike the tail end 219 of block 218, causing it to rotate back to the position of FIG. 19.
Thus, the debris canister has several advantages. It has double the normal litter capacity since it has side-by-side litter containers, each of which may be about 50 gals. in capacity. Further, it has more than one open position facilitating removal of the debris containers once the bags have been tied at their tops and permitting such removal without strain on the operator's back. Rather than lifting the bags directly up, they may be removed by sliding them rearwardly.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto. | A vacuum trash collection vehicle has a debris container and a source of vacuum, both located on the vehicle. There is a hose connected at one end to the debris container and has the source of vacuum applied thereto. The other end of the hose is open to form a collection nozzle. There is a boom for supporting the nozzle during use as a debris collection device with the boom including a rear support arm pivotally mounted to the vehicle and supporting the hose in a rear area and a forward support arm pivotally mounted to the rear arm and supporting the hose at an area forward of the rear support arm. There is a control element accessible to the vehicle driver for moving the hose and nozzle. There is a spring pivotally connected between the rear and front support arms which urges the front support arm in an upward direction to, at least in part, carry the weight of the hose for assisting the vehicle driver in operating the control element. An adjustment means readily accessible to the driver allows him or her to vary the moment arm by which the spring urges the front arm upward, thereby varying the height at which the front arm supports the hose. | 4 |
SUMMARY OF THE INVENTION
This invention relates to a liquid valve and will have specific but not limited application to an angle fire valve having a cooperating valve seat and shiftable seal which reduces the amount of effort required to close the valve when the inlet thereof is subjected to high liquid pressures.
In the valve of this invention, the valve seat is of a two step annular form having a reduced annular flat seal area at the valve inlet. The resilient seal of the valve is carried by a shiftable valve member which includes an annular protrusion or rib located in alignment with the valve seat at its reduced flat seal area adjacent the valve inlet to cause the resilient seal of the valve to be compressed between the rib of the valve member and the valve seat at its inlet. This reduces the effective area of liquid pressure between the valve seat and the valve seal during the sealing operation so as to minimize the torque or effort required to close the valve. When such valves are utilized as fire valves, the water pressure at the inlet of the valve may be in the range of 300 pounds per square inch. Under these circumstances, without the assistance of this invention, it is difficult to close such valves.
Accordingly, it is an object of this invention to provide a liquid valve which requires a minimal amount of effort to close when subjected to high inlet pressures.
Another object of this invention is to provide a liquid valve having a valve seat and a shiftable cooperating valve seal which is constructed to reduce upon closure of the valve the effective diameter of the valve at the inlet to reduce the torque required to close the valve.
Another object of this invention is to provide a fire valve which can be closed with minimal effort when subjected at its inlet to pressures in excess of 200 psi.
Other objects of this invention will become apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of this invention has been chosen for purposes of illustration and description wherein:
FIG. 1 is a sectionalized view of the valve shown in its closed position.
FIG. 2 is a sectionalized view of the valve shown in its open position.
FIG. 3 is an enlarged detailed view of a fragmentary portion of the valve at its valve seat and shown in its closed position.
FIG. 4 is an enlarged detailed view of the valve seat shown in fragmentary sectionalized form.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment illustrated is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described in order to best explain the principles of the invention and its application and practical use to thereby enable others skilled in the art to best utilize the invention.
Valve 10 shown in the figures is of the angle valve type utilized to accommodate liquid flow. Valve 10 includes a housing having a body 12 and a bonnet 14. Body 12 includes an inlet 16 and an outlet 18. A stem 20 is carried in cooperative threaded engagement by bonnet 14 so as to be shiftable longitudinally relative to bonnet 14 and valve body 12 upon rotation of the stem. A valve member, designated generally by the reference numeral 22, is carried at the inner part of stem 20 and a handle or similar gripping device 24 is carried at the projecting outer part of the stem. Valve member 22 includes a disk part 26, a resilient annular seal 28 and a seal securement member 30. Seal 28 is carried within an annular groove 32 in disk part 26 so as to be locatable between the side walls and in abutment with the base wall of the groove. Securement member 30 overlies an annular edge section of seal 28 and is urged against the seal by a retainer nut 34. In this manner, seal 28 is retained within groove 32 of disk part 26. Disk part 26 is journaled upon stem 20 so as to permit the stem to rotate relative to the disk part when seal 28 is brought into sealing engagement with valve seat 36 of valve body 12. Valve member 22 is shiftable between the closed position shown in FIG. 1 with seal 28 engaging valve seat 36 and an open position, such as shown in FIG. 2, upon rotation of stem 20. Nut 38 which encloses stem 20 and is threaded onto bonnet 14 serves to provide a packing seal for the valve at the stem.
Valve 10 as thus far above described is of a standard, well known construction. In this invention the cooperative relationship between seal 28 and valve seat 36 is of a unique modified construction which enables the effective diameter of the valve member at closing to be reduced so as to reduce the closing effort or torque applied to stem 20. Valve seat 36 is of a two-step construction and includes an annular planar area or section 40 which terminates at end edge 42 of valve inlet 16 and an annular planar area or section 44 spaced radially outwardly of section 40. Section 44 of valve seat 36 is offset downstream relative to inlet 16 from section 40 with a conical area or section 46 of the valve member separating sections 40 and 44.
In valves of the nature herein illustrated having a 21/2 inch diameter inlet 16, the width of valve seat section 40 indicated by dimension "C" in FIG. 4 is preferably 0.08 inches, with the offset between sections 40 and 44 as indicated by dimension "B" in FIG. 4 being preferably 0.05 inches and with the taper of conical section 46 relative to section 40 indicated by angle "A" in FIG. 4 being preferably 45°. Also, as best shown in FIG. 4, edge 42 of inlet 16 is abrupt or sharp cornered. Sections 40 and 44 of the valve seat parallel one another and extend at a right angle to inlet 16 of the valve.
An annular rib 48 protrudes from the base wall of groove 32 in disk part 26. Rib 48 is located within disk part groove 32 so as to be positioned over valve seat section 40 and preferably aligned at its interior edge 50 with edge 42 of valve inlet 16. For a disk part 26 having its groove base wall spaced 0.44 inches from end edge 52 of the disk part, rib 48 is preferably formed about a 1/32 inch radius with a maximum height of 0.065 inches.
As stem 20 is rotated and valve member 22 is shifted into its closed position shown in FIG. 1, seal member 28 will first contact valve seat 36 at its section 40 causing the seal to be compressed between section 40 and rib 48 of disk part 26. Further closing movement of valve member 22 upon continued rotation of stem 20 causes seal 28 to first make contact with conical section 46 and thereafter planar section 44 of valve seat 36. This cooperation between disk part rib 48 and stepped valve seat sections 40 and 44 upon compression of seal member 28 during closing movement of the valve member causes a reduction in the effective diameter of the valve member to reduce the amount of twisting effort or torque applied to stem 20 in closing the valve.
It is to be understood that the invention is not to be limited to the details above given but may be modified within the scope of the appended claims. | A valve including a resilient seal which contacts in a sealing relationship an annular valve seat having an offset annular surface area at the valve inlet against which the resilient seal of the valve is compressed by an overlying rigid member to reduce the liquid pressure against the valve seal, thereby easing the effort to close the valve. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to applicator systems for delivering materials into mammalian body cavities having a compact format in which the expulsion member is manipulated to present a shorter than normal length during storage. The applicator is particularly useful for delivering intravaginal devices, such as catamenial devices, into a vaginal canal.
BACKGROUND OF THE INVENTION
[0002] Applicators for delivering materials into a body cavity typically comprise a tubular insertion member having an insertion end and a gripper end opposite thereof, and an elongate expulsion member slideably fitted within the tubular insertion member for expelling the contained materials. A class of applicators is known as compact applicators, because they present a shorter packaged size, especially length, than required for use.
[0003] One type of compact applicator has an insertion member adapted to contain the insertable device and an expulsion member that is stored between the insertable device and the insertion member, e.g., in an annular space between a cylindrical tampon and a cylindrical, tubular insertion member. An example of this type of compact applicator is shown in Ring, U.S. Pat. No. 4,291,696. This type requires the user to prepare the applicator for use by first partially withdrawing the expulsion member in a controlled manner prior to pushing against the insertable device to expel it from the insertion member. This step introduces significant complexity to the applicator, as the insertable device must be prevented from following the expulsion member as it is withdrawn. Additionally, the expulsion member should also be somehow prevented from being completely removed from the insertion member.
[0004] A second type of compact applicator stores substantial portions, if not all, of the expulsion member outside of the insertion member. One example of this approach is disclosed in Buzot, U.S. Ser. No. 09/331907, filed Dec. 23, 1998, based upon WO 99/33429. This applicator includes an external pusher element that is bent and inserted through an opening in the applicator to bear on a rear surface of the tampon. While this is an interesting and promising advance in the art, it requires several manipulations by the user prior to expelling the tampon from the applicator.
[0005] Another approach is described in Sakurai et al. U.S. Pat. No. 4,269,187. This approach incorporates a push-out top end contained within an outer cylinder and at least one inserting supporting piece connected to the push-out top end and folded outwardly from the outer cylinder. A preferred embodiment of this device incorporates a pair of such outwardly folded elements supporting pieces that are locked together prior to use. Again, this approach also appears to require the user to actively unfold and manipulate the push-out elements prior to use.
[0006] Therefore, what is needed is a compact applicator that requires little manipulation by a user prior to use and that is robust to reliably and easily expels an insertable object contained therein.
SUMMARY OF THE INVENTION
[0007] An applicator system for delivering an object into a mammalian body cavity is disclosed. The applicator includes a tubular insertion member arranged and configured to contain the object and a linearly-biased expulsion member having a first end slideably fitted within the tubular insertion member. The tubular insertion member has an insertion end and a gripper end, opposite thereof. The expulsion member extends out of the gripper end of the tubular insertion member, and terminates in a second end. The applicator also includes an expulsion member restraint capable of restraining the second end of the expulsion member proximate an outer surface of the insertion end of the tubular insertion. The expulsion member is bent when so restrained.
[0008] The invention also relates to a method of delivering an object into a body cavity from an applicator. In this method, the applicator is substantially as described above, and the method includes the steps of: a) releasing the expulsion member restraint to permit the expulsion member to 5 spontaneously attain a substantially linear configuration with the second end extending rearwardly away from the gripper end of the tubular insertion member; b) inserting the insertion end of the tubular insertion member into the body cavity; c) applying force on the second end of the expulsion member to move the first end thereof toward the insertion end of the tubular insertion member; d) expelling the object out of the insertion end of the tubular insertion member and into the body cavity; and e) removing the applicator from the body cavity.
BRIEF DESCRIPTION OF THE DRAWING
[0009] [0009]FIG. 1 is a side elevation of a compact tampon applicator according to the present invention in its stored or packaged configuration and, in phantom, locations of a portion of the expulsion member as it moves into a ready-for-use configuration.
[0010] [0010]FIG. 2 is a cross-section of the side elevation of FIG. 1.
[0011] [0011]FIG. 3 is a perspective view of an expulsion member useful in the present invention.
[0012] [0012]FIGS. 4 and 5 are cross-sections taken along lines 4 - 4 and 5 - 5 of FIG. 3.
[0013] [0013]FIGS. 6A and 6B are end elevations of two embodiments of applicators according to the present invention.
[0014] [0014]FIG. 7 is a detail of the insertion end of a tubular insertion member and the second end of an expulsion member according to an alternative embodiment of the present invention.
[0015] [0015]FIG. 8 is a side elevation of an alternative embodiment of the present invention in a ready-for-use configuration.
[0016] [0016]FIG. 9 is a side elevation of the alternative embodiment of FIG. 8 in a stored or packaged configuration.
[0017] [0017]FIG. 10 is a cross-section of the hinge portion of the beam in the alternative embodiment of FIG. 8, taken along line 10 - 10 .
[0018] [0018]FIG. 11 is a detail of the-insertion end of a tubular insertion member and the second end of an expulsion member according to an alternative embodiment of the present invention.
[0019] [0019]FIG. 12 is a side elevation of an alternative embodiment of the present invention in a packaged configuration.
[0020] [0020]FIG. 13 is a side elevation of the alternative embodiment of FIG. 12 in an unpackaged, ready-for-use configuration.
[0021] [0021]FIG. 14 is a side elevation of the embodiment of FIG. 1 in a ready-for-use configuration.
[0022] [0022]FIG. 15 is a side elevation of the embodiment of FIG. 1, as a contained tampon is being expelled.
DETAILED DESCRIPTION OF THE INVENTION
[0023] As used in herein the specification and the claims, an element is “linearly-biased” if it tends to exhibit a substantially linear configuration in the absence of significant outside forces. For example, an element that is capable of being bent under an outside influence, such as a restraint, and of spontaneously reverting to a substantially linear configuration when the outside influence is removed is a linearly-biased element.
[0024] The term “diameter” as used in herein the specification and the claims relates to a chord passing through the center of a figure or body, and it can be measured as the length of this straight line (chord) through the center of the body in a given plane. Unless otherwise noted, this plane is perpendicular to the major longitudinal axis of the body. In a non-circular cross-section, the body may have a maximum diameter and a minimum diameter.
[0025] As used herein, a “unitary” device is one that has the characteristic of being a unit or a whole. This includes both devices that are created from a single element and those formed by fixing together individual elements to form the whole.
[0026] As used herein the specification and the claims, the term “intravaginal device” and related terms includes support devices, obstructing devices useful to block the flow of and/or collect bodily liquids, and the like. The term includes, without limitation, incontinence devices and vaginal supports, such as pessaries; and obstructing devices, such as menstrual collection cups and inflatable or expandable vaginal blocking devices (devices which do not, themselves, absorb the bodily liquids).
[0027] While the present invention generally relates to applicator devices having a tubular insertion member, the following detailed description will refer, specifically, to a tampon applicator for ease of understanding. One of ordinary skill in the art will recognize other uses for this invention.
[0028] Referring now to the drawings, wherein like reference numerals designate like elements, FIGS. 1 and 2 depict an applicator 10 , comprising a tubular insertion member 12 , having an insertion end 14 and a gripper end 16 that is suitable to contain a tampon 18 that can be delivered into the body cavity. The insertion end may have a plurality of inwardly curved petals 20 that form a substantially closed feature 22 . The applicator 10 also includes a linearly-biased expulsion member 24 having a first end 26 that is insertable into the tubular insertion member 12 and is capable of bearing against the tampon 18 . The expulsion member 24 terminates in a second end 28 , opposite the first end 26 , that may be manipulated to move the first end 26 within the tubular insertion member 12 . The first end 26 of the expulsion member 24 is arranged and configured to be slideably introduced into the tubular insertion member 12 through its gripper end 16 .
[0029] The applicators 10 or other tubular devices of the present invention can have tube geometries or cross-sections that are useful to contain the object to be inserted. Often, the shape of the tampon 18 or other element contained suggests the shape of the tubular insertion member 12 , but departures from this general rule may be made. Therefore, the tubular insertion member 12 may take on numerous cross-sectional shapes including, without limitation, circular, oval, polygonal (e.g., trapezoidal, rectangular, triangular), and the like. For example, cylindrical tampons may be contained within rectangular insertion members and trapezoidal tampons (such as those disclosed in Van Iten et al., U.S. Pat. No. 5,350,371) and cup-shaped-tampons (such as those disclosed in Bailey, U.S. Pat. No. 2,330,257) can be contained in a generally cylindrical insertion member. In addition, the insertion member 12 can substantially elongated, curved, or flexible, or it can take on other shapes that are apparent to one of ordinary skill in the art. The specific geometry, itself, is not critical to the practice of the present invention. In addition, the edge of the tubular device (both finished and unfinished) may be a standard, planar edge coincident with a plane perpendicular to the longitudinal axis of the tubular device. However, the edge may also be coincident with a plane oblique to the longitudinal axis, or it may be otherwise contoured and/or recessed as described in the commonly assigned, copending application of Buzot, U.S. Ser. No. 09/454,989 (herein incorporated by reference).
[0030] The first end 26 of the linearly-biased expulsion member 24 is provided to bear against the rear end 19 of the tampon 18 , especially as it is use to expel the tampon 18 . In order to expel the tampon 18 effectively, it is useful to provide a first portion 30 of the expulsion member 24 located adjacent the first end 26 . It is preferred that the first portion 30 has a length that is sufficient to provide some directional stability to the expulsion member 24 in the tubular insertion member 12 . In particular, it is preferred that the enlarged portion 30 corresponds to the size and shape of the interior of the gripper end 16 of the tubular insertion member 12 proximate the first portion 30 . This allows the expulsion member 24 to more easily slide within the tubular insertion member 12 without binding or becoming jammed.
[0031] The expulsion member 24 (shown alone in FIG. 3) also has a second portion 32 extending from the first portion 30 to the second end 28 . Preferably, the second portion is formed of a beam 32 having a reduced cross-section in comparison to the first portion 30 . As this beam 32 is used to transmit force exerted on the second end 28 along the expulsion member 24 and through the first portion 30 to the tampon 18 , the second portion should have sufficient column strength and rigidity to transmit such linear forces without significant deformation. While the linear forces encountered in use of applicators may vary, it is preferred that the beam 32 be capable of withstanding a linear force sufficient to expel the tampon 18 into a user's vaginal canal without buckling. Generally, this force is at least about 5 N (Newtons), more preferably, at least about 10 N, and most preferably, at least about 15 N. This column strength can be determined by securing the first portion of the expulsion member into an appropriately sized receptacle placed on the fixed jaw of a Instron Universal Testing Machine, available from Instron Corporation, Canton, Mass., USA, to prevent the first portion from twisting or bending. The moveable jaw is brought to contact the second end of the expulsion member and is then set to compress the expulsion member at a rate of about 5 cm/minute. The force exerted on the expulsion member is measured continuously, and the point at which this force begins to fall instead of rise is the point at which the expulsion member buckles. The maximum force achieved is the column strength of the expulsion member. Notwithstanding the required column strength and rigidity necessary to transmit the expulsion forces, the beam must also be sufficiently flexible to be bent into a compact configuration, again without permanent damage to itself, such as a permanently set bent configuration.
[0032] The proportion of the expulsion member 24 provided by the first portion 30 and by the second portion 32 can vary. However, the first portion 30 preferably has sufficient length and other external dimensions to help it to be predictably oriented in the tubular insertion member 12 . For example, it is helpful if the first portion has dimensions to allow it to slide within the tubular insertion member 12 while maintaining a substantially uniform orientation to the longitudinal axis of the insertion member 12 . These dimensions may include a length that is approximately equal to the maximum diameter of the first portion 30 or greater.
[0033] The second portion 32 preferably has sufficient length to be wrapped back towards the insertion end of the tubular insertion member 12 . Thus, it preferably extends about ¾ of the length of the expulsion member or less. This provides a sufficient length to dispense an object from the tubular insertion member 12 . An additional relationship can be the relationship of the packaged length of the applicator 10 having a bent expulsion member 24 . Thus, it is preferred that the packaged length of the applicator (“L” as shown in FIG. 1) is less than about 70% of the length of the applicator 10 having an extended expulsion member 24 (“L′” as shown in FIG. 1), and more preferably, less than about 60%.
[0034] The second portion 32 is preferably a beam, and it can have any cross-section that effectively transmits the linear forces described above and permits the required bending. A representative, non-limiting list of useful cross-sections include circular, oval, and the like; polygonal including triangular, trapezoidal, parallelograms such as rectangular, rhomboidal, and the like; “I”-section; angle sections; “T”-sections; “Z”-sections; “H”-sections; channel-section, including standard channel-sections with substantially straight base and walls, “U”-sections, and sections defined by circular segments; and other sections that provide the appropriate balance of column strength and rigidity under linear forces aligned with the longitudinal axis of the beam and flexibility under forces directed at an angle to the longitudinal axis of the beam. Preferred cross-sections of the beam include channel sections, and especially preferred cross-sections include channel-sections defined by circular segments. Such circular segments may be further described by their central angle, θ.
[0035] In a preferred embodiment, the first portion is an enlarged portion, and the second portion comprises a beam having a reduced cross-sectional area in comparison to the enlarged portion. This provides a good bearing surface against the tampon, corresponds to the larger interior dimensions of the tubular insertion member, and allows a less bulky beam to extend outwardly from the tubular insertion member that can be bent around the insertion member for more discrete packaging.
[0036] Preferably, expulsion member 24 has a hinge portion 34 intermediate the first end 26 and the second end 28 . In a particularly preferred embodiment, the hinge portion 34 is adjacent the enlarged portion 30 of the expulsion member 24 . The hinge portion 34 provides a defined bending location for the expulsion member 24 . However, unlike unbiased hinges, the hinge portion 34 doesn't affect the linear bias of the expulsion member 24 . Therefore, the hinge portion 34 , in addition to the usual characteristic of providing a bending location, must be able to transmit linear force from the second end 28 of the expulsion member 24 to the first end 26 and to provide a mechanism to return the expulsion member 24 to a substantially linear configuration once an outside, bending influence is removed.
[0037] Useful hinge portions 34 can be provided by an unmodified portion of the beam 32 ; by a modified portion of the beam 32 ; by an added, biased hinge element such as a spring-biased hinge; and by any other useful element that provides the properties and characteristics described above.
[0038] Preferably, the hinge portion 34 is provided by an unmodified portion of the beam 32 , if the beam 32 is sufficiently flexible to bending moments (or forces) by itself, or by a modified portion of the beam 32 , such as a localized reduction in wall height of a channel-section beam. As used herein the specification and the claims, the term “wall height” relates to a measure of 5 the distance from the uppermost edges of a channel wall or the ends of a circular segment down to the base of a substantially flat-bottomed channel or the midpoint of the circular segment. These measurements can be seen in FIGS. 4 and 5. Other modifications of beam sections can be used. For example, one or more flanges may be locally reduced or removed from a hinge portion of “I”-, “H”-, “Z”-, “T”-, or angle section beams. In the case of the hinge portion 34 formed of either a modified or unmodified portion of the beam 32 , it is preferred that the hinge portion 34 provides a gradual bend of the beam in contrast to a localized angle or crease. This gradual bend results in significantly less material damage of the beam 32 and provides more spring-back upon release.
[0039] Preferably, the hinge portion 34 provides sufficient spring-back to provide an angle a upon release of less than 90°, more preferably, less than about 600 , and most preferably, about 0°. As can be seen in FIG. 1, this angle a is the amount by which the spring-back of the material fails to provide a straight beam 32 . This provides a more rigid structure to transmit the expulsion force applied to the second end 28 through the expulsion member 24 to the tampon. 18 .
[0040] The applicator 10 also includes an expulsion member restraint capable of restraining the second end 28 of the expulsion member 24 proximate an outer surface of the insertion end 14 of the tubular insertion member 12 such that the expulsion member 24 is bent when so restrained. The restraint may be unitary with the applicator, or it may be external to the applicator. Unitary restraints can be unitary with the tubular insertion member 12 or, preferably, unitary with the expulsion member 24 . In several embodiments, illustrated in FIGS. 1-3 and 6 - 11 , the restraint is unitary with the second end 28 of the expulsion member 24 . The first of these embodiments, shown in FIGS. 1-3 and 6 A and 6 B, the expulsion member 24 has a tubular enlarged portion 30 and a beam 32 having a cross-section substantially corresponding to a circular segment having a first central angle providing a first wall height. The second end 28 has a unitary mechanical catch 36 in the form of a portion of the beam having a larger central angle, greater than about 180° providing a greater wall height. The increased central angle provides a mechanical catch 36 that is capable of engaging an outer surface of the tubular insertion member 12 , especially when the tubular insertion member 12 is cylindrical.
[0041] Another embodiment in which the restraint is a mechanical catch that is unitary with the second end 28 of the expulsion member 24 is shown in FIG. 7. In this embodiment, the mechanical catch 36 ′ is a hook 38 . This hook 38 is oriented to engage with a gap disposed between adjacent petals 20 at the insertion end 14 of the tubular insertion member 12 . The hook 38 is sufficiently flexible to be released from this gap to allow the expulsion member 24 to reacquire its substantially linear orientation.
[0042] Yet another restraint that is unitary with the expulsion member 24 is based upon an adhesive material 40 disposed on the second end 28 of the expulsion member 24 . An example of-this embodiment is shown in FIGS. 8-10, which also illustrate a “T” cross-section beam 32 . Preferably, the adhesive material 40 is a pressure sensitive adhesive that is substantially non-transferable to the outer surface of the tubular insertion member 12 .
[0043] In addition, the restraint may be unitary with the tubular insertion member 12 . An example of such a restraint is shown in FIG. 11 in which the tubular insertion member 12 has an aperture 41 or a receptacle (not shown) provided therein to accept at least a portion of the second end 28 of the expulsion member 24 .
[0044] Alternatively, the restraint may be external to the applicator as shown in FIGS. 12 and 13. Preferably, the external restraint substantially surrounds the expulsion member second end 28 and the tubular insertion member 12 . In a particularly preferred embodiment, the external restraint is formed of packaging material 42 . Of course alternatives may be employed, such as a band of elastic material, plastic, or even paper.
[0045] Additional features may be incorporated into the tubular insertion member 12 and/or expulsion member 24 . For example, one or both members may incorporate features to help keep them together prior to and during use. The tubular insertion member 12 may incorporate an internally directed stop 44 to help to contain the tampon 18 and the first portion 30 of the expulsion member 24 . In addition, the expulsion member 24 may incorporate one or more raised features, such as a raised ring 46 . This raised feature 46 can interact with the internally directed stop 44 to improve the ability of the tubular insertion member 12 and the expulsion member 24 to remain interlocked. The expulsion member 24 may also incorporate a locking device to reinforce the hinge portion 34 to prevent premature collapse or otherwise increase the column strength of the extended expulsion member 24 .
[0046] The applicator devices of the present invention can be made of materials known to those of ordinary skill in the art. Generally, the tubular insertion members are plastic or paper. Plastic materials include, without limitation, polyolefins such as polyethylene and polypropylene (including polyolefin copolymers); polyesters such as polyethylene terephthalate; polyamides such as nylon; polyurethanes; polystyrene; polycaprolactone; polyvinyl alcohol; ethylene-vinyl acetate copolymers; elastomers such as silicones, natural rubbers, and synthetic rubbers including block copolymers; cellophane; PHBV such as those disclosed in Dabi et al., U.S. Pat. No. 5,910,520 (herein incorporated by reference); starch-based polymers including those disclosed in Dabi et al., U.S. Pat. No. 5,910,520; and the like.
[0047] Paper materials include, without limitation, paperboard, cardboard, cup stock, paper, and the like. The paper may be a single layer of material, or it can be a plurality of laminated layers to provide multiple benefits relating to the various layers. Laminated paper material may include a surface layer or coating of plastic, wax, silicone, lubricants, and the like, which may be useful to increase the comfort to the user during insertion and withdrawal. The plastic coating may include, without limitation, those plastic materials listed above. Laminated paper material may also include additional layers such as adhesive layers, tie layers, and the like.
[0048] An example of such a surface layer is disclosed in Blanchard, U.S. Pat. No. 6,171,426. A representative, non-limiting list of useful materials to be used as the surface layer includes, waxes, cellophane, polyolefins, polyesters, epoxies, and the like. The surface layers may also include thermal stabilizers, pigments, fragrances, surfactants, antimicrobial agents, medicaments, and the like.
[0049] The tubular insertion member 12 of the applicator 10 provided by the present invention is preferably substantially closed prior to expulsion of the materials contained therein. Alternatively, the insertion end of the applicator can be more or less open, that is the diameter along the length of the tubular insertion member is substantially equivalent to the diameter of the insertion end. Procter & Gamble, of Cincinnati, Ohio, currently offers for sale an open-ended tampon applicator under the trade name TAMPAX flushable applicator tampons.
[0050] The expulsion member 24 of the applicator 10 provided by the present invention can be made from the same materials as discussed above for the tubular insertion member 12 . However, although paper is not as useful unless modified substantially to provide the appropriate spring-back, and some metals such as superelastic metal alloys such as Nitinol (Ni—Ti alloy) may also be used. However, plastics are most preferred materials. The above, representative list of plastics useful for the tubular insertion member are also useful for the expulsion member. The expulsion member 24 having a modified hinge portion 34 may also be optimized by determining a minimum beam dimension for the hinge portion 34 to provide the appropriate column strength to resist buckling failure during expulsion. This minimum beam dimension-may also reduce the likelihood that the beam would become irrecoverably damaged during the bending of the hinge portion 34 to allow the desired spring-back. Additionally, reinforcements to the remainder of the beam 32 may provide benefits in use. This may be especially true in providing appropriate column strength.
[0051] Typical dimensions for each of the tubular insertion and expulsion members include a length of from about 50 to about 100 millimeters, a diameter of from about 8 to about 16 millimeters, and a thickness of from about 0.4 to about 0.6 millimeters. Preferably, the diameter of the expulsion member is less than the diameter of the tubular insertion member to allow for a telescopic arrangement of the two.
[0052] The applicator of the present invention can be made by appropriate processes that will be recognized by those of ordinary skill in the art. For example, paper tubular insertion members can be constructed from a single layer of paper material, or from a plurality of laminated layers to provide multiple benefits relating to the various layers. The applicators can be made from sheets of material using several processing including, without limitation: spiral winding as disclosed in Campion et al., U.S. Pat. No. 5,346,468, convolute winding as disclosed in Whitehead, U.S. Pat. No. 4,508,531, and forming a sheet around a mandrel and then sealing an overlapped seam as disclosed in Hinzmann, U.S. Pat. No. 4,755,164.
[0053] If the applicator includes a surface layer, as described above, it may be applied using any useful technique. Many techniques are known for applying the surface layers. A representative, non-limiting list of such techniques includes spraying, extruding, slot-coating, brushing, transfer coating, and the like. Additional processing steps may be required to cure the surface treatments to a useable form other than simple air curing, such as applying irradiation or other forms of energy.
[0054] Again, the tubular insertion member of the applicator provided by the present invention is preferably substantially closed prior to expulsion of the materials contained therein. One technique for substantially closing the insertion end of the applicator is by employing a plurality of inwardly curved petals. The petals will flex and/or hinge to an open position upon expelling materials contained by the applicator. The number of petals generally ranges from about four to about six. An alternative technique for substantially closing the insertion end of an applicator is by pleating the insertion end. This technique is disclosed in Neilsen et al., U.S. Pat. No. 5,782,793. When an applicator is constructed with more than one layer of material, a single layer may extend into the insertion end in an effort to reduce the force required to expel the contained materials. An example of this is disclosed in Fox et al., U.S. Pat. No. 5,827,214. These collective closures may be of spherical shape, or alternatively tapered shape.
[0055] Plastic applicator members may be manufactured using any useful technique, and many techniques are known for manufacturing plastic applicators. A representative, non-limiting list of such techniques includes injection-molding, blow-molding, extrusion, formation from one or more sheets (as described above for paper), and the like. Generally, the applicator members (for example, the tubular insertion members) can be formed through an injection molding process. This process may be used, because it allows the manufacture to balance some key characteristics of the tubular insertion member. Mold inserts and cores can be machined to form a slightly tapered product. For example, the wall thickness around the gripper end 16 is relatively thick to maintain structural stability during the insertion and expulsion steps of use, while the thickness in the insertion end 14 can be minimized to provide flexibility and low expulsion force. Injection molding also enables the manufacture to make uniquely shaped tubular insertion members and expulsion members. As mentioned above, the less sophisticated and/or less expensive techniques, such as extrusion and blow molding can also be employed. For example, extruded tubes can be further manipulated to form additional features, such as raised or indented rings or other formations. They can also have portions removed to form the hinge portion of the expulsion member. Extruded plastic tubes provide further orientation of the polymer. This orientation may be useful to increase the spring-back and column strength of the expulsion member.
[0056] The applicator of the present invention can be used for the delivery of an object into a mammalian body cavity. Such objects may include suppositories, absorbent devices, and the like, and they may be delivered into body cavities including the mouth, nose, vagina, urethra, and rectum. These materials may be in the form of solids, creams, foams, gels, and the like.
[0057] Preferably, the applicator is used to deliver intravaginal devices, including catamenial devices, such as tampons, intravaginal collection devices, and is interlabial pads; birth control devices such as diaphragms or intrauterine devices (IUDs); compositions in the form of suppositories, such as medicaments, moisturizers, vitamins and minerals, spermicides, and odor controlling agents; medical devices and incontinence devices and vaginal supports such as pessaries; and obstructing devices. Obstructing devices include menstrual collection cups and inflatable or expandable blocking devices.
[0058] In use, the applicator 10 can be removed from its packaging material, e.g., 42 . If the packaging material 42 is used as an external restraint (as in FIG. 12), the expulsion member 24 would then automatically unfold to provide a substantially linear expulsion member 24 , as shown in FIG. 13. Alternatively, the user may need to initiate separation of the second end 28 of the expulsion member 24 from the tubular insertion member 12 by releasing the mechanical catch 36 or adhesive material 40 to allow the expulsion member 24 to unfold (as shown in FIGS. 1 and 14). Next, a user may place insertion end 14 into the body cavity orifice, delivering tampon 18 into the body cavity by pushing on expulsion member 24 until tampon 18 is expelled from tubular insertion member 12 (as shown in FIG. 15) and withdrawing applicator 10 from the body, leaving tampon 18 within the body cavity.
[0059] Alternately, a user could pull tubular insertion member 12 onto expulsion member 24 while maintaining expulsion member 24 steady relative the user's body. This substantially eliminates friction between the tampon 18 and the user's body.
[0060] The specification and embodiments above are presented to aid in the complete and non-limiting understanding of the invention disclosed herein. Since many variations and embodiments of the invention can be made without departing from its spirit and scope, the invention resides in the claims hereinafter appended. | An applicator system for delivering an object into a mammalian body cavity is disclosed. The applicator includes a tubular insertion member arranged and configured to contain the object and a linearly-biased expulsion member having a first end slideably fitted within the tubular insertion member. The tubular insertion member has an insertion end and a gripper end, opposite thereof. The expulsion member extends out of the gripper end of the tubular insertion member, and terminates in a second end. The applicator also includes an expulsion member restraint capable of restraining the second end of the expulsion member proximate an outer surface of the insertion end of the tubular insertion. The expulsion member is bent when so restrained.
The invention also relates to a method of delivering an object into a body cavity from an applicator. In this method, the applicator is substantially as described above, and the method includes the steps of: a) releasing the expulsion member restraint to permit the expulsion member to spontaneously attain a substantially linear configuration with the second end extending rearwardly away from the gripper end of the tubular insertion member; b) inserting the insertion end of the tubular insertion member into the body cavity; c) applying force on the second end of the expulsion member to move the first end thereof toward the insertion end of the tubular insertion member; d) expelling the object out of the insertion end of the tubular insertion member and into the body cavity; and e) removing the applicator from the body cavity. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of solid waste management, and more specifically to systems and methods for improving municipal solid waste (MSW) management to maximize use of renewable resources and benefit a community.
[0003] 2. History of the Related Art
[0004] As waste generation continues to grow faster than population, leaders in MSW services must respond to significant challenges. Disposal of a wide variety of materials poses challenges in handling and disposing of waste in varied shapes, sizes, states, and reusable content. Increases in disposal rates, and reduced public acceptance of constructing and operating traditionally-designed MSW facilities create a deficit of MSW landfill space that must constantly be addressed by solid waste management personnel and companies. Unfortunately, the reality of present-day waste management systems is that landfills are viewed as liabilities, both in the economic sense and the community-development sense. The present invention shifts that paradigm from landfill-as-liability to landfill-as-asset which will only increase the environmental health of communities and permit sustainable growth and development.
[0005] In one kind of municipal waste management, a private waste management company carries out the oversight and operation of a landfill. The economics of the arrangement generally involve a landfill lease payment from the company to the community, and a waste removal and disposal payment made from the community to the company. As such, communities typically select the waste management company that offers the highest lease payments, and companies typically bid on contracts with sufficient waste volume to maintain their profitability. While this business model has proved reliable in the past, the current pace of waste production requires that both communities and companies take an innovative approach to waste management.
[0006] A great deal of the current research and innovation related to MSW management is focused on extending the life and performance of existing landfills. However these types of innovations are generally shortsighted as they merely show how to extend the life of landfills and rather than solve the underlying need to have sustained economic development in our communities. Accordingly, what is needed is a system and method for a MSW operation to address the multiple types of waste that are disposed by the public, and further, to provide a waste management solution that more effectively addresses the issue of sustainable economic development. Additionally, there is a need in the art for a system and method that effectively reduce the total volume of waste through increasing the reuse of products as well as the use of beneficial by-products of the waste management process.
[0007] A further substantial challenge is the management of solid waste (municipal or not) that can contain hazardous components that threaten public health, safety and the environment. Hazardous waste poses additional public fears and handling/disposal issues for waste management personnel. Therefore, what is needed is a system that provides effective screening and separation of hazardous components in the waste stream, and further provides recovery and reuse solutions as alternatives to disposal of hazardous waste.
[0008] An accompanying issue with waste management in general, and specifically in MSW management, is the loss of resources that occurs. The energy required to create products, sustain them throughout use, and ultimately dispose of them are generally lost in the current waste management system. A certain percent can currently be captured through recycling efforts, but on the whole, most “used” products are disposed into a MSW landfill with few options for recovery and use of the energy and/or benefit contained in the disposed MSW. What is needed therefore is a system and method to more effectively capture and use disposed MSW and other waste streams to provide renewable energy sources.
[0009] The concept of “sustainable development” and a “sustainable community” has been in existence for years. According to Webster's New Millennium™ Dictionary of English, the term “sustainable development” means “any construction that can be maintained over time without damaging the environment; development balancing near-term interests with the protection of the interests of future generations”. A sustainable community provides a better quality of life for current and future residents by optimizing nature's ability to effectively and efficiently function over time. An ideal sustainable community has systems in place to minimize waste, prevent pollution and promote efficiency, and further develops resources to revitalize local economies.
[0010] The waste management system is a central component of the infrastructure of a sustainable community. This critical component must be managed by technologies, systems and methods that support and drive sustainable physical environments and communities. Caring for the air, land, water, other natural resources and the public's health is fundamental in attaining the long-term objectives of sustainability and solid waste management. However the reality of the “sustainable community” concept is that this is very difficult to achieve and to date has existed more in theory than in practice. The necessary technologies, systems and methods either do not exist or have not been operated in a synergistic manner to derive the desired economic and environmental benefits and outputs.
[0011] While the goals of sustainable development are universally lauded by both private and public entities, the simple economics of the waste management industry often belie any noble intentions. As previously noted, the public views waste management systems primarily as a liability rather than as an asset. This mindset is based largely upon the emissions that are generated by landfills, including leachate and methane gas, which produce a number of unfortunate side effects. The state of the art has not developed a zero-emissions landfill system that is capable of generating assets such as heat and combustible gas.
[0012] Accordingly, what is needed is an improvement in the art of landfill design and waste management that will accomplish the twin goals of a zero-emissions facility and the development of usable, renewable resources for the community. In short, what is needed is an approach to MSW management that better supports the concept of “sustainable community” and further can be implemented and operated successfully, as opposed to being a theoretical concept. In addition, what is needed is a system that organizes the necessary technologies, systems and methods and operates them in a synergistic manner to provide the desired economic and environmental benefits and outputs. In sum, there is a need in the art for a system and method for waste management that provides the environmental benefits of sustained development while simultaneously providing the economic basis for pubic and private cooperation.
[0013] Therefore it is an object of the present invention to provide a system and method for a MSW system that is both zero-emissions and asset producing and therefore more appealing and beneficial to communities. The present invention addresses the multiple types of waste that are disposed by the public, and further, provides a waste management solution that more effectively addresses the issue of waning landfill capacity, i.e. the present invention increases the size of each landfill through more effective systems configuration and management. It is a further object of the present invention to provide effective screening and separation of hazardous components in the waste stream, and further provides recovery and reuse solutions as alternatives to disposal of hazardous waste. It is yet a further object of the present invention to provide communities with a system and method to more effectively capture and use disposed MSW and other waste streams to provide renewable energy sources. Moreover, it is an object of the present invention to present these and other goals in a methodology that makes sustainable development possible by benefiting the economic and environmental interests of the parties involved.
SUMMARY OF THE PRESENT INVENTION
[0014] The present invention is a system for and method of designing and operating a synergistically connected, sustainable environmental and economic development program to manage solid waste. The present invention is specifically adapted to operate in a zero-emissions state while simultaneously providing numerous assets that will aid in community development and economic growth. Utilization of the system and method of the present invention yields larger landfill space through novel use of recycling, degradation, containment and energy extraction subsystems, described in detail below.
[0015] In part, the present invention includes a synergistic system comprised of various landfill elements such as a municipal recycling facility, an electronic recycling facility, an environmental education center, a landfill gas energy production plant, a waste to energy biomass production plant, a beneficiating facility for glass, plastics and pulp, and means for composting and renewable energy production. The landfill gas energy production plant stores and distributes gas removed from the landfill that can be used for energy. The system may utilize its own conversion means to harness the landfill gas energy for operating the various landfill elements, including the vacuum or other means that remove the gas in the first place. Moreover, the landfill gas can be distributed to the community for use by other industries that consume methane and other chemicals for energy use, including heating uses. Each of these elements is selected and synergistically utilized to meet the unique needs of each community.
[0016] In order to properly implement the sustained development system of the present invention, a method for establishing a community-company venture is also included herein. The method includes the steps of identifying the objectives of both the community and the company and computing an economic value for each of these objectives. The respective economic values are then reconciled in such a manner that a community-company venture can be established that provides ample economic incentives for each party while also improving the general health of the community environment. In particular, the community objectives include a plurality of elements adapted for sustainable development.
[0017] For example, the community may have certain waste management priorities such as renewable energy, recycling facilities, composting of organic and green waste, electronics recycling and environmental and agricultural education. According to the present invention, each of these facilities and programs is provided and operated by the company on behalf of the community. Each of these facilities and programs is assigned an economic value, which in turn is used to offset a portion of the lease payment paid by the company to the community. As such, the company remains in a profitable position with respect to its waste management business and the community is the beneficiary of an improved waste management system with numerous economic and environmental benefits to its population and stakeholders.
[0018] As shown below, the design and implementation of the present invention protects the environment and public health and conserves natural resources more effectively than present municipal waste management services. In particular, the system and method of the present invention creates a symbiotic relationship between the waste management company and the community whereby each party contributes to both the economic vitality and the overall health and welfare of the community. These and numerous other benefits and advantages of the present invention are described in detail below with reference to the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a flow chart depicting a method for establishing a municipal solid waste management system in accordance with the present invention.
[0020] FIG. 2 is a state diagram illustrating a plurality of elements forming a waste management system in accordance with the present invention.
[0021] FIG. 3 is a state diagram illustrating the flow of benefits between parties according to the method of the present invention.
[0022] FIG. 4 is a flow chart illustrating the method of the present invention according to a preferred embodiment.
[0023] FIG. 5 is a flow chart illustrating a method for computing the economic risks and benefits associated with the municipal solid waste management system established in accordance with the present invention.
[0024] FIG. 6 is a flow chart illustrating a method for determining the relative values of services and assets provided by parties according to the method of the present invention.
[0025] FIG. 7 is a flow chart illustrating a method for computing the economic values of the objectives of the parties according to the method of the present invention.
[0026] FIG. 8 is a flow chart illustrating a method for operating a municipal solid waste management system established in accordance with the present invention.
[0027] FIG. 9 is a state diagram of a municipal solid waste management system in a zero-emissions configuration in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] As described in detail below, the present invention includes a method for establishing a municipal solid waste management system 10 preferably composed of a municipality or community and a waste management company. Typically, the burdens of removal, handling, disposal and maintenance of waste falls upon a local government, such as a city or municipality. In the United States, these communities commonly enter into contracts with private companies that construct and maintain landfills and transport the waste from the communities to the landfills for disposal and storage. The companies typically obtain the contracts through a bidding process whereby the highest bidder undertakes the disposal duties in exchange for fees that depend on the volume and frequency of waste disposal.
[0029] While this model has proven economically effective over the years, the current landscape of urban and suburban life has sufficiently modernized so as to require new methods and approaches for dealing with the environmental, historical and economical impacts of waste disposal. As such, the present invention provides a method for establishing a municipal solid waste management system 10 that recognizes the complexity of contemporary waste disposal. As with any commercial arrangement, a waste disposal system contains certain economic externalities, some of which are positive and some of which are negative. Rather than focus on the simple economics of a typical contract, i.e. monetary consideration, the present invention provides a mechanism by which to monetize and value both the positive and negative externalities so as to more clearly reflect the desires and values of the parties to the contract. For example, a community may have certain recycling or energy needs that can be met through the installation of selected landfill components. The present invention provides a method for reconciling the positive impacts of increased recycling and energy production with the potential increased capital costs associated with constructing the landfill. In sum, the present invention provides a methodology for creating a sustainable, economical and environmentally sound municipal waste disposal system 10 .
[0030] FIG. 1 is a flow chart depicting a method for establishing a municipal solid waste management system 10 in accordance with the present invention. As shown, the system 10 includes three principle components. A plurality of source inputs 12 are deposited into a plurality of landfill elements 14 , which in turn are specifically adapted to produce a plurality of value outputs 16 , as described further herein.
[0031] The source inputs 12 shown in FIG. 1 include, for purposes of example, municipal solid waste 120 , construction and demolition waste 122 , green waste 124 including agricultural waste and food waste, electronic waste 126 , liquid waste 128 and recyclables 130 . Likewise, example value outputs 16 include electricity and gas 160 , thermal energy 162 , recycled pulp 164 , created products 166 such as mulch, fill and other agricultural products, and reusable products 168 . The value outputs 16 can be further characterized and valued according to the present invention in order to optimize the performance of the system 10 .
[0032] For example, the electricity and gas 160 that is generated by the landfill elements 14 can be routed to a community power grid and partially utilized by the landfill elements 14 to sustain its own operation. Similarly, the thermal energy 162 generated by the landfill elements 14 can be used for hydroponics and aquaculture in order to grow, maintain and potentially harvest plant products. If the landfill elements 14 include means for generating electricity and gas 160 as well as thermal energy 162 , then the system 10 itself can be designed to include components or attributes the consume electricity and gas 160 and thermal energy 162 . Thus, thermal energy 162 generated by the landfill elements 14 can be used to heat a greenhouse located on the landfill grounds, which in turn will also reduce emissions produced by other source inputs 12 and landfill elements 14 . In sum, by properly matching the source inputs 12 to the landfill elements 14 and the desired value outputs 16 , the system 10 of the present invention can become an integral part of a community's overall environmental health.
[0033] FIG. 2 is a state diagram illustrating a plurality of landfill elements 14 that partially form the waste management system 10 of the present invention. In addition to a landfill itself (not shown), typical landfill elements 14 of the system 10 include a municipal recycling facility 140 (MRF), a renewable energy element 142 and a composting element 144 . Additionally, the system 10 would preferably include a beneficiating element 146 for glass, plastics and pulp, an electronic recycling element 148 and a wood cleaning element 150 for the cleaning and processing of wood products that may be used as pulp, mulch, fill or other agricultural outputs. Lastly, a preferred system 10 includes an environmental education center 152 and a research facility 154 for use by employees and customers related to the system 10 as well as interested members of the community, i.e. the stakeholders in the operation and products of the system 10 .
[0034] FIG. 3 is a state diagram illustrating the flow of economic and environmental benefits between parties according to the method of the present invention. The parties that share the risks and benefits of the method of the present invention are the venture stakeholders 20 , the waste management company 22 , and the community 24 . The venture stakeholders 20 include primarily the citizens and taxpayers of the community 24 , but also include the employees of both the waste management company 22 as well as other scientists, students, business leaders and conservationists that have a vested interest in the sustained economic development of the community 24 .
[0035] In a typical cycle embodied by the present invention, the economic flow of risks and benefits begins with a payment of taxes or other public contributions by the value stakeholders 20 to the community 24 , thereby generating a tax base 26 . The community 24 typically will then solicit bids through which any waste manager may offer to pay a fee for the use of a publicly established landfill (not shown). According to the present invention, the waste management company 22 will proffer a bid 30 and as consideration the community 24 will use its tax base 26 to make a volume payment 28 back to the waste management company 22 . In a typical contract, the volume payment 28 will set forth various schedules of payments that depend upon the type of waste managed, the volume of waste removed from the community, and the frequency of waste removal from the community 24 .
[0036] As noted above, the foregoing analysis would completely describe the economics of waste management according to the state of the art. However, unlike the prior art, the present invention includes another economic transfer from the waste management company 22 to the venture stakeholders 20 that includes all of the tangible and intangible economic and environmental benefits associated with the establishment of the system 10 , i.e. a plurality of positive externalities 32 that lead to environmental health and sustainable development. Accordingly, as the venture stakeholders 20 are receiving economic and environmental benefits directly from the waste management company 22 , and the bid 30 can be customized to meet its unique economic and environmental needs while advancing the sustainability of the community.
[0037] The system 10 of the present invention is a novel means for shifting various service provisions and responsibilities from the community 24 to a private enterprise while growing its economic base and protecting the surrounding environment. Through the methodology of the present invention, the waste management company 22 , in exchange for the customized bid 30 described above, takes responsibility for providing numerous other environmental and economic benefits to the community 24 at large, namely those services that the community 24 has selected according to its own objectives that will increase the sustainability of the community.
[0038] The system 10 of the present invention is established according to the method of the present invention, set forth generally in the flow chart of FIG. 4 . In its preferred embodiments, the method of the present invention is practiced through computer software or other computational means. As the process of establishing a community-company venture is largely interactive and negotiated, the method of the present invention is preferably adapted for receiving input values and computing output values over a range of selected pre-conditions. The present invention is preferably adapted for optimizing the negotiation and contracting processes of entering into a waste management agreement.
[0039] The method of the present invention can be described by reference to an algorithm or series of steps. In step S 102 , the method recites the step of identifying the community objectives; or rather identifying those services and benefits the community would like to receive as value outputs 16 of the waste management system 10 . As previously detailed, sample community objectives could include the production of electricity and gas 160 , the production of thermal energy 162 , recycled pulp 164 and the like.
[0040] Other community objectives may not be derived from the operation of the system 10 , but rather may be negotiated during the formation of the system 10 . For example, the community may have a need for increased education related to the environmental or agricultural sciences, a need for increased research and development related to land use and zoning or otherwise require an investment into the community infrastructure. These types of community objectives are not necessarily met by the recycling of glass or composting of green waste, but they nevertheless constitute a distinct and negotiable value that the community may regard as essential to its sustained development. According to the present invention therefore, the term community objectives does not merely relate to tangible commodities or byproducts of waste management, but in addition it includes the further investment required to maintain and grow an ecologically-conscious populace that recognizes the importance of sustainable development.
[0041] Step S 102 recites valuing the community objectives, which as noted above, requires the monetization of both the tangible byproducts of sound landfill management as well as the capital and investment costs of meeting the rest of the community objectives. Thus the step of valuing the community objectives will preferably include the monetary values of the byproducts of the waste management system 10 , i.e. the value of the gas, electricity, and thermal energy generated by the landfill elements 14 as well as the savings generated through improved recycling of glass and electronics. Step S 102 further includes monetizing the value of the remaining community objectives, such as for example the value of educational scholarships, research fellowships, as well as both research and educational facilities. Accordingly, step S 102 will constitute the full value of the positive externalities 32 described above with respect to FIG. 3 . Additionally, step S 102 will include the value of the bid or lease payments promised by the company as party to the waste management contract.
[0042] Step S 104 requires identifying the company objectives and step S 106 requires valuing the company objectives. The company objectives are typically entry into the waste management contract, and the value of the company objectives will be the projected value of the waste management contract to the company. As previously noted, the company is generally compensated under the contract for waste removal, transport, processing and storage on a volume basis. Thus the value of the company objectives can be computed as the projected revenues derived from these services over the life of the contract.
[0043] In step S 108 , the method recites the step of establishing a community-company venture in response to the relative values of the community objectives and the company objectives. As previously noted, the economics of the contract are determined by the value of the company bid, the value of the positive externalities offered to the community in accordance with the community objectives, and the value of the waste management services provided by the company. In contrast to the prior art, however, any contract or venture established according to the present invention will inevitably shift some of the initial cash burden on the company into other tangible and intangible benefits desired by the community, thus reducing the cash value of the waste management contract and promoting the overall health and economy of the community.
[0044] As noted above, the community receives numerous economic and environmental benefits through the system 10 , including both tangible services and facilities as well as savings from improved recycling, energy conservation and public health. As shown in step S 102 , the method requires that the community determine an economic impact, or value, of its objectives. This valuation process is described in detail in FIG. 5 , a flowchart that depicts the process by which the community values its objectives.
[0045] In step S 1020 , the community data is inputted into the method of the present invention. The community data includes the size and demographics of the community, the types source inputs 12 produced, the location of any sensitive environmental or historical sites and the like. In step S 1022 , the method recites evaluating the impact of the system 10 on the local agriculture. Landfill elements 14 produce a number of byproducts, some of which may impact the soil, water quality and overall health of the agricultural system. A municipal waste system operated according to the present invention however should minimize or eliminate any harmful byproducts of waste disposal following the zero-emissions model described in detail below. In step S 1024 , the method recites assessing the landscape and biodiversity of the community in order to properly optimize the location and functionality of the landfill elements 14 . Again, in a zero-emissions preferred embodiment, the system 10 of the present invention becomes an asset as opposed to a liability, and therefore it is anticipated that the installation and operation of the system 10 in a community may increase the landscape and environmental health of the community.
[0046] In step S 1026 , the method calls for estimating the impact of the system 10 on the local heritage and environmental character of the community, i.e. whether the system 10 will cause or accelerate any degradation of the environment or landmarks or whether the system will preserve or increase the environmental health of the community. Optimal operation of the system 10 of the present invention according to the methods described herein should result in minimal environmental damage. Moreover, following the zero-emissions embodiment described below, the system 10 of the present invention can actually contribute significantly to the environmental health of a community while simultaneously proving to be an economic asset for that same community.
[0047] In step S 1028 , the method recites assessing the impact of the system 10 on the community, including at least any increase in employment and increase in standard of living within the population. In step S 1030 , the method calls for assessing the impact of the system 10 on the climate and environment, which includes projections as to any benefits that may be derived from implementation of the system 10 . As noted above, proper implementation of the methods of the present invention will cause an increase in environmental health by minimizing or eliminating landfill emissions while increasing the size and efficiency of the landfill itself. Other economic and environmental benefits of the system are projected in step S 1032 , in which the method recites calculating the reduction in waste and pollution affected by introduction of the system 10 of the present invention, which according to the zero-emissions embodiment would result in a substantial or total elimination of landfill emissions.
[0048] In step S 1034 , the method requires calculating the economic impact of the community objectives, i.e. whether implementation of the system 10 to meet the community objectives results in a net positive or net negative economic effect. This is preferably accomplished by weighing each of the separate values derived in the preceding steps together and determining a net effect. As one purpose of the present invention is to create and operate a system 10 that is an asset as opposed to a liability, it is the case that the net economic value of the system 10 to the community will be positive.
[0049] Implementation of the system may result in job creation, which in turn may result in higher population, which inevitably will lead to more waste products which in turn will lead to more energy production and recycling. Accordingly, in weighing the separate values in accordance with step S 1034 , the community is providing a cost-benefit analysis of the system 10 . This analysis results in a final estimated economic effect that can be inputted directly into the method of the present invention via step S 1036 , which provides that the results of step S 1034 are inputted into step S 102 . In summary, the method of the present invention factors in the estimated costs and benefits to be had by the community should it choose to establish the system 10 of the present invention.
[0050] The valuation process if further illustrated in FIG. 6 , which is a flow chart illustrating a method for determining the relative values of services and assets provided by parties according to the method of the present invention. In step S 110 , the source inputs 12 of the system 10 are identified. The identification of the source inputs 12 invariably determines to some extent the types of value outputs 16 that can be generated by the landfill elements 14 .
[0051] As shown in FIG. 6 , once the source inputs have been identified, the value of their removal is determined in step S 112 . This value is essentially the value of the waste management contract to the company, described above with reference to FIG. 4 . The output of step S 112 is then monetized over the term of the waste management contract in step S 114 , i.e. the total value is spread out over the life of the contract and discounted to its present value. This monetized value is then fed forward into step S 106 , described with reference to FIG. 4 , and thereafter fed forward into step S 108 in which the community-company venture is established.
[0052] Once the source outputs 12 are identified in step S 110 , the potential byproducts or value outputs 16 are determined in step S 118 . As previously noted, the value outputs 16 include for example the recycled products and energy generated by the landfill elements 14 . In step S 120 , the total volume of the value outputs 16 over the life of the waste management contract is determined, which corresponds to the total expected energy production and savings generated through recycling and reuse of source inputs 12 . In step S 122 , the value of the value outputs 16 is monetized over the term of the waste management contract and discounted to its present value.
[0053] For example, the landfill elements 14 may be expected to produce 100 Megawatts of energy per year for 15 years, which corresponds to a gross value of 1.5 Gigawatts of energy over the life of the contract. This total energy production is valued and discounted such that the community can readily identify its current savings in energy production over the life of the contract. Step S 122 feeds into step S 102 , in which the value of the value outputs 16 is combined with the cash value of the waste management contract to determine the gross value of the community objectives. As noted above, the value of the community objectives is fed forward into step S 108 , in which the community-company venture is established according to the present invention.
[0054] The economics of the community-company venture may also be affected through third-party incentives. For example, there may be tax credits relating to landfill operation available at the local, state and federal levels, all of which operate to effectively increase the profitability of the enterprise to the company. Similarly, there may be preservation, conservation or remediation funds available from local, state or federal environmental agencies that the community can receive through the system 10 of the present invention. A method for valuing these potential incentives is presented in FIG. 7 .
[0055] In step S 130 , the method requires inputting the value of the community objectives as determined according to the processes described above. Similarly, step S 132 requires inputting the value of the company objectives, preferably as expected over the term of the contract according to the tax or accounting year of the company. In step S 134 , value of any third party incentives to the community are valued over the life of the contract. For example, if there is a conservation grant available to the community for its establishment of a municipal recycling facility according to the present invention, then the value of this grant should be monetized as discounted over the life of the contract. In step S 136 , the value of any third party incentives to the company is determined, including any tax rebates or incentives that may be available for the production or distribution of energy through the landfill elements 14 . These incentives would be assigned to the company according to proper accounting methods, and discounted to their present values over the life of the contract. Once the values of any third party incentives are properly valued, step S 138 returns to step S 108 in order to establish the community-company venture.
[0056] The initial conditions for the community-company venture are established as described above. Thereafter, the present invention also includes a method for monitoring and optimizing the status and parameters of the venture. A method for operating municipal solid waste management system established in accordance with the present invention is shown in FIG. 8 . In step S 200 , the landfill operations are initiated. Namely, the landfill elements 14 are brought on-line, source inputs 12 are provided and the value outputs 16 are generated according to the waste management contract. In step S 202 , the initial program begins according to the venture established according to the present invention, thereby generating value outputs in step S 204 . In step S 206 , the method of operation recites that the value outputs 16 are distributed to the community. For example, in step S 206 any electrical energy generated is used for operation of the landfill elements 14 or distributed to the community at large. Similarly, any recycled or created products are distributed to processors for recirculation into the commercial chain as new glass or electronic equipment.
[0057] Step S 208 is an assessment as to whether the objectives of both the community and the company are being met, i.e. whether the value outputs 16 correspond to the community's economic plan and are the source inputs 12 sufficient in volume for the company to remain profitable. If the objectives of both parties are met, then the venture continues as-is in the generation and distribution of value outputs 16 according to steps S 204 and S 206 . If the objectives of the parties are not being met, then the method feeds back to step S 102 , at which time the community will re-identify or re-state its objectives and the method for establishing the venture will begin anew. In short, the method of operating the municipal solid waste management system measures the performance of the venture against the expectations of the parties and provides remedial action when necessary.
[0058] As previously noted, the method of the present invention is preferably embodied in a software or other suitable algorithm that can identify the economic terms of the venture and make the necessary computations in order to ensure the venture continues to operate as intended. In its most preferred embodiments, the source inputs 12 and the value outputs 16 are themselves monetary values that can be entered into a program for optimizing the configuration of the landfill elements. For example, the source inputs 12 can be measured in terms of volume and revenue to the company, while the value outputs 16 can be measured in terms of energy savings, capital formation (in the case of newly constructed landfill elements 14 ), and revenue from recycled and reused products of the system 10 .
[0059] FIG. 9 is a state diagram of the system 10 of the present invention according to its preferred embodiment as a zero-emissions asset operating on behalf of a community. The system 10 is primarily composed of landfill elements 14 , which have been described above in great detail. As previously noted, the landfill elements 14 of the system 10 are selected and operated according to the methods described above, with a primary focus on maximizing the economic and environmental gains to the municipality 24 , the waste management company 24 and the venture stakeholders 20 .
[0060] The landfill elements 14 , in their normal course of operation, will produce a number of byproducts, the most important of which are gas 40 and leachate 44 . The gas 40 is typically methane, which is combustible and noxious; and the leachate 44 may have toxic or otherwise unfriendly chemicals or compounds therein. While the prior art has attempted to deal with these byproducts through dilution, the system 10 of the present invention is configured to harness these would-be liabilities and convert them into assets for the benefit of the municipality 24 .
[0061] In particular, the gas 40 that builds up inside the landfill can be extracted and used for combustion and heating given the proper equipment. For example, a vacuum 41 can remove the gas 40 from beneath the surface and direct along piping to storage and combustion means where the gas 40 can be safely converted to energy 42 . To ensure complete removal of the gas 40 from the landfill elements 14 , it is preferred to utilize a vacuum 41 having a very large diameter. More particularly, a seventy-inch vacuum provides the necessary pressure drop to ensure complete removal of the gas 40 from the landfill itself. As the gas 40 is removed by the vacuum 41 , the overall volume of the waste within the landfill is decreased, thus allowing for even more usage of the system 10 .
[0062] The natural flow of water 46 through the landfill mass produces leachate 44 , which has typically been treated as a substance to be contained using advanced landfill liners and the like. However, the present invention utilizes the leachate 44 to accelerate the decomposition of a compost 48 mass. Thus the leachate 44 , produced by natural or artificial means including the addition of water 46 , is used by the system 10 to increase the rate at which the compost 48 decomposes. The decomposition of the landfill mass will in turn produce a greater volume of gas 40 , which can be extracted as described above. Specially designed landfill liners, known in the art, fitted with channeling means are preferred for directing the leachate flow from the surface into the more dense segments of the landfill mass in order to decompose the waste. More preferably, the landfill elements 14 include means for recirculating the leachate throught the landfill mass to ensure consistent and accelerated decomposition. As the landfill mass decomposes, its volume decreases thereby permitting still more usage from the original site.
[0063] The gas 40 that comes about through composting, as accelerated through the targeted use of leachate 44 , can be converted into energy 42 in the form of heat or electricity. The energy 42 can be distributed to the municipality 24 at large through a power grid, or alternatively at least a portion of the energy 42 can be returned to the landfill elements 14 to improve the performance and efficiency of the system 10 . Various industries that utilize gas 40 extracted from landfills will directly obtain the gas 40 out of the system 10 and consume it for their own purposes, such as heating for example. As before, the extraction of the gas 40 and the usage of the leachate 44 both decrease the volume of the landfill mass, which in turn permits the system 10 to accept still more source inputs 12 through the method described above.
[0064] The complete integration and use of the byproducts of the landfill mass, primarily the gas 40 and the leachate 44 , allow the system 10 of the present invention to operate at or near zero-emissions. By recirculating the leachate 44 through the landfill mass, the system creates a steady volume of gas 40 that can be extracted and used for renewable energy. Thus by utilizing each and every resource available within the system 10 , the byproducts of waste management are consumed for the production of new and usable assets, e.g. energy. The zero-emissions operations of the system 10 also vastly increase the environmental health of the community, while providing numerous other economic and environmental benefits including the production of reusable energy.
[0065] The present invention has been particularly described herein with reference to specific preferred embodiments of a municipal solid waste management system and a method of creating that system. Each element described above should be understood to incorporate those steps and or apparatuses that perform equivalent functions. As such, it should be understood that those skilled in the art could readily devise adaptations and modifications of the present invention that nevertheless fall within the scope of the present invention as defined in the following claims. | The present invention includes a system and method for creating a municipal solid waste (MSW) system to address the multiple types of waste that are disposed by the public, and further, to provide a waste management solution that provides for the sustained economic development and growth of communities. The present invention also provides effective screening and separation of hazardous components in the waste stream, and further provides recovery and reuse solutions as alternatives to disposal of hazardous waste. The present invention further provides communities with a system and method to more effectively capture and use disposed MSW and other waste streams to provide renewable energy sources. Moreover, the present invention includes a method for establishing a municipal solid waste management system that makes sustainable development possible while preserving the economic interests of the parties involved. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 12/614,883, filed Nov. 9, 2009 the entire content and disclosure of which is incorporated herein by reference.
BACKGROUND
The present invention relates to the field of semiconductor structures, and particularly to a decoupling capacitor that employs a conductive through-substrate via and methods of manufacturing the same.
In resent years, “three dimensional silicon” (3DSi) structures have been proposed to enable joining of multiple silicon chips and/or wafers that are mounted on a package or a system board. The 3DSi structures increase the density of active circuits that are integrated in a given space.
As the circuit density increases unit area, the amount of switching activity per unit area also increases. This results in an increase in the noise generated on the reference supplies. As this noise increases, the performance of the internal devices as well as the performance of off-chip drivers is adversely impacted due to the reduction of noise margins available for the system design.
At present, this noise is controlled by embedding deep trench capacitors (DTC) within active silicon devices. To obtain sufficient degree of decoupling, a large array of DTC's are required. As the circuit density, switching activity, and power distribution structures are enhanced in a 3DSi structure, more DTC's will be required to control the noise generation. Further, as a number of DTC arrays are formed, there is an increase in the inductance between the active circuits and the arrays of DTC's, thereby requiring formation of additional DTC's to store the energy to be used to counter-balance a back electromagnetic force noise.
The voltage of the noise Vn is given by the following equation:
Vn=L ×( dI/dt ),
in which L is inductance, I is current, and t is time. As the amount of inductance (L) increases, or as the speed at which the current changes (dI/dt), which is proportional to the switching speed of circuits, the noise Vn increases proportionally.
The above considerations show that capacitive structures having low inductive is needed to control inductively noise generated within and transmitted into a 3DSi structure.
BRIEF SUMMARY
According to an embodiment of the present invention, a capacitor in a semiconductor substrate employs a conductive through-substrate via (TSV) as an inner electrode and a columnar doped semiconductor region as an outer electrode. The capacitor provides a large decoupling capacitance in a small area, and does not impact circuit density or a Si3D structural design. Additional conductive TSV's can be provided in the semiconductor substrate to provide electrical connection for power supplies and signal transmission therethrough. The capacitor has a lower inductance than a conventional array of capacitors having comparable capacitance, thereby enabling reduction of high frequency noise in the power supply system of stacked semiconductor chips.
According to an aspect of the present invention, a semiconductor structure includes a semiconductor chip, which includes a semiconductor substrate; at least one capacitor embedded in the semiconductor substrate; and at least one laterally-insulated conductive through-substrate connection structure. Each of the at least one capacitor includes an inner electrode including a conductive through-substrate via (TSV) structure; a node dielectric laterally contacting and laterally enclosing the inner electrode; and an outer electrode laterally contacting and laterally enclosing a portion of the node dielectric.
According to another aspect of the present invention, a semiconductor structure includes a capacitor located in a semiconductor substrate and a contact structure located on the semiconductor substrate. The capacitor includes an inner electrode, a node dielectric, and an outer electrode. The inner electrode includes a conductive through-substrate via (TSV) structure that contiguously extends at least from an upper surface of the semiconductor substrate to a lower surface of the semiconductor substrate. The node dielectric laterally contacts and laterally encloses the inner electrode and contiguously extends from the upper surface to the lower surface. The outer electrode laterally contacts and laterally encloses a portion of the node dielectric. The contact structure is conductively connected to the outer electrode.
According to yet another aspect of the present invention, a method of forming a semiconductor structure is provided. The method includes forming a capacitor and a laterally-insulated conductive through-substrate connection structure in a semiconductor substrate. The laterally-insulated conductive through-substrate connection structure is formed by forming a dielectric tubular structure around a first through-substrate cavity formed in the semiconductor substrate; and filling a cavity within the dielectric tubular structure with a conductive material. The capacitor is formed by forming an outer electrode by doping a portion of the semiconductor substrate around a second through-substrate cavity; forming a node dielectric on a surface of the second through-substrate cavity; and forming an inner electrode by filling the second through-substrate cavity with the conductive material.
According to still another aspect of the present invention, a method of forming a semiconductor structure is provided. The method includes providing a semiconductor chip and electrically connecting the semiconductor chip to a mounting structure employing an array of solder balls. The semiconductor chip includes a semiconductor substrate; at least one capacitor embedded in the semiconductor substrate; and at least one laterally-insulated conductive through-substrate connection structure. The at least one capacitor has an inner electrode that includes a conductive through-substrate via (TSV) structure.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1-18 are sequential vertical cross-sectional views through various processing steps of a first exemplary structure according to a first embodiment of the present invention.
FIG. 19 is a vertical cross-sectional view of a second exemplary structure according to a second embodiment of the present invention.
FIG. 20 is a vertical cross-sectional view of a third exemplary structure according to a third embodiment of the present invention.
FIG. 21 is a graph showing results of a simulation that shows a noise reduction at high frequency provided by an exemplary structure according to an embodiment of the present invention.
DETAILED DESCRIPTION
As stated above, the present invention relates to semiconductor structures, and particularly to a decoupling capacitor that employs a conductive through-substrate via and methods of manufacturing the same, which are now described in detail with accompanying figures. Throughout the drawings, the same reference numerals or letters are used to designate like or equivalent elements. The drawings are not necessarily drawn to scale.
As used herein, a “conductive through-substrate via (TSV) structure” is a conductive structure that extends through a substrate, i.e., at least from a top surface of the substrate to a bottom surface of the substrate.
As used herein, a “laterally-insulated conductive through-substrate connection structure” is an assembly of a conductive TSV structure and another structure that laterally surrounds the conductive TSV structure and electrically isolates the conductive TSV structure from the substrate.
As used herein, a “mounting structure” is any structure to which a semiconductor chip can be mounded by making electrical connections thereto. A mounting structure can be a packaging substrate, an interposer structure, or another semiconductor chip.
As used herein, a first element “laterally contacts” a second element if there is a direct physical contact between the first element and the second element in a “lateral direction,” which is any direction perpendicular to a top surface or a bottom surface of a substrate.
As used herein, a first element “laterally encloses” a second element if an inner periphery of the first element is located on or outside an outer periphery of the second element.
As used herein, a first element “encapsulates” a second element if all outer surfaces of the second element are located within inner surfaces of the first element.
As used herein, two elements are “conductively connected” to each other if there exists a conductive path between the two elements to allow conduction of electricity.
Referring to FIG. 1 , a first exemplary structure according to a first embodiment of the present invention includes a semiconductor substrate 10 that has a semiconductor material. The semiconductor material of the semiconductor substrate 10 can be selected from, but is not limited to, silicon, germanium, silicon-germanium alloy, silicon carbon alloy, silicon-germanium-carbon alloy, gallium arsenide, indium arsenide, indium phosphide, III-V compound semiconductor materials, II-VI compound semiconductor materials, organic semiconductor materials, and other compound semiconductor materials. Preferably, the semiconductor material of the semiconductor substrate 10 is a single crystalline material. For example, the semiconductor substrate 10 can be a single crystalline silicon layer. The semiconductor substrate 10 can be doped with dopants of a first conductivity type, which can be p-type or n-type. The dopant concentration of the semiconductor substrate 10 can be from 1.0×10 14 /cm 3 to 1.0×10 17 /cm 3 .
A doped well region 12 is formed in the semiconductor substrate 12 by implanting dopants of a second conductivity through a portion of the top surface of the semiconductor substrate 12 . The second conductivity type is the opposite of the first conductivity type. The second conductivity type is n-type if the first conductivity type is p-type, and vice versa. The dopant concentration of the doped well region 12 can be from 1.0×10 18 /cm 3 to 1.0×10 21 /cm 3 to increase the conductivity of the doped well region 12 .
Referring to FIG. 2 , a pad dielectric layer 16 and a first mask layer 18 are formed on the top surface of the semiconductor substrate 10 . The pad dielectric layer 16 may, or may not, be formed on the backside of the semiconductor substrate 10 . The pad dielectric layer 16 includes a dielectric material such as silicon nitride. The first mask layer 18 can be composed of a photoresist or a dielectric material such as silicon oxide or silicon nitride.
Referring for FIG. 3 , the first mask layer 18 is lithographically patterned, and the pattern in the first mask layer 18 is transferred through the semiconductor substrate 10 by an anisotropic etch that employs the first mask layer 18 as an etch mask. A first through-substrate cavity 47 is formed in the semiconductor substrate 10 . The lateral dimensions, e.g., diameter, a major axis, a minor axis, a length of a side, of the first through-substrate cavity 47 can be from 1 micron to 100 microns, and typically from 3 microns to 30 microns, although lesser and greater lateral dimensions can also be employed.
Referring to FIG. 4 , the first mask layer 18 can be removed selective to the semiconductor substrate 10 . A dielectric tubular structure 20 is formed around the first through-substrate cavity 47 , for example, by converting exposed portions of the semiconductor substrate 10 on the sidewalls of the first through-substrate cavity 47 into a dielectric material. For example, the exposed portion of the semiconductor substrate can be converted into a dielectric oxide by thermal oxidation. The dielectric tubular structure 20 can include an oxide of the semiconductor material of the semiconductor substrate 10 . For example, if the semiconductor substrate 10 includes silicon, the dielectric tubular structure 20 can include silicon oxide. The pad dielectric layer 16 prevents conversion of other portions of the semiconductor substrate 10 into a dielectric material. The dielectric tubular structure 20 extends from the top surface of the semiconductor substrate 10 to the bottom surface of the semiconductor substrate 10 . A horizontal cross-sectional area of the dielectric tubular structure 20 includes a hole corresponding to the first through-substrate cavity 47 . The thickness of the dielectric tubular structure 20 , as measured laterally between an inner periphery of the dielectric tubular structure 20 and an outer periphery of the dielectric tubular structure 20 can be from 100 nm to 1 micron, although lesser and greater thicknesses can also be employed.
Referring to FIG. 5 , the pad dielectric layer 16 can be removed. Optionally, a dielectric liner 30 is deposed on the inner sidewalls of the dielectric tubular structure 20 . The dielectric liner 30 can include, for example, a stack of a silicon oxide layer and a silicon nitride layer.
Referring to FIG. 6 , the first through-substrate cavity 47 is filled with a first disposable material to form a first disposable material layer 49 L. The first disposable material layer 49 L extends through the semiconductor substrate 10 and covers both sides of the semiconductor substrate 10 , thereby encapsulating the semiconductor substrate 10 . The first disposable material can be, for example, a polycrystalline silicon-containing material such as polysilicon or an amorphous silicon-containing material such as amorphous silicon.
Referring to FIG. 7 , the first disposable material layer 49 L is removed from the front side and the backside of the semiconductor substrate 10 , for example, by an etch-back process or chemical mechanical planarization (CMP). Further, a portion of the first disposable material layer 49 L is recessed below the top surface of the semiconductor substrate 10 by a recess depth rd, which can be from 200 nm to 2,000 nm, although lesser and greater recess depths rd can also be employed. The remaining portion of the first disposable material layer 49 L constitutes a first disposable material portion 49 .
Referring to FIG. 8 , a dielectric cap portion 50 is formed by filling a cavity above the first disposable material portion 49 with a dielectric material and removing excess dielectric material above a top surface of the dielectric liner 30 . Optionally, a silicon nitride cap layer (not shown) can be deposited on the top surface of the dielectric cap portion 50 and the portion of the dielectric liner 30 located on the front side of the semiconductor substrate 10 .
Referring to FIG. 9 , a second mask layer 51 is formed above the top surface of the semiconductor substrate 10 . The second mask layer 51 can be composed of a photoresist or a dielectric material such as silicon oxide or silicon nitride. The second mask layer 51 is lithographically patterned to form an opening in an area that does not overlie the disposable material portion 49 or the dielectric tubular structure 20 . The opening in the second mask layer 51 is formed over or in proximity to the doped well region 12 . The pattern in the second mask layer 51 is transferred through the semiconductor substrate 10 by an anisotropic etch that employs the second mask layer 51 as an etch mask. A second through-substrate cavity 67 is formed in the semiconductor substrate 10 . The lateral dimensions, e.g., diameter, a major axis, a minor axis, a length of a side, of the second through-substrate cavity 67 can be from 1 micron to 100 microns, and typically from 3 microns to 30 microns, although lesser and greater lateral dimensions can also be employed.
Referring to FIG. 10 , a doped material layer 52 is deposited on the exposed surfaces of the first exemplary structure including the sidewalls of the second through-substrate cavity 67 . The doped material layer 52 includes dopants of the second conductivity type. The doped material layer 52 can be, for example, an arsenosilicate glass (ASG) layer. The thickness of the doped material layer 52 is less than half of the smallest lateral dimension of the second through-substrate cavity 67 to prevent plugging of the second through-substrate cavity 67 . Optionally, a dielectric capping layer (not shown) may be deposited over the doped material layer 52 to prevent loss of dopants during a subsequent drive-in anneal.
Referring to FIG. 11 , a drive-in anneal is performed to induce outdiffusion of dopants of the second conductivity type into a region of the semiconductor substrate 10 that surrounds the second through-substrate cavity 67 . An outer electrode is formed by doping a portion of the semiconductor substrate 10 around the second through-substrate cavity 67 . Specifically, the outer electrode 60 is formed by converting a tubular region, i.e., a region in the shape of a tube, into a doped semiconductor region having a doping of the second conductivity type. For example, a dopant-containing material layer such as an arsenosilicate glass layer can be deposited on sidewalls of the second through-substrate cavity 67 and the dopants can be driven into the semiconductor substrate 10 by a drive-in anneal. The outer electrode 60 is a doped tubular portion including a doped semiconductor material, i.e., has a shape of a tube. The lateral distance between the outer periphery of the outer electrode 60 and the inner periphery of the outer electrode, i.e., the boundary with the doped material layer 52 , can be from 150 nm to 1,000 nm, although a lesser and greater lateral distances can also be employed. The dopant concentration of the outer electrode 60 can be from 1.0×10 18 /cm 3 to 1.0×10 20 /cm 3 , although a lesser and greater dopant concentration can also be employed. The doped material layer 52 is subsequently removed. In an alternate embodiment, the outer electrode 60 can be formed by plasma doping without employing a doped material layer 52 .
Referring to FIG. 12 , a node dielectric 70 is formed on all exposed surfaces of the first exemplary structure including the inner sidewalls of the outer electrode 60 , which are the surfaces of the second through-substrate cavity 67 , and exposed surfaces of the dielectric liner 30 . The node dielectric 70 is formed directly on sidewalls of the doped tubular portion while the disposable material is present in the semiconductor substrate. The thickness of the node dielectric 70 can be from 3 nm to 30 nm, although lesser and greater thicknesses can also be employed.
Referring to FIG. 13 , the second through-substrate cavity 67 is filled with a second disposable material to form a second disposable material layer 77 L. The second disposable material layer 77 L extends through the semiconductor substrate 10 and covers both sides of the semiconductor substrate 10 , thereby encapsulating the semiconductor substrate 10 . The second disposable material can be, for example, a polycrystalline silicon-containing material such as polysilicon or an amorphous silicon-containing material such as amorphous silicon.
Referring to FIG. 14 , the second disposable material layer 77 L is removed from the front side and the backside of the semiconductor substrate 10 , for example, by an etch-back process or chemical mechanical planarization (CMP). The remaining portion of the second disposable material layer 77 L constitutes a second disposable material portion 77 . The top surface of the second disposable material portion 77 can be coplanar with a top surface of the node dielectric 70 on the front side of the semiconductor substrate 20 .
A hard mask layer 72 is formed on one side of the semiconductor substrate 20 , which is preferably the front side of the semiconductor substrate on which the dielectric cap portion 50 is located. The hard mask layer 72 includes a dielectric material such as silicon oxide, silicon nitride, a doped silicate glass, or a combination thereof. The thickness of the hard mask layer 72 can be from 500 nm to 5,000 nm, and typically from 1,000 nm to 3,000 nm, although lesser and greater thicknesses can also be employed.
Referring to FIG. 15 , the hard mask layer 72 is lithographically patterned to form openings over the second disposable material portion 77 and the first disposable material portion 49 . The dielectric cap portion 50 is removed to expose an upper surface of the first disposable material portion 49 . An upper portion of the second disposable material portion 77 can be removed during the removal of the dielectric cap portion 50 .
Referring to FIG. 16 , the first dielectric material of the first disposable material portion 49 and the second dielectric material of the second dielectric material portion 77 are removed by an etch that employs the hard mask layer 72 as an etch mask. Removal of the first disposable material portion 49 forms a cavity in a volume corresponding to the first through-substrate cavity 47 in prior processing steps. This cavity is herein referred to as a re-formed first through-substrate cavity 79 , i.e., a first through-substrate cavity that is formed a second time Likewise, removal of the second disposable material portion 77 forms a cavity in a volume corresponding to the second through-substrate cavity 67 in prior processing steps. This cavity is herein referred to as a re-formed second through-substrate cavity 78 , i.e., a second through-substrate cavity that is formed a second time. The re-formed first through-substrate cavity 79 is formed within the dielectric tubular structure 20 . Surfaces of the node dielectric 70 is exposed around the re-formed second through-substrate cavity 78 , and surfaces of the dielectric liner 30 can be exposed around the re-formed first through-substrate cavity 79 . If the dielectric liner 30 is not present, inner surfaces of the dielectric tubular structure 20 can be exposed in the re-formed first through-substrate cavity 79 .
Referring to FIG. 17 , the re-formed first through-substrate cavity 79 and the re-formed second through-substrate cavity 78 are filled with a conductive material to form a first conductive through-substrate via (TSV) structure 80 and a second conductive TSV structure 82 , respectively. The conductive material of the first conductive TSV structure 80 and the second conductive TSV structure 82 can include a doped semiconductor material, a metallic material, or a combination thereof. The conductive material of the first conductive TSV structure 80 and the second conductive TSV structure 82 can include, but is not limited to, doped polysilicon, a doped silicon-containing alloy, Cu, W, Ta, Ti, WN, TaN, TiN, or a combination thereof. The conductive material can be deposited, for example, by electroplating, electroless plating, physical vapor deposition (PVD), chemical vapor deposition (CVD), or a combination thereof.
After deposition of the conductive material, excess conductive material is removed from the top side and the bottom side of the semiconductor substrate 10 by planarization employing an etch-back process, chemical mechanical planarization, or a combination thereof. Top surfaces of the first conductive TSV structure 80 and the second conductive TSV structure 82 are coplanar with a top surface of the hard mask layer 72 . Bottom surfaces of the conductive TSV structure 80 and the second conductive TSV structure 82 are coplanar with a bottom surface of remaining portions of the first exemplary structure. The bottom surface of the remaining portions of the first exemplary structure can be, for example, an exposed surface of the node dielectric 70 if a bottom portion of the node dielectric 70 remains after planarization or any other exposed surfaces at the bottom of the first exemplary structure. The first conductive TSV structure 80 and the second conductive TSV structure 82 are formed concurrently by employing the same deposition process and the same planarization process.
Referring to FIG. 18 , a contact structure 90 is formed by forming a trench through the hard mask layer 72 , the node dielectric 70 , and the dielectric liner 30 and by filling the trench with a conductive material such as a doped semiconductor material or a metallic material. The contact structure 90 is conductively connected to the outer electrode 60 through the doped well region 12 . The first conductive TSV structure 80 , the node dielectric 70 , and the outer electrode 60 collective constitute a capacitor 180 , in which the first conductive TSV structure 80 is an inner electrode. The second conductive TSV structure 82 , the portion of the dielectric liner contacting the second conductive TSV structure 82 , and the dielectric tubular structure 20 collectively constitute an laterally-insulated conductive through-substrate connection structure 182 . An end surface of the first conductive TSV structure 80 , an end surface of the second conductive TSV structure 82 , and an end surface of the contact structure 90 can be coplanar with an exposed surface of the hard mask layer 72 .
The first exemplary structure can be incorporated in a semiconductor chip. For example, a plurality of instances of the capacitor 180 and a plurality of instances of the laterally-insulated conductive through-substrate connection structure 182 can be embedded in the same semiconductor substrate 10 of the semiconductor chip. The semiconductor chip may, or may not, include other semiconductor devices such as field effect transistors, bipolar transistors, thyristors, and diodes.
Each capacitor 180 can include an inner electrode, which includes a first conductive through-substrate via (TSV) structure 80 , a node dielectric 70 , and an outer electrode 60 . The inner electrode contiguously extends at least from an upper surface of the semiconductor substrate 10 to a lower surface of the semiconductor substrate 10 . The node dielectric 70 laterally contacts and laterally encloses the inner electrode. The node dielectric 70 contiguously extends from the upper surface to the lower surface. The outer electrode 60 laterally contacts and laterally encloses a portion of the node dielectric 70 . The outer electrode 60 includes a doped semiconductor material.
The laterally-insulated conductive through-substrate connection structure 182 includes a second conductive TSV structure 82 located in the semiconductor substrate 10 and a dielectric tubular structure 20 laterally surrounding the second conductive TSV structure 82 and embedded in the semiconductor substrate 10 . The laterally-insulated conductive through-substrate connection structure 182 can include a portion of the dielectric liner 30 .
Referring to FIG. 19 , a second exemplary structure according to a second embodiment of the present invention includes a packaging substrate 200 , a plurality of first semiconductor chips 100 , a plurality of second semiconductor chips 300 , an array of first solder balls 199 electrically connecting each of the first semiconductor chips 100 to the packaging substrate 200 , and an array of second solder balls 299 electrically connecting each of the second semiconductor chips 300 to a first semiconductor chip 100 . Each of the first semiconductor chips 100 includes at least one capacitor 180 and at least one laterally-insulated conductive through-substrate connection structure 182 . The first semiconductor chips 100 may, or may not, include additional semiconductor devices such as field effect transistors, bipolar transistors, thyristors, and diodes. The second semiconductor chips 300 can include any type of semiconductor devices.
The capacitors 180 can function as decoupling capacitors that reduce noise in a power supply system that supplies power to the devices in the second semiconductor chips 300 and, if present, to the devices in the first semiconductor chips 100 . Each capacitor 180 can provide a capacitance on the order of 1 pF to 10 nF, which is equivalent to the capacitance of 40-400,000 typical trench capacitors. Further, the capacitor 180 provides a lower inductance than a trench capacitor array that provides a comparable total capacitance. Thus, the capacitors 180 reduce noise in the power supply system especially during high frequency operations.
Referring to FIG. 20 , a third exemplary structure according to a third embodiment of the present invention includes a packaging substrate 200 , a interposer structure 400 , a plurality of first semiconductor chips 100 , and a plurality of second semiconductor chips 300 . An array of first solder balls 199 electrically connects each of the first semiconductor chips 100 to the interposer structure 400 . An array of second solder balls 299 electrically connects each of the second semiconductor chips 300 to a first semiconductor chip 100 . An array of third solder balls 399 connects the interposer structure 400 to the packaging substrate 200 .
The interposer structure 400 can include an interposer structure substrate layer 410 , a lower dielectric material layer 420 , and an upper dielectric material layer 430 . The interposer structure substrate layer 410 includes a plurality of through-substrate via structures that are schematically illustrated as vertical lines. The plurality of through-substrate via structures includes a plurality of capacitors 180 (See FIG. 18 ) and laterally-insulated conductive through-substrate connection structure 182 (See FIG. 18 ). The lower dielectric material layer 420 and the upper dielectric material layer 430 can include metal lines that provide electrical wiring within the lower dielectric material layer 420 or the upper dielectric material layer 430 .
In general, a semiconductor chip including at least one capacitor 180 and at least one laterally-insulated conductive through-substrate connection structure 182 can be mounted a mounting structure, which can be any structure on which the semiconductor chip can be mounted with electrical connections thereto. The mounting structure can be, but is not limited to, a packaging substrate 200 , an interposer structure 400 , an assembly of an interposer structure 400 and a packaging substrate 200 , or another semiconductor chip such as a second semiconductor chip 300 .
Referring to FIG. 21 , a graph shows results of a simulation that shows a noise reduction at high frequency provided by an exemplary structure according to an embodiment of the present invention. The horizontal axis represents frequency of a noise component in a power supply system, and the vertical axis represents an equivalent impedance of a decoupling system including either a capacitor 180 (See FIG. 18 ) according to an embodiment of the present invention or an array of trench capacitors according to prior art. The electrical noise in a power supply system is proportional to the equivalent impedance. The curve labeled “TSV w/582 pF” represents the equivalent impedance of a capacitor 180 having a capacitance of 582 pF and constructed according to an embodiment of the present invention, e.g., as shown in FIG. 18 . The curves labeled “DTC w/582 pF,” “2 nF,” and “4 nF” represent the equivalent impedance of trench capacitor arrays having a total capacitance of 582 pF, 2 nF, and 4 nF, respectively.
At a frequency range below 0.1 GHz, the voltage noise in the system power supply is limited by the total capacitance of a decoupling capacitor system. Above 1 GHz, however, the voltage noise in decoupling capacitor systems employing any of the trench capacitor arrays increases to with frequency on a converging curve irrespective of the total capacitance of the decoupling capacitor system because inductance of the decoupling capacitor system dominates. The decoupling capacitor system employing a capacitor 180 of an embodiment of the present invention provides a lower voltage noise at frequencies above 1.2 GHz except for a small frequency range between 4 GHz and 4.5 GHz because the capacitor 180 has a low inductance. Thus, the decoupling capacitor system employing a capacitor 180 of an embodiment of the present invention provides a superior performance in noise reduction while consuming less device area. In the second or third exemplary structure, if the first semiconductor chips 100 do not include a semiconductor device, the capacitors 180 can be formed without requiring any area in the third semiconductor chips 300 . In the third exemplary structure, the capacitors 180 can be formed in a smaller area than an array of trench capacitors having a comparable total capacitance, thereby providing more area for other semiconductor devices that can be included in the first semiconductor chips 100 .
While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details can be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims. | A capacitor in a semiconductor substrate employs a conductive through-substrate via (TSV) as an inner electrode and a columnar doped semiconductor region as an outer electrode. The capacitor provides a large decoupling capacitance in a small area, and does not impact circuit density or a Si3D structural design. Additional conductive TSV's can be provided in the semiconductor substrate to provide electrical connection for power supplies and signal transmission therethrough. The capacitor has a lower inductance than a conventional array of capacitors having comparable capacitance, thereby enabling reduction of high frequency noise in the power supply system of stacked semiconductor chips. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a reciprocating motor, and more particularly, to a reciprocating motor which enables to improve productivity and assembling of a magnet.
[0003] 2. Description of the Background Art
[0004] In general, a reciprocating motor has a magnetic flux in a plane form, and a movable unit disposed between an outer stator and an inner stator linearly reciprocates according to variation of the magnetic flux.
[0005] As shown in FIGS. 1 and 2 , the conventional reciprocating motor includes an outer stator 11 having a cylindrical shape by radially stacking a plurality of lamination sheets 14 to an outer side of a winding coil 15 , an inner stator 12 disposed in an inner circumference of the outer stator 11 at a certain air gap from an inner circumferential surface of the outer stator 11 and having a cylindrical shape by radially stacking a plurality of lamination sheets 13 , and a movable unit 20 disposed between the outer stator 11 and the inner stator 12 and linearly reciprocating.
[0006] The movable unit 20 includes a magnet frame 21 disposed between the outer stator 11 and the inner stator 12 , a plurality of magnets 22 installed along the circumference of the magnet frame 21 , and a retainer ring 23 for fixing the magnets 22 on the magnet frame 21 .
[0007] As shown in FIG. 3 , the magnet frame 21 is formed as a cylindrical shape and made of stainless steel (SUS)-based materials. A plurality of grooves 21 a having a predetermined depth are respectively recessed along an outer circumference of the magnet frame 21 so as to mount the magnets 21 a therein.
[0008] The retainer ring 23 is made of thin metallic materials, and compresses each of outer circumferences of a plurality of magnets 22 to thereby fix a plurality of magnets 22 on an outer circumferential surface of the magnet frame 21 . In addition, a plurality of slits 23 a for interrupting an eddy current are formed at the outer circumferential surface of the retainer ring 23 .
[0009] The movable unit 20 is assembled as follows. While a plurality of magnets 22 are being adhered to the grooves 21 a recessed in the outer circumferential surface of the magnet frame 21 by an adhesive, each of them is insertedly fixed to the grooves 21 a . Then, the retainer ring 23 is inserted to encompass the outer circumference of the magnets 22 , and both ends of the retainer ring 23 are bent to fix the magnets 22 .
[0010] In the conventional reciprocating motor, when an external power is applied to the winding coil 15 , magnetic flux is formed around the winding coil 15 . The flux forms a kind of closed loop by flowing to the inner stator 12 along one path of the outer stator 11 and flowing to another path of the outer stator 11 . And, as the magnets 22 are pushed and pulled according to a direction of the flux, the magnet frame 21 linearly reciprocates.
[0011] However, in the conventional reciprocating motor, because a plurality of the magnets 22 should be separately installed at the magnet frame 21 after they are individually fabricated, the assembly process of the magnets 22 is complicated, thereby lowering productivity of products.
[0012] In addition, in order to maintain regular intervals between a plurality of magnets 22 attached to the magnet frame 21 , the magnets 22 are fixed via the retainer ring 23 . Therefore, the number of parts is increased because of the use of the retainer ring 23 to thereby increase a manufacturing cost and complicate the assembly process.
SUMMARY OF THE INVENTION
[0013] Therefore, an object of the present invention is to provide a reciprocating motor capable of improving productivity of a product and reducing the cost by integrally manufacturing a magnet in a cylindrical shape and simplifying the manufacturing process of the magnet and the assembly process of the magnet.
[0014] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a reciprocating motor, comprising a pair of stators, and a cylindrical magnet formed as a single body and disposed between the stators, for linearly reciprocating, wherein the magnet is integrally formed in a cylindrical shape.
[0015] In addition, at least one slit for interrupting an eddy current is formed at an outer circumference of the magnet in a direction that the magnet linearly reciprocates.
[0016] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] 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.
[0018] In the drawings:
[0019] FIG. 1 is a sectional view showing the conventional reciprocating motor;
[0020] FIG. 2 is an enlarged sectional view showing a movable unit of the reciprocating motor of FIG. 1 ;
[0021] FIG. 3 is an exploded perspective view showing the movable unit of the reciprocating motor of FIG. 1 ;
[0022] FIG. 4 is a sectional view showing a reciprocating motor in accordance with one embodiment of the present invention;
[0023] FIG. 5 is an enlarged sectional view showing a movable unit of the reciprocating motor of FIG. 4 ;
[0024] FIG. 6 is an exploded perspective view showing the movable unit of the reciprocating motor of FIG. 4 ; and
[0025] FIG. 7 is an exploded perspective view showing a movable unit of a reciprocating motor in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Hereinafter, reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0027] As shown in FIGS. 4 and 5 , a reciprocating motor in accordance with the present invention includes an outer stator 111 having a cylindrical shape by radially stacking a plurality of lamination sheets 114 on an outer side of a winding coil 115 , an inner stator 112 disposed in an inner circumference of the outer stator 111 at a certain air gap from an inner circumferential surface of the outer stator 111 and having a cylindrical shape by radially stacking a plurality of lamination sheets 113 , and a movable unit 120 disposed between the outer stator 111 and the inner stator 112 and linearly reciprocating.
[0028] As shown in FIG. 6 , the movable unit 120 includes a magnet frame 121 disposed between the outer stator 111 and the inner stator 112 , and a cylindrical magnet 122 formed as a single body and installed on an outer circumferential surface of the magnet frame 121 .
[0029] The magnet frame 121 is formed in a cylindrical shape, and a cylindrical groove 121 a having a predetermined depth are recessed along an outer circumference of the magnet frame 121 so as to mount the magnet 122 therein. In addition, a plurality of through holes 121 b are preferably formed around the magnet frame 121 to reduce resistance generated during the movement of the magnet frame 121 .
[0030] The magnet 122 is insertedly fixed in the groove 121 a , and the magnet 122 can be more stably fixed to the groove 121 a by interposing an adhesive between the magnet 122 and the groove 121 a.
[0031] An inner diameter of the magnet 122 is formed to be substantially identical to an outer diameter of the groove 121 a , which is advantageous in stably insertedly fixing the magnet 122 in the groove 121 a . In this case, the magnet 122 is preferably formed with an elastic material.
[0032] Meanwhile, at least one slit 122 a is formed in the outer circumference of the magnet 122 in an axial direction of the magnet 122 , i.e. in a direction that the assembly of the magnet frame 121 and the magnet 122 linearly reciprocate, in order to interrupt an eddy current. A length of the slit 122 a is shorter than a width of the magnet 122 in the direction that the magnet 122 linearly reciprocates, and a plurality of slits are preferably formed in a circumferential direction of the magnet 122 at the same intervals.
[0033] The slits 122 a are opened toward one side facing the magnet frame 121 and toward another side opposite to one side facing the magnet frame 121 , respectively. Here, the slits opened to one side of the magnet 122 and the slits opened to another side of the magnet 122 are alternately formed, which is an effective way to maintain the intensity of the magnet 122 .
[0034] However, not limited to such construction, as shown in FIG. 7 , all of the slits 122 a can be opened toward one side facing the magnet frame 121 or toward another side opposite to one side facing the magnet frame 121 . In this case, in order to insertedly fix the magnet 122 to the magnet frame 121 a easily, the slits 122 a are preferably opened toward the direction facing the magnet frame 121 .
[0035] In the reciprocating motor having such construction in accordance with the present invention, the assembly of the movable unit 120 is completed by simply insertedly fixing the cylindrical magnet 122 to the magnet frame 121 .
[0036] At this time, since the magnet frame 121 is provided with the groove 121 a , the cylindrical magnet 122 is inserted upon the groove 121 a to be firmly fixed to the groove.
[0037] In addition, since the slits 122 a are formed on the outer circumference of the magnet 122 , when the magnet 122 is installed at the magnet frame 121 , the slits 122 a are spread to a certain degree. Therefore, the magnet 122 can be easily mounted at the magnet frame 121 .
[0038] In the reciprocating motor in accordance with the present invention, when an external power is applied to the winding coil 115 , magnetic flux is formed around the winding coil 115 . The flux flows forms a kind of closed loop by flowing to the inner stator 112 along one path of the outer stator 111 and flowing to another path of the outer stator 111 . And, as the magnet 122 of the movable unit 120 is pushed and pulled according to a direction of the flux, the magnet 122 linearly reciprocates. At this time, the eddy current is generated in the magnet 122 , but such eddy current is interrupted by the silts 122 a formed at the magnet 122 . Therefore, a loss caused by the eddy current is prevented.
[0039] In the reciprocating motor in accordance with the present invention, because a cylindrical magnet formed as a single body is inserted upon a cylindrical magnet frame, in comparison to the conventional reciprocating motor in which a plurality of magnets are individually fabricated and separately fixed into an outer circumference of a magnet frame, the manufacturing process of the magnet and the assembly process of the magnet are simple, thereby improving productivity.
[0040] In addition, the reciprocating motor in accordance with the present invention is provided with the cylindrical magnet formed in a single body. Accordingly, a separate part for fixing magnets to a magnet frame such as a retainer ring of the conventional art is unnecessary, so that the production cost can be reduced.
[0041] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims. | A reciprocating motor includes a pair of stators and a cylindrical magnet formed as a single body and disposed between the stators, for linearly reciprocating. Accordingly, it allows facilitating a job of manufacturing and installing the magnet, so that productivity can be improved. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for heating material, preferably for liquefying glass batch or the like as disclosed in U.S. Pat. No. 4,381,934 (Kunkle et al.), by means of a rotating vessel. A rotating vessel having a vertical axis is disclosed as the preferred embodiment in that patent. Similarly oriented rotary melters are also shown, for example, in U.S. Pat. Nos. 2,007,755 (Ferguson), 2,834,157 (Bowes), and 3,917,479 (Sayce et al.). Such arrangements may be satisfactory for operation on a relatively small scale, but when such a process is carried out on a commercial production scale dynamic instabilities may arise in the rotating apparatus that have the potential to put severe stress on the restraining structure. One source of these instabilities may be non-uniform distribution of material in the vessel. Another may be thermal warpage of the vessel. As long as the mass center of the rotating vessel and its contents is on the vertical axis of rotation, the system is stable. But if the mass center deviates from the axis of rotation, the system attempts to bring the two into conformity, which can force the vessel out of its intended alignment and set up oscillations and vibrations. Prior art approaches typically involve attempts to restrain the rotating vessel from any movement out of its intended alignment, but with a commercial scale vessel the forces entailed by such an attempt can be so great that the vessel or other structural elements are distorted or deflected, setting up other modes of vibration or oscillation. Also, feeding batch materials to a precise location with the vessel can be difficult if its motion is unstable. It would be desirable if the apparatus economies that result from the liquefaction process of the Kunkle et al. patent could be preserved by providing practical means for supporting and rotating a relatively massive vessel with stability.
SUMMARY OF THE INVENTION
In the present invention a support and drive arrangement is provided whereby a massive vessel rotated about a vertical axis is made dynamically self-stabilizing. The invention involves several novel aspects which in combination comprise the preferred embodiment.
One aspect is the separation of the vessel from its support means. The container portion of the vessel, or drum, is spaced from an encircling support table with radial freedom of movement therebetween, thus isolating the support structure from thermal expansion and warpage effects that may be experienced by the drum. Although motion is permitted therebetween, coaxiallity of the vessel and the support structure is preserved. The support table is mounted for rotation about a substantially vertical axis coincident with the cylindrical axis of the vessel.
In another aspect, support for the drum is provided at an elevation above the mass center of the drum and its contents, and the drum is mounted with freedom for its vertical axis to oscillate. The result is a pendulum-like effect that permits self-centering and avoids absolute restraint. If the mass center deviates from the intended axis for rotation, gravity pulls the mass center toward the intended axis. On the other hand, a center of gravity above the plane of support would create an unstable, inverted pendulum situation. Attempts to totally restrain the system against movement of the mass center would produce unduly high stresses in a large scale apparatus.
A bias against gross lateral displacement of the vessel is provided by a conical orientation of the support surfaces, that is, the surface of the support table that contacts supporting rollers slopes downwardly toward the center of the vessel. Thus total reliance on lateral restraint means to keep the vessel in position is avoided. The load bearing surfaces of the support rollers are also preferably conical, with the apex of each cone falling at the axis of rotation of the vessel, so that the tangential velocities of the rollers match that of the support surface along the lines of contact therebetween, thereby reducing wear, noise, and vibration.
In the preferred embodiment, support is provided above the mass center by a support structure separate from the drum and attached to the drum at a lower elevation. Elongated link means extend from the support structure to the points of attachment to the drum. Because of an inward tapering of lining material within the drum, the lower portions of the drum are more insulated from the interior heat than the upper portions. Therefore, the link means are attached to lower portion of the drum because of the stable geometry there. Upper portions of the drum can be subject to thermal expansion and contraction and can sometimes become deformed, so that attachment of the support system there would have the potential of introducing unsymmetrical conditions, and thus instability, into the rotating system. Because of the attachment to the lower, relatively cool portion of the drum, and the preference to support the drum from above its center of gravity, the link means preferably extend downwardly from the support structure to their points of attachment to the drum. The link means also provide flexibility in the radial direction, thereby achieving the advantage of structurally isolating the support means from the drum. This arrangement advantageously permits thermal expansion or warpage of the drum, but maintains the drum fixed relative to the support means. The link means preferably comprise a plurality of rods, but could comprise plates, cables, straps, or the like.
Another important aspect of preferred embodiments is the provision of horizontal restraining means acting on the support table. The horizontal restraining means may comprise wheels separate from the vertical support wheels on which the table is supported. Although the present system does not attempt to provide absolute horizontal restraint, a major stabilizing effect is provided to the system by exerting resilient horizontal centering forces on the support table to control excursions and to damp oscillations (i.e., swinging motions). Providing separate propulsion for rotation of the support table through the horizontal restraining means advantageously enables the load-bearing vertical support means to be lubricated, and allows for various configurations and materials for the vessel support system.
These and other advantages of the invention will be apparent from the drawing and the detailed description of the preferred embodiment which follows.
THE DRAWING
The FIGURE is a vertical cross-section of a preferred embodiment of rotary heating apparatus incorporating the improvements of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This description of a particular preferred embodiment relates to a process for liquefying glass batch but it should be understood that the invention is applicable to other processes as well. Details of the specific process maybe found in U.S. Pat. No. 4,381,934 of Kunkle et al. and need not be repeated here.
Referring to the specific embodiment shown in the figure, the basic structure of the melting vessel is a drum 10 which may be fabricated of steel and which has a generally cylindrical side configuration, a generally open top, and a bottom portion that is closed except for a drain outlet. The drum 10 is mounted for rotation about a vertical axis in a manner to be described in detail hereinbelow. A substantially enclosed cavity is formed within the melting vessel by means of a lid structure generally designated as 11 which is provided with stationary support. The lid 11 may be constructed with a variety of materials and configurations as would be known to those of skill in the furnace construction art. The preferred arrangement depicted in the figure is an upwardly domed, sprung arch construction fabricated from a plurality of refractory blocks 12. In the typical arch construction shown, the arch blocks rest on a peripheral support structure 13. The area between the stationary lid and rotating vessel may be closed in various ways. In the arrangement shown in the drawing, plate blocks 14 extend slightly below upper rim of the drum 10 and are supported by stationary support plate 15. Seal blocks 16 may be provided to close the gap between the arch blocks 12 and the plate blocks 14. It should be understood that monolithic and flat suspended designs and other materials, either cooled or uncooled, could be employed for the lid.
Batch materials, preferably in a pulverulent state, may be fed into the cavity of the heating vessel by means of a water cooled chute 20. A layer 21 of the batch material is retained on the interior walls of the drum 10 to act as an insulating lining. As the drum is rotating, the feed chute 20 directs batch material onto upper portions of the lining 21. Heating for liquefying the batch material may be provided by one or more burners 22 extending through the lid 11. Preferably a plurality of burners 22 are arranged around the perimeter of the lid so as to direct their flames toward a wide area of the lining 21. The burners are preferably water cooled to protect them from the harsh environment within the vessel. Exhaust gases escape from the vessel through an opening 23 in lid 11 or through the bottom outlet 25. As batch material on the surface of lining 21 liquefies it flows down the sloped lining to a central outlet opening 25 at the bottom of the vessel. The outlet 25 may be fitted with a refractory ceramic bushing 26. A stream of liquefied material 27 falls freely from the vessel into a stationary receptacle 28 and may thereafter be subjected to additional treatment to complete the melting process.
The drawing shows several optional features that are included in the preferred embodiment. At the interface between the upper rim of the rotating drum 10 and the stationary lid 11 an atmosphere seal may be provided comprised of a stationary, circular, water-containing trough and a circular flange member 31 extending downwardly into the trough from the rotating drum. A similar stationary water trough 32 and flange 33 extending downwardly from the rotating drum may be provided at the lower end of the drum.
Another optional feature associated with the preferred embodiment is an arrangement to cool the upper rim portion of the drum 10 in the event that irregular retention of the lining 21 on the upper interior portion of the drum causes undue exposure of the upper rim portion of the drum to the heat. To this end, a stream of water may be sprayed against the exterior of the upper portion of the drum. The water spray may be supplied with water by way of conduits 40, and the spray may be confined to the space closely adjacent to the drum by means of a spray shield 41. Spent water may be collected in a circular trough 42 and drained by way of conduits 43 that extend down along the slides of and rotate with the drum 10. Discharge of water from the conduits 43 may conveniently be provided into the water trough 32 of the bottom atmosphere seal.
The base on which the drum 10 is rotatably supported and driven is a support table 50 which, as shown in the drawing, may be configured as a hollow ring of generally rectangular cross-section. The support ring 50 encircles the drum and is spaced therefrom. The link means for connecting the support ring 50 to the drum 10 in this embodiment comprise a plurality of support rods 51. The number and size of the rods 51 are inversely related and depend upon the weight of a particular drum when fully loaded and the transient forces expected to be borne. Three rods could theoretically support the drum, but the use of more (preferably eight or more) rods permits a bicycle spoke type of arrangement to be employed whereby rotating and swinging of the drum 10 relative to the ring 50 is counteracted. In such an arrangement the rods do not lie in radial planes of the drum, but rather extend along vertical planes that do not intersect the vertical axis of the drum, with the planes of adjacent rods passing on opposite sides of the vertical axis of the drum. With larger vessels the number of rods may be increased accordingly in order to distribute the load, and it is contemplated that the number of rods may be on the order of twenty-four in an embodiment of the type shown in the drawing. Rods are the preferred form of link means because they provide little obstruction to the sides of the drum, thereby permitting access for construction and maintenance, providing free circulation of air, and avoiding accumulation of any spilled materials. Because of the isolation between the support mechanism and the vessel provided by elongated link means such as the rods 51, the support mechanism can act as a self-centering system regardless of the configuration of the vessel and its contents.
The rods 51 are preferably held in place at each end by spherical ended nuts 52 which are in turn received in spherical sockets in upper and lower support blocks 53 and 54 respectively. This arrangement causes the rods 51 to carry tensile loads only. The upper support blocks 53 are mounted on the support ring 50 at an elevation above the center of gravity "C" of the loaded vessel in accordance with the preference to support the vessel from an elevation above its center of gravity. The lower support blocks 54 are affixed to a peripheral ring 55 or the like, which is attached to the drum 10 at an elevation lower than the elevation of the upper support blocks 53. Because the lining material 21 tapers to a greater thickness at the bottom of a cylindrical drum as shown in the drawing, the center of gravity will usually be within the lower half of the height of the drum. Accordingly, the elevation of support may alternatively be expressed as being at the upper half of the height of the drum. Elongating the rods 51, within practical limits of the surrounding structure, can be advantageous for better isolation of the drum from the support system because longer, and thus more vertical, rods avoid transmitting drum distortion along the length of a rod.
Attachment of the link means such as rods 51 to the drum preferably is located at a region of the drum that is relatively cool and therefore less susceptible to thermal warpage. The thickening of the lining 21 toward the bottom of the cylindrical drum renders lower portions of the drum more desirable for the attachment locations. Although attachment at the upper half of the drum may sometimes be acceptable, it is preferred to make the attachment at the lower half. In the most preferred arrangement, the attachment is at or below the elevation of the center of gravity "C" of the vessel loaded with a normal amount of material including the lining, which would usually be in a reliably stable portion of the vessel.
The vessel 10, instead of the generally cylindrical shape shown may be provided with other shapes such as a downwardly converging frustoconical shape or a stepped shape as shown in U.S. Pat. No. 4,496,387 (Heithoff et al.). In such cases, the center of gravity may not lie within the lower half of the vessel, but the preferred elevation of support would be above the center of gravity, and the elevation of attachment to the vessel would be at the lower half.
The underside of the support ring 50 is provided with a tapered track 60 that makes rolling contact with a plurality of tapered wheels 61. The wheels 61 are rotatably carried by bearings 62 that are affixed to suitable stationary structural members such as beams 63. The wheels 61 carry the vertical load of the drum and its contents, and the number of wheels should be chosen accordingly to distribute the load, eight wheels being considered suitable in a typical commercial scale installation as shown in the drawing. The contact surface of the track 60 tapers downwardly toward the drum 10, thus being configured as a segment of a cone. The wheels 61 may be tapered at the same slope as the track, and together with the tapered track 60 bias the rotating vessel toward the center. The angle is chosen to avoid velocity differences along the line of contact, thus reducing wear and noise.
Lateral restraint is applied to the rotating drum 10 and support ring 50 by means of a plurality of wheels 70 bearing against the periphery of the support ring 50. The lateral restraint wheels 70 may be rotatably carried on rigid support means 71, which may be adjustable in the radial direction with respect to the drum 10. At least three lateral restraint wheels 70 are provided, and the wheels 70 are preferably resilient, most preferably pneumatic tires. At least one of the wheels 70 is driven by means of a motor (not shown) so as to rotate the support table 50 and thus the drum 10. Rather than serving as absolute restraint for the rotating elements, the wheels 70 serve to damp oscillation or other deviation of the drum axis from its intended locus. The wheels 70 thus serve as a primary centering force to the rotating system.
It should be evident that other variations and modifications as would be known to those of skill in the art, may be resorted to without departing from the scope of the invention as defined by the claims which follow. | A rotary heating apparatus, for example, for liquefying glass batch or the like, is provided with dynamic stability by isolating structural support elements from vessel elements that are subject to thermal distortion and by supporting the vessel so as to be self-centering. The preferred embodiment entails a support ring separate from the vessel, rotatably supported at an elevation above the center of gravity of the vessel, and attached to a lower portion of the vessel by way of a plurality of link rods. Horizontal force is applied to the support ring to damp oscillations of the vessel. Rotation of the ring may be on a conical track to aid self-centering. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to adapters for residential plumbing and, more particularly, to such adapters for coupling an auxiliary appliance to the water line for a toilet tank, sink faucet or the like.
2. Description of the Related Art
In residential plumbing, the water lines which lead to fixtures such as the faucets in kitchen sinks, bathroom sinks and the like, as well as to the ballcock valve assemblies in toilet tanks, generally comprise a tube which extends from the termination of the installed plumbing line at the location of the fixture to the fixture itself. The termination of the installed plumbing line is usually an element known as an angle-stop. This comprises a fitting having a valve which threads onto the end of the pipe where it comes through the wall and delivers water in a direction at right angles to the pipe. The connection between the angle-stop and the fixture is generally by way of a flexible tube or conduit, either plastic or ductile metal such as copper, which is provided with properly sized compression couplings at both ends to make the watertight connections at the angle-stop and at the fixture. The reason this tube is constructed as described is to accommodate for misalignments between the angle-stop and the fixture, as well as to permit the ready removal and repair or replacement of the particular fixture.
In many cases, it is desirable to couple an auxiliary appliance to a plumbing line in a bathroom or kitchen. One example where such a connection is needed adjacent a toilet fixture is for a certain personal hygiene attachment for toilets, sometimes referred to as a bidet attachment. Such devices may include a handheld spray attachment to a flexible hose or a specially designed spray fixture which is adapted to be mounted to extend within the toilet below the toilet bowl rim. Examples of such devices are to be found in the following U.S. Pat. Nos.: 2,605,477 of Monserrat, 3,015,826 of Aranas, 3,425,066 of Berger, 4,596,058 of Nourbakhsh, 5,090,067 of Cogdill, and 5,138,726 of Campbell, to name a few.
In many cases, such auxiliary appliances are installed by way of special plumbing connected directly to the residence water lines. Of the prior art examples listed, such special plumbing installations are to be found in the patents of Monserrat, Aranas and Nourbakhsh. Cogdill calls for modification of the toilet tank itself. Such special installations require the work of a plumber or the skills of one if the homeowner is to perform the job himself. Such plumbing skills are also required if the auxiliary appliance is to be removed or temporarily disconnected for repairs or adjustment.
As an alternative to a specially installed plumbing arrangement for an auxiliary appliance, a device known as a "saddle tee" or "T-tap" is commonly used. This is an element which fastens in place by encircling the conduit from the water supply pipe. A hole is drilled through an opening in the saddle tee which has a collar that permits coupling of the water conduit. Compression seals are provided so that the assembly as installed does not leak. Such a attachment device is disclosed in the Campbell patent. The drawbacks of such an arrangement are obvious: the best designs of saddle tees are prone to leakage and corrosion; and if the appliance is ever to be removed, there is a hole in the water pipe so that the pipe has to be replaced.
The auxiliary appliance in the Berger patent is attached to the water line by installing a standard plumbing tee at the outlet of the angle-stop to which the flexible tube leading to the toilet tank ballcock assembly is coupled. A standard valve is coupled to the side outlet of the tee to control water flow to the auxiliary appliance.
Angle-stops come in a variety of sizes. Thus, to use a plumbing tee installation as shown in Berger, one must select a tee of the same size as the outlet of the angle-stop. Moreover, since conventional plumbing tees are constructed with male threads, as is also the outlet of the conventional angle-stop, an installation as depicted in the Berger patent requires the addition of a coupling, also the same size as the angle-stop, to connect the plumbing tee to the angle-stop. This results in an unsightly and bulky installation which is rather cumbersome, to say the least.
In addition to the auxiliary appliances which are connected to standard plumbing in a bathroom, it is not uncommon to have appliances coupled to the water line feeding a faucet in the kitchen sink. Examples of such appliances are the ice-maker of a refrigerator/freezer, an electric water heater for dispensing high temperature water for instant coffee or tea, water filtering devices, drinking water dispensers and the like, Saddle tees are commonly used for such auxiliary appliance installations with the usual drawbacks described above.
Although angle-stops, whether for plumbing to a sink faucet in the kitchen or bathroom or to a toilet tank valve, come in a variety of sizes, the threaded coupling to the ballcock assembly or other toilet tank valve is almost invariably of the same physical size, thread specification, etc.--i.e., identical from one to the next. In other words, for all of the different sizes of flexible conduits which connect between the angle-stop and the toilet tank fitting which are required in order to establish a match with the size of the angle stop, the coupling at the end which threads onto the toilet tank fitting is always the same size. A similar situation obtains with respect to the fittings for sink faucets, although these fittings are smaller than the toilet tank fittings. Even so, the conduits extending between the angle-stop and the faucet fitting come in a variety of sizes to adapt to the particular size of angle stop while all have couplings the same size and configuration to their outlet ends.
To take advantage of this particular situation, I have devised a very simple and compact, readily installed adapter which greatly simplifies the problem of providing a plumbing connection for the installation of an auxiliary appliance to an existing plumbing system. With my invention only two sizes of adapters are required to accommodate all of the different connections I have described hereinabove: one size for the toilet tank fitting and another size for the faucet fitting. These adapters are identical in concept, construction and function, differing only in size selected for their specific utilization.
This simplification is made possible because the adapter is constructed so as to couple between the flexible conduit extending from the angle-stop and the particular fixture, either faucet or toilet tank, which is involved. This simplification in product design makes it much easier for the home owner to select the particular adapter that is needed (merely specifying whether it is for a toilet or a sink), reduces the inventory requirements in stocking the products required, greatly simplifies the task of installing the auxiliary plumbing appliance, and results in improved appearance of the final installation. There is no modification of existing plumbing and if the appliance is to be removed or disconnected, the adapter of my invention may be easily removed and the plumbing restored to its original condition.
SUMMARY OF THE INVENTION
In brief, arrangements in accordance with the present invention comprise a plumbing adapter having an inlet end, a first outlet end in line with the inlet end and a second outlet end extending to the side. Each of these ends has an opening communicating with a central water passage. The inlet end is threaded and shaped so that it may be engaged in sealing relationship with a flexible water conduit leading to a plumbing fixture. The flexible conduit is generally installed on the outlet of an angle-stop which is connected to a plumbing line.
The first outlet end is provided with a resilient sealing member and a rotatable coupling nut which are shaped and sized to engage a coupling portion of the plumbing fixture in sealing relationship. The second outlet end extending to the side of the adapter is threaded for engagement with an element such as a needle valve coupled to an auxiliary plumbing appliance.
Looking at it another way, the inlet end of the adapter is configured like the coupling portion of the plumbing fixture so that the outlet end of the flexible conduit which normally attaches to the plumbing fixture can instead be connected to the adapter. Similarly, the first outlet end of the adapter is configured like the outlet end of the standard flexible conduit so that it can be connected to the plumbing fixture in place of the outlet end of the conduit. Tightening the rotatable coupling nut of the conduit onto the adapter serves to compress the seal at the end of the conduit, thus providing a leak-proof junction. In similar fashion, tightening the coupling nut at the first outlet end of the adapter onto the threaded coupling portion of the plumbing fixture serves to compress the resilient sealing member at the first outlet end, thereby also establishing a leak-proof coupling. Threading a needle valve into the side outlet of the adapter renders that coupling leak-proof as well.
The entire procedure of uncoupling the conduit, inserting the adapter in place and tightening the coupling elements or removing an installed adapter and restoring the conduit in place can be easily accomplished in less than five minutes, using only a pair of pliers or a small wrench. The adapter of my invention is constructed of sturdy materials which are highly corrosion resistant and should last the lifetime of any plumbing system. Its design and construction are such that it can be marketed at a modest price. It takes the place of more cumbersome and costly alternatives which are known in the prior art and make it possible for any home owner or renter to install an auxiliary appliance in a water line leading to a kitchen or bathroom sink faucet or a toilet tank without the need for any plumbing or other special skills whatsoever. Moreover, if desired, the appliance can be readily removed and the plumbing restored to its original condition just as easily.
DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention may be realized from a consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic elevational view showing the installation of an adapter in accordance with my invention in a water line supplying a plumbing fixture;
FIG. 1A is a partially exploded view of FIG. 1;
FIG. 2 is a perspective view of the adapter of my invention;
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 2, looking in the direction of the arrows; and
FIG. 4 is an exploded view of the adapter of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 1A of the accompanying drawings show an adapter in accordance with the present invention as it would be installed in use. These figures show a typical installation of a flexible water conduit 14 coupled between an angle-stop 16 and a plumbing fixture 12. The angle-stop 16 is connected to a water pipe 18 which extends through a wall 20. The plumbing fixture 12 may be a bathroom toilet in one example, in which case the portion 13 will be understood to represent the bottom of a toilet tank with a threaded portion 26 leading to a ballcock or other valve assembly within the toilet tank. Alternatively, the plumbing fixture 12 may be a bathroom sink faucet or a kitchen sink faucet, in which case the portion 13 represents the segment at the rear of the sink on which the faucets are installed and the threaded portion 26 represents the water inlet to the one of the faucets.
The angle-stop 16 has a handle 22 and a threaded outlet portion 24. The standard flexible conduit 14 comprises a tube 30 having a resilient sealing member 36 and coupling nut 40 on its lower end 32. Similarly, the tube 30 has a resilient sealing member 38 and rotatable coupling nut 42 on its upper end 34. A bearing washer 44 is shown between the seal 38 and nut 42. A similar bearing washer (not shown) is commonly provided on the lower end 32. These washers serve to compress the sealing members 36, 38 as the coupling nuts 40, 42 are tightened on their respective connections 24, 26, thus establishing a leak-proof coupling at each end when the conduit 14 is properly installed. Turning the handle 22 to open the valve of the angle-stop 16 delivers water to the plumbing fixture 12.
As indicated in FIGS. 1 and 1A, an adapter 10 in accordance with my invention is installed between the upper end 34 of the conduit 14 and the plumbing fixture 12. The adapter 10 is so constructed that its lower or inlet end 52 may be coupled to the upper end 34 of the conduit 14 by threading the nut 42 onto the threads 60. Its upper, first outlet end 54 is coupled to the fixture 12 by threading the nut 80 at the upper end of the adapter 10 onto the threaded coupling portion 26 of the plumbing fixture 12.
Structural details of the adapter 10 are shown in FIGS. 2-4. There the adapter 10 is shown with a body 50 having an inlet 52, a first outlet 54 and a second outlet 56. The inlet 52 and outlets 54, 56 are interconnected with a central water passage 58. The inlet end 52 is formed with external male threads 60 extending from a rounded lip 62 at the bottom of the adapter 10 having a beveled inner surface 64. The first outlet 54 is in line with the inlet end 52 while the second outlet 56 extends transversely from a side of the adapter 10.
The upper end of the adapter 10 is formed with a reduced diameter portion 70 terminating in a shoulder portion 72 which extends radially outward from the reduced diameter. This terminates in a beveled surface 24 and serves as a retaining member for a resilient seal 76, bearing washer 78 and rotatable nut 80. The nut 80 is formed with internal female threads suitable for threading on the coupling portion 26 of the fixture 12.
The side outlet 56 has a threaded bore 84 designed to receive a needle valve 86 having a threading coupling 90 which threads into the bore 84 or some other coupling device. The needle valve 86 has another threaded coupling 92 into which a compression fitting 96 on the end of a tube 94 leading to an auxiliary appliance may be installed. The compression fitting 96 comprises a sealing ferrule 98 and a coupling nut 100.
The angle-stop 16 may be of any suitable size. There is a significant variation in sizes of the threaded coupling portion 24. Thus, the flexible conduit 14 is necessarily selected to match the size of the coupling portion 24. On the other hand, the coupling portion 26 of the plumbing fixture 12 is customarily one of only two standard sizes. There is one size for a toilet tank fitting and another size for faucets. Accordingly, the upper end of the flexible conduit 14 is one of only two corresponding sizes. Thus, by placing the adapter 10 in the location shown in FIGS. 1 and 1A the adapter 10 can be made in only two sizes, one to fit onto a toilet tank fitting; the other to fit onto a sink faucet fitting. This advantageously reduces the number of adapters of my invention that must be stocked for suitable inventory.
By virtue of the novel features of my invention and the advantageous results from the use thereof, anyone who so desires is enabled to connect an auxiliary water appliance into existing water lines leading to a sink or toilet without the need for any special skills or knowledge. Products constructed in accordance with my invention are rugged and long lasting. They are esthetically pleasing and yet unobtrusive when installed. They can be manufactured to sell at low cost and are maintenance free. They represent a substantial improvement over alternative approaches to solving the associated problems which are known in the prior art. Finally, the installation of an adapter of my invention does not create any alteration in the plumbing per se, so that if and when it is removed, the plumbing is restored to original condition. This adapter can be installed and removed without violating any building codes or incurring objections from landlords, homeowner associations and the like.
Although there have been described hereinabove various specific arrangements of a plumbing adapter in accordance with the invention for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention as defined in the annexed claims. | A plumbing adapter for installation in series with a flexible conduit leading to a plumbing fixture, such as a toilet tank or a kitchen or bathroom sink. The adapter has a first end suitable for engagement in sealing relationship with the terminal end of the conduit and an opposite, second end configured to engage the coupling portion of the plumbing fixture in sealing relationship. A threaded side extension having an opening communicating with the water passage within the adapter is provided for coupling to an auxiliary appliance through which water is to be supplied. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of co-pending U.S. patent application Ser. No. 10/673,725, filed Sep. 29, 2003, and co-pending U.S. patent application Ser. No. 10/746,465, filed Dec. 24, 2003, from which priority is asserted, and the disclosures of which are herein incorporated by reference in their entirety.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates to a system and method for automated position monitoring and tracking of an object by optical and mechanical means; in particular, scanning an object within a defined zone and utilizing computer-based image processing on a real time basis.
[0004] 2. Discussion of Prior Art
[0005] Monitoring and tracking a laterally moving object is important in many applications. In certain applications, it is desirable to have a tracking device not only to locate the position of the object but also to monitor the movement of the object without any significant delay of information.
[0006] For example, many eye-tracking devices have been recently developed for eye surgery with lasers, in particular, for photo-refractive surgery. A typical photo-refractive surgery scans a UV laser beam on the surface of the cornea to sculpt the profile of the corneal outer surface, one layer at a time. In U.S. Pat. No. 6,179,422, a tracking device is described that employs two scanning beams to scan across a reference mark affixed on the object to be tracked.
[0007] U.S. Pat. No. 5,620,436 discloses the use of a video camera to monitor the eye movements and to determine the position of an aiming beam on the eye. U.S. Pat. No. 5,632,742 utilizes four projecting laser spots on the eye and uses a set of peak-and-hold circuits to determine the position of the eye. In these designs, a ring shaped reference is used for determining the eye position, and spatial stationary infrared beams are applied to illuminate the reference. Sophisticated imaging systems and electronics, such as a CCD camera or four peak-and-hold circuits, are implemented to determine the position of the reference. The ring shape reference area are practically either the limbus of the eye or the iris of the eye; and the whole ring is needed as the reference for determining the eye position.
[0008] Another eye tracking system using infrared light to illuminate the pupil of the eye has been announced by ISCAN, Inc. This system is described as using infrared light to illuminate the eye, with the system then retrieving positioning information to a variety of applications, as e.g. computer control through eye movement as well as for assisting the disabled patient.
[0009] Any of a number of techniques for locating objects can be readily adapted to locate the center of the eye. It has been found desirable to improve the effectiveness and accuracy of such localizing or position determining systems. That is, given an object locating system used in conjunction with an excimer laser system, it has been found desirable to provide means for enhancing the ability of such systems to accurately locate the center of the eye and also accurately aim of the pulsed excimer beam into the eye.
[0010] The disclosures of the aforementioned patents are incorporated herein in their entirety. While these devices fulfill their respective particular objectives and requirements, the prior art does not suggest the novel system for continuously and accurately monitoring or tracking the position and change of position of an object associated with the operational condition of a motor vehicle.
SUMMARY OF THE INVENTION
[0011] The present invention provides a system and method for instantly and continuously defining and monitoring an object associated with the operational condition of a motor vehicle.
[0012] One embodiment of the invention is directed to the system and method of instantly and continuously defining and monitoring the position of the object in association with the operation of a motor vehicle.
[0013] Another embodiment of the invention is directed to a system and method for the real time locating, scanning and tracking of the contour or silhouette of the object located in the vehicle and involved in the operation of said motor vehicle.
[0014] Furthermore, one embodiment of the invention provides real time monitoring of an operator of a motor vehicle by directly scanning and monitoring the eyes or pupils, face and upper torso of the operator of the motor vehicle so as to prevent a breakdown of the operational condition of a motor vehicle at the instance of a faulty, inept, or inattentive operation of said vehicle.
[0015] In accordance with the embodiment of the invention, the system and method serves to prevent faulty or inattentive operation of a motor vehicle by employing intelligent object tracking devices, capable of real time silhouette and eye pupil scanning, monitoring, tracking and real time computer-based image processing.
[0016] The invention also provides an instant operator monitoring system, comprising a contour definition device with a pupil position, location and determination device, which includes: a contour definition device mounted in a vehicle configured to generate an outline of the face/head of the operator of a motor vehicle; a pupil reflex determination device mounted in a vehicle configured to locate the presence of the pupils in a defined zone overlying the outline of the face/head of the operator of a motor vehicle; a device capable of real-time monitoring position of the outline of the face/head of the operator of a motor vehicle while the operator is seated in the operator seat with the engine motor running; a device capable of real-time monitoring of the position of the eye pupils of the operator of a motor vehicle while the operator is seated in the operator seat with the engine motor running; a device capable of real-time tracking of the position of the face/head of the operator of a motor vehicle while the operator is seated in the operator seat with the engine motor running; and a device capable of real-time tracking of the position of the pupils of the operator of a motor vehicle while the operator is seated in the operator seat with the engine motor running.
[0017] One advantageous aspect of the invention provides a scanning system that may be customized to the individual operator.
[0018] Another advantageous aspect of the invention provides a contour or silhouette monitor device that may function separately and/or independently from an eye pupil detecting or localizing device.
[0019] An embodiment of the invention provides a combination of devices capable of adjustingly scanning various normally functional positions, silhouettes or contours for defining a operator operating at different positions or locations in a motorized vehicle.
[0020] The system and method embodiments of the invention provide the capability for monitoring the operational condition of the motor vehicle such as a truck, a bus, a tractor, a crane, a 2- or 3-wheel conveyance, or a motorized water craft.
[0021] The system and method of the invention further provides the means whereby the operational condition is monitored by use of a scanning beam or scanning beams for locating and tracking the presence of the operator in the operator seat.
[0022] The system and method in one of the embodiments of the invention includes determining and monitoring whether the motor vehicle engine is running.
[0023] The system and method for preventing a breakdown in the operation of a motor vehicle provides embodiments wherein the scanning beam for the inventive position monitoring and tracking is generated in the form of: an infrared (IR) beam; radio frequency (Rf) beam; and an ultrasound beam.
[0024] A further embodiment of the invention provides a system and method wherein the silhouette of the operator is defined.
[0025] One specific embodiment of the invention, provides a definition of the operator's silhouette comprising defining the outline of the operator face/head.
[0026] The system and method of the invention provides the capability to store the operator silhouette in memory.
[0027] The system and method of the invention provides the capability to track the operator silhouette for motion or change of position.
[0028] The system and method of the invention provides the capability to track the operator silhouette for any change in its outline.
[0029] The system and method of the invention provides the capability to track the change of the silhouette outline in the form of any change in shape of the silhouette while tracked within a defined zone and any change in position of the silhouette (i.e. lateral, vertical, torsional or oblique) within a defined zone.
[0030] One other embodiment of invention provides a system and method wherein the defined zone comprises an area defined vertically, horizontally and axially within which an operator can safely operate the motor vehicle.
[0031] Another embodiment of the invention includes a system wherein the pupils are detected by scanning beam within the silhouette.
[0032] In this context, the embodiment of the invention may include a system wherein the eye pupils detected within the silhouette are stored in memory.
[0033] Furthermore, the embodiment of the invention may include a system wherein the pupils detected within the silhouette are tracked for the motion.
[0034] More specifically, the embodiment of the invention may include a system wherein the eye pupils detected within the operator silhouette are tracked for any change in its size, shape and/or definition.
[0035] The method according the invention provides a monitoring system, wherein the change of the size, shape and definition comprises any change in size of the pupils, any change in the shape of the pupils, and any change in position of the pupils such in a lateral, vertical, torsional or oblique direction.
[0036] The invention provides a capable embodiment of the instant operator monitoring system may serve as an imminent collision warning system (I.C.W.S.).
[0037] The disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, materials, components, circuit elements, wiring connections and contacts, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The invention providing an instant operator monitoring system as claimed and/or described herein is described below in terms of exemplary embodiments. These exemplary embodiments are described in detail with reference to drawings, which are part of the description of the invention. These embodiments are non-limiting exemplary embodiments, in which like reference numerals represent similar structures throughout the several views of the drawings, and wherein:
[0039] FIG. 1 depicts an exemplary aerial view diagram of a silhouette monitoring system, according to the present invention;
[0040] FIG. 2 depicts an exemplary lateral view diagram of a silhouette monitoring system, according to the present invention;
[0041] FIG. 3 depicts a visualization flow diagram of a silhouette monitoring system, according to the present invention;
[0042] FIG. 4 depicts an exemplary functional block diagram of a silhouette monitoring system, according to the present invention;
[0043] FIG. 5 depicts an exemplary flow diagram of an embodiment defining the steps/processes involved in defining the silhouette and detecting the pupils within the defined zone.
DETAILED DESCRIPTION
[0044] FIG. 1 illustrates an embodiment of the invention. The diagram depicts an exemplary aerial view of an operator 11 with an arrangement to ensure monitoring of the operational condition of the motor driven conveyance on land, water or air. The automatic monitoring system module 15 emits a range of source beam 13 around an area where the operator 11 of the motor vehicle is seated. In this embodiment as illustrated, the emitter 12 is installed in front (elevated position) of the operator. For example, the emitter may be installed on the visor frame of the motor vehicle. The source beam 14 is then transmitted towards the area around the head of the operator of the motor vehicle. The line 13 defines the imaginary boundary of the defined scan zone.
[0045] FIG. 2 illustrates the embodiment of the invention as in FIG. 1 . The diagram depicts an exemplary lateral view of an operator 11 illustrating an arrangement designed to ensure continuous real time monitoring of the operational condition of the motor vehicle. The automatic monitoring system module 15 emits a range of source beams 13 around an area where the operator 11 of the motor vehicle is seated. In this embodiment as illustrated, the emitter 12 is installed in front (elevated position) of the operator. For example, the emitter may be installed on the visor frame of the motor vehicle. The source beam 14 is then transmitted towards the area defined or contoured around the operator of the motor vehicle, including the pupil or face 16 . The line 13 defines an imaginary boundary of the defined scan zone.
[0046] The term motor vehicle in the context of the invention encompasses all kinds of motorized vehicles regardless of whether they are operated on land, underground, on water or in air, wherever the present system is applicable for monitoring the operator or driver of such vehicle or conveyance.
[0047] The source beam may correspond to an RF, ultrasound or an IrDA port, where the RF (radiofrequency) covers an area of about 3 blocks, the ultrasound covers an area of about 4 feet, and an “IrDA” type infrared system generally covers less than 5-10 feet with a proper line of sight. These technologies are described in greater detail below.
[0048] The IrDA specifications, in particular, are intended for high speed short range, line of sight, point-to-point cordless data transfer—suitable for handheld communication devices. Since 1984, “IrDA Data” defines a standard for an interoperable universal two-way infrared light transmission. IrDA technology is already in over 300 million electronic devices including PC's, PDA's, cellular phones, cameras, toys, watches and many other mobile devices. Main characteristics of IrDA signaling include:
Range: Continuous operation between two contacts for at least 1 meter. Bi-directional communication is the basis of all specifications. Data transmission starting from 9600 kbps primary speed going up to 4.0 mbps. Data packets are protected using CRC (from CRC 16 for speeds up to 1.152 mbps to CRC-32 at 4.0 mbps).
[0053] Radio waves are created due to the movement of electrical charges in antennas. As they are created, these waves radiate away from the antenna. All electromagnetic waves travel at the speed of light. The major differences between the different types of waves are the distances covered by one cycle of the wave and the number of waves that pass a certain point during a set time period. The wavelength is the distance covered by one cycle of a wave. The frequency is the number of waves passing a given point in one second. For any electromagnetic wave, the wavelength multiplied by the frequency equals the speed of light. The frequency of an RF signal is usually expressed in units called hertz (Hz). One Hz equals one wave per second. One kilohertz (kHz) equals one thousand waves per second, one megahertz (MHz) equals one million waves per second, and one gigahertz (GHz) equals one billion waves per second.
[0054] RF energy includes waves with frequencies ranging from about 3000 waves per second (3 kHz) to 300 billion waves per second (300 GHz). Microwaves are a subset of radio waves that have frequencies ranging from around 300 million waves per second (300 MHz) to three billion waves per second (3 GHz).
[0055] Further taking reference to FIGS. 1 and 2 , FIG. 3 depicts a visualization diagram of a monitoring embodiment according to the invention. Step 30 —the source beam is activated. Step 31 —the source beam scans for the face/head contour or silhouette. The silhouette scan is capable to generate 3D visual image by means of a source beam. The source beam 14 may be a combination of RF, Infrared, and Ultrasound technology. Step 32 —the pupil determination is performed. Step 33 —the three dimensional image of the scanned surface as defined and delineated by the monitoring module is generated on the parameters provided by the silhouette scan and pupil detection or determination. Step 34 on the base of baseline image generated in Step 33 the scanning, monitoring devices or modules and tracks any changes on occurring on real-time basis. Step 35 —any sudden or dramatic change to the image, an appropriate audio/visual alert is broadcasted. In Step— 36 upon successful acknowledgement, the system returns to the non-alarmed initial stage.
[0056] FIG. 4 depicts a systematic diagram of a scanning/monitoring system embodiment. The power to the monitoring module may be hardwired to conventional AC power lines, to solar panels, to low consumption batteries or a combination of any of these or other power sources. The power supply 49 adapters regulate and supplies the correct voltage to the system. The module has also a provision for secondary power, which can be easily interfaced, via a power interface 48 .
[0057] The device has an onboard microprocessor 52 and is interconnected to the various sub-components such as power adapter 49 and output adapter 51 via a system bus 50 . The system application 53 runs on the processor 52 and provides control and may be used to coordinate the functions of the various components of the system. The system application 53 is stored in ROM 56 . 1 and its sub-functionality can temporarily be made to run from the RAM 56 . 2 increasing the performance of overall system communication.
[0058] The presence of the operator near the monitor module 16 ( FIG. 1 or 2 ) is sensed by a sensor beacon 60 which is connected to a vehicle. Upon successful acknowledgement of the presence of the operator 11 of the motor vehicle (not shown), the system initiates the communication.
[0059] ICWS is equipped with an impact/shock/sound/vibration sensor, which in case of vandalism, accident or in any other designated or emergency situation immediately emits the alert tone. The alert sensor 61 initiates the audio/video transmission based upon the critical information provided by the source beam sensor 58 . All the processed information are logged and saved in the data storage area 57 .
[0060] The source beam 58 is connected via beam emitter 59 . 1 and beam receiver 59 . 2 . In addition to this, both pairs are also capable of producing real-time full motion images from any designated site.
[0061] The instant operator monitoring system has a multi-line LCD panel 55 connected via a display adapter 54 , which is capable of displaying detailed information related to the motor vehicle The source beam sensor 58 differentiates between an incoming signal beam via a beam receiver 59 . 2 and outgoing beam via a beam emitter 59 . 1 .
[0062] FIG. 5 is a flowchart of an exemplary process, in which the is monitoring, tracking and logging the information on real-time basis. In step 70 . 1 , the instant operator monitoring system may initialize itself with the running of the engine motor. In Step 70 . 2 the instant operator monitoring system scan the mode of the vehicle. In Step 71 . 1 the sensor is activated and scans for the operator on the motor vehicle with engine motor running. Step 72 . 1 of the system goes to sleep mode if there is no activity detected within the defined zone.
[0063] In Step 73 . 1 , the active silhouette system scans for the face/head outline and activates pupil determination module 74 . 1 on the real-time basis. Any significant changes or movements tracked within the silhouette or pupils, the alert 78 . 1 is activated. Simultaneously the real-time monitoring and tracking can be recorded on the local storage drive.
[0064] The instant operator monitoring system as described in the various embodiments set forth above, may be provided in the form of a plug-in or a portable module. | A system and method for monitoring the operational condition of a motor vehicle using a silhouette and pupil defining device combined with a capability to analyze and track any changes of the operator's silhouette and of the size, shape and location of the operator's pupils within a defined zone in the motor vehicle. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
This is a continuation-in-part of copending application Ser. No. 782,196 filed Mar. 28, 1977, now abandoned, which is a continuation of application Ser. No. 613,495, filed Sept. 15, 1975, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates generally to the field of precious metal decorations for ceramics and in particular to a decorative composition producing the appearance of gold after firing, but which actually contains no metallic gold.
Decorative compositions for ceramics to achieve a gold appearance have heretofore contained substantial quantities of metallic gold, often of the order of 10-15 weight percent with the balance being fluxing agents and vehicle. Such prior art decorations are disclosed in such patents as U.S. Pat. Nos. 2,994,614 and 3,092,504 which disclose and claim specific gold compounds and compositions which were found useful for decorations having a gold appearance. The maximum gold content is determined primarily by the cost of the gold and the fact that increasing the gold content beyond certain levels does not further improve the appearance. The minimum gold content of such decorations is determined primarily by the poorer adherence and durability of low gold content films and the deterioration in their appearance. It will be appreciated that until recent years gold, although a precious metal, was less expensive than some of the other precious metals. As the price of gold has risen, it has become of interest to reduce the quantity of gold used in decorations since at 4 to 5 times the previous cost the use of gold in decorating compositions becomes prohibitive, except for the most expensive articles.
Palladium has also been used in decorative compositions. In some compositions, it produced a white metal appearance when used in combination with gold, and simulates the heretofore more expensive platinum compositions. In other applications, it has been used to produce a brown color. Thus, in the prior art, palladium has been used both to produce a white color in combination with large amounts of gold, and to produce a brown color when no gold is present. Examples may be found in U.S. Pat. No. 3,216,834, the disclosure of which is incorporated by reference herein, which is principally directed to a new compound of palladium for use in decorative applications. In one example of the patent, a composition containing 1.5 percent palladium, 3 percent silver, and much smaller amounts of rhodium and chromium is shown to produce a chocolate brown color useful for decoration. In other examples, bright palladium decorating compositions are shown to contain large quantities of gold and smaller amounts of palladium. Other patents disclosing palladium compounds useful for decorative applications include U.S. Pat. Nos. 3,718,488 and 3,770,785. The disclosure of U.S. Pat. No. 3,216,834, which is assigned to the assignee of this application, also sets forth a number of the essential oils and hydrocarbon solvents conventionally used in the art.
Palladium has also been used with silver in a film which has the ability to separate gaseous mixtures by hydrogen diffusion through the film. U.S. Pat. No. 3,413,777 discloses such a film which contains an alloy of 5-40 weight percent silver and the remainder palladium, the alloy being mixed with a glaze in the method of forming the desired film.
Silver, when used alone, produces a film having an amber appearance. What has been desired since the cost of gold has increased many-fold is a decoration for ceramics which, while giving the appearance of gold after firing, does not contain substantial quantities of that metal, in order that the cost may be kept at reasonable levels. This objective has been accomplished by the composition and the method of the present invention, in which no metallic gold is used.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a decorating composition for producing a gold appearance after being fired on ceramics which comprises a vehicle containing an organic solvent in which metallo-organic compounds are dissolved. The composition is characterized in that its metal content, in addition to any trace impurities present, consists essentially of
a palladium metallo-organic compound soluble in the solvent;
a silver metallo-organic compound soluble in the solvent; and
a base metal metallo-organic flux compound soluble in the solvent.
The weight ratio, as metal, of the palladium to the silver is in the range of 1:1 to 12:1, the palladium and silver together comprise at least about one percent by weight of the composition, and the base metal flux is present in an amount sufficient to flux the silver and palladium.
In one aspect, the invention provides that the palladium and silver together comprise from about 1 to 12 weight percent of the composition. The weight ratio of palladium to silver may advantageously be in the range of 2.3:1 to 9:1 and the weight ratio of the base metal portion of the flux compound to the combined palladium and silver may advantageously be in the range of about 0.02:1 to 0.2:1.
Another aspect of the present invention provides that the base metal is selected from the class consisting of bismuth, chromium, lead, uranium, tin, iron, titanium, tantalum, zirconium and mixtures thereof. Advantageously, the palladium metallo-organic compound is a palladium salt of carboxylic acid, the silver metallo-organic compound is a silver salt of carboxylic acid and the metal flux metallo-organic compound is a metal salt of carboxylic acid. Most advantageously, the metal compounds are metal neodecanoates.
In another aspect, the invention provides that the palladium metallo-organic compound, the silver metallo-organic compound and the base metal metallo-organic flux compound are selected from the class consisting of metal sulfonates, metal sulfurized resinates, metal mercaptides, metal thioethers, and metal carboxylates.
Another aspect of the present invention provides a method of producing a decoration having a gold appearance on ceramics after firing, the method comprising the steps of preparing a decorating composition comprising a vehicle containing an organic solvent in which metallo-organic compounds are dissolved, and characterized in that the metal content of the composition, in addition to any trace impurities present, consists essentially of:
(1) a palladium metallo-organic compound soluble in the solvent;
(2) a silver metallo-organic compound soluble in the solvent, the weight ratio as metal of the palladium to the silver being in the range of 1:1 to 12:1, the palladium and silver together comprising at least about one percent by weight of the composition; and
(3) a base metal metallo-organic flux compound soluble in the solvent and present in an amount sufficient to flux the silver and the palladium.
The composition of (a) is then applied to the surface of a ceramic material to be decorated and the ceramic material to be decorated is then fired, to produce a film having the appearance of gold on the ceramic surface.
Advantageously, depending on the ceramic material, the firing is carried out at a temperature of between about 500° C. and 800° C.
Generally, in one aspect of the present invention, a gold-free composition is provided which, when applied to ceramics and fired, produces a decoration having a gold appearance. That is, the fired decoration reflects light of such wave lengths that to the human eye it has the yellow metallic appearance characteristic of gold and gold alloys. This composition contains as its principal metallic constituents, minor amounts of palladium and silver in a specific range of weight ratios to produce a gold appearance when the composition is fired on a ceramic. The palladium and silver in the form of solvent-soluble metallo-organic compounds and within the described composition ranges are combined with a suitable flux and vehicles to produce a composition having an appropriate viscosity. Outside these ranges, the color no longer satisfactorily simulates gold-containing decorations and in addition, the film has reduced reflectance or adherence. The gold appearance of the fired decoration of the present invention is particularly enhanced when applied as relatively narrow lines. It is also particularly enhanced when applied to an opaque or translucent ceramic as opposed to a clear transparent ceramic. On clear transparent ceramics some of the gold-like color and luster is lost.
Generally, in another aspect of the present invention, a method for decorating ceramics to produce a gold appearance using the above-described composition is provided. The usual techniques for applying decorative compositions, such as screen printing, rolling, dipping, stamping, spraying, or brushing may be used. Conditions under which the applied coating is fired for removing the vehicles and fusing the remaining residue are determined by the temperature which the substrate will accept, generally between 500° and 650° C. for glass and 650° to 800° C. for other ceramic materials, such as china. As used herein and in the claims, "ceramics" and "ceramic materials" and the like terms include china, dishware, glass and the like.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As indicated above, it has now been found that a combination of palladium and silver within certain narrow ranges of composition produces a decorative composition having the appearance of metallic gold after firing. Outside those ranges, the simulation of gold is unsatisfactory, and the decorative film has reduced reflectance or poorer adherence.
As is known in the art, the composition of the vehicle carring the metallo-organic compounds may be selected from a wide variety of suitable organic solvents in which essential oils may optionally be included. The ingredients and their proportions used in the vehicle are selected, as is known in the art, to adjust the characteristics of the decorating compound before firing. For example, the vehicle may comprise any suitable simple organic solvent, or mixtures of two or more thereof, such as chloroform, carbon tetrachloride, petroleum ether, heptane, kerosene, benzene, toluene, nitrobenzene, methanol, butanol, benzyl alcohol, Cellosolve, butyl Cellosolve, acetone, methyl ethyl ketone, cyclohexanone, ethyl acetate, butyl acetate, ethyl ether, turpentine, terpineol, eugenol, cedrol, amyl acetate, xylene, various terpenes such as pinene, dipentene, and the like. Among the essential oils which may be included are oils of lavender, amyris, rosemary, aniseed, sassafras, wintergreen, fennel, spike, clove and/or camphor.
The vehicle may also include as a tackifier balsams such as Oregon or Canada balsam, i.e., generally, naturally occurring fir tree exudations. Thickened gum turpentine such as obtained by evaporating spirits of gum turpentine may be employed, as well as rosins, gilsonite and any number of synthetic resins.
Plasticizers such as rosin esters may be employed, for example, methyl or glycerol esters of rosin. Suitable rosin esters which have been employed are those sold under the trademarks HERCOLYN and STAYBELITE by Hercules, Incorporated. Phthalates such as diooctyl phthalate and butyl phthalate may also be employed.
Generally, the metallic constituents (palladium, silver and base metal) in compositions of the present invention are present as soluble metallo-organic compounds. The neodecanoates, as shown in the examples, are preferred for ease of availability and low cost. However, other soluble organo-metallic compounds may also be used. For example, any of metal-sulfonates, -sulfurized resinates, -mercaptides, -thio-ethers, and metal carboxylates other than neodecanoates can be substituted for metal neodecanoates.
The palladium component of the composition of the invention, as is true of the silver component and the base metal used as a flux component, must be introduced in a form in which the metal (palladium, silver or flux base metal) is part of a chemical entity which is soluble in the composition. Thus, the palladium compound is introduced in the form of a palladium metallo-organic compound in solution in a solvent. As indicated above, while any suitable palladium metallo-organic compound which is soluble in a suitable solvent may be employed, generally palladium salts of carboxylic acids are preferred, and palladium neodecanoate is most preferred. The silver compound is introduced in a similar form, i.e., as a metallic-organic compound, preferably the silver salt of a carboxylic acid, most preferably silver neodecanoate.
The base metal flux agent, discussed in more detail below, is similarly introduced in the form of a soluble metallo-organic compound of the flux metal, most preferably as the salt of a carboxylic acid. Bismuth neodecanoate is preferred.
In general, branched carboxylic acids are preferred over straight chain carboxylic acids because their reaction products with the metal components of the invention are more soluble in the hydrocarbon solvents than are those of straight chain carboxylic acids.
Characteristics of ceramic decorations of the type provided by the present invention, after firing onto the ceramic surface, are not typically measured by a test method standardized within the industry, but are judged by experience with those color, reflectance, and adherence characteristics are acceptable to purchasers of such decorative compositions. It should be understood, however, that evaluation of color and reflectance, although somewhat subjective, can readily be made when comparing side-by-side samples of various decorations and that those experienced in the art would be expected to concur in such evaluations. Adherence is a more objective quality and is usually judged by rubbing the decoration with a rubber eraser containing abrasive since it is known from experience that such a test correlates well with actual service life.
The following table illustrates the sensitivity of the decorative fired film color, reflectance and adherence to the relative proportions of palladium and silver. All of the compositions shown are identical (and similar to some of the examples given hereinbelow) except for the adjustment of the ratio of palladium to silver. Each composition contained a total of 5 weight percent palladium and silver, since this amount gives particularly good results with a minimum use of these expensive metals. Each was applied by roller topping to the rim of a translucent opal glass saucer and fired at 600° C. before comparison of the film properties was made. It can be seen from the table that palladium alone, without silver, produces a brown colored film with poor adherence. The addition of small quantities of silver are insufficient to change the brown color to gold, but at the composition of 4.5 weight percent palladium and 0.5 weight percent silver, a strong gold color film is produced with good reflectance and adherence. This effect also occurs with a composition containing 4 weight percent palladium and 1 weight percent silver.
TABLE______________________________________Comparison of Palladium - Silver CompositionsWgt. Wgt. Pd:% Pd % Ag Ag Ratio Color Reflectance Adherence______________________________________5 0 -- brown good poor4.8 0.2 24:1 lt. brown good poor4.7 0.3 15.67:1 lt. brown good fair4.6 0.4 11.5:1 dk. golden good good4.5 0.5 9:1 golden good good4.0 1.0 4:1 golden good good3.5 1.5 2.33:1 gold-amber good good3 2 1.5:1 gold-amber good good2.5 2.5 1:1 pale amber fair good2 3 0.67:1 lt. gray poor good1.5 3.5 0.43:1 lt. gray poor good1 4 0.25:1 lt. gray-green dull good0 5 -- amber dull good______________________________________
The color is weakened toward amber when the ratio of palladim to silver is reduced to about 1.5:1, although the reflectance and adherence are still good. At a 1:1 ratio of palladium to silver, the gold appearance has been weakened and the reflectance has been significantly reduced. A ratio of 1 weight percent palladium to 4 weight percent silver produces a green-gray color which is dull and no longer reflective. Also, tarnishing of the film may limit the amount of silver which can be used. Thus, it can be seen that only over a narrow range of compositions can the desired gold appearance be obtained. For a total palladium and silver content of 5 weight percent this range may be more broadly expressed as including compositions between 2.5 and 4.6 weight percent palladium and 0.5 to 2 weight percent silver. The preferred ranges are 3.5 to 4.5 weight percent palladium and 0.5 to 1.5 weight percent silver. Expressed as weight ratios of palladium to silver the broad range is about 1:1 to about 12:1 and the preferred range about 2.3:1 to about 9:1.
Although a total of 5 weight percent palladium plus silver is preferred for rolling application, it has been found that a satisfactory golden appearance can be achieved using both higher and lower total metal contents. Although compositions containing larger metal contents would be more expensive to produce, if such are desired, a golden appearance can be obtained by using palladium/silver weight ratios between 1:1 and 12:1. Metal contents below five percent total of palladium and silver can also be used for roller applications, although a metal content of 4 weight percent is a practical minimum, for machine banding and stamping as limited by reduced abrasion resistance and weakening of the reflective gold appearance.
The foregoing data and discussion is based on compositions suitable for such applications as machine banding and stamping which require a high viscosity mixture, which typically will contain a total of between 4 and 12 weight percent palladium and silver. For other applications which require lower viscosity mixtures, as are typically used for silk screening and brushing, the total content of palladium and silver would be about 2-4 weight percent, and for spraying about 1-2 weight percent. The ratios of palladium to silver would be maintained between 1:1 and 12:1 in such other applications as in the principal exmples.
If corresponding compositions were to be prepared from the prior art using metallic gold, the gold content of such compositions would be about 4-5 weight percent for spraying use, about 8-10 weight percent for brushing and silk screening, 12-15 weight percent for machine banding, and 15-20 weight percent for stamping. Thus, it is clear that in the present invention the total valuable metal content is distinctly lower and the cost of the metals used is less than metallic gold in the present market.
Another important component of the composition of the invention is the flux material, which is typically a soluble metallo-organic compound of a base metal as typically used in the prior art to flux palladium and silver. The fluxes have the property of softening or melting at the firing temperature which, in general, the metallic components do not. They react with the substrate and create an adhesive vitreous layer for the metallic film and at the same time bind the metallic particles in the decorative film thus improving the adherence and abrasion resistance of the fired metal film. Specifically, base metals such as bismuth, chromium, lead, cadmium, uranium, tin, copper, cobalt, antimony, manganese and rhenium are well known in the prior art. Reference may be made to U.S. Pat. No. 3,216,834 previously mentioned. However, not all of the known base metal fluxes are equally useful in the gold appearing decoration of the present invention. In general, those base metal fluxes such as cobalt and copper which form dark metal oxides unduly darken the metal film and/or adversely affect its gold-like luster. Suitable base metals for use as fluxes in the present invention include bismuth (which is most preferred) chromium, lead, uranium, tin, iron, titanium, tantalum and zirconium.
In a preferred embodiment, a metallo-organic bismuth compound, for example, bismuth neodecanoate is used. In the typical decorative compositions for roller topping, the bismuth content is preferably about 0.5 weight percent. Expressed more generally, the weight ratio of bismuth to the combined palladium and silver would typically be in the range of about 0.02:1 to 0.2:1, with a preferred weight ratio of bismuth to the sum of palladium and silver, i.e., Bi:(Pd+Ag), of about 0.1:1 (based on metal content).
Some typical decorative compositions which provide efficacious embodiments of the invention are given in the following examples.
EXAMPLE 1
______________________________________ Weight Percent______________________________________Resin in essential oil 47.17Palladium neodecanoate in solutionin (15% Pd) 26.42Resin ester (plasticizer) 7.55Balsam (tackifier) 5.66Silver neodecanoate in solution(25% Ag) 3.77Organic hydrocarbon solvent (diluentfor viscosity adjustment) 7.55Bismuth neodecanoate in solution(26% Bi) 1.89 ˜100.00______________________________________
The proportions given in EXAMPLE 1 provide a rather viscous composition, well suited for machine roller application to a ceramic material. For spray or brush application, further dilution of the composition of EXAMPLE 1 half and half by weight with toluene, xylene or some other suitable solvent would produce a composition of suitably lower viscosity.
EXAMPLE 2
The composition of Example 1 in which the ingredients are as follows:
The "Resin in essential oil", is gum rosin in dipentene.
Each of palladium-, silver-, and bismuth neodecanoate is in solution in toluene.
The "Resin ester" is rosin methyl ester.
The "Organic hydrocarbon solvent" is toluene.
EXAMPLE 3
The composition of EXAMPLE 1 in which the ingredients are as follows:
The "Resin in essential oil" is gilsonite in oil of spike.
Each of palladium-, silver-, and bismuth neodecanoate is in solution in xylene.
Dioctyl phthalate is substituted for the "Resin ester".
The "Organic hydrocarbon solvent" is xylene.
EXAMPLE 4
In any one of EXAMPLES 1-3, the silver and/or palladium and/or bismuth neodecanoate may be substituted for by any of the following, in which "Met." is silver or palladium (II) or one of the base metal fluxes.
______________________________________In General Specific Example______________________________________Met. mercaptide Met. tertiary nonyl mercaptide " Met. tertiary dodecyl mercaptideMet. sulfurized balsams Met. sulfurized pinenegenerally, e.g., Met. terpenehydrocarbonsMet. sulfonates Met. toluene sulfonate " Met. xylene sulfonateMet. carboxylates Met. 2-ethylhexoateMet. thioethers Met. bis-di-n-butyl sulfide______________________________________
Different types of silver or palladous (or base metal) compounds may be employed in the same composition so long as they are compatible with each other, i.e., will not react to form a precipitate or have other undesirable effects. Some suitable specific compounds useable in accordance with the present invention are:
Silver tertiary nonyl mercaptide
Silver tertiary dodecyl mercaptide
Silver naphthenate
Palladium sulfurized abalyn
Palladium sulfurized turpentine
Palladium 2-Ethylhexanoate
Bismuth rosinate
Bismuth naphthenate
Bismuth 2-Ethylhexanoate
Each of these may be employed in any of EXAMPLES 1-3. Generally, toluene is preferred as a solvent, and tackifiers and plasticizers are selected to suit specific jobs and conditions.
The solvent and resins serve to form a paste or ink-like material and they are added as required to adjust the viscosity needed for particular applications. Generally, it is known in the art that compositions in the range of 50-100 poise are suitable for screen printing, machine lining, rolling, and stamping applications. On the other hand, for spraying or brushing more dilute solutions are applied. Typically, these may have a viscosity of the order of 1 centi-poise. The relative proportion of the metallic constituents remain the same but they are diluted in the formulation in order to adjust the handling qualities of the resulting solution.
After being applied to a ceramic article, the composition of the present invention may be fired at temperatures typical of those of the prior art, glass being fired typically at between about 500° C. and 650° C. and china, between about 650° C. and 800° C. During firing, the organic materials are substantially decomposed and removed, leaving behind a composition which consists essentially of finely divided particles of palladium and silver in a base metal oxide binder.
The resulting fired film gives a gold appearance when the proportions of palladium and silver are properly selected in accordance with the teaching of the invention. Owing to its relatively low cost, the decorative composition of the invention can be applied to many inexpensive applications where gold decorations using the traditional high gold content compositions would be too costly.
The gold appearance of films formed according to the invention is particularly pronounced with narrower lines and an opaque or translucent material. However, the decoration always gives a golden color. The high reflectance property of such films appears to enhance the appearance of bright metallic gold when applied in narrower widths.
The foregoing description of the preferred embodiments is for illustration of the invention only and not to limit the scope of the invention which is defined by the claims which follow. | A decorative coating for application to ceramics contains no metallic gold but has the appearance of gold after firing. The coating is formed by dissolving solvent-soluble metallo-organic compounds of palladium, silver, and a fluxing agent in a vehicle. A weight ratio of palladium to silver of between 1:1 and 12:1 is used and the total content of palladium and silver in the coating as applied will range between 1 and 12 weight percent, the balance being fluxing agents and vehicle. When applied to opaque or translucent ceramic bodies and fired in the usual manner for such decorations, the appearance obtained previously only with decorations containing substantial amounts of metallic gold is simulated. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 10/965,384, filed on Oct. 14, 2004, the entire contents of which is incorporated fully by reference herein.
BACKGROUND OF THE INVENTION
In the case of sporting arms with ball-like ammunition, so-called paint balls, the general problem is feeding the balls into the projectile chamber of the arm. In the simplest version, a magazine is mounted above the projectile chamber, from which the individual balls enter the projectile chamber through the force of gravity.
Also known is U.S. Pat. No. 6,327,953, whose disclosure is herewith included in the disclosure of the present application and whose characteristics are part of the disclosure of the present application. There, the magazine is arranged at a distance from the arm; it is carried in any other place. The transport of the ammunition from the magazine to the arm is by way of a long, flexible feeder tube not impairing the maneuverability of the arm. A motor-driven feeder exercises mechanical pressure on the balls so that the tube is constantly filled with balls and that new balls enter the feeder tube when the first ball is fed into the projectile chamber. To avoid constant operation of the motor, the motor transmits the traction to the feeder via a spring element. The spring element stores the traction force of the motor in such a way that balls can be transported into the ball chamber with the spring tension alone. This allows intermittent operation of the motor. The motor switches off when the spring element is loaded and switches on again only when the spring tension is used for feeding balls. The disadvantage of this type of construction is that controlling of the motor is difficult. If the motor does not switch off on time once the spring element is loaded and therefore the entire traction force is transmitted to the balls, there is the risk that individual balls will explode. The storage device is then no longer operational.
The invention concerns a storage device to reduce operational impairment from exploded balls. On the one hand, the purpose is to reduce the probability of damage to the balls, on the other hand-should the balls explode after all-the purpose is to restore operational readiness as soon as possible.
SUMMARY OF THE INVENTION
The solution according to the invention lies in features which provide for a device for storing balls and for feeding said balls into the ball chamber of a hand gun. A ball container is used for storing the balls, having a feeder tube attached to it which leads to the arm. A feeder is provided for feeding the balls into the feeder tube, the feeder being driven by a motor. When the motor is switched off, a spring device helps maintain the feeding pressure on the balls inside the tube whose spring travel is at least the magnitude of the diameter of the ball. This ensures that immediately following a discharge and opening of the projectile chamber, the spring tension pushes the next ball into the projectile chamber, this process not requiring any previous switching on of the feeder motor. The traction force of the motor which ensures the rotation of the feeder is transmitted to the feeder via a slip clutch, that limits torque transmission.
The slip clutch can comprise a transmission element and a spring element. The spring element is connected with the feeder in such a way that any rotation of the spring element causes a rotation of the feeder. For transmitting the force from the transmission element to the spring element, the transmission element is equipped with a number of protrusions. The protrusions are arranged concentrically with respect to the axle, at a distance from same. On one end, the spring element has a protrusion that bears against one of the protrusions of the transmission element. The transmission element is connected with the drive shaft of the motor and is set in motion by same. The rotation of the transmission element is transmitted to the feeder via the spring element.
The protrusions of the spring element and/or the protrusions of the transmission element are of a flexible kind. If the power transmission from the protrusions of the transmission element to the protrusion of the spring element becomes too great, the flexible protrusion bends in the direction of the force. The protrusions slip past each other and the protrusion of the spring element comes to bear on the next protrusion of the transmission element. This way, the torque that can be transmitted from the motor to the feeder is limited. The torque threshold at which the protrusions slip past each another, is set in such a way that the balls are not damaged.
Instead of providing one protrusion at the spring element and a number of protrusions on the transmission element, there is the other option of equipping the transmission element with one protrusion and the spring element with a number of protrusions, or equipping both with a number of protrusions. Nor is it absolutely necessary to reserve the feature of flexibility only to the transmission element. In fact, all protrusions may be flexible; however, either the protrusions of the spring element or those of the transmission element must be flexible.
If a ball is damaged in spite of these devices for limiting the force, for example in the case that said ball had a flaw, the storage device is to be restored to operational readiness as quickly as possible. For this, the feeder is connected through a bayonet-like connection with the drive element under load from the spring. This way, the feeder can be removed from the ball chamber with one manipulation, and the remainders of the destroyed ball can be simply removed from the ball chamber.
In general, loading the spring by the drive motor has the effect that the position of the protrusion of the feeder element changes in relation to the protrusion of the transmission element. The effect of this could be that the maximum possible power transmission from the spring element to the transmission element changes. In order to maintain the same position of the protrusions relative to one another, a distance holder can be provided. The distance holder swings freely around the same axle as the transmission element, thereby keeping the protrusion of the spring element at a constant distance from the axle.
It is essential that the ball, which is driven by the feeder into the feeder tube, moves along a defined path. If the ball is not on the defined path there is the risk that the ball is pushed against the edge of the entrance to the feeder tube instead of entering the feeder tube. The force of the feeder can damage the ball. To minimize the risk of damage the device can comprise a flexible element above the feeder adjacent to the feeder tube. The flexible element is fixed to the ball container with its one end. A ball that is not in the correct position relative to the feeder touches the flexible element, before it is pushed against the edge of the feeder tube. The flexible element deflects the ball back into the ball container.
As there is enough energy stored in the spring element for feeding the balls into the projectile chamber, it is not necessary for the motor to run all the time. Therefore, a device can be provided for intermittent switching-on of the motor, i.e., a device switching off the motor when the spring element is loaded, and switching it on again only when the spring element has transmitted energy to the balls. For all practical purposes, the device for intermittent switching on is dependent on the movement of the balls inside the feeder tube. The spring element transmits its force to the balls in the feeder tube; consequently, the movement of the balls in the feeder tube is a measure for the energy used by the spring element. The movement of the balls in the feeder tube is preferably determined by means of a sensor that is arranged on that end of the feeder tube which is adjacent to the hand gun. This sensor transmits a signal to the drive motor when it detects a movement of the balls.
The feeder can transport balls effectively only when it is ensured that the balls arrive in the feeder areas of the feeder. If the feeder is a rotary feeder in which the feeding chambers are located at the perimeter, a cone-shaped protrusion can be provided on the upper side of the feeder. Balls lying on this protrusion roll down its sides and come to rest in the feeder chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is described below with reference to the figures in the annex, wherein:
FIG. 1 shows the device according to the invention when being in use;
FIG. 2 shows the partially sectioned ball container and feeder;
FIG. 3 shows a transversal section through the ball container, looking towards the feeder;
FIG. 4 shows a lateral view of the transmission between the drive motor and the feeder;
FIG. 5 shows a view of the connection or clutch from below; and
FIG. 6 shows the view in FIG. 5 in a different operating position of the connection or clutch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to FIG. 1 , a shooter uses an arm 1 , for example an air gun for so-called paint balls, which is connected with a ball container 3 containing balls 14 , through a flexible feeder tube 2 . The balls 14 are fed in a continuous process through a feeder 8 (to be described below) to the projectile chamber of the gun 1 . In this process, they are under pressure from a spring, so that every time a ball is fired and the empty projectile chamber opens, a new ball is fed from the feeder tube 2 into the projectile chamber. The ball container 3 is attached to the belt 4 of the shooter.
According to FIG. 2 , the ball container 3 is of a cylindrical shape and provided with a cover lid 5 connected with a pressure plate 7 via a schematically indicated tension spring 6 . The pressure plate 7 , under the impact from the spring 6 , pushes the contents of the container away from the open end of the container, shut by the lid, to its other end. At this other end is the feeder 8 that feeds the balls into the discharge canal 9 of the ball container 3 which is connected to the input end of the feeder tube 2 . The feeder 8 is driven by an electric motor 28 , shown schematically in FIG. 4 , via a slip clutch 17 , 18 , 19 that will be described below. The motor 28 is supplied with power from a battery (also not shown) that is arranged in a suitable place. The container can be hooked onto the belt 4 of the shooter by means of hooks 12 . In addition, a connector device 13 can be provided for the optional attachment of the container 3 to the arm 1 .
The pressure plate 7 ensures that the balls contained in the container can be fed into the feeder in any position of the container 3 .
According to FIGS. 2 and 3 , the container 3 is in the shape of a disk that is concentrically arranged in the cylindrical ball container 3 . By rotating the feeder 8 in the direction of the arrow 10 , the balls 14 in the feeder chambers 11 located at the periphery of the feeder 8 are fed into the discharge canal 9 of the ball container 3 . The balls in the ball container 3 are pressed by the pressure plate 7 against the upper side of the feeder 8 . The feeder 8 has a conical surface 15 , so that the balls, under pressure from the pressure plate 7 , are deviated outward to the feeding chambers 11 . This ensures that the feeding chamber 11 from which a ball was fed into the discharge canal is immediately filled with a new ball. The rear part of the feeding chamber 11 , which pushes the ball in the direction of the discharge canal 9 , is preferably shaped in such a way that the ball is pushed simultaneously outward toward the wall of the ball container 3 and downward toward the bottom of the ball container, so that the ball moves along a defined path in the direction of the discharge canal 9 .
Above the discharge canal 9 a flexible element 26 is fixed with its one end to the wall of the ball container 3 . The lower end of the flexible element 26 is located at the same height as the upper end of the entrance to the discharge canal 9 . A ball, which is not in the correct position within the feeding chamber 11 and projects over the upper end of the feeding chamber 11 , touches the flexible element 26 , before it is pushed against the edge of the feeder tube. The flexible element deflects the ball back into the ball container 3 .
At the start of operation, the feeder 8 feeds balls in the direction of the discharge canal 9 until the feeder tube 2 is completely filled. When the feeder tube 3 is completely filled, the feeder 8 continues to exercise pressure on the series of balls, so that, under this pressure, the ball chamber of the arm 1 fills again immediately after a shot has been fired. The pressure exercised by the feeder 8 on the series of balls must be calculated in such a way as to be sufficient for feeding into the ball chamber, but must not be so great that the balls would explode from the pressure. For this purpose, the ball container 3 is equipped with the connection or clutch according to the invention as shown in FIGS. 4 to 6 .
The drive motor 28 drives a drive shaft 16 on which are arranged, concentrically one on top of the other, a transmission element 19 , a distance keeper 18 , a spiral spring 17 and the feeder 8 . The transmission element 19 is firmly connected with the drive shaft 16 ; the distance keeper 18 , the spring element 17 and the feeder 8 are journaled on the drive shaft 16 in such a way that they can be freely rotated relative to the drive shaft 16 . The spiral spring 17 , being the spring element storing the energy necessary for feeding the balls, is connected with its inner end 25 with the feeder via a bayonet-like link.
As shown in FIGS. 5 and 6 , the transmission element 19 is disk-like and comprises protrusions 20 that are arranged at the periphery of the disk.
At its outer end, the spiral spring 17 has a pin 21 which, being a protrusion, bears on one of the flexible protrusions 20 of the transmission element 19 . When the shaft 16 is put in rotation by the motor 28 , the flexible protrusion 20 of the transmission element 19 transmits this rotation to the pin. The feeder 8 is also put into rotation together with the spiral spring 17 , feeding the balls 14 into the discharge canal 9 of the ball container. If the feeder tube 2 is filled with balls 14 , both the feeder 8 and the spiral spring cannot rotate any further. The pin bears on the flexible protrusion 20 in a stable position; the remaining drive energy of the motor 28 that is transmitted to the spiral spring 17 via the transmission element 19 , is stored in the spiral spring 17 . The spiral spring 17 coils up, thus decreasing the diameter of the coils. In order to avoid that the pin 21 is also pulled radially inward, the distance keeper 18 is arranged between the spiral spring 17 and the transmission element 19 . The distance keeper 18 is in the shape of a disk and has a recess 22 in its periphery, in which the pin 21 comes to rest. The distance keeper 18 prevents the pin 21 from being pulled inward; the pin 21 always bears on the same position on the flexible protrusion 20 .
While the spiral spring 17 is increasingly loaded by the rotating shaft 16 , the force being transmitted by the flexible protrusion 20 to the pin 21 also increases. The flexible protrusion 20 bends under this load in the direction of the force. The position of the pin 21 relative to the flexible protrusion 20 in the case of a small force being transmitted is shown in FIG. 5 , in the case of a large force, in FIG. 6 . At a certain threshold value of the force, the flexible protrusion 20 is bent to such an extent that the pin 21 slips past it and, pushed by the energy stored in the spiral spring, jumps on to the next protrusion 20 . The threshold at which the pin 21 starts slipping is calculated in such a way that the pressure exerted on the series of balls 14 in the feeder tube 2 by the feeder 8 is too small to damage the balls 14 .
In order to save energy, the drive motor 28 does not run continuously, but essentially only when balls 14 are being transported. For this purpose, a sensor 23 is arranged on an adapter 27 through which the feeder tube 2 is connected with the gun 1 . The sensor 23 determines whether, at a given moment, balls 14 are being transported through the feeder tube 2 . If no transport is taking place, the sensor 23 transmits a signal to the receiver 24 arranged on the ball container 3 . The receiver 24 allows the motor to run for another 1sec. in order to ensure that the spiral spring is fully loaded, and then switches off the drive motor 28 . If the balls 14 start moving again through the feeder tube 2 , the sensor 23 sends another signal to the receiver 24 , where-upon the receiver 24 activates the motor once again.
If, in spite of this limitation of force, a ball 14 should explode, the contents of the ball is spilled across the bottom of the ball container 3 . In order to restore the storage device to operability, the ball container 3 must be cleaned and the contents of the ball 14 wiped off. In order to facilitate the task, the feeder 8 , as shown in FIG. 3 , is detachably connected with the drive shaft 16 . For this purpose, the feeder 8 is stuck on the drive shaft 16 from above. During this process, the inner end 25 of the spiral spring 17 locks like a bayonet into a recess in the feeder 8 , thus preventing counter-rotation. The type of transmission element 19 described here, in which the flexible protrusions 20 are arranged at the periphery, is only one of several possible embodiments. Another option would be to give the entire transmission element a ring shape and to direct the protrusions inward or to direct the protrusions from the transmission element in an axial direction. It is also possible, within the frame of an equivalent solution, to arrange only one protrusion on the transmission element and to compensate by arranging a plurality on the spring element. In addition, depending on the purpose, it is possible to provide flexibility only to the protrusions of the spring element or to both the protrusions of the spring element and those of the transmission element. | The invention relates to a device for feeding ball-like ammunition, so-called paint balls, into the projectile chamber of a sporting arm. The magazine is arranged separately from the arm and is connected to same by a feeder tube. A feeder driven by a motor feeds the balls from the ball container into the feeder tube. Traction from the motor is transmitted via a connection or clutch which can consist of a flexible member and a transmission element. Protrusions are arranged on both the flexible member and the transmission element, which come to bear on each other for transmitting traction. The protrusions are at least partially flexible, so that the transmitted force is limited. This way, explosion of the balls from excessive pressure is prevented. In addition, the feeder is detachably connected to the drive element by means of a bayonet-like connection to facilitate the cleaning of the ball container. | 5 |
DESCRIPTION
1. Field of the Invention
The present invention relates to a disposable hygienic support for cleaning and drying reactive diagnostic strips which are commonly used, not only in medical analysis laboratories, but also in hospital departments, in medical out-patients departments and also in the patient's home.
2. Background of the Invention
As is known, such strips are supports of synthetic material, at one end of which a surface is fixed, referred to as the reactive surface, on which the chemical system on which the reaction is based has been absorbed or adsorbed. At the moment of use, such surface is bathed, by immersion or by dripping, with the biological material to be examined (blood, urine, serum, plasma, etc.). Such material remains on the reactive surface for the time determined by the method, after which it is removed, drying the strip with absorbent material, or dripping or washing with water, depending upon the type of reaction which takes place on the strip. Subsequently the reaction proceeds, generally developing a colour on the said reactive surface in proportion to the concentration of the substance to be assayed.
Some of the instances of use of these reactive strips involve the risk that extraneous persons (particularly the operator) and the environment (particularly the surfaces on which the test are undertaken) will become contaminated with the biological material to be examined, thus involving the danger of infection and contamination. There has been constantly increasing awareness of the need to provide protection systems which are simple to use and involve low cost, which permit the avoidance, or at least the greatest possible limitation, of the risks of infection and contamination, this need being emphasized, above all, following the deepening of awareness concerning the diffusion routes of particularly serious diseases, such as viral hepatitis and Aids.
The object of the present invention is therefore to provide an adequate protection, both for environments and for operators, whether in the health sector or not, from the risk of contamination with biological material during certain phases of implementation of the tests using the reactive strips.
SUMMARY OF THE INVENTION
This object is achieved with the disposable hygienic support for cleaning and drying reactive diagnostic strips according to the invention, characterized in that it is composed of a substantially rigid outer covering, in particular formed by a flat element folded into two parts along an intermediate ribbing line, within which there is anchored an element of absorbent material accessible from at least two opposite ends of the said covering to permit the passage of the said strips through the latter both at the time of the arrangement of the strip in such a manner that its reactive surface is on the outside, and on removing the said surface after a predetermined time of reaction with the biological material, in such a manner as to permit the cleaning and the drying thereof with the absorbent element contained within the covering.
DESCRIPTION OF THE DRAWINGS
The invention will now be illustrated in greater detail by the description, which follows, of one of its embodiments, on an exemplifying and not-limiting basis, given with reference to the accompanying drawings, in which:
FIG. 1 shows a hygienic support according to the present invention, in which a reactive strip ready for use has been inserted on an exemplifying basis;
FIG. 2 is a profile view of the support according to FIG. 1;
FIG. 3 illustrates the support of FIG. 1 in the open condition.
DESCRIPTION OF A PREFERRED EMBODIMENT
With reference to the aforementioned figures, 1 indicates a covering of substantially rigid or semirigid material formed by a flat element folded into two parts 1a and 1b along a preprinted transverse ribbing line 2. The flat element 1 may be constructed, for example, of card which is preferably externally plasticoated, in order to impart thereto a sufficient impermeability. On the internal face of the two parts of the flat element 1, for example on the internal face of the part 1b, there is fixed an absorbent element 3 (for example cotton, gauze, cellulose in general, synthetic material and the like). Along the two free sides of the two parts 1a and 1b, parallel to the ribbing line 2, there extend two tabs 4, by means of which the two aforementioned parts of the flat element 1 are closed, for example by means of adhesive, in such a manner as to form a substantially tubular covering which is pressed down, in the present embodiment, within which the absorbent element 3 is contained. A projected edge 5 is then provided along one of the remaining sides of the part 1 a of the flat element 1, i.e. that to which, in the present embodiment of the invention, the absorbent element 3 is not fixed. Finally, the part 1b, to which the absorbent element 3 is fixed, exhibits a further intermediate transverse fold line 6, as a result of which the part 1b assumes a shape which is substantially that of an inverted V broadly opened out towards the internal face of part 1a.
In the use of the hygienic support according to the invention, a reactive strip S is inserted within the flat element 1 which has been folded and closed, and in particular between the internal face of the part 1a and the absorbent element 3 fixed to the internal face of the part 1b. The insertion is facilitated by the fact that the part 1b is V-shaped, as a result of which, centrally, the absorbent element 3 is not compressed against the internal face of the part 1a. The reactive surface R of the strip S is positioned in correspondence with the edge 6, which consequently acts as support for the same, while the part 1a itself serves as sliding base for the strip S. After the organic material has been deposited on the reactive surface R, and the predetermined reaction time has elapsed, the strip S is extracted from the covering in such a manner that the reactive surface R slides in contact with the absorbent element 3, which cleans it and dries it. During the removal of the strip S, in order to ensure an improved contact with the absorbent element 3, it is expedient to press the part 1b centrally against the part 1a, in correspondence with the fold line 6. Once removed, the strip S is perfectly cleaned and dried and ready for the completion of the reaction, while the covering 1 is thrown away.
It may be advantageous to provide on the part of the covering 1 to which the absorbent element 3 is fixed (the part 1b, in the embodiment illustrated here) a liftable edge 7 taken along the transverse fold line 6 in correspondence with the margin close to the projecting edge 5, on which rests the portion of the strip S carrying the reactive surface R. In this way, even in the presence of reactive surfaces of solid thickness, the entrance of such surface R between the part 1a and the absorbent element 3 is not obstructed. By virtue of this expedient, moreover, the contact pressure which the absorbent element exerts on the reactive surface R is substantially constant from one test to the other and independent of the pressure exerted by the operator. It must, in fact, be borne in mind that, while the operator presses on the zone 8 of the support, which zone is indicated by the broken line in FIG. 1, the cleaning of the reactive surface R takes place almost exclusively in correspondence with the absorbent area portion 3 underneath, or near, the liftable edge 7. This ensures a marked reliability of the results of the tests.
In particular, when the reactive strip is used for tests on blood, a drop of which is generally taken from a finger, the part 1b may exhibit an opening in correspondence with the zone 8. From such opening a portion of the absorbent element 3 underneath is accessible, which can therefore be used to clean the point where the blood is taken. In this case, the absorbent element may be formed by two distinct elements, one of which is applied in proximity to the liftable edge 7 and intended to clean the reactive strip, and the other applied in correspondence with the opening 8 to clean the finger.
Clearly, the configuration and the dimensions of the disposable hygienic support according to the present invention, illustrated above, are purely exempliflying and indicative, and it is clear that this may be implemented in any tubular or non-tubular conformation (for example folding) provided that it is suitable for the positioning of a reactive strip and for its subsequent cleaning and drying by means of contact with an absorbent element contained therein. The covering 1 may then be constructed of any suitable material, provided that it has sufficient rigidity and, preferably, impermeability, such as, for example, polystyrene, PVC, tin foil, possibly covered with PVC, etc. The absorbent element 3 may also be impregnated with chemical substances of various types, which are suitable, for example, to react with the reactive surface or with other specific properties.
The disposable hygienic support according to the invention may be supplied in packs containing one or more units, possibly contained in cellophane-wrapped bags. Moreover, the hygienic support according to the invention may advantageously be supplied in combination with the reactive strip in suitable packs in foil, already inserted into the support and ready for use.
The invention is not limited to the embodiment described and illustrated above, but includes any variants of implementation thereof. | A disposable hygienic support for cleaning and drying reactive diagnostic strips, these strips exhibiting a reacting surface portion in contact with which a fraction of biological material to be analyzed is placed. The support comprises a substantially rigid covering (1) and an element of absorbent material (3) fixed therein. The element is accessible from at least two opposite ends of the covering to permit the insertion of the strip, in such a manner that its reactive portion is on the outside, and the removal of the latter by passing the absorbent element through after a predetermined time of reaction between the reactive portion and the biological liquid. The invention provides a very useful article for handling diagnostic strips in safety conditions. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to non-animal polymer compositions suitable for film forming, particularly hard and soft capsules, comprising water soluble cellulose ethers, hydrocolloids and sequestering agents.
[0003] 2. Description of Related Art
[0004] Capsules are widely used in the pharmaceutical industry as well as in the health food supplement market. The main usage thereof is as dosage form for solid, semi-solid, liquid, pellet or herbal preparations. A primary objection of these dosage forms is to have a good disintegration after being administered in order to enable an effective dissolution of the active substances in the appropriate digestive organ. Consequently, this disintegration characteristic has to remain stable over time when finished products are stored prior to use.
[0005] The traditional material for forming the capsule shell is gelatin, because it has the correct and quite ideal properties. Nevertheless, gelatin has some disadvantages which make it necessary to have other capsule shell materials available. A major unfavorable aspect is the animal origin of gelatin. Other disadvantages are the inconveniences of relatively high water content (10-17%) and the loss of elasticity with decreasing water content. Furthermore gelatin capsules are sensitive to heat and humidity which affects the usability of the product. In particular, soft gelatin capsules are known to aggregate under hot and humid conditions. Under dry conditions gelatin films may induce static charge build up affecting later processing.
[0006] As a gelatin substitute the use of water soluble film forming cellulose derivatives is widely described in the literature. Reports of capsules made from cellulose derivatives refer to poor disintegration in vivo especially when compared with gelatin. To overcome this drawback in EP0714656 it is suggested to use hydroxypropylmethylcellulose (HPMC) with a viscosity of 2.4 to 5.4 centistokes in 2% aqueous solution at 20° C. with carrageenan as gelling agent and calcium or potassium ions as co-gelling agent. However the very low viscosity of HPMC resulting from lower molecular weight chains induces higher film brittleness. Furthermore, the use of this composition results in an undesirable loss of transparency of the film. Attempts to improve transparency are disclosed in EP0592130 by exposing HPMC to UV radiation prior to capsule processing.
SUMMARY OF THE INVENTION
[0007] It has been found that a polymer film composition for capsules wherein the ratios of cellulose ethers, hydrocolloids and sequestering agents are 90 to 99.98% by weight of a cellulose ether or mixture of cellulose ethers with a water content of 2 to 10%, 0.01 to 5% by weight of a hydrocolloid or mixtures of hydrocolloids, and 0.01 to 5% by weight of a sequestering agent or agents do not have the mentioned disadvantages.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] Suitable cellulose ethers for the present invention are alkyl- and/or hydroxyalkyl substituted cellulose ether with 1 to 4 carbon atoms in the alkyl chains, preferably methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethylmethyl cellulose, hydroxyethylethyl cellulose, hydroxypropylmethyl cellulose or the like. Especially preferred is HPMC. The amount of the cellulose ether or mixture of cellulose ethers is preferably 95 to 99.98% by weight. The viscosity of the cellulose ether or blend is 3 to 15 cps in 2% aqueous solution at 20° C., preferred 5 to 10, especially preferred 6 cps.
[0009] Suitable hydrocolloids include such items as synthetic gums which are capable of gelling without the addition of alkaline or alkaline earth metal ions. The preferred gum for this purpose is gellan gum. Such gum, particularly including gellan gum, may be combined in mixtures producing synergistic properties which mixtures may also include natural seaweeds, natural seed gums, natural plant exudates, natural fruit extracts, bio-synthetic gums, bio-synthetic processed starch or cellulosic materials. More specifically, the mixture may include alginates, agar gum, guar gum, locust bean gum (carob), carrageenan, tara gum, gum arabic, ghatti gum, Khaya grandifolia gum, tragacanth gum, karaya gum, pectin, arabian (araban), xanthan, gellan, starch, Konjac mannan, galactomannan, funoran, and other exocellular polysaccharides of which are preferred the exocellular polysaccharides, such as xanthan, acetan, gellan, welan, rhamsan, furcelleran, succinoglycan, scleroglycan, schizophyllan, tamarind gum, curdlan, pullulan, dextran. The amount of gum present is preferably 0.01 to 2% by weight and especially preferred 0.1 to 1.0%.
[0010] The preferred sequestering agents are ethylenediaminetetraacetic acid, acetic acid, boric acid, citric acid, gluconic acid, lactic acid, phosphoric acid, tartaric acid or salts thereof, methaphosphates, dihydroxyethylglycine, lecithin or beta cyclodextrin and combinations thereof Especially preferred is ethylenediaminetetraacetic acid or salts thereof or citric acid or salts thereof The amount is preferably 0.01 to 3%, especially 0.1 to 2% by weight.
[0011] The sequestering mechanism can be adjusted by addition of either monovalent or divalent cations, such a Ca++, Mg++, K+, Na+, Li+, NH 4 + or the like.
[0012] Capsules or films with the inventive polymer composition may be manufactured with conventional machines by the conventional processes like extrusion moulding, injection moulding, casting or dip moulding.
[0013] The capsules and films have a non-animal polymer composition, an improved dissolution behavior, an enhanced elasticity and show higher transparency. The enhanced elasticity makes the capsules more useful for inhalation products. Furthermore the capsules are not sensitive to formaldehyde, for e.g. from a contaminated fill and they have a better temperature stability compared to gelatin capsules, because a crosslinking at storage on elevated temperatures does not occur.
[0014] The inventive polymer composition may contain additionally acceptable plasticizers in a range from about 0 to 40% based upon the weight of the cellulose ether. Suitable plasticizers are polyethylene glycol, glycerol, sorbitol, sucrose, corn syrup, fructose, dioctyl-sodium sulfosuccinate, triethyl citrate, tributyl citrate, 1,2-propylenglycol, mono-, di- or triacetates of glycerol, natural gums or the like as well as mixtures thereof.
[0015] The inventive polymer composition may contain in a further aspect additionally pharmaceutically or food acceptable coloring agents in the range of from about 0 to about 10% based upon the weight of the cellulose ether. The coloring agents may be selected from azo-, quinophthalone-, triphenylmethane-, xanthene- or indigoid dyes, iron oxides or hydroxides, titanium dioxide or natural dyes or mixtures thereof Examples are patent blue V, acid brilliant green BS, red 2G, azorubine, ponceau 4R, amaranth, D+C red 33, D+C red 22, D+C red 26, D+C red 28, D+C yellow 10-, yellow 2G, FD+C yellow 5, FD+C yellow 6, FD+C red 3, FD+C red 40, FD+C blue 1, FD+C blue 2, FD+C green 3, brilliant black BN, carbon black, iron oxide black, iron oxide red, iron oxide yellow, titanium dioxide, riboflavin, carotenes, anthocyanines, turmeric, cochineal extract, clorophyllin, canthaxanthin, caramel, or betanin.
[0016] The shaped polymer composition of the invention or the final product thereof may be coated with a suitable coating agent like cellulose acetate phthalate, polyvinyl acetate phthalate, methacrylic acid polymers, hypromellose phthalate, hydroxypropylmethyl cellulose phthalate, hydroxyalkyl methyl cellulose phthalates or mixtures thereof to provide e.g. enteric properties.
[0017] The polymer composition of the invention may be used for the production of containers for providing unit dosage forms for example for agrochemicals, seeds, herbs, foodstuffs, dyestuffs, pharmaceuticals, flavoring agents and the like.
[0018] The improved elasticity of the inventive polymer composition makes it useful for the encapsulation of caplets in a capsule, especially in a tamper-proof form. The encapsulation of a caplet in a capsule is preferred processed by cold shrinking together capsule parts, which are filled with a caplet, which comprises the steps providing empty capsule parts, filling at least one of said capsule parts with one or more caplets, putting said capsule parts together, and treating the combined capsule parts by cold shrinking.
[0019] The inventive polymer composition is also useful for encapsulating and sealing the two capsule halves in a process in which one or more layers of the composition are applied over the seam of the cap and body, or by a liquid fusion process wherein the filled capsules are wetted with a hydroalcoholic solution that penetrates into the space where the cap overlaps the body, and then dried.
[0020] The improved properties of the polymer composition are demonstrated by the following composition and comparative examples.
COMPOSITION EXAMPLES
[0021] [0021] COMPOS. COMPONENTS COMPOS 1 COMPOS. 2 COMPOS. 3 4* HIPMC(1) 99.26% 99.62% 99.46% 98.1% Gellan 0.54% 0.22% 0.54% 0 Na citrate 0.20% 0 0 0 Citric Acid 0 0.16% 0 0 Carrageenan 0 0 0 1.3% KC1 0 0 0 0.6%
Mechanical Impact Test
[0022] Capsule body parts are submitted to mechanical impact stress of 80 mJ and the percentage of fractured capsules are checked.
EQUILIBRIUM COMPOS. RH COMPOS. 1 COMPOS. 2 COMPOS. 5 6 50% 0 0 0 0 10% 0 0 0 5 2.5% 0 0 10 45
Inhalator Piercing Test
[0023] Capsules are pierced by inhalator device and the percentage of cracks and/or fracture is recorded.
EQUILIBRIUM COMPOS. RH COMPOS. 1 COMPOS. 2 COMPOS. 5 6 50% 0 0 0 0 10% 0 0 95 80 2.5% 0 0 95 75
Capsule Transparency Test
[0024] Capsule bodies are measured for transmittance at 650 nm
CAPSULE TRANSPARENCY Composition 1 74% Composition 2 75% Composition 4 60% Composition 5 81%
Dissolution Test
[0025] Acetaminophen dissolved from capsules immersed in deionised water at 37° C. (USP XXIII), listed is the percentage of acetaminophen after 45 min.
CAPSULE % DISSOLVED Composition 1 90% Composition 2 90% Composition 3 63% Composition 5 91%
Dissolution Test After Exposure to Crosslinking Agent
[0026] Capsules were filled with lactose containing 40 ppm of HCHO and stored under room conditions for one month, measured is the percentage of acetaminophen dissolved after 45 min.
CAPSULE % DISSOLVED Composition 1 90% Composition 5 22%
Moisture Exchange Test
[0027] Capsules were filled with dry carboxymethylcellulose sodium salt (CMC) and stored in closed bottle under room conditions.
INITIAL WATER FINAL WATER CONTENT CONTENT Capsule Fill Capsule Fill Composition 1 6.4% 0% 1.4% 1.1% Composition 5 14% 0% 4.7% 2.0% | The present invention relates to non-animal polymer compositions suitable for film forming, particularly hard and soft capsules, comprising water soluble cellulose ethers, hydrocolloides and sequestering agents. | 2 |
BACKGROUND OF THE INVENTION
The subject invention is directed toward a rotor tiller having a counter-rotating twin shaft system. This new design eliminates many problems associated with conventional tillers and increases the utility of the subject tiller.
Conventional rotor tillers used for tilling soil and cultivating in gardening or agriculture works characteristically have a single shaft with a plurality of tines, usually four, affixed to it. In operation, the engine drives the shaft and its tines to rotate in unison in one direction, either clockwise or counter-clockwise and will till the ground while propelling the rotor tiller forward or backward.
These conventional, single shaft machines will do a good job of tilling previously tilled soil or light sandy soil. On hard soils, or rocky grounds however, conventional rotor tiller of any type becomes less efficient because the force required to till the hard ground exceeds the force exerted on the ground by the weight of the machine. Consequently, the machine will "walk" over the ground and skip spots, resulting in uneven tilling of the ground and also to a very shallow depth.
This problem is partially circumvented by installing a drag bar system or counter-rotating traction wheel which has the net effect of slowing the advance of the machine so that the tines can stay on a given spot longer, allowing deeper penetration of the tines into the soil. However, neither the drag bar system not the counter-rotating wheel by itself produces any useful work other than holding the machine back from advancing too quickly and the problem of uneven and shallow tilling remains, although somewhat diminished.
Secondly, to generate counter-rotating traction, special traction wheels and gear transmission have to be used and frequent switching between transmissions is required. Thirdly, on tilling hard soil, the motion of the tines often overpowered the stopping force of the drag bar or the traction of the counter-rotating wheels; this results in uncontrollable back and forth jerking motions of the machine and uneven tilling of the soil. In order to smooth the advance of the machine on hard soil surfaces, the operator has to pull and shove the machine forwardly and backwardly, causing human fatigue.
Fourthly, soil, especially hard soil dug up by the tines of conventional rotor tiller is in large chunks (held together by roots, grass etc.) that often requires further breaking apart either manually or by running the chunks of soil over and over with the machine in order to achieve a fine consistency. Finally, roots, vines, plastic sheets, cloths, ropes and other fabric like material etc. are often picked up by the blades and winds around the rotating shaft and tines. These tangling mass of non-soil materials can overload the engine and greatly reduce the digging power of the machine.
Besides the problems mentioned above, typically all conventional rotor tillers are designed for one single purpose such as tilling of the ground. Clearly, there is a need for a more efficient machine that is not only devoid of problems associated with the conventional rotor tillers, but is more versatile capable of tilling the ground in the spring and removal of snow in the winter.
SUMMARY OF THE INVENTION
The present invention comprises two counter rotating shafts inside a housing having depending side walls, a rear mounted handle and an engine located at the top. The shafts are rotatably mounted on the side walls transversely thereof relative to the direction of machine travel. One member of the shaft is forwardly mounted and the other, being parallel in position on the same horizontal plane, is rearwardly mounted. Affixed to each shaft are "digging and/or transporting means" which can be tines of conventional design, blades, paddles or other digging apparatus which can be attached to the shafts. In another embodiment a helical auger blade can be affixed to each shaft instead, and a plurality of digging bits can be attached to the helical balde for simultaneous digging and transporting of material being operated on such as soil, gravel or snow. The number of "digging and/or transporting means" such as tines or the lateral length of each helical auger blade is sufficient to cover the entire tilling area inside the machine housing.
A transmission box is located to either side of the machine housing as viewed from the rear (for purposes of explanation the transmission box is located on the left side and is triangular). A short segment of the respective shafts extends through an aperture in the housing wall into the base of the transmission box and terminates thereof in a chain sprocket of identical size. Also extending into the top of the box through another aperture, and generally in parallel to the shafts below, is an engine drive shaft which terminates in a chain sprocket of smaller diameter. The three chain sprockets are drivingly linked together in the box by a drive chain. To create counter rotation of the two shaft members, the drive chain winds circumferentially around the opposite sides of their respective sprockets. Therefore, viewing from the left side of the machine into the box, the chain winds on the teeth around the right, bottom and lower left circumference of the rearwardly mounted shaft sprocket; then, the chain reverses direction by winding around the teeth at the top, left and lower left circumference of the forwardly mounted shaft sprocket; here, a pulley idler is required to hold the chain against the left and lower left side of the forwardly mounted shaft sprocket so that a firm engagement of the chain with the teeth thereof can be maintained at all times. After the chain leaves the pulley idler, it is drivingly engaged with the engine drive shaft sprocket to complete the drive cycle. This way, a clockwise rotation of the engine shaft will drive the rearwardly mounted shaft and its two tines to rotate also clockwise, but the forwardly mounted shaft member and its two tines will rotate in the exact opposite direction, counter-clockwise, to create the counter rotating shafts and tines configuration.
Normally, the twin counter rotating shaft members and their respective tines are held together in close apposition by extension springs without actually touching. Their close proximity would have the advantage of breaking up soil into fine consistency. However, the close proximity can also trap rock/hard matter in between the rotating mechanism as the counter rotating shafts and tines move towards each other. This problem can be resolved by permitting the rearwardly mounted shaft and tine member to slide parallel and rearward relative to the fix positioned forwardly mounted shaft and tine. The rearward sliding movement is made possible by rotatably resting each end of the rearwardly mounted shaft on a sliding track in the housing walls. The track allows only horizontal, with no vertical nor lateral movements for the rearwardly mounted shaft and its tines at anytime. If a rock is caught in between the counter rotating tines, the rearwardly mounted shaft will respond by sliding rearward, thus creating space between the two sets of counter rotating tines and to allow the tines to continue to rotate until the rock/hard matter is ejected from between the counter rotating tines. After rocks/hard matter is ejected, the extension springs on either side of the housing pulls the rearwardly mounted shaft and its tines forward along the path defined by the sliding tracks; thus the original close proximity configuration of the counter rotating shaft and tine members is restored.
If the counter rotating tines are of exact size and shape and have a similar degree of rotation, they will dig/till the ground/soil with equal but opposing force; and the forward digging force generated by the tines of the forwardly mounted shaft will be canceled by an equal, rearwardly directed digging force generated by the tines of the rearwardly mounted shaft. The balanced but opposed digging force generated by the counter rotating tines allows the machine to stay stationary while the ground/soil is being dug/tilled continuously beneath the machine. On the other hand, if the machine is tilted forward as by tilting the rearwardly mounted handle upwards, the weight of the machine will be shifted forward allowing the tines of the forwardly mounted shaft to dig deeper into the soil; the excess traction developed by these tines will overcome that of the rearwardly mounted tines, and the machine will move forward instantly. Likewise, if the machine is tilted rearward as by lowering the rearwardly mounted handle, the rearward traction will increase and the machine will move backward instantly. The depth of ground digging and the speed of forward or backward movement can be readily controlled by the amount of upward or downward tilt of the handle. If a constant advance of the machine in either direction is desired, the operator can adjust the handle height using a supporting pole that moves along on the ground on a wheel.
To make this invention more versatile, tines on the counter rotating shafts can be replaced by helical auger blades that run angularly along the entire axis of the shaft. The juxtapositioned helical blades facing each other have opposite helix angles and alternating turns. As the shafts counter rotate, the opposing blades will move towards each other and also towards one side of the machine; this will channel loose soil or granular material towards the space between the opposing blades and then to one side of the machine whereby the loose material is collected in a chute and is discharged to the outside by a blower mechanism. The blower is driven to rotate inside the chute by either shaft through a belt-pulley system. The helix angle and the direction of rotation of the blade can be configured to channel loose granular material to the center of machine to be discharged thereof by a similar chute and blower mechanism.
Further, on the helical blades, a plurality of tilling bits of suitable shape and size can be affixed to pre-determined positions such that the tilling bits reach out of the outer perimeter of the blade. As the blades counter rotate, the tilling bits will dig/till the soil and the loose soil will be channelled at once by the rotating blades to the blower to be discharged outside the machine.
The advantages offered by this invention are 1) stationary but continuous digging action; 2) self-propelled, forward digging action without the use of transmissions; 3) self-propelled, rearward digging action without the use of transmissions; 4) instant machine advance or retreat without the use of transmissions, best suited for tight corners and small plots; 5) little effort is required for deep and even ground tilling; 6) Simultaneous digging and removal of soil; and 7) removal of snow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a 60 degree angle, perspective left side view of the machine with cut-outs showing the rotating twin shafts and tines, the sliding tracks. Also shown is the transmission box opened, revealing a drive chain and sprockets engaged properly for counter-rotation.
FIG. 1A and 1B differs only in showing respectively, the forward and rearward sliding positions of the rearwardly mounted shaft.
FIG. 2 is shown with the engine, the machine and transmission housing removed, revealing the components interconnected to function as a complete drive unit. FIG. 2A and 2B differs only in showing respectively, the forward and rearward sliding positions of the rearwardly mounted shaft.
FIG. 3 shows the rearwardly mounted shaft properly mounted on the slide tracks and their relationship to the forwardly fix mounted shaft. FIG. 3A and 3B differs only in showing respectively, the forward and rearward sliding positions of the rearwardly mounted shaft.
FIG. 4 is an overall outside view of the machine.
FIG. 5A, 5B, 5C are respective repeats of FIG. 1B, 2B and 4, differing only by showing that the transmission is centrally located.
FIG. 6 is the outside view of the machine with handle and handle height adjuster properly installed.
FIG. 7 shows the tines of FIG. 2 are replaced by a pair helical auger blade, one on each shaft.
FIG. 8 is similar to FIG. 7 but additionally showing tilling/digging bits installed properly on the helical auger blades. The insert is an enlarged portion of a blade section with pre-determined holes through which the digging bits can be secured to the blade by a pair of bolts and nuts.
FIG. 9 is similar to FIG. 8 with the chute and fan blower also shown on the right of the machine.
FIG. 10 shows the outside of the machine with cut-outs revealing the shafts, their helical augur blades, sliding track, chute and fan blower contained inside the housing.
FIG. 11,12,13 showing the helical auger blades and their digging bits, chute and fan blower configured for discharge of materials from the center portion of the machine.
FIG. 14 shows the helical auger blade configuration contained inside the machine housing and with the handle properly installed. Retractable wheels are shown for support of the machine.
DETAILED DESCRIPTION OF THE INVENTION
I. Counter-rotating Twin Shafts with Tines
FIGS. 1 through 4 show the twin shafts 1, 2, being mounted transversely thereof inside the housing 3 relative to the forward 4 and rearward 5 direction of machine travel; shaft 1 is mounted forwardly and shaft 2, positioned parallel lengthwise, is mounted rearwardly on the walls 6,7 on opposite sides of the housing 3.
Shaft 1 rotates 8 freely on a ball bearing 9 one in each side wall 6 or 7 and shaft 2 rotates 10 freely on a similar ball bearing 11 in the side walls 6,7. As viewed from the rearward direction 5, the shafts 2,1 extend through an aperture 12,13 respectively in the side wall 6 into the bottom portion of a gear-chain transmission box 14 having a triangular shape; aperture 12 is elongated horizontally. Inside the transmission box 14, shaft 1 and 2 terminate respectively in chain sprockets 15 and 16, both having a similar diameter; rotation of sprocket 15,16 causes an exact rotation of their respective shaft 1 and 2 and the tines 17,18 affixed thereupon. At the top of said transmission box 14 and generally in parallel to shafts 1, 2 below is the drive shaft 19 of an engine 20. The drive shaft 19 terminates in a smaller chain sprocket 21. All chain sprockets 15,16,21 are linked in the box 14 by a drive chain 22. To create counter rotational movement between sprockets 15 and 16, drive chain 22 winds circumferentially around the opposite sides of sprocket members 15,16. Therefore, from side wall 6 on the left looking into the transmission box 14, the drive chain 22 winds around the teeth of sprocket 16 at the top, right, bottom and lower left circumference; then, it reverses its direction by winding around the teeth on the opposite side of sprocket 15 at its top, left and lower left circumference; here, in order to keep the chain 22 firmly engaged with sprocket 15 at all times, a pulley idler 23 is used to push the chain 22 against the left and lower left circumference of sprocket 15; the pulley idler 23 is rotatably mounted on the side wall of transmission box 14. After chain 22 leaves the pulley idler 23, it is engaged with the sprocket 21 on the engine drive shaft 19 for completion of a drive cycle 24. This way, a clockwise rotation of the engine drive shaft 19 will drive the rearwardly mounted shaft 2 and its two tines 18 to rotate clockwise 10, but forwardly mounted shaft 1 and its two tines 17 to rotate in the exact opposite direction, counter-clockwise 8 causing the tines 17 to move towards tine 18, and vice versa; likewise, if the engine drive shaft 19 rotates counter-clockwise, the tines 17 and 18 will move away from each other; and this, is the basis for the instant invention. Obviously, there are other ways to create counter rotation as by a direct engagement of the gear teeth with two neighboring gears. However, the chain and sprocket arrangement described here represents one of the simplest, most reliable and economical way to creating counter rotation of two opposing shaft members.
The tines 17,18 are removably fixed on their respective shaft using nuts and bolts and their positions on the shafts 1, 2 cover the entire lateral width of ground inside the machine housing 3; for example, the two rear tines 18 can be placed wide apart, one near each end of shaft 2 closest to the housing walls 6,7; and the forward tines 17 can be positioned closer together, near the mid-section of shaft 1. Further, equal and adequate lateral spacing are provided for all tines so that they would not touch each other or any parts of the machine except the ground at all times. The shafts 1,2 and their bearings 9,11 are removably mounted in the housing walls 6,7 and the shafts 1,2 can be further removed from their bearing 9,11 by removing a washer and lock-pin for servicing or replacement of the tines with helical auger blades.
Normally, as shown in FIG. 1A, 2A, 3A, the twin counter rotating shaft members 1,2 and their respective tines 17,18 are held in close juxtaposition with each other without touching while rotating. This close configuration have the advantage of breaking up the dug up soil into fine consistency, but the chance of trapping rock/hard matter in between the counter rotating tines 17,18 also increases. This problem can be resolved by permitting the rearwardly mounted shaft 2, its tines 18 and its sprocket member 16 to slide rearward 25 relative to the fix positioned counterparts, 1,17 and 15. The rearward sliding movement 25 can be achieved by mounting the ball bearing 11 on a sliding mechanism. For example, each ball bearing 11 can rest on the mid section of supporting arm 26 positioned horizontally and perpendicularly to the long axis of shaft 2; either end of arm 26 terminates in a ball bearing roller 27 which slides horizontally inside a sliding track 28 located in the side walls 6,7. Since roller 27, arm 26, ball bearing 11 and shaft 2 are tightly interconnected forming one slidable unit, they are collectively referred to hereafter as the slidable unit. The sliding track 28 is constructed to allow only horizontal and a juxtaposition sliding of shaft 2 relative to the position of shaft 1; no lateral and vertical movements of either shafts 1 or 2 are allowed at any time. Inside the transmission box, excess chain length 22 is provided to allow sprocket 16 to slide along aperture 12 freely with the slidable unit. To properly tension the chain 22 of excess length so that a firm engagement of chain 22 with all sprockets 15,16,21 can be maintained at all times, a tensioner 30,31 can be used; the tensioner can be of any type such as in the form of a flat spring 30 whose one end is affixed to the wall of transmission box 14 facing the lower right side of sprockets 21 while its other end terminates in a roller 31. The tensioner 30,31 exerts a constant force on chain 22 to keep it fully stretched and firmly engaged with the teeth of chain sprockets 15,16,21 at all times.
Therefore, with this or similar arrangements, shaft 2, while rotating, can also slide either forwardly 29 or rearwardly 25 for a distance as defined by sliding track 28. The components of the slidable unit can be comprised of any suitable parts and means as to provide maximal ease for shaft 2 to rotate and slide simultaneously in a manner just described. For example, each bearing 11 carrying the rearwardly mounted shaft 2 can be placed directly in the sliding track 28 without use of the arms 26 and roller 27. To prevent dust and debris from entering the sliding track 28 and the rollers 27, a rubber diaphragm or other appropriate sealing means can be used to cover these components.
On tilling of light sandy soil or previous tilled soil, the slidable unit is held to its forward most position on the sliding tracks 28 by an extension spring 32 with adjustable force; one end of spring 32 is anchored on either the side walls 6,7 or the sliding track 28 and its other end is achored on the supporting arm 26 or a stationary spot on ball bearing 11. If tines 18 dig into a hard ground or rock that generate a resistance force greater than the pull of springs 32, the spring will extend allowing the slidable unit slide rearwardly 25 along track 28; as new space 33 is created in between the juxtapositioned shafts 1 and 2, the tines 17,18 can continue to rotate to eventually loosen the hard soil or eject the rock from between the counter rotating tines 17,18. Normally, for tilling of ordinary or hard rocky grounds, enough rearward travel distance for the slidable unit and its tines 18 is allowed by sliding track 28 to prevent a lock up of the tines 17,18 by rock/hard matter caught in between the counter rotating mechanism. Upon loosening of the hard ground or ejection of rocks caught between tines 17,18, the slidable unit will automatically slide forward 29 along track 28 under the pull of the extension springs 32 to resume its original close juxtaposition with shaft 1. During transitional back 25 and forth 29 sliding movements, free rotation of shaft 1 and 2 and their respective tines 17,18 will be maintained.
The chain and gear transmission box 14 can be located either on the left or right side of the machine. Similarly, the box 14 and its contents of chain 22 and sprockets 15, 16, 21 can be arranged on the mid-section of shafts 1, 2 as shown in FIGS. 5A, 5B, 5C. In this configuration, the engine 20 can be mounted at the rear top, midsection of the machine housing 3; the engine drive shaft 19 is shown to be connected through a pulley 34,35 and belt 36 system. This mid-section transmission box 14 configuration does not alter counter rotational principle and its unique functions in any way except to provide an example among a variety of different configurations that the instant invention can exist.
FIG. 6 is shown with the handle 37 installed. Because of the unique counter rotational tines 17, 18, the handle 37, besides for guiding the machine, performs three important functions normally requiring complex transmissions: a. stationary tilling; b. self propel forward or backward tilling; c. control on speed of machine travel. All three function can be readily obtained and interconverted by simply adjusting the height of handle 37. The stationary tilling is one of the most unique and useful functions of this invention; it is made possible by the counter rotating tines 17, 18 having a similar size and shape and an equal degree of rotation. As the machine is levelled with the ground by levelling of handle 37, the forward digging force generated by the tines 17 on shaft 1 will be canceled by an equal, rearwardly directed digging force generated by tines 18 of shaft 2. The balanced but opposed digging force generated by the counter rotating tines 17,18 allows the machine to stay stationary while the ground/soil is being dug continuously beneath the machine. On the other hand, if the rear end of the machine is tilted upwards 40 by tilling handle 37 upwards 38, the weight of the machine will be shifted forward allowing the tines 17 of shaft 1 to dig deeper into the soil; the excess traction developed by tines 17 will overcome that of the rearwardly mounted tines 18, and the machine will move forward 29 instantly. Likewise, if the rear end of the machine is lowered 41 by lowering 39 the handle 37, rearward traction will increase and the machine will move backward 25 instantly. The depth of ground tilling and the speed of forward 29 or backward 25 movements can be readily controlled by the amount of upward 38 or downward 39 tilt of handle 37. If a constant advance of the machine in either direction is desired, the handle height can be adjusted by using a supporting leg 42 that glides along the ground on a wheels 43.
II. Counter-rotating Twin Shafts with Helical Auger Blades
In another embodiment, the tines 17, 18 can be conveniently replaced by a helical auger blade system for added functions.
FIGS. 7 through 10 illustrate a helical auger blades system that can perform both tilling and removal of soil material simultaneously from underneath the machine housing 3. In this configuration, the tines 17,18 on each shaft 1,2 are replaced by a helical auger blade 44, 45 refered hereafter as blades 44,45. These blades 44,45 run angularly about the axis along the entire length of each shaft 1 or 2 inside the machine housing (FIG. 7). Each shaft can have a single blade or a plurality of blades affixed to it. For the purpose of description, a single, continuous blade 44 or 45, covering the entire long axis of the shaft 1 or 2 is illustrated. The blades 44,45, facing each other on the respective shafts 1, 2 have opposite helix angles. To allow close apposition of the blades 44,45 for efficient lateral transfer of materials, the turns 46 of each blade 44 alternate with the turns of the opposing blade 45. According to FIG. 7-10, as shafts 1 and 2 counter rotate in respective directions 8 and 10, the blades will move towards 46 each other and away from the left side 6 towards 47 the right side 7 of the machine. The continuous counter rotating motion of the opposing blades 44,45 will channel loose soil or granular materials to the space 48 between the blades 44,45 and then to the right side wall 7 inside the machine housing 3. Materials thus channelled there 7 is discharged outside of the housing 3 by a blower 49, 50, 52. Preferentially, the blower is rotatably mounted on the left side wall 7, behind shaft 1, and is driven to rotate either by shaft 1 or 2 through a belt 51 and pulley 52 system; A blower chute 53 in side wall 7 collects and channels the material to the blower 49,50,52 to be discharged outside 54; the vane members 50 on the blower fan 49,50 can be flat or helical in shape so as to generate maximal lift on material to be discharged. This helical auger blade configuration is well suited for the removal of loose granular materials such as soil, sand, fine gravel or snow.
If simultaneous soil tilling and removal is required, tilling bits 55 of suitable shape, size and number can be affixed to pre-determined positions 56 on the same blades 44 or 45 by nuts 58 and bolts 59 as shown in FIG. 8; the tilling bits 55 have forwardly directed hooks 60 pointing toward those on the opposite blade members 44 or 45. As blades 44,45 counter rotate, the tilling bits 55 will dig and till the soil loose and the loose soil will be channelled by the blades 44,45 at once to the right side wall 7 for example, where it is discharged to the outside 54 of the machine housing 3 by the blower 49,50.
The machine configured in FIGS. 7 to 10 discharges material to one side 7 of the machine housing 3. FIG. 11 to 13 is the same machine but is configured to discharge materials from the center area 61 of the machine. This requires two helical auger blades 62, 63 each 62 having a reversed helical angle to the other 63 mounted on the same shaft 1, but on opposite sides of the centrally located transmission box 14. An identical set of blades 64,65 with opposite helix angles to those of 62, 63 are mounted similarly on shaft 2. As shafts 1, 2 counter rotates, the opposing blades 62, 63 and 64, 65 will move toward each other and toward the transmission box 14, Loose soil will then be channelled from both side walls 6,7 of the machine housing 3 towards the centrally located transmission box 14. Two blowers 49, 50, 66, each rotatably mounted on each side of the transmission box 14, discharge the soil materials through a chute 67 away from the machine in a manner similar to a conventional two stage snow blower. In this case, the blower can be driven to rotate through a small chain sprocket 66 by the same drive chain 22 inside the transmission box 14. As is in the case for the side discharge helical blade configuration, the central discharge helical blade configuration is suitable for snow or soil removal purposes; if tilling bits 55 are affixed to these blades 62, 63, 64, 65, simultaneous soil tilling and removal can be done.
Finally, if tilling bits 55 are affixed to the counter rotating helical auger blade configuration, either the side discharge or central discharge version, the machine operates and moves in exactly the same way as the counter rotating tine 17,18 configuration; that is, stationary tilling, self-propelled forward or backward tilling and control of speed of machine travel are all controlled by the tilt of handle 37 (FIG. 14). On the other hand, if tilling bits 55 are not attached to the blades, then the machine travels on four wheels 68 with one mounted on each of the four corners of the machine housing 3 (FIG. 14).
Therefore, unlike conventional machines, the counter rotating twin shaft system can perform a number of functions depending on the attachments affixed to the shafts; if conventional tines 17,18 are affixed to the shafts 1, 2, the machine resembles a conventional tiller but with much improved power and ease of machine movements required for efficient tilling of the ground (FIG. 1-6). If helical auger blades 44,45 or 62,63,64,65 with tilling bits 55 are installed instead on the same shaft 1,2, the machine can till and remove soil simultaneously (FIG. 8-10, 12-13). And if helical blades 44,45 or 62,63,64,65 are used without the tilling bits 55 (FIG. 7,11). the machine can travel on retractable wheels 68 for snow removal purposes (FIG. 14). | A rotor tiller having a counter-rotating twin shaft system and counter-rotating digging means such as tines, paddles, or blades for efficient tilling of soil. In another embodiment, the tines on the twin shafts can be replaced by counter-rotating helical auger blades for removal of loose soil or snow. Furthermore, digging bits of suitable kind and size can be affixed to the helical auger blades for simultaneous digging/tilling and removing of soil, snow. This new design eliminates many problems associated with conventional tillers and increases the utility of the subject tiller. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Application No. 60/657,647, filed on Feb. 28, 2005, which is incorporated herein by reference as if fully set forth.
BRIEF DESCRIPTION OF DRAWINGS
[0002] FIG. 1A depicts an embodiment of the invention in still image status.
[0003] FIG. 1B shows the embodiment of FIG. 1A after the still image has been transformed into a video.
DESCRIPTION
[0004] The Image to Video Device (Device) displays at least one image in normal mode. The image can be in any form, including the following: picture, painting or photograph. In one step, e.g., press of a button, remote control or motion detector, the image transforms into a video. The video may include audio. The video may relate to the still image.
[0005] A person skilled in the art would be able to construct the Device using already existing technology for image display devices, video display devices, motion detector devices, etc.
[0006] In one preferred embodiment, the Device can be incorporated into an advertisement display. In such embodiment, the Device could be a store sign or billboard. In one example, shown in FIGS. 1A and 1B , the advertisement could be used to promote an upcoming movie and the image 1 could be that of a character in the movie. If powered by a motion detector 2 , the still image 1 of the character could transform into a video 3 of the character when a viewer approaches the advertisement display and activates the motion detector 2 . The video 3 could include sound.
[0007] In one preferred embodiment, at the completion of the video, the Device again displays the still image.
[0008] In another preferred embodiment, the Device can display as a picture frame or poster. In such embodiment, the Device can be hung on a wall or placed on furniture, e.g., desk. In such embodiments, the Device can be in various sizes and styles.
[0009] In another preferred embodiment, the Device can be incorporated into a photo frame. In one example, the Device can display a still image of the family dog. At the push of a button, the image of the dog transforms into a video of the dog running, with barking and other sounds included.
[0010] In one embodiment, the Device can be a postcard suitable for carrying around in one's pocket, purse or wallet.
[0011] In preferred embodiments, the Device is powered by electricity, including by battery.
[0012] Embodiments also could incorporate and/or be used with memory devices such as memory stick technology and/or memory cards. For example, the Device could have the capability to contain and read a memory stick or memory cards. In such embodiments, the memory devices can be used to change or supplement the images and videos to be displayed in the Device.
[0013] The Device also could be capable of storing more than one video and/or image memory at a time. In such embodiments, the still image displayed in normal mode can change each time the video mode is played. For example, in the family dog embodiment described above, a different still image of the dog can be displayed after the video is played.
[0014] Embodiments also could incorporate and/or be used with LCD technology. Also, the Device can be connected to the Internet via a USB connection or other means. | A device for storing and displaying at least one still image, wherein the at least one still image can convert to a video display. A method for presenting a still image and then converting the still image to display a video. | 6 |
FIELD OF INVENTION
[0001] The present invention relates to the catalytic oxidation and/or bleaching of substrates.
BACKGROUND OF INVENTION
[0002] U.S. Pat. Nos. 5,516,738 and 5,329,024 disclose the use of a manganese transition metal catalyst of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) for epoxidizing olefins; the transition metal catalyst has as a non-coordinating counter ion ClO 4 − . U.S. Pat. No. 5,329,024 also discloses the use of the free Me 3 -TACN ligand together with manganese chloride in epoxidizing olefins.
[0003] WO 2002/088063, to Lonza A G, discloses a process for the production of ketones using PF 6 − salts of manganese Me 3 -TACN.
[0004] WO 2005/033070, to BASF, discloses the addition of an aqueous solution of Mn(II)acetate to an aqueous solution of Me 3 -TACN followed by addition of a organic substrate followed by addition of hydrogen peroxide.
[0005] WO2006/125517 discloses the use of manganese complexes with 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) and 1,2-bis-(4,7-dimethyl-1,4,7-triazacyclonon-1-yl)-ethane (Me 4 -DTNE) as highly-water soluble salts in bleaching.
[0006] WO08086937 and EP1934396B both disclose oxidative/bleaching processes with manganese complexes with 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) and 1,2-bis-(4,7-dimethyl-1,4,7-triazacyclonon-1-yl)-ethane (Me 4 -DTNE) salts.
[0007] R. Hage et al. in Nature, 369, 637 (1994) teaches the optimal use of manganese complexes containing Me 3 -TACN to be at around pH 10.0-10.5 and for the manganese complex containing Me 4 -DTNE to be at around pH 11.0
SUMMARY OF INVENTION
[0008] The present method provides a method of bleaching of cellulosic substrates, of treatment of effluent waste streams, removal of starches and polyphenolic substrates from hard surfaces, modification of starch, oxidations of alkenes into epoxides and/or diols and/or dicarboxylic acids, alcohol into aldehyde and/or carboxylic acids, alkanes into alcohols and ketones.
[0009] We have found that by using a preformed manganese transition metal catalyst at a high pH permits effective bleaching such that levels of the preformed manganese transition metal catalyst may be kept at a minimum.
[0010] In one aspect the present invention provides a method of treating a substrate comprising the following step: contacting the substrate with an aqueous medium, having at least 1% of water and from 1 to 1500 mM of hydrogen peroxide, to form an oxidative medium, the aqueous medium comprising a transition metal catalyst, wherein the transition metal catalyst is preformed and a dinuclear Mn(II)Mn(II), Mn(II)Mn(III), Mn(III)Mn(III), Mn(III)Mn(IV) or Mn(IV)Mn(IV) transition metal catalyst, the ligand of the transition metal catalyst of formula (I):
[0000]
[0011] p is 3;
[0012] R is independently selected from: hydrogen; C1-C6-alkyl, C2OH; C1COOH; and, pyridin-2-ylmethyl and one of R is linked to the N of another Q from another ring via an ethylene bridge;
[0013] R1, R2, R3, and R4 are independently selected from: H; C1-C4-alkyl; and, C1-C4-alkylhydroxy, wherein the oxidative medium has a pH in the range 11 to 13 and the concentration of the transition metal catalyst is in the range from 0.0001 to 1.5 microM.
[0014] The transition metal catalyst may be a single transition metal catalyst or a mixture of the transition metal catalysts as defined above.
DETAILED DESCRIPTION OF THE INVENTION
Transition Metal Catalyst
[0015] The manganese transition metal catalyst used may be non-deliquescent by using counter ions such as PF 6 − or ClO 4 − , it is preferred for industrial substrates that the transition metal complex is water soluble. It is preferred that the preformed transition metal is in the form of a salt such that it has a water solubility of at least 50 g/l at 20° C. Preferred salts are those of chloride, acetate, sulphate, and nitrate. These salts are described in WO 2006/125517.
[0016] It will be understood from the foregoing description that begins of formula (I) may alternatively be represented by the following structure:
[0000]
[0000] wherein R, R1, R2, R3, and R4 are as herein defined.
[0017] Preferably R is independently selected from: hydrogen, CH3, C2H5, CH2CH2OH and CH2COOH.
[0018] More preferably R, R1, R2, R3, and R4 are independently selected from: H and Me.
[0019] Most preferably, the catalyst is derived from the ligand 1,2,-bis-(4,7,-dimethyl-1,4,7,-triazacyclonon-1-yl)-ethane (Me-4-DTNE).
[0020] The preformed transition metal catalyst salt is preferably a dinuclear Mn(III) or Mn(IV) complex with at least one O 2− bridge. For example, the preformed transition metal catalyst salt may be a salt of the metal complex [Mn III Mn IV (μ-O) 2 (μ-CH 3 COO) (Me 4 -DTNE)] 2+ .
[0021] Preferably, the pH of the oxidative medium is from pH 11.2 to 12.8, more preferably from pH 11.5 and 12.5.
[0022] Preferably, the concentration of the transition metal catalyst is from 0.0005 to 1 microM, more preferably from 0.001 to 0.7 microM.
Substrates
[0023] Cellulosic substrates are found widely in domestic laundry, industrial and institutional laundry, wood-pulp, cotton processing industries and the like. Although target cleaning can be different, it is the objective in all cases to bleach these substrate, i.e., either removing undesired stains or solids (laundry applications), or bleaching polyphenolic substrates that are present in the natural cotton materials (raw cotton and wood pulp).
[0024] For laundry (both domestic as well as institutional & industrial cleaning), bleaching agents are used for cleaning and hygiene purposes. Especially hydrogen peroxide and peracids are being employed widely. As highlighted above, hydrogen peroxide can be activated by catalysts to allow cleaning at lower bleaching temperatures.
[0025] The term “crockery” encompasses plates, dishes and other eating (e.g., cutlery) and serving tableware, usually made of some ceramic material; crocks, earthenware vessels, especially domestic utensils.
Synthetic Applications
[0026] Although not limited, examples include alkene oxidations into epoxide, cis-diol, trans-diol (formed from the epoxide upon alkaline hydrolysis), and via C—C cleavage into the carboxylic acid. Examples (but not limited to these examples) of alkenes to give epoxide include cyclooctene conversions, styrene, 1-octene, dimethylmaleate. It should be noted that, as persons skilled in the art will appreciate, that these epoxides may be hydrolysed into trans-diol groups.
[0027] In this regard, alkenes, aldehydes, and alkanes are preferred substrates and it is preferred that when these substrates are oxidised they are present (including isomers and enantiomers) at least 90% purity; this level of purity does not include the oxidative medium.
[0028] This invention is supported by the following non-limiting examples.
EXPERIMENTAL
[0029] [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 was obtained as disclosed elsewhere (K.-O. Olivier et al., J. Am. Chem. Soc., 120, 13104-13120 (1998)).
Experiment 1
Bleaching of Pulp with Very Low Levels of Catalyst ([Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 )
Softwood Pulp
[0030] Softwood pulp with a starting ISO-brightness of 84.3 was treated as follows: 1 g of oven-dry pulp was added to a series of mini-bottles containing various levels of catalyst, 4 kg/t H 2 O 2 (equals to 5.9 mM H 2 O 2 ), and 0.5 kg/t DTPMP (Diethylenetriaminepenta(methylene-phosphonic acid)—(ex Solutia; trade name Dequest 2066; purity is 32%). The pH-values were adjusted to desired level @pH 11.5 (measured at 20° C.).
[0031] Note 1: This softwood pulp has been delignified in a O 2 -delignification step, and partly further bleached by a ClO 2 step, a Ep(H 2 O 2 ) and a ClO 2 step.
[0032] Note 2: In practice, pulp was used that contained 30% dry matter and 70% water (30% dry content). Therefore 3.33 g of ‘wet’ pulp was used for each experiment.
[0033] Note 3: All experiments were carried out at 5% consistency.
[0034] The mini-bottles are put in a pre-heated water bath (70° C.) for 1 hour and are shaken throughout the bleaching process. Subsequently the pulp mixture is filtrated through a Buchner funnel, washed with copious amounts of demineralised water and dried overnight at ambient conditions. The optical properties of the pulp heaps were then measured using a Minolta spectrophotometer CM-3700d, using L, a, b values which are converted to whiteness values through the following formula:
[0000] 100−√{square root over ((100 −L ) 2 +a 2 +b 2 )}
[0035] The ISO-Brightness values are calculated through the following formula:
[0000] ISO-Brightness=(1.98*whiteness)−100.3
[0036] The results of the experiment are given in Table 1.
[0000]
TABLE 1
ISO-Brightness results of bleaching softwood pulp using
various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 at
pH 11.5 at 70° C. for 60 minutes. The error of
the experiments is around 0.4 ISO Brightness values.
[Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
Brightness
(micromolar)
(ISO %)
0 (blank)
86.4
0.06
87.2
0.12
87.3
0.3
87.9
Eucalyptus Hardwood Pulp
[0037] The same set of experiments were conducted using eucalyptus hardwood pulp (starting brightness of 72.0% ISO). In the solutions various levels of catalyst were added and 3 kg/t H 2 O 2 (equals to 4.4 mM H 2 O 2 ). The pH-values were adjusted to desired level @pH 11.6 (measured at 20° C.).
[0038] Note 1: This eucalyptus pulp has been delignified in a O 2 -delignification step, and partly further treated by an acidic wash and a ClO 2 step.
[0039] Note 2: In practice, pulp was used that contained 31.4% dry matter and 68.6% water (31.4% dry content). Therefore 3.18 g of ‘wet’ pulp was used for each experiment.
[0040] Note 3: All experiments were carried out at 5% consistency.
[0041] The results of the experiment are given in Table 2.
[0000]
TABLE 2
ISO-Brightness results of bleaching eucalyptus hardwood D1
using various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
at pH 11.6 at 85° C. for 90 minutes.
[Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
Brightness
(micromolar)
(ISO %)
0 (blank)
81.5 (0.11)
0.16
83.0 (0.12)
0.4
83.3 (0.04)
[0042] An additional set of experiments was carried out using another batch of eucalyptus hardwood pulp (starting brightness of 71.5% ISO), that has been treated before with hot ClO 2 . This set of bleaching experiments was also carried out at 5% consistency, but now using 5 kg/t H 2 O 2 . The results of these bleaching experiments are given in Table 3.
[0000]
TABLE 3
ISO-Brightness results of bleaching eucalyptus hardwood D1
using various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
at pH 12.0, 12.5, and 13.0 at 80° C. for 90 minutes.
[Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
Brightness (% ISO)
pH 12.0; 0 μM
80.7 (0.4)—4
pH 12.0; 0.0005 μM
81.3 (0.1)—4
pH 12.0; 0.05 μM
82.2 (0.3)—4
pH 12.5; 0 μM
80.7 (0.6)—4
pH 12.5; 0.008 μM
82.3 (0.0)—4
pH 12.5; 0.08 μM
83.4 (0.1)—2
pH 13.0; 0 μM
80.3 (0.2)—4
pH 13.0; 0.025 μM
82.5 (0.5)—2
pH 13.0; 0.082 μM
83.0 (0.4)—2
[0043] Experiments are done in fourfold or two-fold (values given after standard deviations).
[0044] The results gathered in Table 1 and 2 show that the addition of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 at very low levels leads to an increase in Brightness of the pulp samples as compared to the references. Even levels as low as 0.06 microM gives a significant bleach effect under these conditions.
[0045] Moreover, the results gathered in Table 3 show that the addition of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 at levels as low as 0.0005 microM give a significant bleach effect under these conditions. Further, these data show that at pH 11.6, 12.0, pH 12.5, and pH 13.0, a significant benefit of the catalyst can be obtained.
Experiment 2
[0046] Raw cotton with a Berger Whiteness value of 7.5+/−1.0 was treated as follows: 2 grams of the cotton was immersed into mini-bottles containing a 20 ml solution (cloth/liquor ratio of 1/10) containing various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 , 35 mM to 120 mM H 2 O 2 (equals to 3 to 10 ml/l 35% w/w H 2 O 2 ), pH-value adjusted to desired level, 1 g/l Sandoclean PCJ (ex Clariant). Different levels of Dequest 2066 were used: 0.9 g/l Dequest 2066, ex Solutia (purity of 32%) was used (=DTPMP—Diethylenetriaminepenta(methylene-phosphonic acid) for the data given in table 4. For the experiments shown in table 5, 0.3 g/l Dequest 2066 solution was used.
[0047] The mini-bottles were put in a pre-heated water bath (77° C.) for 30 to 35 minutes (the temperature of the bleaching solutions in the bottles is then 75° C.). Subsequently the cotton swatches were rinsed twice with 1 litre of hot demineralised water (95° C.), then with 1 litre of 40° C. demineralised water containing 1 ml/l acetic acid and then washed with copious amounts of demineralised water and dried overnight under ambient conditions. The optical properties of the cloths were then measured using a Minolta spectrophotometer CM-3700d, using X, Y, Z values which are converted to Berger Whiteness values.
[0048] The values of the whiteness are expressed in Berger units. The formula of Berger whiteness is given below:
[0000] W berger =Y+a·Z−b·X , where a= 3.448 and b= 3.904.
[0049] The values X, Y, Z are the coordinates of the achromatic point. The results of the experiments are given in Table 4.
[0000]
TABLE 4
Berger Whiteness results of bleaching raw cotton using
various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
at various pH's at 75° C. for 30 to 35 minutes.
Reaction
[Mn 2 O 2 (CH 3 COO)(Me 4 -
Peroxide
time
DTNE)](PF 6 ) 2
Whiteness
(mmolar)
(minutes)
pH
(micromolar)
(Berger)
75
30
11.0
0 (blank)
54.7 ± 1.2
75
30
11.0
0.1
57.5 ± 0.8
75
30
11.0
0.25
59.4 ± 0.6
75
30
11.0
0.5
59.2 ± 0.7
75
30
11.0
1
61.5 ± 0.1
75
30
11.0
1.5
61.2 ± 0.5
75
30
12.0
0 (blank)
60.6 ± 0.8
75
30
12.0
0.1
63.5 ± 0.6
75
30
12.0
0.25
65.6 ± 0.7
75
30
12.0
0.5
66.8 ± 0.6
75
30
12.0
1
68.6 ± 0.6
75
30
12.0
1.5
69.7 ± 0.6
120
35
12.0
0 (blank)
68.1 ± 1.0
120
35
12.0
0.1
70.3 ± 0.7
120
35
12.0
0.25
71.8 ± 0.4
120
35
12.0
0.5
73.3 ± 0.2
120
35
12.0
1
74.0 ± 0.8
120
35
12.0
1.5
74.5 ± 0.6
35
35
12.0
0 (blank)
52.5 ± 0.7
35
35
12.0
0.1
55.8 ± 0.5
35
35
12.0
0.25
56.8 ± 0.7
35
35
12.0
0.5
58.6 ± 0.7
35
35
12.0
1.0
60.3 ± 0.4
35
35
12.0
1.5
61.1 ± 0.6
58
35
12.0
0 (blank)
59.3 ± 1.1
58
35
12.0
0.1
62.9 ± 0.9
58
35
12.0
0.25
64.1 ± 0.3
58
35
12.0
0.5
64.7 ± 0.7
58
35
12.0
1
66.9 ± 0.5
58
35
12.0
1.5
67.8 ± 0.9
[0050] The results gathered in Table 4 show that under the range of pH and levels of peroxide tested the addition of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 always leads to an increase in the whiteness of the swatches versus the blank (without catalyst), even with very low levels (an increase by 2-3 Berger is obtained by addition of only 0.1 micromol/L of the catalyst).
[0000]
TABLE 5
Berger Whiteness results of bleaching raw cotton using
various levels of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2
at various pH's at 75° C. for 30 minutes.
Reaction
time
[Mn 2 O 2 (CH 3 COO)(Me 4 -
Whiteness
H 2 O 2 (mM)
(minutes)
pH
DTNE)](PF6) 2 (μM)
(Berger)
75
30
12.5
0 (blank)
61.6 ± 0.4
75
30
12.5
0.05
63.4 ± 0.9
75
30
12.5
0.1
65.1 ± 0.5
75
30
12.5
0.5
68.2 ± 0.4
75
30
12.5
1
69.8 ± 0.7
75
30
12.5
2
71.3 ± 0.6
75
30
13.0
0 (blank)
61.4 ± 0.6
75
30
13.0
0.05
63.2 ± 0.7
75
30
13.0
0.1
65.8 ± 0.5
75
30
13.0
0.5
68.3 ± 0.4
75
30
13.0
1
70.2 ± 0.3
[0051] Taken together, the results gathered in Tables 4 and 5 show that, under the range of pH and levels of peroxide tested, the addition of [Mn 2 O 2 (CH 3 COO)(Me 4 -DTNE)](PF 6 ) 2 always leads to an increase in the whiteness of the swatches versus the blank (without catalyst), even at pH 12.5 and 13.0. Even with very low levels of catalyst (0.05 μM) an increase by 2-3 Berger is obtained.
[0052] Overall, the data support the claim on the range of pHs to be applied (11.0-13.0), ranging from low end (data on pH 11—table 4; pH 11.6—table 1 and 2, pH 12.0/pH 12.5/pH 13.0—tables 2, 3, 4, 5) and on the range of catalyst that can give significant benefits (from 0.0005 μM—table 3, till 1.5 μM—tables 4 and 5). | The present invention concerns the treatment of substrates with a preformed transition metal catalyst in an aqueous solution. The transitional metal catalyst is a dinuclear Mn transitional metal catalyst and its ligand has the following formula (I):
and p is 3. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION:
This application is a continuation-in-part of my application Ser. No. 293,819, filed Oct. 2, 1972, now abandoned.
BACKGROUND OF THE INVENTION
This invention has relation to hydraulic circuitry for a backhoe excavator. The same pair of hydraulic pumps is used to power a first set of functions such as one side of a crawler track drive, and also a second or other set of functions such as boom, bucket, stick or auxiliary drum drives.
It is desirable to perform the no-load movement of hydraulic piston-cylinder motors at relatively high speed to achieve minimum operating times for movement of boom, bucket and stick, for example. If this is achieved by use of a constant volume source of hydraulic fluid, when resistance to movement is encountered in a particular motor, as when coming under load, the pressure inside the motor will rapidly exceed the safe overload pressure and a large volume of fluid will pass out of the overload relief valve back to the fluid tank or reservoir. This is a waste of power, and occasions excessive heating of the fluid which must be compensated for by incorporation of an overly large hydraulic fluid cooling system.
If no-load movement of the hydraulic piston-cylinder motors is achieved at relatively high speed by use of large, constant horsepower control, pressure compensated variable displacement pumps as sometimes employed in prior art structures common in Europe, the flow volume will begin decreasing when something like one-half of the maximum pressure develops in the system under load, and this slow down of movement of the piston-cylinder motors will continue until the saft overload pressure is exceeded, at which point about 40% of the pumps maximum volume will pass over the relief valve and back to the fluid tank or reservoir, thus constituting a waste of power and excessive heating of the fluid.
One way to overcome these problems is by the use of two sources of fluid and an unloading valve which disconnects one of the sources from the motor and bypasses it to the return line under low pressure when the pressure in the motor lines exceeds a predetermined pressure less than the relief valve pressure.
Such high speed to low speed hydraulic systems are well known. See the patent to Vickers, U.S. Pat. No. 1,982,711, issued Dec. 4, 1934, in which pumps 1 and 2 furnish hydraulic fluid to move a power cylinder 22 until such time as a predetermined high pressure is built up in cylinder 22. At that time, an unloading valve unloads pump 2 so that Pump 1 can continue to activate the power cylinder, but at slow speed. When the pressure in cylinder 22 is reduced, as when the direction of hydraulic fluid flow into the cylinder is reversed, the unloading valve allows the hydraulic fluid from pump 2 to once again be introduced into the system for high speed operation.
The use of an unloading valve in a hydraulic circuit incorporating two hydraulic pumps to unload one of the pumps when a considerable resistance is encountered is also shown in the patent to LaRou, U.S. Pat. No. 3,156,098, issued Nov. 10, 1964. This patent is related to backhoes and diggers.
Use of a hydraulic circuit for an excavator with means to propel the excavator and associated means to power the implement is shown in the patent to Metailler, U.S. Pat. No. 3,172,552, issued Mar. 9, 1965. See FIG. 6.
Use of a low volume pump and a high volume pump to perform various functions in a backhoe vehicle is shown in the patent to Arnold, U.S. Pat. No. 3,257,013, issued June 21, 1966. A manually operable selector valve 86 can be activated to direct the output of one of the pumps to add to the output of the other pump when high speed operation is advantageous. The difficulty here is that when high resistance and therefore high pressure is encountered with the controls in that position, the overload valves will be activated, thus dumping the hydraulic fluid into the return tank, causing power waste and undue overheating of the hydraulic fluid. See FIG. 6 of Arnold.
Use of a plurality of fluid motors to operate backhoe functions at high speeds under light loads and at low speeds but higher fluid pressures under heavy loads is shown in the patent to Stacey, U.S. Pat. No. 3,146,593, issued Sept. 1, 1964.
A patent which shows two pumps operating independent track drives on a backhoe excavator is the patent to Morrison et al., U.S. Pat. No. 3,466,770, issued Sept. 16, 1969. The valving here is through a single manifold 196, however. See FIG. 7.
In the past, in order to prevent duplication of hydraulic pump circuits and controls, it has been customary to forego the ability to move a hydraulic backhoe on its crawler assembly while performing full force operations with the bucket, stick and boom.
BRIEF SUMMARY OF THE INVENTION
In hydraulic circuitry for independently driving left and right traction drive assemblies, and other functions such as the boom, bucket and stick cylinders of a backhoe, a first hydraulic circuit including two separate hydraulic pumps is utilized to drive a first of said traction drive assemblies and certain of the other functions such as the boom motor and the bucket motor, while a second hydraulic circuit including two other hydraulic pumps is utilized to drive the second of the traction drive assemblies and other functions such, for example, as the stick motor. Each of these circuits operates in essentially the same manner as the other, so the description can be limited to either of the circuits.
In a first form of the invention, the two separate hydraulic pumps utilized in each instance are disclosed as being fixed displacement pumps. In a modified form of the invention, one of the pumps remains a fixed displacement pump, while the other pump is disclosed as being a fully compensated variable displacement pump. Otherwise, the hydraulic circuitry remains the same.
In each of the disclosed forms of the invention, a first of the two independent circuits includes a normal path from a first of said pumps to a traction function valve capable of three modes of operation to either:
1. bypass the hydraulic fluid through the valve when the track is not to be driven,
2. direct the hydraulic fluid to drive a track drive motor in a forward direction, or
3. direct the hydraulic fluid to drive the motor in the reverse direction.
The output from the second pump passes to a traction speed selector valve which is normally positioned for low speed operation, directing the hydraulic fluid through it to an unloading valve, but which can be actuated for high speed operation, directing the hydraulic fluid into the traction function valve along with the output of the first pump.
The output of the second hydraulic pump and output of the first pump through bypass mode of the traction function valve and through the check valve, proceeds to another function control valve where the hydraulic fluid can be directed to bypass through that valve or operate the other functions in either forward or reverse direction.
A pressure control line transmits the pressure in the line between the traction function valve and the check valve to the unloading valve. Until a predetermined high value of pressure is reached in the hydraulic system operating one of the other functions, output from the second pump through the traction speed selection valve in its normal position joins with the output through the check valve to increase the volume of flow into and through the other function control valve, thus providing high speed operation of the other function. When resistance is encountered in the other function, however, the back pressure along the lines will rise until that in the pressure control line reaches the predetermined point at which time it will block further flow through the unloading valve and dump the fluid from pump 2 back to the reservoir. This will allow the output from pump 1 only to continue to rise in pressure until the relief valve setting is reached.
It is the excessive operation of this relief valve in machines not utilizing this invention which causes wasted power and undue heating in the hydraulic system, thus necessitating use of larger than economically feasible cooling systems for the hydraulic fluid.
The traction speed selector valve normally directs the output from the second pump to the other function control valve except at such time as the traction speed selector valve is activated to divert the output of the second pump into the traction drive function valve. At that time it is possible to drive the track at high speed, but, when the track is actually being driven at high speed there will be no hydraulic fluid available to perform the other functions. At all other times, all of the other functions and the drive of the track can be accomplished simultaneously. When the track is not being driven at any speed, the conventional high-low or unloading circuit operation of the other functions is in full effect.
When a traction drive motor is in slow speed operation, there is no flow of fluid from the traction drive function valve to the check valve. The presence of the check valve prevents back pressure from building up in the pressure control line, so the fluid flow from the second pump cannot be interrupted by the unloading valve. The precise location of the unloading pilot pressure pickup between the check valve and the traction function valve allows operation of the second pump to a relief valve pressure higher than the unloading pressure while the first pump is at full relief pressure of the traction function valve.
In a modified form of the invention, the "first pump" referred to above will be a pressure compensated variable displacement pump. The circuit will unload as set out above when a predetermined pressure exists within the system due to resistance encountered by the hydraulic piston-cylinder motor. The second pump can be a large fixed displacement pump, and after it is unloaded to deliver its hydraulic fluid to the reservoir under low pressure, the first pump will continue to deliver at substantially constant volume at higher pressures. When the pressure approaches the established maximum, the pump compensator reduces the pump displacement to its minimum, while maintaining the high pressure within the system, thus eliminating flow of high pressure fluid over a relief valve and back to the reservoir. A very small expenditure of power, say 5% of the total available horsepower in a typical case, is used to sustain the system at maximum pressure.In the drawings:
FIG. 1 is a side elevational view of a backhoe excavator showing the positioning of the boom, bucket and stick, and the boom, bucket and stick control motors;
FIG. 2 is an enlarged horizontal sectional view taken on the line 2--2 in FIG. 1 showing the positioning of the track drive motors and the track drive mechanism;
FIG. 3 is a schematic representation of the hydraulic circuitry of a first form of the invention;
FIG. 4 is a schematic representation of hydraulic circuitry in accordance with a modified form of the invention;
FIG. 5 is a partially schematic, elevational view of a pressure compensated variable displacement pump useful in connection with the modified form of the invention, with parts in section and parts broken away.
FIG. 6 is a chart of hydraulic fluid flow available to perform functions other than track drive functions plotted against pressure in the hydraulic system performing such other functions in the hydraulic circuit of the first form of the invention;
FIG. 7 is a comparable chart of flow and pressure in such other function forming part of the hydraulic circuit in the modified form of the invention; and
FIG. 8 is a comparable chart of flow and pressure in a hydraulic system of the prior art employing one constant horsepower, pressure compensated variable displacement pump.
DESCRIPTION OF PREFERRED EMBODIMENTS
In a first form of the invention as disclosed in FIGS. 1-3 and 6, a hydraulic backhoe excavator 10 includes a platform 11 rotatably mounted on a car body 12 in any usual or preferred manner. This car body is supported on axles 14 in crawler frames 16, 16. Hydraulic track drive or traction motors 18 and 19 are mounted one on each crawler frame and drive sprockets 20 and crawler tracks 22 and 23 are operably mounted on the crawler frames in any usual or preferred manner. Traction motor lines 24 and 26 extend to left traction motor 18 while traction motor lines 28 and 30 extend to the right traction motor 19. When hydraulic fluid is forced through lines 24 and 28 and into the motors 18 and 19, respectively, and consequently, out through lines 26 and 30, respectively, the motors will cause the tracks to drive the car body in forward direction. When the flow is reversed, the tracks will move the car body in reverse direction.
Pivotally mounted to the rotating platform 11 is boom 36 as at 34. A stick 38 is pivotally mounted as at 40 to the boom point; and a backhoe bucket 42 is pivotally mounted as at 44 to the outer end of the stick.
Movement of the boom 36 with respect to the rotating platform 11 is controlled by one or more boom piston-cylinder motors 46, pivotally connected between the rotating platform and the boom, as shown in FIG. 1. Boom control lines 48 and 49 extend to the boom piston-cylinder motors to selectively control extension and retraction thereof.
The relative position of the stick 38 with respect to the boom 36 is controlled by the stick piston-cylinder motor 52, to which stick control lines 54 and 56 extend.
The angular positioning of the bucket 42 with respect to the stick 38 is controlled by a bucket piston-cylinder motor 58, and bucket control lines 60 and 62 extend to this piston-cylinder motor.
As best seen from the schematic representation of the hydraulic circuits in FIG. 3, a three position crawler track or traction function valve 64 is associated with left track drive motor 18, and handles hydraulic fluid to lines 24 and 26; while a similar three position crawler track or traction function valve 66 is associated with right track drive motor 19 and handles the hydraulic fluid to lines 28 and 30. By operation of spool control 68 on each of these valves 64 and 66, hydraulic fluid supplied to the valves can be caused to flow to drive the tracks in forward direction, to drive the tracks in reverse direction, or to bypass the fluid through the valve with minimum resistance to flow.
As shown, a first hydraulic pump 70 and a second hydraulic pump 72 are both driven by a prime mover (not shown) through the instrumentality of drive shaft 74. Similarly, third hydraulic pump 76 and fourth hydraulic pump 78 are driven through the instrumentality of drive shaft 80. These become the first and second pumps of the right hydraulic system.
A reservoir for hydraulic fluid to be used by these pumps is designated conventionally by 82 as a series of open tanks wherever they appear on the hydraulic circuitry of FIG. 3.
A first hydraulic supply line 84 extends from the outlet of first pump 70 to an inlet connection of crawler track function valve 64; and a comparable hydraulic supply line 86 extends from third pump 76 to the inlet side of crawler track function valve 66. A high-low traction speed selector valve 88 is supplied by a hydraulic line 90 from the output of the second hydraulic pump 72; while a similar selector valve 92 is supplied from fourth hydraulic pump 78 through hydraulic supply line 94. These valves are normally spring biased to bypass the fluid through the valve and out through outlet lines 96 and 98, respectively; but can each be controlled, by movement of spool control 100 to divert flow to outlet lines 102 and 104, respectively. The lines 102 and 104 open into hydraulic supply lines 84 and 86, respectively, thus directing the flow from both sets of pumps into the respective crawler track function valves 64 and 66.
Normally open outlet lines 96 and 98 from the speed selector valves open to unloading valves 106 and 108, respectively. These unloading valves, when not subjected to a predetermined control pressure, permit free passage of the fluid from lines 96 and 98, through the unloading valves to lines 110 and 112, respectively, these lines forming inlet lines to function control valves 114 and 116, respectively, which control the operation of the other functions such as those of the boom, bucket and stick hydraulic-cylinder motors. To differentiate from the track function valves 64 and 66, these valves will be referred to as the other function control valves 114 and 116.
The previously mentioned flow out from the track function valves 64 and 66 is along hydraulic lines 118 and 120, respectively, and through one way check valves 122 and 124 to lines 110 and 112, thus directing hydraulic fluid from the track function valves to the other function control valves whenever the trach function valves are not being utilized to divert hydraulic fluid to power the track drive motors.
Open to each of lines 118 and 120 are hydraulic pressure control lines 126 and 128 which also open to unloading valves 106 and 108, respectively. These unloading valves can be of any usual or preferred construction, such that when the predetermined pressure builds up in line 118, for example, and consequently in pressure control line 126, unloading valve 106 will be activated to block flow to line 110 and to dump the flow at low pressure into the hydraulic reservoir 82 through return line 129. Similarly, exceeding the predetermined pressure in line 120 will result in an unloading action of valve 108 through line 129 to the reservoir.
The other function control valves 114 and 116 are of the three position type, as shown. Thus, for example, operation of the spool control 130 on other function control valve 114 can position the valve spool to either direct flow from line 110 through the valve to line 132 to the reservoir, direct flow into line 54 to cause the piston-cylinder motor 52 to retract, or can direct flow into line 56 to cause the motor to extend. Similar parts on other function control valve 116 control the functions of the boom piston-cylinder motor 46 and the bucket piston cylinder motor 58. As shown, there is one bank of function control valves not connected, but it is to be understood that this valve bank cound be connected to operate a drag line winch, for example, or to perform any other necessary or desired function. There could be any number of similar control valves banked on as a part of either of the other function control valves.
OPERATION
Since the two separate hydraulic circuits are identical in their operation, the operation of the left track and stick circuit is all that is necessary to be described.
With track function valve 64 and other function control valve 114 in neutral position and with traction speed selector valve 88 in its normal or nominal position, hydraulic fluid from reservoir 82 will flow through intake line 83 to pump 70 and out from the first pump 70, along line 84, through track function valve 64, line 118, check valve 122, line 110 and through other function control valve 114 and line 132 to the reservoir 82. At the same time, hydraulic fluid from reservoir 82 will flow through second hydraulic pump 72, line 90, traction speed selector valve 88, line 96, unloading valve 106, and into line 110 where it joins the output from the first pump in flowing through the other function control valve 114, line 132 and back to the reservoir.
When it is desired to drive the left track assembly in forward direction at normal slow speed, the spool control 68 on track function valve 64 will be activated to cause hydraulic fluid to be directed into the line 24, through right traction motor 18, and back through line 26, through the valve 64 and through outlet line 134 to reservoir 82. At that point, there will be no flow of hydraulic fluid along line 118, but the flow from second pump 72 is still present in lines 90, 96 and 110, so the stick motor 52 could be activated at low speed high pressure during the driving of the track.
Should it be desired that the track be driven in high speed, the spool control 100 will be activated to divert the flow from second pump 72 to the line 102, where the fluid from this second pump joins with the fluid from the first pump in line 84 and increases the speed of the track motor.
In this mode of operation, there is, of course, no hydraulic fluid entering the unloading valve 106, and hence no fluid flow through line 110 to power other functions controlled by valve 114.
When the track is not being driven at all, and the hydraulic fluid from pump 70 is flowing through right track function valve 64, line 118 and check valve 122 to line 110, any operation of spool control 130 to extend or contract the stick motor 52 will initially result in high speed operation of the motor 52 inasmuch as fluid from both first and second pumps 70 and 72 is being directed to the other function control valve 114 and through that valve to the stick motor 52. When the pressure in the lines builds up, as, for example, when the stick motor 52 comes under heavy load during a digging operation, the resistance to flow through line 110 will allow and cause a pressure buildup all the way back to the pumps, including in line 118. The pressure in line 118, being transmitted to the unloading valve 106 through pressure control line 126 will, when the predetermined pressure for which that valve is set is attained, cause the valve to divert flow of hydraulic fluid from line 96 to line 129, and back to the reservoir. Then only the fluid from first pump 70 will flow through line 110, and the stick motor 52 will operate in the low speed high pressure mode. This prevents excessive flow over the relief valves when the resistance to the piston-cylinder motors, motor 52, for example, becomes sufficient to stop motion thereof. Waste of energy and undue heating of the hydraulic fluid is thus substantially reduced.
While shown only in an illustrative and schematic manner, valves 64, 66, 114 and 116 contain conventional relief valves. Other relief valves are indicated at 136. The pressure at which the unloading valves 106 and 108 are triggered is below the pressure relief point of these relief valves. Thus, the relief valves never operate at the combined flow rate of both pumps during normal digging operation. When an overload causes stalling, it is only the affected first pump 70 or 76 which will be delivering full volume through the relief valves, and the energy so wasted will be only the energy lost form that pump.
While first and second pumps 70 and 72, have been shown driven by a common shaft 74 from a prime mover, this arrangement is not essential to the invention. Four individually driven pumps or any combination of multiple pumps would serve equally well.
Pumps 70 and 76 could be of either fixed or variable displacement, but the circuitry of FIG. 3 was described above as if they were fixed displacement pumps. The modified form of the invention as shown and illustrated in FIGS. 4, 5 and 7 utilizes first pumps 70 and 76 which are pressure compensated variable displacement pumps.
The circuit of FIG. 4 is identical in all respects but one with the circuit of FIG. 3. Also, the circuit acts and reacts in the same manner as the circuit shown in FIG. 3. Therefore a detailed description of the operation of the circuit of FIG. 4 is unnecessary. Identical parts in FIGS. 3 and 4 are identically numbered.
In the modified form of the invention, a particular adaptation using a pressure compensated variable displacement pump will be set forth. As seen in FIG. 4, a first pump 70 is driven by the shaft 74 from prime mover 73 while first pump 76 is driven by shaft 80 and powered by prime mover 79. The structure of the pressure compensated pump 70 can be the same as the pressure compensated first pump 76, which is disclosed in FIG. 5. A swash-plate pump 200 is shown, but other types of variable displacement pumps would serve equally well. First pump 76 includes swash-plate pump 200 having a swash-plate 201 and a first servo controlled cylinder 202 in which a compression coil spring 204 is situated to mechanically force first servo controlled piston 206 to the position as seen in FIG. 5, thus affording the maximum displacement of pump pistons 208 and 210 in pump cylinders 212 and 214 respectively. This causes the pump 76 to deliver its maximum volume through internal pump discharge passageway 216, and to the first hydraulic supply line 86.
Pump 76 continues to supply its full volume of hydraulic fluid to the line 86 up to and beyond the point that the pressure in line 120 and through control line 128 causes unloading valve 108 to dump the flow of hydraulic fluid from second pump 78 to the reservoir.
If the resistance to movement continues to increase, the pressure will continue to build up in first pump 76 and in pressure control line 218 in that pump which is open to a spool control valve cylinder 220 of a spool control valve 224. This pressure control line 218 is also open to the first hydraulic supply line 86. A spool 226 of the spool control valve 224 is spring forced in direction to the right as seen in FIG. 5 by a compression coil spring 228. The spool also includes a piston 230 sealingly and operatively mounted in spool control valve cylinder 220.
Adjustment structure 232 is provided to control the force exerted by spring 228 to an amount such that the spool 226 will not begin to move to the left until just before the maximum allowable pressure in the system is reached. At this point, the pressure of the system through line 86 and pressure control line 218, acting in spool control valve cylinder 220 on piston 230 does force the spool to the left until such time as a port in valve 224 open to a conduit 234 receives fluid past the piston 230 from the cylinder 220. This conduit 234 leads to a second servo control cylinder 236 having a piston 238 therein. This hydraulic fluid under pressure forces the swash-plate 201 toward a position parallel with the pump, thus reducing the output of the pump to the point where the only hydraulic fluid flowing at stalled conditions is the fluid necessary to main the pressure in control line 218 to the point where the spool 226 has sufficient movement to maintain cutoff pressure in second servo control cylinder 236 through conduit 234.
In a typical case where, in accordance with the first form of the invention, a constant displacement pump is used as the first pump, the power lost through the relief valves under stall conditions can be on the order of 60% of the horsepower available. in contrast, with a pressure compensated pump acting in the manner described, the power lost under stall conditions will be on the order of magnitude of 5% of the available horsepower.
This savings in power is illustrated graphically in FIGS. 6 and 7 in which pressure and flow is expressed as percentages.
In FIG. 6, for the form of the invention as shown in FIG. 3 and with the first pump being of the constant displacement type, the pressure developed in line 110 or line 112 is plotted at 240 against the flow in the same line. Flow rate determines the speed with which a piston is moving with respect to its cylinder in one of the other function motors. Under low pressure, maximum speed is obtained until the control pressure for operation of the unloading valves 106 or 108 is reached.
At that point, at 70% pressure as shown, the output of the second pump is switched off, and the flow or speed of the parts is reduced. At stall, when 100% of the available pressure is achieved, the relief valves will open, and all of the energy of the first pump will be lost through the relief valve in the form of heat in the hydraulic fluid.
To the right of FIG. 6, the percentage of available horsepower is indicated at the top of the chart. A typical figure for available horsepower at stall is 60%, as shown at the stall point on the chart of FIG. 6. This 60% horsepower is being wasted under stall conditions.
FIG. 7 is a plot at 242 of flow against pressure in line 112, for example, in the form of the invention as seen in FIG. 4, and in which first pump 76 is a pressure compensated variable displacement pump operating in the manner described above. Under low pressure conditions, as seen in FIG. 7, the flow rate, or speed of the parts relative to each other stays at a maximum until such time as the pressure in line 120 and control line 128 causes left unloading valve 108 to dump the fluid from second motor 78 to the reservoir 82 at low pressure. At this point, the first pump 76 continues to deliver hydraulic fluid into first hydraulic line 86 at its maximum rate until just before the stall point is reached. At this point, the spool control valve 224 introduces hydraulic fluid under the maximum pressure into the second servo control cylinder 236 in the manner described above, and the volume from the swash-plate pump 200 is drastically curtailed. Then when the stall out pressure is reached and the parts no longer move with respect to each other at the hydraulic piston-cylinder other function motor, the first pump 76 is delivering only enough fluid to maintain pressure sufficient to balance spring 228.
FIG. 8 is a similar flow against pressure plot at 244 for a prior art situation in which a large single constant horsepower pressure compensated variable displacement pump is used. In order to be able to provide sufficient flow so that the no load and low load speed of the parts relative to each other in the hydraulic piston-cylinder other function motors such as 46 and 58 is comparable with the no load speeds achieved in connection with the present invention, an extremely large pump must be used. This is economically a very substantial drawback. Further, with only one pump there can be no unloading system, and the pump must be so constituted that the pressure compensation begins to take place when the pressure is somewhere in the general neighborhood of 40% of the maximum pressure allowable. At this point, the flow-pressure curve falls and, as the pressure increases, the speed of the other functions must continually decrease until the stall point is reached. At that stall, a typical value of the horsepower available would be 45% of the maximum. At this point, 45% horsepower is being delivered by the single pump through the relief valves and into the reservoir system in the form of heat in the hydraulic fluid. This is all lost energy.
Referring back to FIG. 7, the curved portion of plot 244 of FIG. 8 has been superimposed on FIG. 7, to show the difference in performance characteristics as far as speed of performing the functions is concerned. The shaded area represents the difference in effective power supplied to the functions under the two situations. The difference in the flow or speed of performing the function is readily apparent as well. In the apparatus of the invention, the speed holds up to substantially 100% until the point where the unloading valve works, and then holds up at substantially half speed until just before the first pump 76 drops the great majority of its power and cuts its volume, preparatory to reaching the stall pressure, at which only 5% horsepower goes to heat in the hydraulic fluid. | A hydraulic backhoe utilizes two pairs of hydraulic pumps to power independent crawler track drives in any forward or reverse direction, and high or low speed ranges; allowing, for example, a wide arc turn either left or right, forward or backward. Through a novel hydraulic circuit, these pumps also power other functions such as boom, bucket and stick drives in high speed or low speed modes. This flexibility is accomplished by the use of a manually controlled track speed selector valve, an unloading valve and check valve between a track function valve and another function valve in each of the two hydraulic circuits. Full hydraulic pressure is available to all functions at all times except when a track drive is in high speed range. Conventional high-low or unloading operation of the other functions is had when the related track drive is not operating. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to printers and, more particularly, to an improved printer paper feeder for feeding continuous paper.
2. Description of the Related Art
Printers which have continuous paper feeders are generally known. A typical such feeder has a pair of front and a pair of back pin tractors disposed on a paper feeding route. A platen roller is positioned therebetween. Each tractor has a plurality of rotatable pins. The pins are arranged to engage with holes formed on both side ends of a continuous paper. Thus, the rotating motion of the pins will feed the continuous paper.
In order to set the continuous paper in the above feeder, the tip of the paper is first set at the back pin tractors. Then, the back pin tractors are rotated to feed the paper tip to the front pin tractors via the platen roller so as to position the tip at the front pin tractors. However, when the paper is tensed to be set in the front pin tractors, the holes at the paper rarely geometrically correspond to the pin positions of the front pin tractors. Thus, the paper usually has a looseness between the front and back tractors when it is set. Accordingly, users have to manually adjust the front pin tractors' position to remove any slack in the paper.
However, such manual adjustments are troublesome. Therefore, feeders which automatically remove the looseness of the continuous paper have been proposed.
In such feeders, the continuous paper also has a looseness between the front and back pin tractors at setting. After such setting is finished, the pins of the back pin tractors rotate in reverse. At this time, a mechanism such as a one-way spring clutch or the like cuts off the drive transfer to the front pin tractors. Accordingly, the back pin tractors pull the paper backward while the front pin tractors remain stationary and thus remove the looseness of the paper between the front and back pin tractors.
In the aforementioned feeder, the continuous paper may also be set from the bottom of the printer or the like without passing through the back pin tractors. In this case, a paper feed is performed only by the front pin tractors. If the paper is fed only frontward, there is no problem. However, it may occasionally be necessary to feed the paper a relatively large distance backward, such as when enlarged letters or the like are to be printed. In such cases, the one-way spring clutch or the like prevents the front pin tractors from rotating in reverse and thereby prevent the retraction of the continuous paper.
SUMMARY OF THE INVENTION
Accordingly, it is a primary objective of the present invention to provide a paper feeder for printers which automatically removes the looseness of the continuous paper and also is capable of feeding and retracting the paper even when the front pin tractors are used alone.
To achieve the foregoing and other objects and in accordance with the purpose of the present invention, an improved paper feeder for printers is provided. The paper feeder is adapted to feed continuous paper to a platen roller disposed in a paper feed path. The feeder has two pairs of pin tractor assemblies which are located on opposite sides of the platen roller with respect to the paper feed path. The tractors each have a plurality of pins which are rotatable to convey the paper. The pins engage with holes on the continuous paper. A reversible drive means powers the rotation of the pins via a drive mechanism. A clutch mechanism selectively decouples the front pin tractor assembly from the drive means depending upon the rotational direction of the drive means. Moreover, a switching mechanism is provided between the drive mechanism and the front pin tractors. The switching mechanism selectively decouples the front pin tractors from the drive means independent of the clutch mechanism.
In accordance with a second aspect of the invention, a controller is provided for removing slack from between the tractor assemblies. The controller first rotates the tractors in a forward direction. The back pin tractors are then rotated in the reverse direction to pull the paper backward. Thus, the looseness, between the front and back pin tractors, of the continuous paper is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with the objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a partially broken sectional side view showing one embodiment of a printer paper feeder in accordance with the present invention.
FIG. 2 is a simplified sectional side view showing the paper feeder including two pairs of pin tractors.
FIG. 3 is a sectional view showing front pin tractors without a guide plate.
FIG. 4 is a partial side view showing the front pin tractors.
FIG. 5 is a partially broken sectional plan view showing a tractor gear and the like of the front pin tractors.
FIG. 6 is a perspective view showing a switch lever and the like of the front pin tractors.
FIG. 7 is a block diagram showing a control circuit for the paper feeder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in the drawings, a preferred embodiment of the present invention will be described in detail hereinafer.
As shown in FIG. 1, a platen roller 2 is supported on a printer case 1 by means of a platen shaft 3. The platen roller 2 is located on a running route of a continuous paper P and extends along the width direction of the paper P. A platen gear 4 is fixed to one end of the platen shaft 3. A paper guiding plate 6 is provided below the platen roller 2 and supports a plurality of paper holding rollers 5. A printing head 7 is provided before the platen roller 2 and reciprocates back and forth along the roller 2.
A front tractor unit 8 is disposed in front, on the running route of the paper P, of the platen roller 2. As shown in FIGS. 1 to 3, the tractor unit 8 has a pair of detachable side plates 9 which are assembled on opposite ends of the platen shaft 3. A square drive shaft 10 and connecting shaft 11 are provided between the side plates 9 and extend in parallel with the platen roller 2. A pair of front pin tractors 12 are supported on both the shafts 10 and 11 and may move thereon in the width direction of the paper P for adjustment. A supporting plate 13 is also supported on both the shafts 10 and 11 between the pin tractors 12.
As shown in FIGS. 1 and 4, the side plates 9 each have a recess 9a which is to be fitted to each end of the platen shaft 3 so as to attach the unit 8 to an upper portion of the printer. The side plates 9 each support a release lever 14 at an inner side thereof by means of a pivot 14a, about which the levers 14 are rotatable. A tension spring 15 is hooked at each lever 14 and urges the levers 14 so as to engage hook portions 14b (the lower portions of the levers 14) with engaging pins 16 of the printer case 1 when the front tractor unit 8 is assembled to the printer case 1. When the unit 8 is disassembled from the printer, the release levers 14 are rotated against the force of the tension spring 15 to detach the hook portions 14b from the engaging pins 16.
As shown in FIGS. 1 to 3, the front pin tractors 12 have a tractor frame 17. The tractor frame 17 supports a pair of follower pulleys 19 and a pair of drive pulleys 18 which rotate together with the drive shaft 10. A pin belt 20 having a plurality of pins 20a is hooked between the pulleys 18 and 19 respectively. The pins 20a are spaced to engage holes Pa in the continuous paper P. When the pins 20a rotate, they engage the holes Pa as shown in FIG. 3, thereby conveying the continuous paper P. The tractor frame 17 also has a guide plate 21 which is switched between two positions. One is a lying position shown as solid lines in FIGS. 1 and 4. The other is a standing position shown as two dot chain lines in FIGS. 1 and 4. The paper P may be placed on or removed from the tractors when the guide plate is in the standing position. The paper is held at the lying position.
As shown in FIG. 5, a tractor gear 22 is disposed at one end of the drive shaft 10 outside the side plate 9 and has a one-way spring clutch 22a. The one way spring clutch 22a only transfers the forward rotation (in the direction of arrow A shown in FIGS. 2 and 4) of the gear 22 to the drive shaft 10 and does not transfer the backward rotation. An axle 23 is provided standing on the side plate 9 adjacent the tractor gear 22 and supports an intermediate gear 24 which is rotatable about the axle 23. The intermediate gear 24 connects the tractor gear 22 and the platen gear 4 together.
The end of the drive shaft 10 projecting from the gear 22 is cut off to form a flat surface 10a. A beveled clutch plate 25 is fitted to the flat surface 10a and is movable along the axial direction of the shaft 10. The clutch plate 25 rotates together with the drive shaft 10.
A single or a plurality of engaging projections 25a are provided on a surface, adjacent the tractor gear 22, of the clutch plate 25 and project toward the gear 22. By way of example, eight engaging projections 25a are coaxially arranged at equal intervals in this embodiment (only a part thereof is shown in FIGS. 5 and 6). The clutch plate 25 is beveled and has a tapered portion 25b at the periphery thereof. The tapered portion 25b converges toward the gear 22.
Eight engaging recesses 22b corresponding to the engaging projections 25a are formed on a surface, adjacent the clutch plate 25, of the tractor gear 22 coaxially at equal intervals (only a part thereof is shown in FIGS. 5 and 6).
A switch lever 26 is supported on the axle 23, about which the lever 26 swings. The switch lever 26 has an opening 26a which is tapered. The tapered opening 26a converges toward the gear 22. The clutch plate 25 is to be inserted into the opening 26a. When the clutch plate 25 is inserted into the opening 26a, a predetermined space is defined between the tapered portion 25b and the opening 26a. The switch lever 26 also has an elastic arm 26c which has a nib 26b at a tip thereof.
As shown in FIGS. 3 and 5, the gears 22 and 24 and both ends of each shaft 10 and 11 are covered with covers 27 which are attached to the side plates 9 from outside. One of the covers 27 adjacent the tractor gear 22 has a catch 27a (refer to FIG. 4). A part of the switch lever 26 is located outside the cover 27 and the catch 27a is to be engaged with the nib 26b. When the nib 26b is engaged with the catch 27a, the switch lever 26 is held at a position shown in FIG. 4. And when the switch lever 26 is swung in the direction of arrow B in FIG. 4, the elastic arm 26c is elastically deformed. Thus, the nib 26b goes over the catch 27a and is positioned at the opposing side of the catch 27a.
A spring 28 is disposed between the cover 27 and the clutch plate 25 and always urges the clutch plate 25 toward the tractor gear 22. When the center of the opening 26a overlaps the center of the drive shaft 10 as the switch lever 26 swings, the spring 28 brings the clutch plate 25 into the opening 26a. Then, the engaging projections 25a are engaged with the engaging recesses 22b. The tractor gear 22, the clutch plate 25, the switch lever 26, and the spring 28 compose a switching mechanism.
As shown in FIGS. 1 and 2, a back tractor unit 30 is disposed behind the platen roller 2 relative to the running route of the paper P. The back tractor unit 30 extends in parallel with the platen roller 2 and has a guide shaft 32 and a drive shaft 31 which is supported and rotatable on the printer case 1. A pair of back pin tractors 33 are disposed on both the shafts 31 and 32 and are movable in the width direction of the continuous paper P for adjustment.
The back pin tractors 33 are designed similar to the front pin tractors 12. A pair of drive pulleys 35 are supported on a tractor frame 34 via the drive shaft 31 and a pair of follower pulleys 36 are also supported on the frame 34. A pin belt 37 having a plurality of pins 37a is strung between the pulleys 35 and 36 respectively. A guide plate 38 which may be shifted between standing and lying positions is disposed on the tractor frame 34.
As shown in FIG. 1, a tractor gear 39 is fixed to one end of the drive shaft 31 outside one of the back pin tractors 33. The tractor gear 39 is connected to the platen gear 4 via intermediate gears 40 and 41 which are supported by and rotatable with respect to the printer case 1. The intermediate gear 40 is also connected to a motor gear 43 of a motor 42, which works as a drive source and may rotate both ways.
In this embodiment, the gears 4, 22, 24, and 39 through 41 compose a drive mechanism which transfers a drive force of the motor 42 to both the front and back pin tractors 12 and 33.
The printer case 1 has a paper feed 44 at the bottom thereof. A pair of guide plates 45 and 46 are disposed adjacent the paper feed and form a chute, namely a paper pathway 47. The continuous paper P may be inserted through the paper pathway 47 without passing through the back pin tractors 33. The guide plate 46 has a fin 48, which elastically press the paper P against the platen roller 2, at an end thereof adjacent and along the platen roller 2.
A control circuit for the foregoing paper feeder will be explained hereinafter in accordance with FIG. 7.
This feeder has a microprocessor (which will be referred to as MP hereinafter) 51 which works as the control circuit of the motor 42. The MP 51 stores a control program for the motor 42. A feed button 52 outputs a feed signal to the MP 51 via an input-output interface unit 53 to rotate the motor 42 in the forward direction. A retract button 54 outputs a retract signal to the MP 51 via the interface unit 53 to rotate the motor 42 backward. The MP 51 outputs a control signal to the motor 42 via the input-output interface unit 53 in accordance with the signals from the buttons 52 and 54.
The method for feeding a continuous paper P by means of both the front and back pin tractors 12 and 33 will be explained next.
In order to feed the paper P by using both the tractors 12 and 33, the switch lever 26 should be moved in the direction arrow B. As the nib 26b passes over the catch 27a, almost a half of the inner surface of the opening 26a comes into contact with a corresponding half of the periphery of the tapered portion 25b. As the switch lever 26 is moved further in the direction of the arrow B, the half periphery of the tapered portion 25b slides on the tapered inner surface of the opening 26a. Thus, the clutch plate 25 is pushed outward along the drive shaft 10 against the urging force of the spring 28, and the engaging projections 25a are separated from the engaging recesses 22b. Accordingly, the clutch plate 25 is separated from the tractor gear 22. At this point, the switch lever 26 has past beyond the catch 27a and is held at the opposing side of the catch 27a.
Then, a paper P is set at the back pin tractors 33 so that holes Pa at the tip of the paper P are engaged with the pins 37a. The feed button 52 is depressed to input a feed signal into the MP 51. In accordance with the inputted signal, the MP 51 drives the motor 42 forward to feed the continuous paper P in a predetermined distance.
The drive force of the motor 42 is transferred via the gears 4, 22, 24, and 39 through 41 and the one-way spring clutch 22a to the front and back pin tractors 12 and 33. Thus, the pins 20a and 37a rotate forward to feed the paper P. The tip of the paper P is thus fed from the back pin tractors 33 to the front pin tractors 12 via the platen roller 2 and the paper holding roller 5.
After the paper P is sufficiently fed so that the tip of the paper P may be set at the front pin tractors 12, the tip holes Pa are engaged with the pins 20a of the front pin tractors 12. In order to completely overlap the holes Pa and the pins 20a, the continuous paper P usually requires a little looseness between both the front and back pin tractors 12 and 33 for setting.
When the retract button 54 is depressed, the MP 51 first rotates the motor 42 frontward to feed the paper P for a predetermined distance. The forward feeding here insures that the paper P is securely hooked on the front pin tractors. Thus, the paper P will not accidentally fall off from the front pin tractors 12 when retracted in the next step.
Then, the MP 51 rotates the motor 42 backward to retract the paper P for a predetermined distance. The drive force is transferred to the back pin tractors 33 via the gears 43, 40, and 39. However, a retract drive transfer to the front pin tractors 12 is cut off by means of the one-way spring clutch 22a and also because of the separation of the clutch plate 25 from the tractor gear 22. Therefore, only the back pin tractors 33 rotates backward to retract the paper P a predetermined distance. The retract distance is determined so that the continuous paper P does not fall off from the front pin tractors 12 and that the tractors 12 rotate backward slightly by means of the retract force given by the paper P itself. Accordingly, the retract distance is a little larger than the preceding feed distance. Thus, the paper P is given a tension and its looseness is automatically removed.
After the looseness of the paper P is thus removed, the MP 51 again rotates the motor 42 forward a predetermined distance and then stops the motor 42 to wait for a printing operation. Accordingly, backlashes of the gears 4, 22, 24, and 39 through 41 are eliminated, and a firm engagement between the holes Pa and the pins 20a and 37a is obtained.
Therefore, in the present embodiment, it is unnecessary to move and adjust the front tractor unit 8 manually so as to remove the looseness of the paper P, which has been required in a prior art embodiment, and the looseness may be easily and effectively removed upon a simple operation of the retract button 54. Moreover, subsequent paper feeding will be smoothly performed since the drive force from the motor 42 always provides a constant tension to the paper P.
The method for feeding a paper P by means of only the front pin tractors 12 will be explained hereinafter.
In order to feed the paper P by the tractors 12 alone, the switch lever 26 has to be moved in the opposite direction to the arrow B. Thus, the nib 26b passes over the catch 27a and the switch lever 26 is shifted from a position shown in FIG. 6 to a position shown in FIG. 4. In this position, the center of the opening 26a overlaps the center of the drive shaft 10. Thus, the clutch plate 25 is brought into the opening 26a toward the tractor gear 22 by means of the urging force of the spring 28. If the engaging projections and recesses 25a and 22b overlap one another, they come to be engaged. Even if the projections and recesses 25a and 22b do not overlap one another at this point, they will overlap and come to be engaged when the motor 42 rotates the tractor gear 22 in the following step. Therefore, the forward and backward rotations of the tractor gear 22 are transferred to the drive shaft 10 via the clutch plate 25.
Continuous paper P is inserted from the paper feed 44 through the paper pathway 47 and then goes through the platen roller 2 to the front pin tractors 12. The paper P is set at the tractors 12 by engaging the holes Pa at the tip of the paper P with the pins 20a. As the paper P is set in this way, the rolled angle of the paper P on the platen roller 2 becomes more moderate than when the paper P is set through both the tractors 12 and 33. Thus, even if the paper P fed into the printer has several laminated sheets, the various sheets will not be shifted with respect to one another. It will be appreciated that this is particularly useful when printing on forms or the like having multiple sheets of carbon paper.
Once the paper is set, the MP 51 rotates the motor 42 to feed the paper P for a predetermined distance in accordance with printing data. The drive force from the motor 42 is transferred to the tractor gear 22 via the gears 40, 41, 4, and 24 and the one-way spring clutch 22a and via the clutch plate 25. Thus, the front pin tractors 12 rotate frontward to feed the paper P.
At times, the MP 51 may rotate the motor 42 backward in order to retract the continuous paper P a predetermined distance. For example, the paper P occasionally has to be retracted for the purpose of printing enlarged letters or the like thereon. In the retraction mode, the drive force from the motor 42 is transferred to the tractor gear 22 via the gears 40, 41, 4, and 24 and the clutch plate 25 to rotate the front pin tractors 12 backward. Accordingly, the paper P is retracted. At this time, the back pin tractors 33 also rotate but idly.
The front pin tractors 12 thus may rotate backward because the clutch plate 25 is connected to the drive shaft 10 according to the operation of the switch lever 26. Therefore, the paper P may be inserted into the printer through the paper pathway 47 without passing through the back pin tractors 33 and may be both fed and retracted by means of only the front pin tractors 12. Thus, enlarged letters or the like may be printed without having misplacements of the laminated pieces of the paper P using only the front pin tractors 12.
Although only one embodiment of the present invention has been described herein, it should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly, it should be understood that following modes are contemplated as well.
An electromagnetic clutch may replace the foregoing one-way spring clutch 22a as the clutching mechanism so as to allow or prevent the rotation of the drive shaft 10.
A one-way clutch including a ratchet pawl may replace the clutch plate 25 so that the drive shaft 10 can rotate both ways when the ratchet pawl is in engagement.
In the foregoing embodiment, the front tractor unit 8 is detachable, but it can be integrally assembled in the printer together with the back tractor unit 30.
Therefore, the present examples and 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 of the appended claims. | A paper feeder for printers having front and back pin tractor assemblies disposed on opposite sides of a platen roller with respect to the paper feed route. Each tractor has a plurality of pins which are rotatable so as to convey the continuous paper. A reversible drive source is coupled to both the pin tractors. A clutch selectively decouples the drive source from the front pin tractors in accordance with the rotational direction of the drive source. A switch mechanism independent of the clutch also selectively decouples the front pin tractor from the drive source. The described structure allows paper stack to be automatically removed from between the tractors. | 1 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a sewing machine with a differential work transport, consisting of a lower main feed and lower and upper auxiliary feeds, with the step sizes of the auxiliary feeds being adjustable from the step size substantially concording with that of the main feed, against spring bias, by setting devices whose setting members are connected, through a lever drive, with a common actuating means.
DESCRIPTION OF THE PRIOR ART
Sewing machines of this type, known up to now, require, for the shirring or gathering of stiff sewing material, an intermediate plate between the ply to be gathered and the ply which is not to be gathered, because the two superposed plies do not slide sufficiently on each other without the use of such an intermediate plate. This is due to their mutual friction and, therefore, an insufficient gathering effect is obtained. However, even with the intermediate plate, sufficient gathering of one fabric ply relative to the other fabric ply cannot be attained as soon as the ply to be gathered falls short of a certain flexibility. Besides, the pivoting in and out of the intermediate plate, which is necessary for closed seams, slows up the operation to be executed.
SUMMARY OF THE INVENTION
The objective of the present invention is to improve the known differential sewing machines so that, even when operating with relatively stiff fabric plies, for example when sewing the fabric inner sole into textile shoe uppers, sufficient gathering of one ply relative to the other ply can be carried out without using an intermediate plate.
To this end, the sewing machine of the present invention is designed with a differential work transport whereby the two auxiliary feeds exert, during the gathering process, a very large magnitude differential action on the superposed plies. In accordance with the present invention, this problem is solved in a surprisingly simple manner by designing a lever drive, disposed between the setting members of the setting devices for the two auxiliary feeds, operable to vary the respective step sizes of the two auxiliary feeds so that one of said lower and upper auxiliary feeds increases as the other of said lower and upper auxiliary feeds decreases.
Advantageously, the transmission ratio of the lever drive is adjustable so that optimum gathering ratios thus can be set at different step sizes of the main feed.
In order to be able to use the arrangement embodying the invention on a sewing machine wherein the setting members of the setting devices for the two auxiliary feeds are coupled, by respective force-locking couplings, with the adjusting member of the setting device for the main feed, which is connected with a shifting handle, the lever drive comprises a driver connection acting in only one direction. Consequently, this driver connection is effective only upon variation of the step sizes of the auxiliary feeds relative to the step size of the main feed. In machines where the step sizes of the auxiliary feeds automatically readjust themselves to the step size of the main feed in normal sewing, the contrasting problem, of being able to vary the step size of the auxiliary feeds when gathering in different directions, is solved in this manner.
An object of the invention is to provide an improved sewing machine with a differential work transport consisting of a lower main feed and lower and upper auxiliary feeds whose step sizes are adjustable from the step size substantially concording with the main feed against the spring bias by setting devices whose setting members are connected with a common actuating means to a lever drive.
Another object of the invention is to provide such a sewing machine which does not require an intermediate plate to be interposed between two plies which are to be gathered relative to each other.
A further object of the invention is to provide an improved differential sewing machine in which relatively stiff fabric plies can be sufficiently gathered, relative to each other, without the use of an intermediate plate.
Yet another object of the invention is to provide a sewing machine with such a differential work transport in which the two auxiliary feeds exert, during the gathering process, a very large magnitude differential action on the superposed plies.
A further object of the invention is to provide such a sewing machine, with a differential work transport, in which a lever drive, disposed between the setting members of the setting devices for the two auxiliary feeds, varies the respective step sizes of the two auxiliary feeds so that one of said lower and upper auxiliary feeds increases as the other of said lower and upper auxiliary feeds decreases.
For an understanding of the principles of the invention, reference is made to the following description of a typical embodiment thereof as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a perspective view of the head of a sewing machine embodying the invention, illustrating the stitch-forming point and the upper sewing tools; and
FIG. 2 is a perspective view of the drive mechanism for the feed tools of the sewing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 2, the sewing machine embodying the invention comprises a main feed 1, which is a lower feed, and a lower auxiliary feed 2, which are carried by respective supports 3 and 4. Supports 3 and 4 are formed with respective fork-type ends 5 and 6, each having extending thereinto, a respective eccentric 8, 9, secured on a shaft 7. Shaft 7 is driven in the usual manner, not shown, to impart lifting movements to the feeds 1 and 2.
Another shaft 10, in driving connection with shaft 7, is rotatably mounted to extend parallel to shaft 7, and has secured thereon eccentrics 11 and 12 embraced by respective eccentric rods or links 13 and 14.
Two coaxial shafts 15 and 16 are mounted parallel and in spaced relation to shaft 10, with the inner shaft 16 protruding from the outer shaft 15. A fork-type lever 17 is firmly connected with shaft 15, and support 3 for main feed 1 is articulated to lever 17. Similarly, a fork-type lever 18 is firmly connected to shaft 16, and support 4, for the lower auxiliary feed 2, is articulated to lever 18.
The free end of eccentric rod 13 is articulated to a stud 19 which is firmly secured to a link 20 and is rotatably engaged in a link 21. Link 21 is articulated, by means of a journal 22, to a lever 23 having its hub secured on shaft 15, while link 20 is articulated, by means of a journal 24, with a lever 25 which is secured on a setting shaft 26. Parts 19 through 26 form a setting device 27 for setting the step size of the main feed 1, with lever 25 and links 20 and 21 having the same effective length.
A double lever 28 is secured on setting shaft 26 and is connected, through a link 29, with one arm of a lever 30. Lever 30 is secured on a shaft 31 mounted in the housing of the sewing machine, and its other arm is engaged in a groove 32 of a setting disc 33 which is secured on a shaft 34 also mounted rotatably in the housing of the sewing machine. Setting disc 33 cooperates with a setting mark 36 conveniently provided on the housing of the sewing machine.
A spiral spring 37 is secured at one end to the housing of the sewing machine and at its other end with setting shaft 26, so as to effect a rotation of setting shaft 26 in a direction until lever 30 strikes against the outer wall of the grooves 32 so that main feed 1 shifts the work in the forward direction and in accordance with the value on scale 35 opposite setting mark 36. To reverse the main feed direction, a key lever 38 is fixed on shaft 31 at its end protruding from the sewing machine housing.
The free end of eccentric rod 14 is articulated to a stud 39 firmly connected with a link 40 and rotatably engaged in a link 41. Link 41 is articulated, by means of a journal 42, to a lever 43 whose hub is secured to shaft 16, while link 40 is articulated, by means of a journal 44, with a lever 45 which is secured on a setting shaft 46. Parts 39 through 46 form a setting device 47 for setting the step size of the lower auxiliary feed 2, with lever 45 and links 40 and 41 having the same effective length.
A bridge 48 is oscillatably mounted on setting shaft 46, and is connected, through a connecting rod 49, with double lever 28. With this arrangement, bridge 48, due to connecting rod 49 and double lever 28, is rotated through the same angular extent as setting shaft 26 is rotated.
In order to be able to adjust setting shaft 46 for variation of the step size of the lower auxiliary feed 2 relative to that of the main feed 1, setting screws 50 and 51 are threaded into bridge 48 and cooperate with a two-arm abutment piece 52 secured on setting shaft 46. A spiral spring 53 embraces setting shaft 46, and is secured at one end to bridge 48 and at its other end to setting shaft 46. Spring 53 rotates abutment piece 52 in a direction such that one arm thereof makes contact on setting screw 50.
By means of a foot pedal, which has not been shown, setting shaft 46 can be rotated through a connecting rod 54 articulated to an arm 55a of a double-lever 55 secured on setting shaft 46, until abutment piece 52 contacts setting screw 51.
A connecting rod 56 connects double-lever 28 with a bridge 57 which is oscillatably mounted on a setting shaft 58. To be able also to vary the angular position of setting shaft 58 relative to the angular position of setting shaft 26, two setting screws 59 and 60 are threaded into bridge 57 and cooperate with a two-arm abutment piece 61 secured on setting shaft 58. A spiral spring 62 embraces setting shaft 58, and has one end secured to setting shaft 58 and the other end secured to bridge 57. Spring 62 tends to rotate abutment piece 61 so that one arm thereof contacts setting screw 60.
Setting shaft 58 is connected with a channel-shape bracket 63 between whose arms another channel-shape bracket 64 is rotatably mounted by means of journals 65. The arms of bracket 64 are connected by a stud 66 secured to a link 67. Link 67 is articulated, by means of a journal 68, to a lever arm 69 secured to one end of a rocking shaft 70 mounted in the housing of the sewing machine. An eccentric 72, which is secured on an arm shaft 71 mounted in the sewing machine housing to extend parallel to rocking shaft 70, and which is embraced by an eccentric rod 73, imparts swinging movements to stud 66 about the journals 65. Parts 58 and 63 through 69 form a setting device 74, with lever arm 69 and the effective lever arms of brackets 63 and 64 having the same effective length.
A lever arm 75 is secured to the other end of oscillatable shaft 70 and is connected, through a link 76, with one arm of a double-arm lever 77 also oscillatably mounted in the housing. Referring to FIG. 1, the other arm of lever 77 is pivotally connected with a link 78 connected, by a journal 79, with an upper auxiliary feed 80. Auxiliary feed 80 is supported by a pair of links 81 articulated to a support 83 secured to a presser bar 82 of known design. A presser foot 84 is also secured to support 83 and has a sole 85 cooperating with main feed 1 and lower auxiliary feed 2, sole 85 having cutouts 86 for the passage of toes 87 of auxiliary feed 80 engaging the work.
A bar 88 is mounted in the tubular presser bar 82 and has, at its lower end, a journal 90 engaging in a fork 89 of upper auxiliary feed 80. Bar 88 is reciprocated up and down in an axial direction in a known manner, for the execution of lift movements for upper auxiliary feed 80.
A crank 91, secured on arm shaft 71 shown in FIG. 2, is in operative connection, through a link 92, with a needle bar 95 carrying a needle 93 and mounted in a guideway 94. As best seen in FIG. 1, needle 93 cooperates, through a stitch hole 97, with a looper which has not been shown and which is driven under stitch plate 96 in a known manner. Respective slots 98 and 99 for the passage of main feed 1 and lower auxiliary feed 2, are provided in stitch plate 96 before and behind the stitch hole 97. Feeds 1, 2 and 80 are so arranged that main feed 1 engages the work with the sole 85 of presser foot 84 behind stitch hole 97, seen in the sewing direction, while the auxiliary feeds 2 and 80 engage the work in advance of stitch hole 97.
A bar 100 is articulated on the second arm 55b of lever 55 secured on setting shaft 46, and is connected, by a trunnion screw 101, with another bar 102. Trunnion screw 101 is guided in a slot 103 in bar 102. Bar 102 is articulated, by means of a collar screw 104 to a lever arm 105 secured on setting shaft 58, and which extends in a direction opposite to the extent of arm 55b. To vary the effective length of lever arm 105, collar screw 104 can be adjusted inside a slot 106 in lever arm 105.
OPERATION OF THE DIFFERENTIAL WORK TRANSPORT DEVICE
The work transport device operates in a manner which will now be described. The variation of the step size of main feed 1 is effected by rotating setting disc 33 so that, under the bias of spiral spring 37, setting shaft 26 also rotates until lever 30, which is articulatedly connected with setting shaft 26, contacts that wall of groove 32 of setting disc 33 engaged for the forward stroke of the work transport.
During its rotation, setting shaft 26 rotates lever 25 and thus displaces journal 24, serving as the axis of rotation for link 20, relative to journal 22. During the swinging out movement of stud 19 by eccentric rod 13, link 20 consequently executes a pure rotary movement around journal 24, whereas link 21 executes, in addition to this rotary movement, a relative motion about the axis of shaft 15. This relative motion is transmitted by lever 23, as a swinging motion, to lever 17, which imparts speed movements to main feed 1 through support 3. The magnitude of these feed movements depends on the position of setting disc 33, and hence on the magnitude of the displacement difference between journals 22 and 24. The magnitude can be read on scale 35 with the aid of setting mark 36.
Responsive to the displacement of setting shaft 26, the angular position of bridge 48 changes, in the same amount, through the connecting rod 49. As bridge 48 is rotated, setting screw 50 rotates abutment piece 52, so that setting shaft 46, fixedly connected with abutment piece 52, is rotated through the same angle as that through which setting shaft 26 is rotated.
Lever 45, fixed on setting shaft 46, pivots link 40 so that journal 44, serving as the axis of rotation for link 40, is displaced relative to journal 42. During the swinging-out movement of stud 39 by eccentric rod 14, and in analogy to the above-described setting device 27, link 40 executes a pure rotary movement around journal 44, whereas link 41 executes, in addition, a relative motion about the axis of shaft 16 and thus imparts swinging movements to the latter through the lever arm 43. These swinging movements are transmitted by shaft 16, through lever 18 and support 4, to the lower auxiliary feed 2, as feed movements.
Also synchronously with the angular adjustment of setting shaft 26, the angular position of bridge 57 is changed due to its coupling to shaft 26 through connecting rod 56 and double-lever 28. Spiral spring 62 holds abutment piece 61 in contact with setting screw 60, so that setting shaft 58 is also rotated by the same angular amount. Setting shaft 58 rotates bracket 63 and, in so doing, displaces bracket 64, so that journals 65 are displaced relative to journals 68. During the swinging-out movement of stud 66 by eccentric rod 73, bracket 64 consequently executes swinging movements around the axis of shaft 70 in addition to a rotary movement around the axis of journal 65, for the reasons mentioned in the description of the operation of setting device 27. These movements are transmitted to upper auxiliary feed 80, as feed movements, through lever arm 75, link 76, lever 77 and link 78 (FIG. 1).
The adjustment of setting screw 50 in bridge 48, as well as the adjustment of setting screw 60 in bridge 57, is so chosen that, in normal sewing, the step length of the two auxiliary feeds 2 and 80 is exactly the same as the step length of the main feed 1, that is, the feed value set on scale 35 by reference to mark 36 is executed by all three feeds 1, 2 and 80. In such case, two fabric plies lying between stitch plate 96 and sole 85 of presser foot 84 are sewn in the normal manner without mutual gathering.
To gather the lower fabric ply relative to the upper fabric ply, the operator actuates the pedal (not shown) whereby, double lever 55 rotates setting shaft 46, through connecting rod 54 and against the bias of spiral spring 53, until setting screw 51 contacts abutment piece 52. Setting shaft 46 rotates lever 45, with journal 44 being still further displaced relative to journal 42, and stud 39, swinging out constantly through eccentric rod 14 imparting to lever 43, through link 41, an increased swinging-out movement. Thereby, the step size of lower feed 2 increases relative to the step size of main feed 1 by the value set at setting screw 51.
Simultaneously with such rotation of setting shaft 46, setting shaft 58 is also rotated through bars 100 and 102 and lever arm 105, against the bias of spiral spring 62. Setting shaft 58 rotates bracket 63, so that journals 65 are displaced toward journal 68. During the constant swinging-out of stud 66 by eccentric rod 73, smaller swinging-out movements consequently are imparted to lever arm 69 than were imparted before. Thereby, also the step size of upper auxiliary feed 80 is reduced to zero when the step size of lower auxiliary feed 2 has reached its maximum set size. This mutual displacement ratio results in a maximum of gathering effect.
During the gathering, the upper fabric ply is not only stretched by the reduced feed movement of upper auxiliary feed 80, but is also decelerated very strongly relative to the lower fabric ply transported with the increased feed movement of the lower feed. Although the upper ply transported more slowly rests on the lower ply under pressure, frictional entrainment by the lower ply is ruled out by this arrangement. Consequently, with the differential work transport of the present invention, very large magnitude gathering effects can be obtained also on relatively stiff materials.
While the setting screws 50 and 60 of the respective bridges 48 and 57 form the abutments for that position of setting devices 47 and 74 at which auxiliary feeds 2 and 80 execute the same step sizes as main feed 1, that is, at which no gathering of the plies takes place, setting screw 51 of bridge 48 forms the abutment for that position of the two setting devices 47 and 74 at which the maximum gathering effect, as desired by the operator, of the two auxiliary feeds 2 and 80, relative to main feed 1, appears. Between these two positions, it is possible, by appropriate setting of the screws 50 and 60 as well as the screw 51, to set any desired end positions for the gathering effect of the two auxiliary feeds 2 and 80 relative to main feed 1.
To lock the seam at the beginning or at the end, the operator actuates key lever 38 against the bias of spiral spring 37, whereby setting shaft 26 and, through connecting rods 49 and 56, also setting shafts 46 and 48, are rotated so that the setting devices 27, 47 and 74 reverse the feed direction for the main feed 1 and the two auxiliary feeds 2 and 80. In such operation, the end of lever 30 engages the inner wall of the groove 32 in setting disc 33.
The dimension of slot 103 in bar 102 is so selected that, at the maximum step size of main feed 1, of about 4 mm, the trunnion screw 101 just strikes against the upper limiting wall of slot 103, and that, upon reversal of the feed direction by actuation of key 38, the effective total length of the two bars 100 and 102 can increase to the extent that the transport stroke of feeds 1, 2 and 80 is not impaired in the backward sewing direction.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | The sewing machine has a differential work transport, consisting of a lower main feed and lower and upper auxiliary feeds, with the step sizes of the auxiliary feeds being adjustable, from a step size substantially in accordance with the step size of the main feed, against spring bias. The step sizes are adjusted by respective setting devices having associated setting members connected, through a lever drive, to a common actuating device. The lever drive interconnecting the setting members of the setting devices for the lower and upper auxiliary feeds is operable to vary the step sizes of the lower and upper auxiliary feeds so that one of said lower and upper auxiliary feeds increases as the other of said lower and upper auxiliary feeds decreases. The transmission ratio of the lever drive is adjustable, and the lever drive includes a driver connection operative in one direction only. | 3 |
My invention relates generally to handles to facilitate sliding or other movement of small elements, and is especially applicable to drawers of furniture known as "case goods." In such case an item embodying my invention might be called a drawer pull.
My invention, while primarily utilitarian and intended for application to cabinets in places of business such as offices, stores and factories, nonetheless is susceptible to a wide scope of esthetic treatment.
BACKGROUND
Drawer pulls are generally old in various forms such as knobs, balls, recessed fixtures adapted to receive part of a person's hand, etc.
BRIEF OUTLINE OF INVENTION
A particular object of my invention is to provide a handle for a drawer or the like susceptible of mass production at low cost, which is convenient in use and also susceptible to wide esthetic variation.
While not necessarily so restricted, my invention is especially designed for production by standard molding practices, employing known or other plastics having high impact resistance, and thus characterized by high durability under rough usage.
A special feature of handles embodying my invention is that they are designed, in connection with the drawer or other item with which assembled, to be capable of being securely and permanently locked in place without screws, but further designed to permit use of screws for additional security. However, they may readily be removed if desired for replacement.
Various other objects and advantages will suggest themselves to those skilled in the art as the description proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings forming a part of this specification and illustrating a preferred embodiment of my invention,
FIG. 1 is a fragmentary front perspective view of a slidable drawer for an article of furniture carrying a drawer pull or handle embodying my invention;
FIG. 2 is a fragmentary rear perspective of the front panel of a drawer such as that of FIG. 1, carrying an embodiment of my invention;
FIG. 3 is a fragmentary rear perspective of the drawer of FIGS. 1 and 2 as prepared for the attachment of a handle as seen in FIGS. 1 and 2;
FIG. 4 is a rear perspective of the handle seen in FIGS. 1 and 2;
FIG. 5 is a section-elevation as seen substantially along line 5--5 of FIG. 2;
FIG. 6 is a vertical section taken substantially along line 6--6 of FIG. 2;
FIG. 7 is a fragmentary rear elevation of the handle of FIG. 4, and
FIG. 8 is a fragmentary horizontal sectional view taken substantially along line 8--8 of FIG. 1.
DETAILED DESCRIPTION
Numeral 10 indicates a slidable drawer for an article of case goods such as a chest, table, desk or cabinet, having side panels 12, 12 and a front panel 13 carrying a handle H embodying my invention.
My invention is especially applicable to a front panel 13 of sheet metal or like material susceptible of working such as cutting and bending in certain areas of panel 13 adjacent an aperture A formed therein to seat a handle H embodying my invention.
My improved handle H is especially capable of production by conventional molding techniques from plastics having the desired properties such as infrangibility and resistance to scratching and marring. I have found especially suitable such commercially available plastics as those known in the industry as acrylics, butadienes, styrenes and other having the desired characteristics.
Handle H (FIG. 1) comprises a front plate-like frame portion 15 designed to serve as an escutcheon exposed on the outer face of front panel 13. While I have shown plate 15 as oblong, with an angular bend in its top edge, it will be understood that said plate is susceptible of widely varying esthetic treatment. Thus, said plate might be square, circular, elliptical, etc.
Extending rearwardly and integral with plate 15 is a cup-like portion adapted to receive a person's fingers for manipulating the drawer, including an upwardly and rearwardly curving plate 18 abutting at its ends integral flat side plates 20--20 which, as seen in FIG. 8, are slightly inclined inwardly and rearwardly in accordance with good molding practice. A longitudinal recess or groove 23 in curvilinear plate 18 permits seating therein an edge 13' of drawer panel 13 adjacent aperture A. (FIGS. 3 and 6.)
It will also be noted that side plates 20 of the handle are spaced a slight distance inwardly of the side edges of escutcheon plate 15, providing side flanges 25 behind which are seated side edges of panel 13 adjacent aperture A. (FIG. 8.)
Extending rearwardly from top bar 16 of the handle is an integral flat, generally horizontal bar 28 having a raised shoulder portion 30 formed therein, bar 28 being spaced below the upper extremity of bar 16 (FIGS. 5 and 6) for purposes that will hereinafter appear.
Also integral with front plate 15 and side plates 20, 20 are similar bosses 30,30 abutting opposite extremities of plates 20 (FIGS. 2, 4, 7) with top faces F sloping downwardly and rearwardly, with a groove G therebetween, to a shoulder 32.
Handle H, as to all elements hereinabove described, is molded as a unit, leaving an elongated rectangular aperture 35 (FIG. 7) for practical molding considerations apparent to those skilled in the art. Said aperture 35 may be closed, to impart a neat finish, by means of a similarly shaped plate P of similar material, if desired, said plate being secured in place by tongue-and-groove or other suitable connecting means.
DRAWER PANEL
A modicum of work is required on front panel 13 for seating my improved handle, aperture A being deformed from a straight line on only one edge thereof, namely, its upper edge (FIG. 3). Thus, in stamping panel 13, I provide an elongated tab 40 and relatively short tabs 45, all of said tabs being bent at angles suitable to their functions as will now be described.
Assembly of the handle with said front panel is a quick, simple operation, the handle being applied to aperture A from the front side of the panel so that the frame portion of escutcheon plate 15 will overlie the edges of aperture A, as described hereabove and illustrated in the drawings, to provide an attractive, finished appearance. Tabs 40 and 45, being of resilient material, will snap into locking position with the handle, tab 40 against shoulder 30 (FIGS. 5 and 6) and tabs 45, 45 against shoulders 32, 32.
Such assembly is sufficiently secure for most purposes. However, if desired for added security, screws (not shown) may be inserted through apertures 50, 50 provided in tabs 45, 45, engaging the sides of grooves G.
As seen in FIG. 6, top bar 16 of escutcheon plate 15 has a portion 16' depending below bar 28, thus providing space in the upper portion of cup 18 for a person's fingers and an inner surface area of bar portion 16' readily engageable for opening the drawer.
Obviously, the handle may readily be disassembled from the panel if desired, as for replacement, only a screwdriver being required to remove the screws, if employed, and to lift the tabs out of engagement with their respective shoulders.
CONCLUSION
It will be seen that I have provided an improved handle of attractive appearance and of such construction as to be producible at extremely low cost by mass production methods and capable of assembly with a minimum of labor.
Various changes coming within the spirit of my invention may suggest themselves to those skilled in the art. Hence, I do not wish to be limited to the specific form shown or uses mentioned herein, except to the extent indicated in the appended claims. | A handle for a drawer of an article of furniture, designed especially for optimum economy of production combined with attractive appearance susceptible of wide esthetic variation. These objectives are accomplished by mass production methods, preferably by molding or casting inexpensive materials, preferably plastics, and so forming cooperating parts of the handle and drawer that assembly may quickly be accomplished without use of tools, as by merely snapping the handle into place. | 0 |
TECHNICAL FIELD OF THE INVENTION
This invention relates generally to the field of magnetic resonance imaging technology. Specifically this invention relates to several improved methods for the electrical adjustment of two or more magnetic resonance coils to assure the proper isolation and/or orthogonal relationship of the coil fields in order to increase the signal to noise ratio of the magnetic resonance signal.
BACKGROUND OF THE INVENTION
Quadrature magnetic resonance imaging coils, and more recently, multicoil systems using a plurality of independent data acquisition channels, are generally known in the art. Quadrature magnetic resonance systems offer advantages over previous magnetic resonance imaging techniques in that they provide a better signal to noise ratio by utilizing both component vectors of the circularly polarized field of the magnetic resonance phenomenon, and lower RF transmitter power requirements when used as transmit coils. Multicoil systems offer some or all of the above-noted advantages, plus additional advantages in enhancing the imaging signal to noise ratio due to the reduced imaging volume of each independent coil and data acquisition path in the multicoil system. However, when these systems are used for magnetic resonance imaging, the isolation of the signal currents in one coil mode or coil system from currents in the other mode or coil system must be at a high level to obtain the benefits of quadrature operation, or multicoil operation.
Those skilled in the art will appreciate that it is desirable to reduce or eliminate the inductive coupling between the two coil systems forming the RF quadrature coil used in a magnetic resonance imaging system in order to solve these and other problems. Additionally, it is desirable to reduce or eliminate the inductive coupling betwixt the various coil systems in a multicoil configuration. Ideally there should be no inductive coupling between the coil systems comprising the RF quadrature coil or multicoil system. Previously the adjustment of such coils to minimize the coupling between the coils was accomplished by either the physical movement of the coils or the physical adjustment of a variable element to electrically accomplish the same result.
Changing a single element generally alters the tuning or other coil parameters. In the past, adjusting the isolation or orthogonality of a coil has yielded undesirable secondary adjustment of one or more other coil parameters. Further, if physical adjustment of the location of the coils is employed to accomplish this result, many coil formations are eliminated as a practical matter, thereby dramatically decreasing the versatility of these systems.
While the conventional devices have made significant advances in the art of magnetic resonance imaging, it is clear that much more versatile and useful magnetic resonance imaging systems will result from a quadrature magnetic resonance coil system that can be adjusted, or remotely adjusted, to only optimize the isolation of the coil elements without affecting other operational characteristics.
SUMMARY OF THE INVENTION
The above-noted quadrature coil adjustment problems of conventional systems are solved by the present invention. In accordance with one aspect of the invention, a magnetic resonance coil system includes a first coil, and a second coil having first and second segments configured in parallel. The second coil physically overlaps the first coil. A differential capacitor is provided which contributes a first capacitance in series with the first parallel segment of the second coil and a second capacitance in series with the second parallel segment of the second coil. The differential capacitor is operable to vary the first and second capacitances so as to vary the ratio of RF current present in the two segments.
Preferably, adjusting the differential capacitor to increase the first capacitance will proportionally reduce the second capacitance, and vice versa. This variation in the first and second capacitances changes the relative current flow in the first and second sections of the split conductor or parallel segment, and thereby adjusts the orthogonality of the second coil field with respect to the first by altering the proportion of overlapped to non-overlapped areas. The total net capacitance remains essentially constant, and thus the tuning and matching characteristics of the coil system are not materially affected.
In a first preferred embodiment, the capacitors are remotely operable to vary the first and second capacitances such that the capacitors and associated circuitry do not have to be physically disturbed. With the use of a differential capacitor, the ratio of capacitance may further be varied such when the first capacitance is increased, the second capacitance is reduced. Adjusting the capacitance in this manner changes the ratio of the RF current flowing through each segment, causing a sharing of the proper amount of out-of-phase flux to cancel the balance of the shared in-phase flux between the first and second coils. When the differential capacitor is set to an appropriate position, the net shared flux, and therefore the mutual inductance, approach zero.
In another preferred embodiment, the differential capacitor comprises first and second varactor diodes which are disposed in respective parallel segments of the second coil. Variable voltage circuitry is coupled to PN junctions of these diodes to vary the reverse bias on the varactor diodes which thereby adjusts the first and second capacitances. A plurality of potentiometers or other voltage adjustment means within the variable voltage circuitry are supplied in order to vary the voltages appearing at these diodes.
The present invention confers a principal technical advantage in that the orthogonality of RF quadrature coils can be precisely adjusted without disturbing the coils either by making physical adjustments to variable capacitors or by physically moving the coils themselves. Differential adjustment of the voltages on the varactor diodes provides orthogonality adjustment, whilst common mode adjustment of the voltages can be employed to provide tuning adjustment. The present invention has applications in many different types of quadrature magnetic resonance surface coils and/or multicoil systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects of the invention may be discerned from the following detailed description when read in conjunction with the drawings, in which:
FIG. 1 is an electrical schematic diagram illustrating the invention embodied in a quad cervical-spine coil;
FIG. 2 is a detail of FIG. 1 more particularly showing a differential capacitor;
FIG. 3 is an electrical schematic diagram illustrating another NMR quadrature coil pair, varactor diodes making up a differential capacitor for adjusting coil orthogonality, and bias circuitry for control of the varactor diodes;
FIG. 4 is an electrical schematic diagram corresponding to FIG. 2, showing how varactor diodes may be used according to the invention;
FIG. 5 is an electrical schematic diagram illustrating the invention embodied in a quad birdcage coil;
FIG. 6 is an electrical schematic diagram illustrating the invention embodied in a quad multiple port birdcage coil;
FIG. 7 is an electrical schematic diagram illustrating the invention embodied in a quad saddle coil;
FIG. 8 is an electrical schematic diagram illustrating the invention embodied in a quad multiple port planar coil; and
FIG. 9 is an electrical schematic diagram illustrating the invention in use with a quadrature planar multiport coil system.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with the present invention a quadrature magnetic resonance surface coil assembly is disclosed which includes first and second coils with generally perpendicular fields. The first and second coils are mounted parallel to each other and in a preferred embodiment share a critically overlapped area. In the preferred embodiment, each of the coils is intentionally split into two separate parallel segments within the critically overlapped area. It is apparent, however, that the invention would provide satisfactory results if only one of the coils was divided into separate parallel segments,
The coils are shaped and positioned so that the mutual inductance and therefore the majority of the coupling between the loops are minimized. This is usually accomplished by physically overlapping a critical portion of the area enclosed by the loops, such that the vector sum of all flux acting on one coil due to the other coil is near zero. However, the positioning of the loops is highly critical and is too sensitive to allow mass-produced devices to perform well without further individual adjustment to compensate for tolerances in physical dimensions and in values of electrical components,
The net mutual inductance of coils in a particular individual unit can be reduced to a level approaching zero when a differential capacitor or reactor is placed in series with the parallel segments and is appropriately adjusted. The results of such an individual adjustment can be measured using a network analyzer set to display the S21 (transmission) parameter. With one coil on each analyzer port, the coils are adjusted to minimize the value of S21. In the preferred embodiments, the differential element is a capacitor that can be adjusted to vary the ratio of current in each of the parallel segments of the coils. Isolation and orthogonality between the coils can be adjusted if the adjustable element performs the function of a differential capacitor.
Adjusting the capacitance in series with each of the parallel segments varies the ratio of the RF current flowing through each segment of the loop. This accomplishes an effect equivalent to physically moving the loops to change the amount of overlap area and shared flux. The resulting effective change in the overlapped area effectively changes the ratio of the out-of-phase flux to in-phase flux of the loops.
In another embodiment, the first and second coils are disposed such that a principal electromagnetic field of the first coil is orthogonal to a principal electromagnetic field of the second coil. The split conductor segments and associated differential reactive element serve to adjust the relative orthogonality of the fields of one or more of the coils with respect to the field from another coil or coils. In yet a further embodiment, the split parallel conductors may lay either wholly or partially outside of a critical overlap area. The coil systems according to the invention may be configured as multicoil or phased array coil systems. Some or all of the component coil subsystems may be quadrature coils. Below are described several examples of how the coils may be configured.
FIG. 1 is a schematic diagram illustrating a representative NMR quadrature coil indicated generally at 10. System 10 includes a surface coil circuit 12, indicated by a dashed enclosure, and a balun/combiner circuit 14, also indicated by a dashed enclosure. The surface coil circuit 12 includes a first coil 16 and a second coil 18. Coil 16 includes two split conductors or parallel segments 20 and 22 which are spatially displaced from each other. The inductance of each of the parallel conductor segments 20 and 22 is respectively represented by inductor 24 or 26.
Split conductors 20 and 22 are joined at node 28 to a single conductor 30 which completes the coil loop. A variable capacitor 32 is inserted in series in conductor segment 30 between nodes 34 and 36. A capacitor 38 is inserted in series between node 36 and a port 40 of the balun/computer circuit 14. Likewise, a capacitor 42 is inserted in series between node 34 and a port 44 of the balun/computer circuit 14. A fixed capacitor 46 and a variable capacitor 48 are connected between ports or nodes 40 and 44.
The inductance of coil 30 is represented at 50. Node 52 is the other terminus of split conductors 20 and 22. A capacitor 54 is connected between node 52 and a node 56. A further capacitor 58 is connected between node 52 and node 56. A variable inductor 60 is inserted in series between node 52 and a node 62. Back-to-back diodes 64 and 66 are connected in parallel between node 62 and node 56.
A fixed capacitor 68 is connected between node 56 and a node 70. In the other parallel segment or split conductor 20, a fixed capacitor 72 is connected between node 56 and a node 74. A differential capacitor indicated generally at 76 has three electrodes, two of which are connected to nodes 70 and 74, respectively, and a third of which is connected to the node 56.
Coil 18 likewise has a portion thereof split between parallel conductor segments 78 and 80 between nodes 82 and 84. The inductances of split conductors 78 and 80 are represented at 86 and 88. Fixed capacitors 90 and 92 are respectively connected in series in split conductors 78 and 80. One electrode each of capacitors 90 and 92 is connected to a node 94. A pair of fixed capacitors 96 and 98 is connected in parallel between node 84 and node 94. A pair of back-to-back diodes 100 and 102 connects node 94 to a node 104, which in turn is connected by a variable inductor 106 to the node 84.
A single conductor segment 110 is connected between junction nodes 82 and 84, and its inductance is represented at 112. A node 114 on the single conductor 110 is connected to a fixed capacitor 116, which in turn is connected to a node or port 118 of the balun/combiner circuit 14. A variable capacitor 120 is connected in series between node 114 and a node 122, both of which are on single element conductor 110. The node 122 is connected via a fixed capacitor 124 to a port or node 126 of the balun/combiner circuit 14. The balun/combiner circuit 14, the details of which are mostly unimportant here, includes a 90° combiner network 128. A fixed capacitor 130 and a variable capacitor 132 span the ports 118 and 126 in parallel.
The second pair of parallel segments 78 and 80 form an overlap area with the coil 16 containing parallel segments 20 and 22. By "overlapping" or "overlap," we mean the area of projection of one coil onto the other, where both coils define areas that may or may not be substantially planar, and are positioned with respect to each other such that pan of the area of one coil has a projection onto pan of the area of the other coil. Each of the loops 16 and 18 is split into respective parallel signal path segments 20, 22 and 78, 80 located within critically overlapped area 140. Differential capacitor 76 is connected to segments 20 and 22 to differentially adjust the capacitance in series thereof, and therefore the ratio of the RF current flowing through these paths. Adjusting the relative capacitance in a differential manner allows the isolation to be adjusted without significantly changing other coil parameters such as resonant frequency or impedance matching.
A detail of the differential capacitor circuit is given in FIG. 2. In FIG. 2, the differential capacitor 76 is placed in line with parallel loop segments 20 and 22. Adjustment of the differential capacitor 76 varies the ratio of RF current flowing through parallel segments 20 and 22 of magnetic resonance coil 16.
The coils 16 and 18 (FIG. 1) are shaped in position such that the mutual inductance and therefore the majority of the coupling between the loops are minimized. This is accomplished by overlapping a critical portion of the area enclosed by the loops, such that the vector sum of all flux acting on one coil due to the other coil is near zero. However, the positioning of the loops 16 and 18 is highly critical and too sensitive to allow mass-produced devices to perform well without further individual adjustment to compensate for tolerances in physical dimensions and in values of electrical components.
To effect individual adjustment of coil system 10, an adjustment is made of differential capacitor 76 once it has been inserted into surface coil circuit 12. The results of such an individual adjustment can be measured using a network analyzer set to display the S21 (transmission) parameter. With coils 16 and 18 on a corresponding analyzer port, the coils are adjusted to minimize the value of S21.
Adjusting the capacitance in series with each of the parallel segments 20, 22 varies the ratio of the RF current flowing through each segment of the loop. This accomplishes an effect equivalent to physically moving the loops to change the amount of overlap area and shared flux. The resulting effective change in the overlapped area effectively changes the ratio of the out-of-phase flux to in-phase flux of the loops.
FIG. 3 is a schematic diagram of an alternative embodiment of the invention, further including a representative NMR quadrature coil pair 150, a pair of varactor dimes 152 and 154 coupled to coil 158, and bias circuitry for control of the electrical adjustment of the quadrature magnetic resonance surface coil pair 150. In this example, two coils 156 and 158 are shown with an overlap area 160. Each of the loops 156 and 158 is split into respective parallel signal path segments 162, 164 and 166, 168 located within a critically overlapped area 160. Varactor diodes 152 and 154 are respectively connected to segments 168 and 166 and act to adjust the capacitance thereof, and therefore the ratio of the RF current flowing through these paths.
The capacitance of varactor diodes 152 and 154 is adjusted by varying the reverse bias voltage on the varactor diodes 152 and 154. The varactor diodes 152 and 154 have a reverse orientation with respect to each other so that adjustment of the reverse bias voltage will have an opposite effect on the capacitance of each varactor diode. The reverse bias voltage is applied to varactor diodes 152 and 154 at nodes 170 and 172.
The bias voltage is supplied from DC voltage source 174 and variable resistor 176. Variable resistor 176 adjusts the capacitance of parallel signal paths 166 and 168 by varying the magnitude of reverse bias on varactor diodes 1.70 and 172. Adjustment of variable resistor 176 alters the capacitance of varactor diodes 152 and 154 in a common mode manner, changing the resonance as if a conventional variable capacitor were employed. The bias voltage is connected through RF chokes 178, 180 and 182 to prevent the loss of RF energy from the resonant circuit of the coils. DC blocking capacitors 184 and 186 prevent the DC bias voltage from creating current flow in the magnetic resonance loop 158. Fixed capacitors 188 and 190 establish a resonance condition in coil loop 156 equivalent to that in loop 158. It is clear that capacitors 188 and 190 could be replaced with a second varactor diode configuration similar to that used on loop 158.
Variable resistor 176 controls the bias voltage applied to both varactor dimes 152 and 154; it provides adjustment to the resonant frequency of the loop without changing the orthogonality adjustment established by the ratio of currents in segments 166 and 168. Variable resistor 192 is connected to the bias voltage output from variable resistor 176 and provides a secondary adjustment of the bias voltage by varying the voltage ratio between varactor dimes 152 and 154. Adjustment of variable resistor 192 varies the capacitance of varactor dimes 152 and 154 in a differential manner, allowing the isolation to be adjusted by changing the ratio of current in segments 166 and 168 without changing the resonant frequency of the coil system, as if a differential capacitor were employed.
A differential capacitor is shown generally in FIG. 2 and a functional equivalent thereof, namely a pair of varactor dimes, is shown in FIG. 4. The varactor dime pair 200, 202 of FIG. 4 is interchangeable in function with the differential capacitor circuit 76 of FIG. 2, but with the added ability to be controlled in a common mode manner also to adjust coil tuning. In FIG. 2, the differential capacitor 76 is placed in line with parallel loop segments 20 and 22. Adjustment of the differential capacitor 76 varies the ratio of RF current flowing through parallel segments 20 and 22 of magnetic resonance coil 16.
FIG. 4 shows a pair of varactor dimes 200 and 202 which are placed in line with parallel segments 204 and 206 of magnetic resonance coil 208. The capacitances of varactor dimes 200 and 202 are adjusted by varying a bias voltage 210, which is connected to varactor dimes 200 and 202 through RF dimes 212 and 214, respectively. Adjustment of the bias voltage 210 therefore adjusts the ratio of the RF current flowing through parallel segments of magnetic resonance coil 208. Throughout the remaining FIGUREs, the varactor diode pair 200, 202 and associated bias voltage circuitry may be substituted for each differential capacitor symbol. The illustrated varactor diode pair 200, 202 could be replaced by a differential capacitor 76 of FIG. 1 in the form of a mechanical device with moving plates as actuated by an operator, a motor, or the like.
FIG. 5 shows an application of the present invention to a quad birdcage coil shown generally at 220. First and second differential capacitors 222 and 224 operate in a manner identical to that described previously; however, each differential capacitor is connected to a separate loop with respective parallel segments 226, 228 and 230, 232. Each differential capacitor may be independently tuned as previously discussed to provide the desired isolation of the coils. The differential capacitors may be formed by a pair of varactor diodes as previously described. First and second outputs are available across inductors 234 and 236, respectively.
FIG. 6 is a schematic diagram illustrating the application of the present invention to a quad multiple port birdcage coil shown generally at 238. In this example four differential capacitors 240, 242, 244, and 246 are employed to provide the desired isolation of respective coil pairs. Each of the differential capacitors is connected to respective parallel segments 248, 250; 252, 254; 256, 258; and 260, 262 to provide for the adjustment of the RF current flowing through the respective paths as previously discussed. As with the other designs it is contemplated that in one embodiment the differential capacitors be formed by pairs of varactor diodes. Output coils 264 and 266 are provided in conjunction with parallel segments 248 and 250. Output coils 268 and 270 are provided in conjunction with parallel segments 252 and 254.
FIG. 7 is a schematic electrical diagram illustrating the application of the present invention to a quad saddle coil design shown generally at 280. A first saddle coil 282 has coil halves 284 and 286. A second saddle coil 288 has coil halves 290 and 292. A differential capacitor 294 is connected to loop segments 296 and 298, which overlap with loop segments 300 and 302 of coil half 290 of second saddle coil 288. A second differential capacitor 304 is connected to loop segments 300 and 302 to increase the tunable range of the coils. In this arrangement, the differential capacitors operate as previously discussed and in one embodiment may be formed by varactor diodes.
FIG. 8 is a schematic diagram illustrating the present invention embodied in a multiple port planar coil shown generally at 310. The diagram illustrates a pair of differential capacitors 312 and 314 respectively located in line with separate, overlapping coils 316 and 3 18. Coil 316 is separated into parallel segments 320 and 322. Coil 318 is formed with parallel segments 324 and 326. Segments 320-326 are located within a critically overlapped area 328. The differential capacitors 312 and 314 operate in an identical manner to that previously discussed and may be formed by varactor diodes. In this embodiment differential capacitors 312 and 314 may be adjusted independently or simultaneously to provide the desired isolation of the coils.
FIG. 9 is a schematic diagram illustrating the application of the present invention to a quadrature planar multiport coil shown generally at 330. In this example two differential capacitors 332 and 334 are employed to provide the desired isolation of respective coil pairs 336 and 338. Each of the differential capacitors 332 and 334 is connected in series to respective parallel segments 340, 342 and 344, 346 to provide for the adjustment of the RF current ratio flowing through the respective paths as previously discussed. As with other designs, it is understood that more or less pairs of parallel segments in the critically overlapped areas 348, 350 can be used to increase the flexibility of orthogonality and isolation adjustment available. Also as with the other designs it is contemplated that the differential capacitors may be formed by pairs of varactor diodes.
In alternative embodiments, the differential capacitors disclosed in FIGS. 1-9 are replaced by differential reactive elements. These are adjusted in a fashion similar to the adjustments made in the differential capacitors to contribute varying amounts of reactance to related coil segments to thereby achieve coil isolation.
In summary, a novel means of adjusting the orthogonality of fields generated by overlapping quadrature coils, or individual coil systems in a multicoil configuration, is disclosed. However, the above description is not intended to limit the present invention in any way, which is limited only by the scope and spirit of the following claims. | An NMR magnetic coil system (10) is disclosed wherein the isolation between the coils (16, 18) can be adjusted to decrease or virtually eliminate the coupling between quadrature magnetic resonance imaging coils (16, 18). At least one of the coils (16) is separated into parallel segments (20, 22), located in a critically overlapped area. The capacitance of the segments is adjusted by a differential capacitor (76) to vary the ratio of the RF current flowing through the parallel segments. Appropriate adjustment of the capacitance of these paths (20, 22) causes a sharing of the appropriate amount of the out of phase flux to cancel the balance of the shared flux and therefore results in a net mutual inductance of zero. | 6 |
FIELD OF THE INVENTION
[0001] The present invention involves the formation of chiral-nematic liquid-crystal (LC) compositions using nematic materials in combination with chiral dopants.
BACKGROUND OF THE INVENTION
[0002] Chiral-nematic, also known as cholesteric, liquid-crystalline materials are useful in a variety of applications including various LC display components, reflective films, optical filters, polarizers, paints, and inks, among others. Methods for preparing such materials are well established. See, e.g., Giovanni Gottarelli and Gian P. Spada, Mol. Cryst. Liq. Crys., Vol. 123, pp. 377-388 (1985); Gian Piero Spada and Gloria Proni, Enantiomer, Vol. 3, pp. 301-314 (1998). However, improvement is still needed. While early uses of chiral-nematic compositions relied upon mixtures composed mostly of chiral components, more recently such materials are composed of nematic LC mixtures combined with small amounts of chiral dopants. In such new compositions the properties of the nematic host material, for example viscosity, birefringence, electrical anisotropy, and magnetic anisotropy among others, are tailored to the desired usage by altering the chemical composition of the nematic mixture, and then a chiral dopant is incorporated to induce helical twisting so as to provide the desire chiral-nematic pitch. It is apparent that the properties of this chiral nematic composition are therefore a combination of the properties of the nematic host plus those of the dopant. It is further well understood that by reducing the amount of dopant, the properties of the host nematic LC formulation might be better preserved. Certainly, reducing the concentration of a specific dopant also reduces the pitch of the resulting chiral-nematic formulation. Many uses of chiral-nematic compositions require the formulation to reflect or transmit visible light, thus requiring compositions with substantial helical twist, i.e. short helical pitch (“p”). These considerations indicate that dopants that induce large amounts of nematic helical twist per unit concentration are prized. The figure of merit for such materials is its Helical Twisting Power (“HTP” or β).
[0003] A dopant material's HTP (β) is defined, in a specified host at a particular temperature, by Equation 1:
β=(pcr) −1 (Equation 1)
wherein the “p” is the measured helical pitch of the doped nematic (μm); “c” is the measure of the dopant concentration (usually in terms of mole fraction, weight fraction, or weight percent on a unitless scale, wherein mole fraction and weight fraction is on a scale of 0 to 1); and “r” is the enantiomeric excess of the dopant (on a unitless scale of 0 to 1). Enantiomeric excess (r) is defined as the absolute value of the difference in mole fraction (F) of the two enantiomer in a sample r equals |F (+) −F (−) |. Thus, for a racemic mixture r equals |0.5−0.5|=0; for an enantiomerically pure material r equals |1.0−0|=1; and for a 75% pure mixture the r equals |0.75−0.25|=0.5. The larger the HTP the lower the concentration of dopant needed to provide a specific pitch, and thereby yield a particular reflectance or transmission. The pitch of a chiral-nematic formulation can be measured using a variety of optical techniques. For example, see Zvonimir Dogic and Seth Fraden, Langmuir, Vol. 16, pp. 7820-7824 (2000). The dopant concentration is as formulated and the enantiomeric excess can be measured via chiral high-performance liquid chromatography (HPLC) or nuclear magnetic resonance (NMR) spectroscopy. Typically, for useful enantiomerically pure dopants, their HTP's range from one to several hundred (μm −1 ). Dopants with twisting power greater than 100 (based on dopant mole fraction) are often described as “high twist” dopants. The discovery of new dopants, particularly high twist dopants, is important to broadening the utility of chiral-nematic formulations.
[0004] Not only can chiral-nematic liquid crystals be formulated to reflect various wavelengths of incident electromagnetic radiation, but it is well understood that reflected light is circularly polarized, depending upon the sense of chirality of the helical pitch. Thus, a chiral nematic displaying a right-handed helical mesostructure will reflect right-handed incident light. For many applications it is useful to be able to reflect both right-handed and left-handed senses of circularly polarized light, for example, in a vertically layered structure. It is further well known that enantiomers of a chiral-dopant structure induce the opposite polarity of helical rotation and, therefore, afford oppositely polarized light reflections. For this reason the preparation of enantiomeric pairs of dopants for use in separate light modulating layers can be particularly useful.
[0005] There are three general sources for obtaining substantially enantiomerically pure organic compounds for use as dopants or more likely as synthetic precursors for dopants: (1) compounds available from natural sources; (2) the preparative separation of racemic mixtures of enantiomers; or (3) chiral synthetic methods that directly afford desired enantiomers. Most commonly, only the latter two methods provide access to both enantiomers of a potential dopant. Natural sources generally provide only one of any enantiomeric pair, reflecting the fundamental chirality of life. Thus, using natural sources for dopants or their precursors can lead to limitations in dopant utility. A discovery of new dopants available from non-natural sources would therefore be especially useful.
SUMMARY OF THE INVENTION
[0006] Applicants have found a class of compounds useful as chiral dopants, which compounds are available in both enantiomeric forms. Another aspect of the invention relates to chiral-nematic liquid-crystal formulations comprising such chiral dopants. Such formulations are useful in displays and other products. Optionally, the chiral dopants can be capable of polymerization.
DETAILED DESCRIPTION OF THE INVENTION
[0007] We have found that certain compounds represented by the following Structure 1 are useful as a source of chiral dopants. In particular, the enantiomerically enriched form of such compounds, including the substantially enantiomerically pure form, introduced into nematic compositions, afford useful chiral nematic mixtures.
[0008] As evident, compounds of Structure 1 comprise a central nucleus comprising a spirodiphenoxy moiety. In Structure 1, A, B, C, and D are independent divalent groups; each X is any independently selected ring substituent, or X can form a fused ring with another X or R O ; n independently varies from 0 to 3, and the R O groups are independently selected from hydrogen or any substituent capping the phenolic oxygen in Structure 1. Preferably, A, B, C, and D are such that A and B comprise a first five or six-membered ring, and C and D comprise a second five or six-membered ring which rings share a spirocarbon atom to which A and C are attached.
[0009] A preferred embodiment is represented by the following Structure 2: wherein R CO is any suitable substituent, each X is any independently selected ring substituent or hydrogen, and R 1 and R 2 groups are independently hydrogen or an alkyl substituent.
[0010] In general, when reference in this application is made to a particular moiety or group it is to be understood that such reference encompasses that moiety whether unsubstituted or substituted with one or more substituents (up to the maximum possible number. For example, “alkyl” or “alkyl group” refers to substituted or unsubstituted alkyl, while “benzene group” refers to a substituted or unsubstituted benzene (with up to six substituents). Generally, unless otherwise specifically stated, substituent groups usable on molecules herein include any groups, whether substituted or unsubstituted, which do not destroy properties necessary for mesophase utility. Examples of substituents on any of the mentioned groups can include known substituents, such as: chloro, fluoro, bromo, iodo; hydroxy; alkoxy, particularly those “lower alkyl” (that is, with 1 to 12 carbon atoms, for example, methoxy, ethoxy; substituted or unsubstituted alkyl, particularly lower alkyl (for example, methyl, trifluoromethyl); thioalkyl (for example, methylthio or ethylthio), particularly either of those with 1 to 12 carbon atoms; substituted or unsubstituted alkenyl, preferably of 2 to 12 carbon atoms (for example, ethenyl, propenyl, or butenyl); substituted and unsubstituted aryl, particularly those having from 6 to 20 carbon atoms (for example, phenyl); and substituted or unsubstituted heteroaryl, particularly those having a 5 or 6-membered ring containing 1 to 3 heteroatoms selected from N, O, or S (for example, pyridyl, thienyl, furyl, pyrrolyl); acid or acid salt groups; such groups as hydroxyl, amino, alkylamino, cyano, nitro, carboxy, carboxylate, acyl, alkoxycarbonyl, aminocarbonyl, sulfonamido, sulfamoyl, sulfo, sulfonate, or alkylammonium; and other groups known in the art. Alkyl substituents may specifically include “lower alkyl” (that is, having 1-12 carbon atoms), for example, methyl, ethyl, and the like. Further, with regard to any alkyl group or alkylene group, it will be understood that these can be branched or unbranched and include ring structures.
[0011] In general, when reference herein is made to the formation of a ring or rings between various structural elements or groups of Structure 1, this should be understood as excluding from the definition of Structure 1 macrocyclic compounds including two or more structural units based on Structure 1 connected to each other in a ring. Such macrocyclic compounds are specifically excluded from this invention. However, linear oligomeric structures containing two or more structural units based on Structure 1 are not so excluded, wherein a structural unit based on Structure 1 are defined as a bivalent moiety obtained from a compound of Structure 1 by the removal of a hydrogen from two groups in the compound of Structure 1 to form two connecting bonds on opposite sides of the compound from the two rings containing the spiro carbon in the structural unit. Such excluded macrocyclic compounds are disclosed by Köhler, Bernhard et al. in “Novel Chiral Macrocyles containing Two Electronically Interacting Arylene Chromophores,” Chem. Eur. J. 2001, 7, No. 14. Compounds of Structure 1 are disclosed for making such macrocyclic compounds, but only the macrocyclic compound is disclosed as useful chiral dopants in liquid crystal compositions.
[0012] A, B, C, and D in Structure 1 can independently be any bivalent substituent such as methylene, oxygen, sulfur, sulfoxyl, sulfonyl, carbonyl, mono-substituted nitrogen (N—R), di-substituted carbon (R 1 —C—R 2 ), wherein R, R 1 and R 2 are independently hydrogen or any substituent. It is preferred the A, B, C, and D independently be methylene or di-substituted carbon (R 1 —C—R 2 ). It is more preferred that both A or B (and/or C or D) be methylene or di-substituted carbon (R 1 —C—R 2 ). In one embodiment, A and B are the same, respectively as C and D. R, R and R′ can independently be the same as X. Organic carbon-containing substituents having 1 to 12 carbon atoms are preferred.
[0013] The X substituent in Structure 1 can be any substituent. It is preferred to be an oxygen-containing organic substituent and/or a carbon-containing substituent. Preferred oxygen-containing substituents include alkoxy, aryloxy, carboalkyl (O—C(═O)R), carboaryl (O—C(═O)Ar), carboalkoxy (O—C(═O)OR), carboaryloxy (O—C(═O)OAr) either substituted or unsubstituted. Preferred carbon-containing substituents include alkyl groups of about 1-20 carbons, cycloalkyl groups of about 1-20 carbons, aryl groups of about 6-20 carbons, alkaryl groups of about 6-20 carbons, and heterocyclic groups having at least one heteroatom and 2-20 carbons; all either substituted or unsubstituted. Other preferred oxygen-containing organic substituents include carboalkoxy (C—C(═O)OR), carboaryloxy (C—C(═O)OAr), aryl or alkyl ketones (C—C(═O)R) or (C—C(═O)Ar), all either substituted or unsubstituted. Other suitable X substituents include, but are not limited to halogens; cyano (—CN); hydroxyl, amino, alkylamino, cyano, nitro, carboxy, aminocarbonyl, sulfonamido, sulfamoyl, sulfo, sulfonate, or alkylammonium; as well as a siloxane residue or polymerizable groups as mentioned below. Preferably, an X group meeting the definition of —OR 0 is not located on both aromatic rings in Structure 1 in a position adjacent each ring containing the spiro carbon (i.e., substituted on an aromatic carbon bonded to said ring). Spirodiphenol derivatives having an —OR 0 group in such a position (in the 7,7′position as compared to the 6,6′ position) are disclosed in copending, commonly assigned U.S. Ser. No. 10/651,692, filed Aug. 29, 2003 by Welter et al., hereby incorporated by reference.
[0014] Furthermore, any two members of the following set: X and R 0 on the same aromatic ring in Structure 1 may be joined to form a fused ring, either aliphatic, unsaturated or aromatic provided that creation of the ring will not interfere with the functioning of the chiral dopant.
[0015] In one preferred embodiment of Structure 1, both “n” subscripts are 0 or 1.
[0016] The R O group in Structure 1 is independently any substituent or hydrogen, preferably having 1 to 24 carbon atoms, more preferably 8 to 18 carbon atoms. It is preferred to be alkyl, cycloalkyl, aryl, aralkyl, carbonyl such as alkylcarbonyl, arylcarbonyl, alkoxycarbonyl, aryloxycarbonyl, alkylsulfoxy, or arylsulfonyl, substituted or unsubstituted. It is more preferred to be carbonyl, C(═O)R CO , where R CO is aryl, alkyl, cycloalkyl, or alkaryl, or heterocyclic either substituted or unsubstituted. It is particularly preferred for the R CO group to contain an aromatic ring, for example, a phenyl-containing group. It is most preferred that R CO be aryl either substituted or unsubstituted as defined by: —R CO ═—(Y—L) m —Z: wherein L is a single bond e.g. —(Y) m —Z or bivalent linking group chosen from the following groups: —C(═O)O—; —OC(═O)—; —CH 2 CH 2 —; —CH═CH—; —C≡C—; —OCH 2 —; —CH 2 O—; —N═CH—; —CH═N—; —OC(═O)O—; —C≡C—C≡C—; —COCH═CH—; —CH═CHCO—; —O—; —S—; -and SO 2 ; wherein Y and Z independently may be 1,4-phenylene in which, in addition, one or more methylene may be replaced by —N═, 1,4-cyclohexyl in which, in addition, one or more non-adjacent methylene units may be replaced by O or S, 1,4-cyclohexylene, 1,4-bicyclo[2.2.2]octylene, piperidine-1,4-diyl, naphthalene-1,6-diyl, dechydronaphthalene-1,6-diyl, 1,2,3,4-tetrahydronaphthalene-1,6-diyl, in which each of these groups be unsubstituted or mono-substituted or poly-substituted with halogen, cyano, isocyanato, or nitro groups; or alkyl, alkoxyl or alkanoyl groups bearing 1-12 carbons where one or more hydrogens may be substituted with chlorine or fluorine and wherein m=0, 1, 2, 3, 4. As indicated above, R 0 can form a fused ring with an X group. The two R 0 groups in Structure 1 (or the two RCO groups in Structure 2) can also be connected to form a bridge between the two phenyl rings in, respectively, Structure 1 or Structure 2.
[0017] A few examples of compounds according to the present invention, which examples are merely illustrative and not intended to be limiting, are as follows:
I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11 I-12 I-13 I-14 I-15 I-16 I-17 I-18 I-19 I-20 I-21 I-22 I-23 I-24 I-25 I-26 I-27 I-28 I-29 I-30 I-31 I-32 I-33
[0018] In a further embodiment, the dopant compound of Structure 1 or Structure 2 may contain as a part of A, B, C, D, X, R O , R CO , R, R 1 , R 2 , Y, and/or Z a polymerizable group, including, for example, a vinyl, acryloyl, methacryloyl, styryl, cyanoacrylate, vinyl ether, vinyl ester, isocyanate, epoxy, and/or derivatives thereof that are polymerizable moieties or a siloxane residue.
[0019] In one preferred embodiment of Structure 1, A is a carbon atom bearing two groups R A , (C(R A ) 2 ), B is a carbon atom bearing two groups R B (C(R B ) 2 ), C is a carbon atom bearing two groups R C , (C(R C ) 2 ), and D is a carbon atom bearing two groups R D , (C(R D ) 2 ), wherein each R A , R B , R C , and R D group is independently hydrogen or a substituent such as X above, preferably hydrogen or an organic substituent such as a substituted or unsubstituted alkyl; and X is any independently selected substituent, n varies from 0-3, and R O is a suitable substituent. In a preferred embodiment, the R O groups in Structure 1 are independently R CO as in Structure 2.
[0020] In a more preferred embodiment of Structure 1, the A, B, C, and D groups are each methylene (—CH 2 —) as in Structure 2; each X is any independently selected substituent, n varies from 0-3, and each R O is independently a suitable substituent.
[0021] In another more preferred embodiment of Structure 1, the A and C groups are each methylene and B and D groups are carbon bearing two hydrogens or two alkyl groups, each X is independently H or a substituent; and n is 1 on both rings common to the spirocarbon with the proviso that any X substituent in each ring is found on the carbon para (C-4 and C-4′) to the indicated oxygen substituent, as in Structure 2, and each R O is any suitable substituent.
[0022] An example of a particularly preferred embodiment is described by Structure 2 wherein R 1 and R 2 are methyl groups and R CO is a carbocyclic aromatic substituent either substituted or unsubstituted.
[0023] Compounds of the present invention, used in a non-racemic mixture or with an enantiomeric excess of one enantiomer, are useful as chiral dopants in liquid-crystal compositions in an effective amount. One or more chiral dopants can be used cumulatively in an effective amount, either of Structure 1 or combined with other types of dopants. Suitably, the compound of Structure 1 can be used in the amount of 0.1 to 20 weight percent, based on the total weight of the liquid-crystal composition, preferably 0.5 to 10 weight percent, more preferably 1 to 6 weight percent. Preferably the non-racemic mixture comprises at least 60 weight percent of one of the enantiomers, based on the weight of both enantiomers, preferably at least 80 weight percent, more preferably greater than 90 weight percent. The enantiomeric excess is greater than 0, preferably greater than 0.6. Most preferably the non-racemic mixture is a substantially or essentially pure enantiomer. As mentioned above, the more pure the enantiomer, the less chiral dopant necessary to obtain the desired HTP and, hence, less chance of incompatibilities or adversely affecting the desired anisotropic properties of the liquid-crystal composition.
[0024] Preferably the HTP, on a dopant mole fraction basis, of the compound of Structure 1, when used in a particular liquid crystal composition, is greater than 80, more preferably at least 100, most preferably greater than 100.
[0025] Compounds of this invention can be readily prepared by those skilled in the art employing standard chemical transformations. Further, these materials can be isolated in enantiomerically pure form using standard methods including but not limited to: chiral HPLC, chiral synthesis, chemical or chromatographic separation of chiral derivatives of the spirophenol, e.g. via diastereomeric esters, urethanes, carbonates, and the like.
[0026] The preparation of the spirophenol derivative of the following substructure 3 has been previously described.
[0027] See for example a. Gary Ray Faler and Jerry Charles Lynch, EP 264026 A1 19880420 (1988); b. Vladimir Prelog and Davor Bedekovic, Helvetica Chimica Acta, 62(7), 2285-302 (1979); c. Bernhard Kohler, Volker Enkelmann, Masao Oda, Silvia Pieraccini, and Gian Piero Spada, Ullrich Scherf, Chemistry—A European Journal, 7(14), 3000-3004 (2001); and d. Jens Cuntze and Francois Diederich, Helvetica Chimica Acta (1997), 80(3), 897-911. The preparative isolation of the enantiomerically pure derivatives has also been described: a. Romas J. Kazlauskas, Journal of the American Chemical Society, 111(13), 4953-9 (1989); and b. Romas J. Kazlauskas, U.S. Pat. No. 4,879,421 (1989);
[0028] These and related methods may be employed to prepare enantiomerically enriched samples of the requisite spirophenols.
[0029] The use of chiral compounds of the present invention, or a polymerized form thereof, in admixture with a liquid crystal material, can be used for a wide variety of uses, including displays, polarizers, color filters, non-absorptive color filters, liquid crystal pigments for decorative or security purposes or coatings, optical switching, and optical information storage. For example, compositions according to the present invention can be used for making interference pigments with a viewing-angle-dependent color impression in printing inks and surface coatings. The compounds of the present invention can also be used in diagnostic, medical, or cosmetic compositions. For example, liquid-crystal compositions in accordance with the present invention can be used to detect body temperature or to protect the human skin or hair from UV radiation.
[0030] The liquid-crystalline composition can comprise STN, TN, chiral nematic, and ferroelectric materials or compounds. Preferably, the material comprises one or more liquid crystal compounds forming a chiral nematic material. The composition can be coated on a substrate, for example, during the manufacture of a display comprising the coated substrate. In one embodiment of a display, the liquid-crystalline composition is disposed between first and second electrodes, wherein the chiral compound according to the present invention is a chiral dopant in liquid crystals.
[0031] Novel liquid-crystalline compositions contain one or more chiral compounds of the Structure 1 or 2 as chiral dopants, usually in concentrations of from 0.1 to 10% by weight, based on the total amount of the liquid crystal. The concentration can be selected so that the desired interference hue is formed. Higher concentrations shift the hue into the blue region, and lower ones shift it into the red region.
[0032] Preferably, the liquid crystal mixture comprises 2 to 25 compounds, preferably 3 to 15 compounds. Particularly suitable liquid-crystalline compositions are those in which the achiral liquid-crystalline compounds comprise cyclic compounds, for example biphenyls, as will be appreciated by the skilled artisan. Suitable liquid-crystalline compounds are well known to the skilled artisan. The liquid-crystalline compositions can advantageously be used for coating substrates. Examples of suitable substrates are metal surfaces, plastic surfaces, glass or ceramic surfaces or films. Furthermore, the novel liquid-crystalline compositions can be used for the preparation of liquid-crystal displays. To this end, the compositions are, for example, applied to a substrate, preferably a polymeric film, if desired by knife coating or other physical influences. One embodiment of a display in which domains of a cholesteric liquid-crystal composition are dispersed in a polymeric matrix, disposed between electrodes is, for example, disclosed in U.S. Pat. No. 6,236,442 issued May 22, 2001 to Stephenson et al. and U.S. Pat. No. 5,695,682 issued Dec. 9, 1997 to Doane et al., the disclosures of which are incorporated by reference. In one embodiment, a display comprises: (a) a flexible transparent support; (b) a patterned first conductor layer comprising transparent first conductors; (c) a patterned second conductor layer comprising second optionally transparent conductors; and (d) at least one imaging layer comprising domains of polymer-dispersed chiral nematic (cholesteric) liquid-crystal material dispersed in a continuous polymeric matrix, the imaging layer disposed between the first and second conductors. Such chiral nematic liquid-crystal material can exhibit two contrasting stable states, a reflecting planar state and a light-transmissive focal conic state, which two states can be switched from one to the other by application of suitable voltages.
EXAMPLES
[0000] 1. Preparation of Compounds of the Invention:
[0033] The synthesis of representative compounds of the invention, as shown in Scheme 1 below, begins with preparation of racemic Int-2, followed by chiral resolution of this enantiomeric mixture to provide I-1, and finally derivatization of the enantiomerically enriched spirodiphenols I-3. The preparation of 3,3,3′,3′-tetramethyl-1,1′-spirobiindan-6,6′-diol using a minor variant of the method described by Faler and Lynch (vide supra). This synthetic route and its subsequent partial enantiomeric resolution are outlined in Scheme 1. The preparation of related, but previously undescribed, nortetramethyl I-2, 1,1′-spirobiindan-6,6′-diol along with preparation of an ester derivative, are outlined in Scheme 2.
[0000] Preparation of (±)-Int-1:
[0034] Using a minor variant of the procedure of Faler and Lynch (vide supra), a mixture of bis-phenol A (Int-1; CAS 80-05-7; 100 g, 0.438 mole) and methanesulfonic acid (5 mL) were heated at 135° C. for three hours then cautiously poured into 550 mL water with stirring. After stirring a short while the liquid was decanted and the remaining solid diluted with 350 mL water and the stirring continued. This procedure was repeated twice further to provide a semi-solid mass. The damped solid was heated to reflux with 150 mL methylene chloride for one hour then chilled. The solid was collected, washed with minimal cold methylene chloride and ligroin to provide Int-2 as a white solid 29.1 g (65%).
[0035] This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
[0000] Preparation of Diastereomeric mixture of Int-3 and Int-4 and Isolation of Int-3:
[0036] A solution of Int-2 (12.3 g; 40 mmol), triethylamine (TEA; 20 mL, 144 mmol), and 4-dimethylaminopyridine (DMAP; 1 g, 8 mmol) in 200 mL methylene chloride was treated over circa ten minutes with a solution of menthyl chloroformate (CAS 14602-86-9; 18 mL, 84 mmol) in 5 mL methylene chloride. The resulting mixture stirred at ambient temperature for three hours then was washed with dilute hydrochloric acid, dried with sodium sulfate, filtered and concentrated in vacuo. The glassy residue, containing an equimolar mixture of the diastereomers Int-3 and Int-4 as assessed by NMR spectroscopy, was dissolved in 150 mL heptanes. Shortly, crystallization initiated and the slurry stirred at ambient temperature for twenty hours. The slurry was chilled then filtered; the solids washed with minimal cold heptanes and low-boiling ligroin to provide Int-3 as a colorless solid, 9.46 g (35%; 70% based on single diastereomer). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. High field NMR detected none of the alternative diastereomer, Int-4.
Preparation of (+) I-1:
[0037] A solution of Int-3 (9.00 g, 13.4 mmol) and hydrazine monohydrate (4.6 mL, 95 mmol) in 85 mL tetrahydrofuran (THF) was heated at reflux for three hours then portioned between dilute hydrochloric acid and ethyl acetate. The organic layer wash dried with sodium sulfate, filtered and concentrated in vacuo to provide an oil. Two silica gel chromatographies, first eluting with mixture of methylene chloride and ethyl acetate, then secondly, eluting with mixtures of heptanes and isopropyl ether, gave a purified oil. Trituration with IPE/heptanes, followed by filtration and drying, finally yielded Int-1 as a colorless solid, 3.66 g (88.6%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Chiral HPLC analysis indicate an % ee of >98%; Polarimetry provided [α] D 23 =+37.4° (methanol, c=0.010).
[0000] Preparation of I-3:
[0038] A solution of (+)-I-1 (154 mg, 0.50 mmol) and anisoyl chloride (CAS 100-07-2; 0.20 g, 1.2 mmol) in 5.0 mL acetonitrile was treated sequentially with TEA (0.2 mL, 13 mmol) and DMAP (20 mg, 0.2 mmol). The mixture stirred at ambient temperature for two hours then the mixture was partitioned between dilute hydrochloric acid and ethyl acetate. Work afforded an oil, which was purified via silica gel chromatography, eluting with mixtures of heptanes and isopropyl ether. Finally, trituration provided I-3 as a colorless solid, 0.15 g (51%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
[0000] Preparation of Int-7:
[0039] A mixture Montmorillonite K10 clay (CAS 1318-93-0; 20 g, dried ≧100° C. in vacuo) and 100 mL xylenes were refluxed under a Dean-Stark trap for twenty minutes, then 1,5-(4-methoxyphenyl)-3-pentanone (Int-6; CAS 74882-32-9, prepared via standard synthetic procedures outlined in Scheme 2; 4.00 g, 13.4 mmol) was added and the reflux continued for twenty hours. The mixture was briefly cooled and then filtered through diatomaceous earth. The solids were washed with toluene (100 mL in portions). The combined filtrates were concentrated in vacuo to provide a crude solid. This material was carefully chromatographed on silica gel, eluting with mixtures of heptanes and ethyl acetate, to provide a purified semi-solid. Trituration of this material with cold isopropyl ether then provided Int-7 as a colorless solid, 0.75 g (20%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
Preparation of Int-8:
[0040] A solution of Int-7 (0.56 g, 2.0 mmol) in 10 mL methylene chloride was chilled in an ice-acetone bath then treated with boron tribromide (0.45 mL, 4.8 mmol). The mixture stirred at ambient temperature for one hour then was cooled and the reaction quenched by the cautious addition of 5 mL water. The organics were separated, dried with sodium sulfate, filtered and concentrated in vacuo. The residue was treated with isopropyl ether and heptane to induce crystal formation. These solvents were removed in vacuo to provide Int-8 as a colorless solid, 0.5 g (circa 100%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
[0000] Preparation of Int-9:
[0041] A slurry of Int-8 (0.45 g, 1.8 mmol) in 15 mL methylene chloride, at ambient temperature, was sequentially treated menthyl chloroformate (0.8 mL, 3.7 mmol), triethylamine (0.9 mL, 6.5 mmol) and DMAP (0.05 g, 0.4 mmol). The mixture was stirred at ambient temperature for one hour, and then washed with dilute hydrochloric acid. The organics were dried with sodium sulfate, filtered and concentrated in vacuo. The residue was chromatographed on silica gel, eluting with methylene chloride, top provide the expected mixture of diastereomers as a colorless oil, 1.1 g (circa 100%). NMR analysis indicated a equimolar mixture of diastereomers. This residue was dissolved in 15 mL heptanes after which crystallization initiated. The mixture stirred at ambient temperature for thirty minutes then was filtered, to yield Int-9 as a colorless solid, 0.39 g (35%, 71% based on a single diastereomer). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Careful NMR analysis indicated the presence of a single diastereomer.
[0000] Preparation of I-2:
[0042] A solution of Int-9 (0.35 g, 0.57 mmol) in 7.5 mL THF was treated with hydrazine monohydrate (0.25 mL, 5.2 mmol) then heated at reflux for thirty minutes. Additional hydrazine monohydrate was added (0.15 mL, 3.1 mmol) and mix heated another hour. The mix stirred at ambient temperature overnight then was partitioned between dilute hydrochloric acid and ethyl acetate. The organic layer was dried with sodium sulfate, filtered and concentrated in vacuo to provide a glassy residue. Silica gel chromatography, eluting with mixtures of methylene chloride and ethyl acetate, gave a purified oil. This oil was dissolved ethyl acetate then washed with dilute aqueous sodium hydroxide. The aqueous layer was acidified with hydrochloric acid and extracted with ethyl acetate. The organics were dried, filtered, and concentrated to provide I-2 as a colorless oil, 0.14 g ((100%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
[0000] Preparation of I-11:
[0043] A solution of I-2 (50 mg, 0.12 mmol) and 4-cyanobenzoyl chloride (CAS 6068-72-0; 70 mg, 0.42 mmol) in 5 mL acetonitrile at ambient temperature was sequentially treated with triethylamine (0.10 mL, 0.72 mmol) and DMAP (5 mg, 0.04 mmol). The mixture stirred for forty-five minutes then was partitioned between dilute hydrochloric acid and ethyl acetate. The organic layer was dried with sodium sulfate, filtered and concentrated in vacuo to provide a glassy residue. This material was chromatographed on silica gel, eluting with methylene chloride, to afford I-11 as a colorless solid, 90 mg, (90%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
Example 1
[0044] Several enantiomerically pure derivatives of the invention were prepared (vide infra) and known amounts of these compounds combined with the commercially available liquid crystalline compound 4-n-pentyl-4′-cyanobiphenyl, 5CB, having the following structure:
[0045] The mixture was heated above its clearing point, thoroughly mixed and allowed to cool to ambient temperature. The pitches of these samples were then measured either from standard reflectance response curves or by the method of Dogic and Fraden (vide supra). The HTP's (β) of these samples, on a mole fraction basis, were then calculated as described above. Results of this experiment are found in Table 1 showing the HTP's in 5CB at ambient temperatures.
TABLE 1 Compound β (μm −1 ) I-3 0.1 I-6 0.4 I-7 30
Example 2
[0046] Several enantiomerically pure derivatives of the invention were prepared (vide supra) and known amounts of these compounds combined with the commercially available liquid crystalline mixture BL087 (described as a mixture of 5CB (25-40%), the structurally related 2CB wherein the n-pentyl group is replaced by an ethyl group (10-25%), and a proprietary LC mixture (35-65%)) available from Merck KGaA, Darmstadt, Germany. The mixture was heated above its clearing point, thoroughly mixed and allowed to cool to ambient temperature. The pitches of these samples were then measured either from standard reflectance response curves or by the method of Dogic and Fraden (vide supra). The HTP (β) of these samples was then calculated as described above, except on a weight percent basis. Results of this experiment are found in Table 2 below showing HTP's in 5CB at ambient temperatures.
TABLE 2 β (μm −1 ) Compound weight % I-3 0.61 I-5 0.63 I-6 0.53 I-8 0.60 I-10 0.63 I-12 0.14 I-13 0.17
[0047] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention | The invention relates to a class of compounds useful as chiral dopants, which compounds are available in both enantiomeric forms, in liquid-crystal formulations. Such formulations are advantageous in displays and various other products. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/DE2003/003904 filed Nov. 26, 2003, which claims priority to German Patent Application No. DE 102 56 197.4 filed on Dec. 2, 2002. The disclosures of the above applications are incorporated herein by reference.
FIELD OF THE INVENTION
The invention concerns an exterior rearview mirror for vehicles, more particularly motor vehicles.
BACKGROUND OF THE INVENTION
Exterior rearview mirrors are known in which the mirror mounting bracket is provided with a perimeter light containing at least one lighting means. Such lighting means develop relatively intense heat which can lead to damage to the perimeter light and/or the exterior rearview mirror.
The object of the invention is to design an exterior rearview mirror of this type such that the heat generated by the lighting means has no adverse effects.
This object is attained in accordance with the invention in an exterior rearview mirror of the type of the present invention.
SUMMARY OF THE INVENTION
As a result of the inventive design, the heat generated by the lighting means is transmitted by the carrier to the mirror mounting bracket. In this way, excessive heating of the perimeter light and mirror mounting bracket is avoided.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DESCRIPTION OF THE DRAWINGS
Additional features of the invention are apparent from the other claims, the description, and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in detail below on the basis of several example embodiments shown in the drawings. The drawings show:
i. FIG. 1 a perspective view in cross-section of a mirror mounting bracket of an inventive exterior rearview mirror with a perimeter light,
ii. FIGS. 2-6 each show an additional embodiment of an inventive exterior rearview mirror in views similar to that of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a mirror mounting bracket 1 with a cover 2 and a perimeter light 3 of an exterior rearview mirror that is attached to a vehicle (not shown) by the mirror mounting bracket 1 . Fastened to the mirror mounting bracket 1 in an articulated fashion is a mirror head 100 (shown in phantom) that can be swiveled from an operating position into a non-operating position adjacent to the vehicle. An area beneath the exterior rearview mirror and adjacent to the vehicle or vehicle doors can be illuminated by means of the perimeter light 3 .
The mirror mounting bracket 1 has a receptacle 4 for the light 3 , preferably composed of a surrounding ridge 5 . The receptacle 4 may have a round or angular cross-section. The height of the ridge 5 varies over its extent to correspond to the varying overall height of the mirror mounting bracket 1 in the vicinity of the installation space for the perimeter light 3 . In the example embodiment, the receptacle 4 is located in the vicinity of a hole 7 that accommodates a bearing pin for swivel mounting of the mirror head.
The mirror mounting bracket 1 has a support 48 , which preferably is made of metal or rigid plastic. The support 48 is covered with respect to the outside by the cap-like cover 2 , which has an opening 9 for an optical window 10 of the light 3 . In advantageous fashion, the cover 2 is made of plastic. Said cover is held on the support 48 by one or more interlocking connectors 11 . The cover 2 has a curved edge section 12 and, extending approximately parallel thereto and spaced apart from it, an inner ridge 13 , the two of which define a receptacle opening 14 for a free edge 15 of the support 48 .
As lighting means, the perimeter light 3 has an LED 16 , which is arranged on a printed circuit board 17 , and a light housing 18 that has the optical window 10 . The printed circuit board 17 is a flat plastic plate that contains a metal core (not shown) as a thermal conductor, preferably a metal plate having a regular outer contour. In the installation position, the full surface of the metal-core circuit board rests on the flat bottom 8 of the receptacle 4 .
The light housing 18 is manufactured as a single piece with the optical window 10 of a light-transmissible plastic. The housing has a circular cross-section with a surrounding edge 19 , which edge is L-shaped in cross-section and defines an annular groove 20 for a ring seal 21 . The free end of the ridge 5 of the receptacle 4 of the support 1 ′ projects into the annular groove 20 . In this way, the housing 18 is secured against rotation in the receptacle 4 in the assembled position. The printed circuit board 17 closes the housing 18 at the end opposite the optical window 10 .
A central section 22 of the optical window 10 projects into the housing opening 9 such that the end face 25 of the section 22 is located in the outer side of the cover 2 . The housing section 22 completely fills the opening 9 and transitions into the remaining part of the housing through a shoulder 24 . The end face 25 is domed outward in an arc with a large radius of curvature over an adjacent lower wall 30 of the cover 2 . In the assembled position of the cover 2 , the optical window 10 projects into the opening 9 of the cover 2 so that the rim 26 of the opening is located in the shoulder 24 . The light housing 18 rests against the inside of the cover 2 adjacent to the rim 26 of the opening. The height of the light housing 18 is slightly greater than the distance between the cover 2 in the vicinity of the housing and the bottom 8 of the receptacle 4 of the support 1 ′. As a result, the light housing 18 is preloaded with respect to the printed circuit board 17 in the assembled position and with cover 2 installed, so that said circuit board rests, with preloading, against the bottom 8 of the mirror mounting bracket receptacle 4 . Since the LED 16 produces very high lumen values per watt, intense heat is developed; said heat is transmitted through the metal core in the printed circuit board 17 directly to the support 1 ′ or conducted to it. In this way, the perimeter light 3 and its housing 18 are protected from excessive heat or overheating.
The cover 2 is pushed over the preassembled optical window 10 . During this process, the cover 2 slides over the end face 25 of the optical window 10 with elastic expansion until the rim 26 of the opening snaps into the shoulder 24 of the optical window. In this way, the optical window 10 is braced and held against the carrier 17 . Hence additional fastening means for the optical window 10 are unnecessary.
Due to the preloading of the light housing 18 , the seal 21 is also elastically compressed between the ridge 5 and the housing 18 , thus reliably preventing the penetration of moisture into the housing 18 .
The mirror mounting bracket 71 embodiment shown in FIG. 2 differs from the embodiment described above only in that the light housing 54 has a preferably ring-shaped cavity 27 provided between the housing walls 29 , 29 ′ and a central midsection 28 . This midsection 28 has at its free end a recess 28 ′ into which the LED 16 projects in a form-fitting manner in the assembled light housing 54 . The optical window 50 has the central, protruding housing section 51 , which rests in the opening 9 . In contrast to the mirror mounting bracket 1 embodiment described above, the end face 52 of the central housing section 51 is designed with a convex curvature so that it lies approximately in a plane with the adjacent lower wall 30 of the cover 2 . In this mirror mounting bracket 71 embodiment as well, the light housing 54 is made of light-transmissible plastic.
The light housing 54 has, directly adjoining the outside shoulder 24 , another outside shoulder 43 in which is arranged a ring seal 42 . In the installation position, the ring seal 42 lies with elastic deformation between the light housing 54 and the inner side of the cover 2 , and prevents moisture and/or dirt from entering the mirror mounting bracket 71 through the opening 9 . The design of this mirror mounting bracket 71 embodiment is otherwise the same as the previous example embodiment. The metal-core of the printed circuit board 17 is again pressed firmly against the bottom 8 of the receptacle 4 of the support 48 , so the heat produced when the LED 16 is turned on is reliably conducted into the support 48 .
The mirror mounting bracket 81 embodiment in FIG. 3 corresponds to the mirror mounting bracket 71 in FIG. 2 with the sole difference that the light housing 55 is designed without the midsection 28 . Together with the LED 16 , the printed circuit board 17 with the metal core once again rests with its entire surface against the bottom 8 of the receptacle 4 of the support 48 under pressure. In the assembled position, the housing 55 in FIG. 3 is loaded by the cover 2 in the direction of the support 48 . As a result, the ring seal 21 is elastically deformed in the annular groove 20 and the circuit board 17 is pressed against the bottom 8 of the receptacle 4 , ensuring rapid and complete heat conduction and reliable sealing of the housing 55 .
FIG. 4 shows a mirror mounting bracket 91 embodiment corresponding to that in FIG. 3 , wherein a light housing 57 has a reflector as an insert reflector 31 . It rests against the inner wall of the housing 57 and is provided with an opening 32 through which the LED 16 projects. The reflector 31 has a reflective surface 33 , which reflects the light emitted by the LED 16 to an optical window 58 . The reflector 31 can have various designs depending on the desired lighting effect, for example it can take the shape of a paraboloid. The free edge of the reflector 31 is supported on an inner shoulder 34 of the housing 58 , which shoulder is also present in the housings 18 , 54 in FIGS. 2 and 3 . The inner shoulder 34 is recessed inward with respect to the outer shoulder 24 . The reflector 31 also rests on the printed circuit board 17 . The reflector 31 is preferably made of heat-resistant plastic. The design of the perimeter light 59 is otherwise the same as in the perimeter light 61 embodiment shown in FIG. 3 .
The reflector 31 can also be designed as a heat-dissipating element. In this case, it is made of metallic material and is designed such that it incorporates the shape of the light housing 57 . The annular groove 20 is then located on the outside of the reflector 31 . A lens is then set into the free end of such a reflector. In such a design, not only is the heat generated by the LED 16 conducted into the support 48 through the carrier 17 , it is also conducted through the reflector 31 into the ridge 5 .
Here, too, the heat generated by the LED 16 is rapidly and completely conducted into the support 48 through the printed circuit board 17 of the perimeter light 3 .
FIG. 5 shows a mirror mounting bracket 92 embodiment in which the light housing 63 largely corresponds to that shown in FIG. 3 . However, an end face 65 of a central section 66 of the optical window has a concave curvature as in the mirror mounting bracket 1 embodiment in FIG. 1 . The inner side of the optical window 66 is provided with an optical structure 38 which can be used to achieve a directed guidance of the light emitted by the LED 16 . Located a distance behind the optical window 66 is an optical element 39 , which is designed as a Fresnel lens, for example. A lens 40 is accommodated in the housing 63 between the optical element 39 and the LED 16 . The optical elements 38 through 40 can, of course, also be built into the housing in a different arrangement. Different combinations of these optical elements can also be employed to achieve directed guidance of the light.
The optical elements 67 , 39 and 4 are provided in the mirror mounting bracket 96 embodiment in FIG. 6 as in the previous example mirror mounting bracket 91 embodiment. In addition, a face 68 of the optical window 69 is provided with an optical structure 41 .
In place of the light housings, described in the embodiments shown in FIGS. 1-6 , an optical waveguide or a combination of an optical waveguide and light housing can also be used. The installation depth of the LEDs can likewise be varied with appropriate adjustment of the mirror mounting bracket in order to change the illuminated area.
Finally, the position of the perimeter light on the mirror mounting brackets described in FIGS. 1-6 on the mirror mounting bracket support 48 can also be changed as desired depending on which area next to the vehicle and on the ground is to be illuminated.
Of course, additional LEDs, for example arranged next to one another in rows, can also be used in place of the one LED 16 to increase the light intensity.
In all the embodiments described, there may be built into the exterior rearview mirror, in particular into the mirror head, lighting means as auxiliary turn signals, transmitters and/or receivers for garage door openers and/or for navigation systems, sensors as part of the control system for an EC or LCD glass, antennas for automotive radios, compasses and the like, loudspeakers and the like. Additional components, such as transmitters and/or receivers for garage door openers or for navigation systems, may also be built into the mirror mounting bracket.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An exterior rearview mirror including a mirror mounting bracket for attachment to a vehicle, and at least one perimeter light with a light source arranged on a thermally conductive carrier (e.g. a printed circuit board) in thermally conductive connection with the mirror mounting bracket. The light source is preferably an LED. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention describes phenazopyridine covalently attached to various conjugates. These compounds and compositions are useful for providing increased (oral) bioavailability with reduced side effects.
[0003] 2. Related Art
[0004] Various publications are cited herein, the disclosures of which are incorporated by reference in their entireties. However, the citation of any reference herein should not be construed as an admission that such reference is available as prior art to the present application.
[0005] Phenazopyridine is an analgesic compound indicated for urinary tract pain, burning, irritation, and discomfort, as well as urgent and frequent urination caused by urinary tract infections, surgery, injury, or examination procedures. Phenazopyridine, while an effective analgesic, carries with it a foreboding side effect profile, with nausea, vomiting, and general GI upset being the most severe events. In an effort to improve the side effect profile and expand the use of phenazopyridine, it is proposed to pursue the development of a prodrug compound that results in the formation of the active drug following transport across the gastrointestinal epithelium.
[0006] Phenazopyridine or 2,6-pyridinediamine, 3-(phenylazo), monochloride (CAS number 94-78-0) is an azo dye that exerts topical analgesic or local anesthetic action on the urinary tract mucosa and provides symptomatic relief of pain, burning, urgency, frequency and other discomforts arising from irritation of lower urinary tract caused by infections, trauma, surgery, endoscopic procedures or use of catheters. Phenazopyridine has been marketed since 1925 and since 1951 has had a dual status of prescription and over-the-counter (OTC).
[0007] Phenazopyridine is marketed as single agent 100 and 200 mg tablets under a number of brand names including Nefrecil, Phenazodine, Pyridiate, Pyridium, Sedural, Uricalm, Uropyrine, Urodine, and Urogesic. Single agent OTC medications include Azo-Gesic, Azo-Standard, and Uristat (95 mg tablets), ReAzo (97 mg tablets), and URIRelief and Baridium (97.2 mg tablets). Phenazopyridine is available as a combined prescription with sulfisoxazole or sulfamethoxazole/trimethoprim and as Phenazopyridine plus in combination with hyosciamine and secbarbitol.
[0008] The usual adult dosage is 100-200 mg three times daily after meals for no more than two days and 12 mg/kg/day in three divided doses after meals in children for no more than two days. The pharmacological mechanism of the analgesic effect of phenazopyridine is unknown.
[0009] Phenazopyridine is absorbed from the gastrointestinal tract following oral administration. Although the absolute bioavailability in humans has not been determined it is apparently poorly absorbed with the highest prescribed dose of 200 mg yielding maximum plasma levels between 10 and 20 ng/mL. Phenazopyridine is rapidly excreted up to 65% unchanged in urine with approximately 90% of a single dose cleared within 24 hours. Metabolites include aniline, N-acetyl-p-aminophenol (NAPA or acetaminophen) and p-amino phenol. Aniline may contribute to the analgesic effect of orally administered phenazopyridine in the urinary tract mucosa.
[0010] Adverse reactions associated with therapeutic doses of phenazopyridine include headache, rash pruritus, gastrointestinal disturbances (nausea, vomiting, and diarrhea), orange to red urine discoloration and staining of soft contact lenses. In cases of insufficient renal clearance phenazopyridine can tinge skin, sclera or fluids yellow due to accumulation of the drug. Methemaglobenemia, hemolytic anemia, renal and hepatic toxicity have been reported, usually at overdose levels. Anaphylactoid reactions have been reported.
[0011] Phenazopyridine and the metabolite aniline can cause oxidative stress within red blood cells by conversion of hemoglobin to methemaglobin. Patients with glucose-6-phosphate dehydrogenase deficiency may be predisposed to hemolytic anemia. Phenazopyridine should not be administered to patients with impaired renal function. Exceeding the recommended dose may lead to increased serum levels and toxic reactions. Methemaglobinemia generally follows excessive acute overdose. Considering the long history and fairly widespread use of phenazopyridine, reports of serious toxicity are relatively uncommon.
[0012] Long term (2 years) administration of phenazopyridine hydrochloride induced adenomas and adenocarcinomas in the large intestine of rats and lifetime administration caused hepatocellular adenomas and carcinomas in female mice. Phenazopyridine has been shown to be mutagenic in bacteria and mutagenic and clastogenic in mammalian cells. In one limited epidemiological study of 2,214 patients who received phenazopyridine hydrochloride there was no observed increase in the occurrence of any type of cancer over a minimum period of 3 years. Current phenazopyridine product labeling indicates: “Long term administration of phenazopyridine hydrochloride has induced neoplasia in rats (large intestine) and mice (liver). Although no association between phenazopyridine hydrochloride and human neoplasia has been reported, adequate epidemiological studies along these lines have not been conducted.”
[0013] Reproduction studies at doses up to 50 mg/kg/day or 110 mg/kg/day in rats and 39 mg/kg/day in rabbits showed no effects on fertility or embryo-fetal development. Phenazopyridine is currently classified in pregnancy category B. There have been no adequate and well controlled studies of phenazopyridine exposure in pregnant women. Surveillance studies have been reported with no link of phenazopyridine use to congenital defects. The Collaborative Perinatal Project monitored 50,282 mother-child pairs with 1,109 exposures recorded during pregnancy and 219 exposures during the first trimester. No association was found with major or minor malformations or individual defects. Surveillance of 229,101 Michigan Medicaid patents identified 469 phenazopyridine exposures during the first trimester. No data was obtained to indicate any association of the drug with abnormalities.
[0014] The acute toxicity LD50 for phenazopyridine has been reported as 472 mg/kg (oral) and 200 (i.p.) in rats; and 180 mg/kg (i.p.) in mice. Adequate safety pharmacology and repeat dose nonclinical toxicology studies have not been performed for phenazopyridine.
BRIEF SUMMARY OF THE INVENTION
[0015] The invention provides covalent attachment of phenazopyridine and derivatives or analogs thereof to a variety of chemical moieties. The chemical moieties may include any substance which results in a prodrug form, i.e., a molecule which is converted into its active form in the body by normal metabolic processes. For example, the chemical moieties may be single amino acids, dipeptides, or polypeptides.
[0016] The chemical moiety is covalently attached either directly or indirectly through a linker to the phenazopyridine. The site of attachment is typically determined by the functional group(s) available on the phenazopyridine.
[0017] In one embodiment, the phenazopyridine is attached to a single amino acid which is either naturally occurring or a synthetic amino acid. In another embodiment, the phenazopyridine is attached to a dipeptide or tripeptide, which could be any combination of the naturally occurring amino acids and synthetic amino acids. In another embodiment, the amino acids are selected from L-amino acids for digestion by proteases.
[0018] Other objects, advantages and embodiments of the invention are described below and will be obvious from this description and practice of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a graph showing the plasma concentrations of various phenazopyridine-amino acid conjugates in rats following oral administration of the phenazopyridine conjugates. Phenazopyridine (PAP) plasma concentrations versus time profiles are shown following administration of PAP.HCl, Gly-PAP, alanyl-PAP, methionyl-PAP, histidinyl-PAP, tryptophanyl-PAP, valyl-PAP, and lysyl-PAP.
[0020] FIG. 2 is a depiction of 2-amino-6-aminoacetamido-3-E-phenazopyridine dihydrochloride.
[0021] FIG. 3 is a graph showing mean rat (male) plasma concentration curves of 1) phenazopyridine from phenazopyridine hydrochloride (2.8 mg/kg containing 2.5 mg/kg phenazopyridine base), 2) phenazopyridine from Gly-PAP (4 mg/kg, containing 2.5 mg/kg phenazopyridine base), and 3) Gly-PAP intact prodrug from Gly-PAP (4 mg/kg, containing 2.5 mg/kg phenazopyridine base).
[0022] FIG. 4 is a graph showing mean rat (male) plasma concentration curves of 1) phenazopyridine from phenazopyridine hydrochloride (2.8 mg/kg containing 2.5 mg/kg phenazopyridine base) and 2) phenazopyridine from Gly-PAP (0.9 mg/kg, containing 0.6 mg/kg phenazopyridine base).
[0023] FIG. 5 is a table showing the solubility of Gly-PAP at room temperature as a free base and HCl salt.
[0024] FIG. 6 is a table showing the solubility of Gly-PAP salts in water and bioavailability in rats.
[0025] FIG. 7 is a table showing the results of a stability study of Gly-PAP by UV-HPLC.
[0026] FIG. 8 is a table showing the results of a stability study of Gly-PAP-HCl in water solution at 4° C. by UV-HPLC at 0.2 mg/ml.
[0027] FIG. 9 is a table showing the results of a stability study of Gly-PAP-HCl in water solution at 4° C. by UV-HPLC at 8.8 mg/ml.
[0028] FIG. 10 is a table showing the results of a stability study of Gly-PAP-HCL in water solution at room temperature by UV-HPLC.
[0029] FIG. 11 is a table summary of phenazopyridine pharmacokinetics following oral administration of Gly-PAP or phenazopyridine HCl in male rats.
[0030] FIG. 12 is a table summary of Gly-PAP pharmacokinetics following oral administration of Gly-PAP in male rats.
[0031] FIG. 13 is a graph showing mean dog (male) plasma concentration curves of 2) phenazopyridine from phenazopyridine hydrochloride (5.9 mg/kg containing 5 mg/kg phenazopyridine base), 2) phenazopyridine from Gly-PAP (8.1 mg/kg, containing 5 mg/kg phenazopyridine base), and 3) Gly-PAP intact prodrug from Gly-PAP (8.1 mg/kg, containing 5 mg/kg phenazopyridine base).
[0032] FIG. 14 is a table summary of pharmacokinetic parameters in plasma collected from male dogs following a single oral administration of Gly-PAP (Group 1) or PAP HCl (Group 2).
[0033] FIG. 15 is a table summary of concentrations of PAP and Gly-PAP in urine following a single oral dose of Gly-PAP (Group 1) or PAP HCl (Group 2) to male dogs.
[0034] FIG. 16 is a synthetic scheme for production of 2-amino-6-aminoacetamido-3-E-phenazopyridine dihydrochloride.
[0035] FIG. 17 is a table demonstrating oral bioavailability of Gly-PAP salts in rats.
[0036] FIG. 18 is a table demonstrating reduction of the GI side effect of emesis.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Throughout this application the use of “peptide” is meant to include a single amino acid, a dipeptide, a tripeptide, an oligopeptide, a polypeptide, or the carrier peptide. Oligopeptide is meant to include from 2 amino acids to 70 amino acids. Further, at times the invention is described as being an active agent attached to an amino acid, a dipeptide, a tripeptide, an oligopeptide, polypeptide or carrier peptide to illustrate specific embodiments for the active agent conjugate. Preferred lengths of the conjugates and other preferred embodiments are described herein.
[0038] A “composition” as used herein refers broadly to any composition containing a described molecule conjugate(s). The composition may comprise a dry formulation, an aqueous solution, or a sterile composition. Compositions comprising the molecules described herein may be stored in freeze-dried form and may be associated with a stabilizing agent such as a carbohydrate. In use, the composition may be deployed in an aqueous solution containing salts, e.g., NaCl, detergents, e.g., sodium dodecyl sulfate (SDS), and other components.
[0039] “Phenazopyridine” shall mean:
[0000]
[0040] Compounds useful in the present invention are represented by Formula I:
[0000]
[0000] wherein,
R 1 and R 2 are independently
(a) hydrogen; (b) the residue of an amino acid or peptide; (c)
[0000]
[0044] wherein R 3 is an optionally substituted alkyl or arylalkyl; or
(d) the residue of an amino acid wherein the amine of the amino acid is protected with a t-butylcarbonyl;
wherein at least one of R 1 and R 2 is other than hydrogen.
[0046] This patent is meant to cover all compounds discussed regardless of absolute configurations. Thus, natural, L-amino acids are discussed but the use of D-amino acids are also included.
[0047] Use of the phrases such as, “decreased”, “reduced”, “diminished” or “lowered” is meant to include at least a 10% change in side effects with greater percentage changes being preferred. For instance, the change may also be greater than 25%, 35%, 45%, 55%, 65%, 75%, 85%, 95%, 96%, 97%, 98%, 99%, or increments therein.
[0048] The purity of the prodrug will preferably be greater than 25%, 35%, 45%, 55%, 65%, 75%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, or increments therein.
[0049] The term increments is shall include without limitation, ones, tens, and fractions thereof, for instance, 1, 2, 3, 4, . . . or 0.1, 0.2, 0.3, 0.4 etc.
[0050] For each of the recited embodiments, the amino acid or peptide may comprise one or more of glycine or of the naturally occurring (L-) amino acids: alanine, arginine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, histidine, isoleucine, leucine, lysine, methionine, proline, phenylalanine, serine, tryptophan, threonine, tyrosine, and valine. In another embodiment, the amino acid or peptide is comprised of one or more of glycine or of the naturally occurring (D) amino acids: alanine, arginine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, histidine, isoleucine, leucine, lysine, methionine, proline, phenylalanine, serine, tryptophan, threonine, tyrosine, and valine. In another embodiment, the amino acid or peptide is comprised of one or more unnatural, non-standard or synthetic amino acids such as, aminohexanoic acid, biphenylalanine, cyclohexylalanine, cyclohexylglycine, diethylglycine, dipropylglycine, 2,3-diaminopropionic acid, homophenylalanine, homoserine, homotyrosine, naphthylalanine, norleucine, ornithine, (4-fluoro)phenylalanine, (2,3,4,5,6 pentafluoro)phenylalanine, (4-nitro)phenylalanine, phenylglycine, pipecolic acid, sarcosine, tetrahydroisoquinoline-3-carboxylic acid, and tert.-leucine. In another embodiment, the amino acid or peptide comprises one or more amino acid alcohols, for example, serine and threonine. In another embodiment the amino acid or peptide comprises one or more N-methyl amino acids, for example, N-methylaspartic acid. In another embodiment, the amino acid or peptide comprises one or more cyclic amino acids, for example, cis-4-hydroxy-D-proline.
[0051] In another embodiment, the specific carriers are utilized as a base short chain amino acid sequence and additional amino acids are added to the terminus or side chain. In another embodiment, the above amino acid sequence may have one more of the amino acids substituted with one of the 20 naturally occurring amino acids. It is preferred that the substitution be with an amino acid which is similar in structure or charge compared to the amino acid in the sequence. For instance, isoleucine (Ile)[I] is structurally very similar to leucine (Leu)[L], whereas, tyrosine (Tyr)[Y] is similar to phenylalanine (Phe)[F], whereas serine (Ser)[S] is similar to threonine (Thr)[T], whereas cysteine (Cys)[C] is similar to methionine (Met)[M], whereas alanine (Ala)[A] is similar to valine (Val)[V], whereas lysine (Lys)[K] is similar to arginine (Arg)[R], whereas asparagine (Asn)[N] is similar to glutamine (Gln)[Q], whereas aspartic acid (Asp)[D] is similar to glutamic acid (Glu)[E]. In the alternative, the preferred amino acid substitutions may be selected according to hydrophilic properties (i.e., polarity) or other common characteristics associated with the 20 essential amino acids. While preferred embodiments utilize the 20 natural amino acids for their GRAS characteristics, it is recognized that minor substitutions along the amino acid chain which do not affect the essential characteristics of the amino acid chain are also contemplated.
[0052] In one embodiment, the carrier range is between one to 12 chemical moieties with one to 8 moieties being preferred. In another embodiment, the number of chemical moieties is selected from 1, 2, 3, 4, 5, 6, or 7.
[0053] Formulations of the invention suitable for oral administration can be presented as discrete units, such as capsules, caplets or tablets. These oral formulations also can comprise a solution or a suspension in an aqueous liquid or a non-aqueous liquid. The formulation can be an emulsion, such as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The oils can be administered by adding the purified and sterilized liquids to a prepared enteral formula, which is then placed in the feeding tube of a patient who is unable to swallow.
[0054] Soft gel or soft gelatin capsules may be prepared, for example by dispersing the formulation in an appropriate vehicle (vegetable oils are commonly used) to form a high viscosity mixture. This mixture is then encapsulated with a gelatin based film using technology and machinery known to those in the soft gel industry. The industrial units so formed are then dried to constant weight.
[0055] Chewable tablets, for example may be prepared by mixing the formulations with excipients designed to form a relatively soft, flavored, tablet dosage form that is intended to be chewed rather than swallowed. Conventional tablet machinery and procedures, that is both direct compression and granulation, i.e., or slugging, before compression, can be utilized. Those individuals involved in pharmaceutical solid dosage form production are versed in the processes and the machinery used as the chewable dosage form is a very common dosage form in the pharmaceutical industry.
[0056] Film-coated tablets, for example may be prepared by coating tablets using techniques such as rotating pan coating methods or air suspension methods to deposit a contiguous film layer on a tablet.
[0057] Compressed tablets, for example may be prepared by mixing the formulation with excipients intended to add binding qualities to disintegration qualities. The mixture is either directly compressed or granulated then compressed using methods and machinery known to those in the industry. The resultant compressed tablet dosage units are then packaged according to market need, i.e., unit dose, rolls, bulk bottles, blister packs, etc.
[0058] The invention also contemplates the use of biologically-acceptable carriers which may be prepared from a wide range of materials. Without being limited thereto, such materials include diluents, binders and adhesives, lubricants, plasticizers, disintegrants, colorants, bulking substances, flavorings, sweeteners and miscellaneous materials such as buffers and adsorbents in order to prepare a particular medicated composition.
[0059] Binders may be selected from a wide range of materials such as hydroxypropylmethylcellulose, ethylcellulose, or other suitable cellulose derivatives, povidone, acrylic and methacrylic acid co-polymers, pharmaceutical glaze, gums, milk derivatives, such as whey, starches, and derivatives, as well as other conventional binders known to persons skilled in the art. Exemplary non-limiting solvents are water, ethanol, isopropyl alcohol, methylene chloride or mixtures and combinations thereof. Exemplary non-limiting bulking substances include sugar, lactose, gelatin, starch, and silicon dioxide.
[0060] Preferred plasticizers may be selected from the group consisting of diethyl phthalate, diethyl sebacate, triethyl citrate, cronotic acid, propylene glycol, butyl phthalate, dibutyl sebacate, castor oil and mixtures thereof, without limitation. As is evident, the plasticizers may be hydrophobic as well as hydrophilic in nature. Water-insoluble hydrophobic substances, such as diethyl phthalate, diethyl sebacate and castor oil are used to delay the release of water-soluble vitamins, such as vitamin B6 and vitamin C. In contrast, hydrophilic plasticizers are used when water-insoluble vitamins are employed which aid in dissolving the encapsulated film, making channels in the surface, which aid in nutritional composition release.
[0061] It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention can include other suitable agents such as flavoring agents, preservatives and antioxidants. Such antioxidants would be food acceptable and could include vitamin E, carotene, BHT or other antioxidants known to those of skill in the art.
[0062] Other compounds which may be included by admixture are, for example, medically inert ingredients, e.g., solid and liquid diluent, such as lactose, dextrose, saccharose, cellulose, starch or calcium phosphate for tablets or capsules, olive oil or ethyl oleate for soft capsules and water or vegetable oil for suspensions or emulsions; lubricating agents such as silica, talc, stearic acid, magnesium or calcium stearate and/or polyethylene glycols; gelling agents such as colloidal clays; thickening agents such as gum tragacanth or sodium alginate, binding agents such as starches, arabic gums, gelatin, methylcellulose, carboxymethylcellulose or polyvinylpyrrolidone; disintegrating agents such as starch, alginic acid, alginates or sodium starch glycolate; effervescing mixtures; dyestuff; sweeteners; wetting agents such as lecithin, polysorbates or lauryl sulfates; and other therapeutically acceptable accessory ingredients, such as humectants, preservatives, buffers and antioxidants, which are known additives for such formulations.
[0063] For oral administration, fine powders or granules containing diluting, dispersing and/or surface-active agents may be presented in a draught, in water or a syrup, in capsules or sachets in the dry state, in a non-aqueous suspension wherein suspending agents may be included, or in a suspension in water or a syrup. Where desirable or necessary, flavoring, preserving, suspending, thickening or emulsifying agents can be included.
[0064] Liquid dispersions for oral administration may be syrups, emulsions or suspensions. The syrups may contain as carrier, for example, saccharose or saccharose with glycerol and/or mannitol and/or sorbitol. The suspensions and the emulsions may contain a carrier, for example a natural gum, agar, sodium alginate, pectin, methylcellulose, carboxymethylcellulose or polyvinyl alcohol.
[0065] The dose range for adult human beings will depend on a number of factors including the age, weight and condition of the patient. Tablets and other forms of presentation provided in discrete units conveniently contain a daily dose, or an appropriate fraction thereof, of one or more of the compounds of the invention. For example, units may contain from 5 mg to 500 mg, but more usually from 10 mg to 250 mg, of one or more of the compounds of the invention.
[0066] It is also possible for the dosage form to combine any forms of release known to persons of ordinary skill in the art. These include immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting, and combinations thereof. The ability to obtain immediate release, extended release, pulse release, variable release, controlled release, timed release, sustained release, delayed release, long acting characteristics and combinations thereof is known in the art.
[0067] Compositions of the invention may be administered in a partial, i.e., fractional dose, one or more times during a 24 hour period, a single dose during a 24 hour period of time, a double dose during a 24 hour period of time, or more than a double dose during a 24 hour period of time. Fractional, double or other multiple doses may be taken simultaneously or at different times during the 24 hour period. The doses may be uneven doses with regard to one another or with regard to the individual components at different administration times.
[0068] Likewise, the compositions of the invention may be provided in a blister pack or other such pharmaceutical package. Further, the compositions of the present inventive subject matter may further include or be accompanied by indicia allowing individuals to identify the compositions as products for a prescribed treatment. The indicia may additionally include an indication of the above specified time periods for administering the compositions. For example, the indicia may be time indicia indicating a specific or general time of day for administration of the composition, or the indicia may be a day indicia indicating a day of the week for administration of the composition. The blister pack or other combination package may also include a second pharmaceutical product.
[0069] It will be appreciated that the pharmacological activity of the compositions of the invention can be demonstrated using standard pharmacological models that are known in the art. Furthermore, it will be appreciated that the inventive compositions can be incorporated or encapsulated in a suitable polymer matrix or membrane for site-specific delivery, or can be functionalized with specific targeting agents capable of effecting site specific delivery. These techniques, as well as other drug delivery techniques, are well known in the art.
[0070] In another embodiment of the invention, the solubility and dissolution rate of the composition is substantially changed under physiological conditions encountered in the intestine, at mucosal surfaces, or in the bloodstream. In another embodiment the solubility and dissolution rate substantially decrease the bioavailability of the phenazopyridine, particularly at doses above those intended for therapy.
[0071] For each of the described embodiments, one or both of the following characteristics may be realized: The toxicity or side effects associated with the phenazopyridine conjugate are substantially lower than that of phenazopyridine itself. Some of the additional proposed benefits include the fact that the prodrug is hydrolyzed following oral administration, resulting in increased bioavailability, Tmax increase, increased polarity and solubility, and possible active transport by PepT1 or other transporters. As such the benefits of the prodrug may also provide reduced GI exposure to PAP (and commensurate reduction in side effects), a reduced total dose and longer duration of action.
[0072] Another embodiment of the present invention provides phenazopyridine covalently bound to any single amino acid which include the twenty naturally occurring amino acids such as isoleucine, leucine, lysine, methionine, phenylalanine, threonine, tryptophan, valine, alanine, asparagine, aspartate, cysteine, glutamate, glutamine, glycine, proline, serine, tyrosine, arginine, or histidine.
[0073] In another embodiment, phenazopyridine is covalently bound to a dipeptide or a polypeptide.
[0074] In another embodiment, phenazopyridine is covalently bound to glycine.
[0075] In another embodiment, phenazopyridine is covalently bound to at least one glycine and an additional amino acid.
[0076] In another embodiment, phenazopyridine conjugates of the present invention are administered in a therapeutically effective amount to a patient to treat, for example, urinary tract pain, burning, irritation, discomfort, or urgent or frequent urination caused by urinary tract infections, surgery, injury, or examination procedures, wherein the amount administered to the patient is 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 5%, 1%, or other fractional amount of the standard dose of unconjugated phenazopyridine that would be administered according to standard clinical protocols.
[0077] In one embodiment, the phenazopyridine conjugates of the present invention are administered to a patient and the levels of observed side effects such as, for example, nausea, vomiting, and general GI upset, are reduced by 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, or more relative to the levels of side effects observed when a standard dose of phenazopyridine is administered to a patient.
[0078] For each of the recited embodiments, covalent attachment may comprise an amide or carbamate bond.
[0079] The abbreviations used herein have their conventional meaning within the chemical and biological arts, unless otherwise specified. For example: “h” or “hr” means hour(s), “min” means minute(s), “sec” means second(s), “d” means day(s), “μL” means microliter(s), “mL” means milliliter(s), “L” means liter(s), “μM” means micromolar, “mM” means millimolar, “M” means molar, “mol” means mole(s), “mmol” means millimole(s), “μg” means microgram(s), “mg” means milligram(s), “×g” means times gravity, “aa” means amino acid(s), “k” means kilo, “μ” means micro, “° C.” means degrees Celsius, “THF” means tetrahydrofuran, “DME” means dimethoxyethane, “DMF” means dimethylformamide, “NMR” means nuclear magnetic resonance, “BOC” means t-butoxycarbonyl, “psi” refers to pounds per square inch, and “TLC” means thin layer chromatography.
[0080] The term “alkyl” as used herein by itself or part of another group refers to a straight-chain, branched, or cyclic saturated aliphatic hydrocarbon having from one to ten carbons or the number of carbons designated (C 1 -C 10 means 1 to 10 carbons). Exemplary alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, isohexyl, n-heptyl, 4,4-dimethylpentyl, n-octyl, 2,2,4-trimethylpentyl, nonyl, decyl and the like.
[0081] The term “optionally substituted alkyl” as used herein by itself or part of another group refers to an alkyl as defined above that is optionally substituted with one to three substituents independently selected from nitro, cyano, amino, optionally substituted cycloalkyl, optionally substituted heteroaryl, optionally substituted heterocycle, alkoxy, aryloxy, arylalkyloxy, alkylthio, carboxamido, sulfonamido, —COR, —SO 2 R, —N(R)COR, —N(R)SO 2 R or —N(R)C═N(R)-amino, wherein R may be an alkyl group. Exemplary substituted alkyl groups include —CH 2 OCH 3 , —CH 2 CH 2 NH 2 , —CH 2 CH 2 CN, —CH 2 SO 2 CH 3 and the like.
[0082] The compounds of the present invention may form salts which are also within the scope of this invention. Reference to a compound of the present invention herein is understood to include reference to salts thereof, unless otherwise indicated. The term “salt(s)” as used herein denotes acidic and/or basic salts formed with inorganic and/or organic acids and bases. In addition, when a compound of the present invention contains both a basic moiety and an acidic moiety, zwitterions (“inner salts”) may be formed and are included within the term “salt(s)” as used herein. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, although other salts are also useful, e.g., in isolation or purification steps which may be employed during preparation. Salts of the compounds of the present invention may be formed, for example, by reacting a compound with an amount of acid or base, such as an equivalent amount, in a medium such as one in which the salt precipitates or in an aqueous medium followed by lyophilization.
[0083] The compounds of the present invention which contain a basic moiety may form salts with a variety of organic and inorganic acids. Exemplary acid addition salts include acetates (such as those formed with acetic acid or trihaloacetic acid, for example, trifluoroacetic acid), adipates, alginates, ascorbates, aspartates, benzoates, benzenesulfonates, bisulfates, borates, butyrates, citrates, camphorates, camphorsulfonates, cyclopentanepropionates, digluconates, dodecyl sulfates, ethanesulfonates, fumarates, glucoheptanoates, glycerophosphates, hemisulfates, heptanoates, hexanoates, hydrochlorides (formed with hydrochloric acid), hydrobromides (formed with hydrobromic acid), hydroiodides, 2-hydroxyethanesulfonates, lactates, maleates (formed with maleic acid), methanesulfonates (formed with methanesulfonic acid), 2-naphthalenesulfonates, nicotinates, nitrates, oxalates, pectinates, persulfates, 3-phenylpropionates, phosphates, picrates, pivalates, propionates, salicylates, succinates, sulfates (such as those formed with sulfuric acid), sulfonates (such as those mentioned herein), tartrates, thiocyanates, toluenesulfonates such as tosylates, undecanoates, and the like.
[0084] The compounds of the present invention which contain an acidic moiety may form salts with a variety of organic and inorganic bases. Exemplary basic salts include ammonium salts, alkali metal salts such as sodium, lithium, and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, salts with organic bases (for example, organic amines) such as benzathines, dicyclohexylamines, hydrabamines (formed with N,N-bis(dehydroabietyl)ethylenediamine), N-methyl-D-glucamines, N-methyl-D-glucamides, t-butyl amines, and salts with amino acids such as arginine, lysine and the like.
[0085] The stereochemical terms and conventions used in the specification are consistent with those described in Pure & Appl. Chem. 68:2193 (1996), unless otherwise indicated.
[0086] The term “enantiomeric excess” or “ee” refers to a measure for how much of one enantiomer is present compared to the other. For a mixture of R and S enantiomers, the percent enantiomeric excess is defined as |R−S|*100, where R and S are the respective mole or weight fractions of enantiomers in a mixture such that R+S=1. With knowledge of the optical rotation of a chiral substance, the percent enantiomeric excess is defined as ([α] obs /[α] max )*100, where [α] obs is the optical rotation of the mixture of enantiomers and [α] max is the optical rotation of the pure enantiomer. Determination of enantiomeric excess is possible using a variety of analytical techniques, including NMR spectroscopy, chiral column chromatography or optical polarimetry.
[0087] The terms “enantiomerically pure” or “enantiopure” refer to a sample of a chiral substance all of whose molecules (within the limits of detection) have the same chirality sense.
[0088] The terms “enantiomerically enriched” or “enantioenriched” refer to a sample of a chiral substance whose enantiomeric ratio is greater than 50:50. Enantiomerically enriched compounds may be enantiomerically pure.
[0089] The term “asymmetric carbon atom” refers to a carbon atom in a molecule of an organic compound that is attached to four different atoms or groups of atoms.
[0090] The term “predominantly” means in a ratio greater than 50:50.
[0091] The term “leaving group” or “LG” refers to an atom or group that becomes detached from an atom or group in what is considered to be the residual or main part of the substrate in a specified reaction. In amide coupling reactions, exemplary leaving groups include —F, —Cl, —Br, —OC 6 F 5 and the like.
[0092] The term “isolated” for the purposes of the present invention designates a material (e.g. a chemical compound) that has been removed from its original environment (the environment in which it is naturally present).
[0093] Pharmaceutically acceptable carriers include fillers such as saccharides, for example lactose or sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, as well as binders such as starch paste, using, for example, maize starch, wheat starch, rice starch, potato starch, gelatin, tragacanth, methyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, and/or polyvinyl pyrrolidone. If desired, disintegrating agents may be added such as the above-mentioned starches and also carboxymethyl-starch, cross-linked polyvinyl pyrrolidone, agar, or alginic acid or a salt thereof, such as sodium alginate. Auxiliaries are flow-regulating agents and lubricants, for example, silica, talc, stearic acid or salts thereof, such as magnesium stearate or calcium stearate, and/or polyethylene glycol. In one embodiment, dragee cores are provided with suitable coatings which, if desired, are resistant to gastric juices. For this purpose, concentrated saccharide solutions may be used, which may optionally contain gum arabic, talc, polyvinyl pyrrolidone, polyethylene glycol and/or titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. In order to produce coatings resistant to gastric juices, solutions of suitable cellulose preparations such as acetylcellulose phthalate or hydroxypropylmethyl-cellulose phthalate, are used. Dye stuffs or pigments may be added to the tablets or dragee coatings, for example, for identification or in order to characterize combinations of active compound doses.
[0094] Other pharmaceutical preparations which can be used orally include push-fit capsules made of gelatin, as well as soft, sealed capsules made of gelatin and a plasticizer such as glycerol or sorbitol. The push-fit capsules can contain the active compounds in the form of granules or nanoparticles which may optionally be mixed with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate and, optionally, stabilizers. In one embodiment, the active compound is dissolved or suspended in suitable liquids, such as fatty oils, or liquid paraffin, optionally with stabilizers.
[0095] Fatty oils may comprise mono-, di- or triglycerides. Mono-, di- and triglycerides include those that are derived from C 6 , C 8 , C 10 , C 12 , C 14 , C 16 , C 18 , C 20 and C 22 acids. Exemplary diglycerides include, in particular, diolein, dipalmitolein, and mixed caprylin-caprin diglycerides. Preferred triglycerides include vegetable oils, fish oils, animal fats, hydrogenated vegetable oils, partially hydrogenated vegetable oils, synthetic triglycerides, modified triglycerides, fractionated triglycerides, medium and long-chain triglycerides, structured triglycerides, and mixtures thereof. Exemplary triglycerides include: almond oil; babassu oil; borage oil; blackcurrant seed oil; canola oil; castor oil; coconut oil; corn oil; cottonseed oil; evening primrose oil; grapeseed oil; groundnut oil; mustard seed oil; olive oil; palm oil; palm kernel oil; peanut oil; rapeseed oil; safflower oil; sesame oil; shark liver oil; soybean oil; sunflower oil; hydrogenated castor oil; hydrogenated coconut oil; hydrogenated palm oil; hydrogenated soybean oil; hydrogenated vegetable oil; hydrogenated cottonseed and castor oil; partially hydrogenated soybean oil; partially soy and cottonseed oil; glyceryl tricaproate; glyceryl tricaprylate; glyceryl tricaprate; glyceryl triundecanoate; glyceryl trilaurate; glyceryl trioleate; glyceryl trilinoleate; glyceryl trilinolenate; glyceryl tricaprylate/caprate; glyceryl tricaprylate/caprate/laurate; glyceryl tricaprylate/caprate/linoleate; and glyceryl tricaprylate/caprate/stearate.
[0096] Suitable formulations for parenteral administration include aqueous solutions of the ligand in water-soluble form, for example, water-soluble salts and alkaline solutions. In addition, suspensions of the active agent as appropriate oily injection suspensions may be administered. Suitable lipophilic solvents or vehicles include fatty oils, for example, sesame oil, or synthetic fatty acid esters, for example, ethyl oleate or triglycerides or polyethylene glycol-400. Aqueous injection suspensions may contain substances which increase the viscosity of the suspension include, for example, sodium carboxymethyl cellulose, sorbitol, and/or dextran. Optionally, the suspension may also contain stabilizers.
[0097] Examples of antioxidants which may be added to the pharmaceutical compositions include BHA and BHT.
[0098] Pharmaceutical compositions may contain from 0.01% to 99% by weight of the active agent. Compositions may be either in single or multiple dose forms. The amount of ligand in any particular pharmaceutical composition will depend upon the effective dose, that is, the dose required to elicit the desired gene expression or suppression
[0099] Suitable routes of administering the pharmaceutical compositions include oral, buccal, sublingual, parenteral (including subcutaneous, intramuscular, intravenous, and by naso-gastric tube). It will be understood by those skilled in the art that the preferred route of administration will depend upon the condition being treated and may vary with factors such as the condition of the recipient. The pharmaceutical compositions may be administered one or more times daily.
EXAMPLES OF GENERAL SYNTHETIC METHODS
Synthesis of Aminoacyl-phenazopyridine (PAP) Derivatives
Example 1
Preparation of Boc-glycyl-phenazopyridine
[0100]
[0101] To a solution of 875 mg (5 mmol) of Boc-glycine in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 22 h at room temperature at which point an additional 875 mg (5 mmol) of Boc-glycine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride were added. After stirring for an additional 48 h, the precipitated solid was filtered and the filtrate was concentrated to dryness. The residue was dissolved in 40 mL of ethyl acetate and washed with two 40-mL portions of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give 2.24 g of the crude product as an orange oil. The product was purified by column chromatography on 62 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-glycyl-phenazopyridine was obtained as an orange oil: yield 330 mg (18%); 1 H NMR (CDCl 3 ) δ 1.58 (s, 9H), 4.00 (d, 2H, J=4 Hz), 7.47 (m, 4H), 7.80 (m, 2H), 8.17 (d, 1H, J=9 Hz) and 8.29 (br s, 1H). Anal. Calcd for C 18 H 22 N 6 O 3 .0.25 H 2 O: C, 57.67; H, 6.05; N, 22.42. Found: C, 57.86; H, 6.01; N, 22.42.
Example 2
Preparation of Glycyl-phenazopyridine (6-N-Glycylphenazopyridine)
[0102]
[0103] To a solution of 330 mg (0.89 mmol) of Boc-glycyl-phenazopyridine in 20 mL of dichloromethane was added 3.10 mL (41.3 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 2.5 h at which point the reaction was complete. The reaction mixture was poured into 40 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated sodium bicarbonate solution. After drying over sodium sulfate, filtration and removal of the solvent under diminished pressure, glycyl-phenazopyridine was obtained as an orange solid: yield 140 mg (58%); 1 H NMR (CDCl 3 ) δ 3.5 (s, 2H), 7.4-7.6 (m, 3H), 7.75-7.8 (m, 3H) and 8.2 (d, 1H); mass spectrum (ESI), m/z 271 (M+H) + and 293 (M+Na) + . Anal. calcd for C 13 H 14 N 6 O.0.50 H 2 O: C, 55.90; H, 5.41; N, 30.09. Found: C, 56.13; H, 5.16; N, 29.87.
Example 3
Preparation of Glycyl-phenazopyridine Hydrochloride Salt
[0104]
[0105] To a cooled (0−5° C.) solution of 1.0 g (2.70 mmol) of Boc-glycyl-phenazopyridine in 20 mL of EtOAc was bubbled slowly dry HCl (g) [prepared by adding a 36% solution of HCl (5 mL) to H 2 SO 4 ]. The reaction mixture was stirred at room temperature for 3 h following which HPLC analysis showed that the reaction was complete. The thick mixture was filtered and the product was washed with four 15-mL portions of EtOAc and dried under diminished pressure over P 2 O 5 at 45° C. for 6 h. Glycyl-phenazopyridine dihydrochloride was obtained as an orange solid: yield 878 mg (94%); 1 H NMR (DMSO-d 6 ) δ 3.88 (s, 2H), 7.51 (m, 4H), 7.89 (d, 2H, J=7.2 Hz), 8.09 (d, 1H, J=8.7 Hz), 8.46 (m, 3H) and 11.10 (s, 1H). Anal. calcd for C 13 H 16 Cl 2 N 6 O.0.80 H 2 O: C, 43.66; H, 4.96; N, 23.50; Cl, 19.83. Found: C, 43.96; H, 4.64; N, 23.60; Cl, 20.10.
Example 4
Preparation of Glycyl-phenazopyridine Mesylate Salt
[0106]
[0107] To a solution of 300 mg (0.8 mmol) of Boc-glycyl-phenazopyridine in 8 mL of dioxane was added dropwise 207 μL (3.2 mmol) of methanesulfonic acid. The reaction mixture was stirred at room temperature for 90 min after which only 4% conversion was observed. After 1 h 45 min, another 414 μL (6.4 mmol) of methanesulfonic acid were added and stirring was continued at room temperature for 3 h. The precipitated product was filtered, washed with three 6-mL portions of 1,4-dioxane and three 6-mL portions of acetone and dried under vacuum at 45° C. over P 2 O 5 for 18 h. Glycyl-phenazopyridine mesylate salt was obtained as an orange solid: yield 352 mg (94%); 1 H NMR (DMSO-d 6 ) δ 2.41 (s, 6H), 3.89 (s, 2H), 7.43-7.56 (m, 4H), 7.89 (d, 2H, J=7.5 Hz), 8.10 (m, 4H) and 10.87 (s, 1H). Anal. calcd for C 13 H 14 N 6 O.2.65 CH 3 SO 3 H: C, 35.81; H, 4.72; N, 16.01; S, 16.19. Found: C, 35.47; H, 4.79; N, 15.82; S, 15.85.
Example 5
Preparation of Boc-alanyl-phenazopyridine
[0108]
[0109] To a solution of 945 mg (5 mmol) Boc-alanine in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 65 h at room temperature at which point an additional 945 mg (5 mmol) of Boc-alanine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added. After stirring for an additional 24 h, the reaction mixture was concentrated to dryness, dissolved in 40 mL of ethyl acetate and extracted with two 40-mL portions of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate and filtered. The filtrate was concentrated under diminished pressure to give 2.1 g of an orange oil. The oil was purified by column chromatography on 60 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-alanyl-phenazopyridine was obtained as an orange oil: yield 610 mg (32%).
Example 6
Preparation of Alanyl-phenazopyridine
[0110]
[0111] To a solution of 610 mg (1.59 mmol) of Boc-alanyl-phenazopyridine in 15 mL of dichloromethane was added 5.51 mL (73.6 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 3 h at which point the reaction was complete. The reaction mixture was poured into 40 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. Alanyl-phenazopyridine was obtained as an orange solid: yield 290 mg (64%); 1 H NMR (DMSO-d 6 ) δ 1.3 (d, 3H), 3.6 (q, 1H), 7.4-7.7 (m, 4H), 7.9-8.0 (m, 2H) and 8.1 (d, 1H); mass spectrum (ESI), m/z 285 (M+H) + and 307 (M+Na) + .
Example 7
Preparation of Boc-methionyl-phenazopyridine
[0112]
[0113] To a solution of 1.24 g (5 mmol) of Boc-methionine in 10 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h at which point an additional 1.24 g (5 mmol) of Boc-methionine and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride were added. After stirring for an additional 48 h, the reaction mixture was concentrated to dryness, dissolved in 40 mL of ethyl acetate and extracted with two 40 mL portions of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude orange oil was purified by column chromatography on 32 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Boc-methionyl-phenazopyridine was obtained as an orange oil: yield 700 mg (32%).
Example 8
Preparation of Methionyl-phenazopyridine
[0114]
[0115] To a solution of 700 mg (1.57 mmol) of Boc-methionyl-phenazopyridine in 15 mL of dichloromethane was added 2.3 mL (31.4 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 2 h at which point the reaction was complete. The reaction mixture was poured into 60 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed with 40 mL of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. Methionyl-phenazopyridine was obtained as an orange solid: yield 247 mg (46%); 1 H NMR (CDCl 3 ) δ 1.8-1.9 (m, 1H), 2.1 (s, 3H), 2.2-2.4 (m, 1H), 2.6-2.8 (m, 2H), 3.7 (m, 1H), 7.4-7.6 (m, 3H), 7.8-7.9 (m, 3H) and 8.2 (d, 1H); mass spectrum (ESI), m/z 345 (M+H) + and 367 (M+Na) + .
Example 9
Preparation of bis-Boc-tryptophanyl-phenazopyridine
[0116]
[0117] To a solution of 2.0 g (5 mmol) of bis-Boc-tryptophan in 15 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred for 6 h at room temperature at which point an additional 2.0 g (5 mmol) of bis-Boc-tryptophan and 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride were added. After stirring for an additional 72 h, the reaction mixture was filtered and the filtrate was concentrated under diminished pressure. The residue was dissolved in 40 mL of ethyl acetate and extracted with two 40-mL portions of saturated aqueous sodium bicarbonate. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give 5.47 g of an orange foam. The crude product was purified by column chromatography on 41 g of silica gel using 50:50 hexane-ethyl acetate as the eluant. Bis-Boc-tryptophanyl-phenazopyridine was obtained as an orange solid: yield 2.43 g (81%).
Example 10
Preparation of Tryptophanyl-phenazopyridine
[0118]
[0119] To a solution of 360 mg (0.60 mmol) of bis-Boc-tryptophanyl-phenazopyridine in 15 mL of dichloromethane was added 1.80 mL (24.0 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 1.5 h at which point the reaction was complete. The reaction mixture was poured into 50 mL of saturated aqueous sodium bicarbonate solution, the layers were separated and the organic layer was washed once with 40 mL of saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude product was purified by chromatography on 41 g of silica gel using 50:50 hexane-ethyl acetate as eluant. Tryptophanyl-phenazopyridine was obtained as an orange solid: yield 10 mg (4%); 1 H NMR (CDCl 3 ) δ 3.0-3.2 (m, 1H), 3.4-3.6 (m, 1H), 3.8-4.0 (m, 1H), 7.0-7.3 (m, 4H), 7.4-7.6 (m, 4H), 7.8-8.0 (m, 2H), 8.2 (d, 1H) and 10.0 (br s, 1H); mass spectrum (ESI) m/z 400 (M+H) + and 422 (M+Na) + .
Example 11
Preparation of Boc-valyl-phenazopyridine
[0120]
[0121] To a solution of 1.51 g (7.0 mmol) of Boc-valine in 10 mL of THF was added 1.33 g (7.0 mmol) of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC) followed by 1.5 g (7.0 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h at which point an additional 1.51 g (7.0 mmol) of Boc-valine, 1.33 g (7.0 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride and 1.4 g (14 mmol) of N-methylmorpholine were added, and the mixture was stirred for an additional 24 h. The solvent was concentrated under diminished pressure and the residue was dissolved in ethyl acetate and washed two times with saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure. The crude product was purified by column chromatography on silica gel eluting with 1:1 hexanes-ethyl acetate to give Boc-valyl-phenazopyridine as an orange oil: yield 300 mg (10%).
Example 12
Preparation of Valyl-phenazopyridine
[0122]
[0123] To a solution of 300 mg (0.73 mmol) of Boc-valyl-phenazopyridine in 10 mL of dichloromethane was added 1.72 g (1.1 mL, 14.6 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 3.5 h, then was added dropwise to a saturated aqueous sodium bicarbonate solution. The layers were separated and the aqueous layer was extracted once with dichloromethane. The combined organic layer was dried over sodium sulfate, filtered and the filtrate concentrated under diminished pressure. Valyl-phenazopyridine was obtained as an orange solid: yield 110 mg (48%); 1 H NMR (CDCl 3 ) δ 0.95 (d, 3H), 1.05 (d, 3H), 2.4 (m, 1H), 3.4 (s, 1H), 7.4-7.6 (m, 3H), 7.7-7.9 (m, 3H) and 8.1 (d, 1H); mass spectrum (ESI), m/z 313 (M+H) + and 335 (M+Na) + .
Example 13
Preparation of bis-Boc-lysyl-phenazopyridine
[0124]
[0125] To a solution of 1.73 g (5 mmol) of bis-Boc-lysine in 10 mL of THF was added 955 mg (5 mmol) of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (EDC) followed by 1.06 g (5 mmol) of phenazopyridine. The reaction mixture was stirred at room temperature for 24 h. The solvent was removed under diminished pressure and the residue was dissolved in ethyl acetate and washed twice with saturated aqueous sodium bicarbonate solution. The organic layer was dried over sodium sulfate, filtered and the filtrate was concentrated under diminished pressure to give the crude product as a red oil. Purification of the crude product on a silica gel column, eluting with 1:1 hexanes-ethyl acetate, gave bis-Boc-lysyl-PAP as an orange oil: yield 360 mg (13%).
Example 14
Preparation of Lysyl-phenazopyridine
[0126]
[0127] To a solution of 360 mg (0.66 mmol) of bis-Boc-lysyl-phenazopyridine in 20 mL of dichloromethane was added 3.40 g (2.2 mL, 29.7 mmol) of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 22 h. An additional 1.53 g (13.4 mmol) of trifluoroacetic acid was added and stirring was continued at room temperature for 2 h. The reaction mixture was added to saturated aqueous sodium bicarbonate solution, causing an orange solid to precipitate. The product was filtered, washed twice with heptane and isopropanol, and dried under diminished pressure at room temperature: yield 200 mg (88%); 1 H NMR (CD 3 OD) δ 1.5-2.2 (m, 6H), 2.9 (t, 2H), 3.7 (t, 1H), 7.5-7.7 (m, 4H), 8.0 (m, 2H) and 8.3 (d, 1H); mass spectrum (ESI), m/z 342 (M+H) + and 364 (M+Na) + .
Example 15
Preparation of Boc-(N-tosyl-histidinyl)-phenazopyridine
[0128]
[0129] A sample of 1.40 g (7.33 mmol) of EDCI was added in one portion to a solution of 3.00 g (7.33 mmol) of Boc-his(Tos)-OH in 60 mL of anhydrous THF. The reaction mixture was stirred at room temperature for 30 min, then 1.56 g (7.33 mmol) of phenazopyridine was added in one portion. The reaction mixture was stirred at room temperature for 96 h (until no further reaction progress was detected by HPLC). The solvent was concentrated under diminished pressure and the residue was dissolved in 200 mL of EtOAc, washed successively with 150 mL of water, 150 mL of satd. aq. NaHCO 3 solution, 150 mL of brine, and dried (Na 2 SO 4 ). The solvent was concentrated under diminished pressure. To remove unreacted phenazopyridine, the oily residue was purified by chromatography on an alumina oxide column (elution with CHCl 3 , then 99:1 CHCl 3 -MeOH). Further purification on a silica gel column (elution with 99:1 CHCl 3 -MeOH, then 98:2 CHCl 3 -MeOH) afforded the product as an orange solid: yield 0.43 g (10%).
Example 16
Preparation of N-Tosyl-histidinyl-phenazopyridine
[0130]
[0131] A sample of 1.28 mL (17.2 mmol) of trifluoroacetic acid was added dropwise to a solution of 0.26 g (0.43 mmol) of Boc-(N-tosylhistidinyl)-phenazopyridine in 12 mL of anhydrous CH 2 Cl 2 . The reaction mixture was stirred at room temperature for 3 h, and then added to a saturated aqueous solution of NaHCO 3 . The organic layer was separated and dried (Na 2 SO 4 ). The solvent was concentrated under diminished pressure to give the crude product as an orange solid: yield 200 mg (100%). A pure sample was obtained using preparative HPLC (93% yield); elution was with 0.1% HOAc in a gradient of CH 3 CN; mass spectrum (ESI) m/z 505 (M+H) + and 527 (M+Na) + . Anal. calcd for C 24 H 24 O 3 S.HOAc: C, 55.31; H, 5.00; N, 19.85. Found: C, 55.71; H, 4.78; N, 19.57.
Example 17
Preparation of Histidinyl-phenazopyridine
[0132]
[0133] A sample of 65 mg (0.48 mmol) of 1-hydroxybenzotriazole was added to a suspension of 12 mg (0.24 mmol) of N-tosylhistidinyl-phenazopyridine (0.12 g, 0.24 mmol) in 10 mL of anhydrous THF. The reaction mixture was stirred at room temperature for 2 h before an additional 65 mg (0.48 mmol) portion of 1-hydroxybenzotriazole was added and the mixture was stirred for an additional 3 h. The solvent was concentrated under diminished pressure and the residue was dissolved in 15 mL of EtOAc and extracted with two 10-mL portions of 0.05 N HCl. The combined aqueous layer was adjusted to pH˜8 by the addition of a saturated aqueous solution of Na 2 CO 3 and then extracted with three 15-mL portions of EtOAc. The combined organic layer was dried (Na 2 SO 4 ) and the solvent was concentrated under diminished pressure to give an orange solid. It was purified by preparative HPLC to give the product as a dark orange solid: yield 40 mg (41%); 1 H NMR (500 MHz, DMSO-d 6 ) δ 1.86 (s, 6H), 3.19-3.31 (m, 2H), 4.39 (br s, 1H), 7.46-7.53 (m, 6H), 7.88 (d, 2H), 8.07 (d, 1H), 8.45 (br s, 4H) and 9.03 (s, 1H); mass spectrum (ESI) m/z 373 (M+Na + ); mass spectrum (ESI) m/z 373 (M+Na) + .
Synthesis of Phenazopyridine (PAP) Carbamates
Example 18
Preparation of Ethylcarbamyl-phenazopyridine
[0134]
[0135] A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide (LiHMDS) (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min, a solution of 0.26 g (0.23 mL, 2.40 mmol) of ethyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 1 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (17×3 cm). Elution with a stepwise gradient of dichloromethane in hexane (20→80%) gave the monocarbamate as an orange solid: yield 203 mg (30%); 1 H NMR (CD 3 OD) δ 1.32 (t, 3H, J=7.0 Hz), 4.22 (q, 2H, J=7.0, 14.2 Hz), 7.33 (d, 1H, J=9.0 Hz), 7.40 (m, 1H), 7.48 (t, 2H, J=7.2 Hz), 7.82 (d, 2H, J=9.9 Hz) and 8.06 (d, 1H, J=9.0 Hz); mass spectrum (ESI) m/z 286 (M+H) + and 308 (M+Na) + .
Example 19
Preparation of Benzylcarbamyl-phenazopyridine
[0136]
[0137] A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide (LiHMDS) (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min, a solution of 0.41 g (0.34 mL, 2.40 mmol) of benzyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 1 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with a stepwise gradient of dichloromethane in hexane (50→80%), then 1% Et 3 N in dichloromethane gave the monocarbamate as an orange solid: yield 273 mg (33%); 1 H NMR (CD 3 OD) δ 5.21 (s, 2H), 7.32−7.50 (m, 9H), 7.81 (d, 2H, J=9.0 Hz) and 8.06 (d, 1H, J=8.7 Hz); mass spectrum (ESI) m/z 348 (M+H) + and 370 (M+Na + ) + .
Example 20
Preparation of Isobutylcarbamyl-phenazopyridine
[0138]
[0139] A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min., a solution of 0.32 g (0.31 mL, 2.40 mmol) of isobutyl chloroformate in 5 mL of THF was added dropwise to the reaction mixture over a period of 5 min. The reaction mixture was stirred at room temperature for 18 h. The solvent was concentrated under diminished pressure and the residue purified on a silica gel column (17×3 cm). Elution with a stepwise gradient of EtOAc in hexane (0 to 15%) gave the bis-carbamate as an orange solid: yield 140 mg (14%), followed by the monocarbamate as an orange solid: yield 202 mg (27%); 1 H NMR (DMSO-d 6 ) δ 0.93 (d, 6H, J=6.9 Hz), 1.92 (m, 1H), 3.89 (d, 2H, J=6.6 Hz), 7.31 (d, 1H, J=8.7 Hz), 7.44 (m, 1H), 7.52 (t, 2H, J=8.7 Hz), 7.86 (d, 2H, J=8.1 Hz) and 8.02 (d, 1H, J=8.7 Hz); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + .
Example 21
Preparation of Dodecylcarbamyl-phenazopyridine
[0140]
[0141] A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 10 min at room temperature, to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min at −5° C., a solution of 0.59 g (0.65 mL, 2.40 mmol) of dodecyl chloroformate in 5 mL of THF (5 mL) was added dropwise to the reaction mixture at −5° C. over a period 5 min. The reaction mixture was stirred at −5° C.-0° C. for 1 h and then at room temperature for 24 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with 20% EtOAc in hexane gave the slightly impure monocarbamate as an orange solid. The product was dissolved in hot EtOAc (5 mL) and the mixture was left to cool to room temperature. The precipitated product was collected by filtration and dried under diminished pressure. The phenazopyridine dodecyl monocarbamate was obtained as an orange solid: yield 361 mg (36%); 1 H NMR (DMSO-d 6 ) δ 0.83 (t, 3H, J=6.3 Hz), 1.22 (m, 18H), 1.6 (m, 2H), 4.09 (t, 2H, J=6.6 Hz), 7.30 (d, 1H, J=8.7 Hz), 7.43 (m, 1H), 7.51 (t, 2H, J=7.6 Hz), 7.61 (br s, 2H), 7.85 (d, 2H, J=8.4 Hz), 8.01 (d, 1H, J=8.7 Hz) and 10.08 (s, 1H). Anal. calcd for C 24 H 35 N 5 O 2 .1.25 H 2 O: C, 64.33; H, 8.44; N, 15.63. Found: C, 63.96; H, 7.83; N, 15.44.
Example 22
Preparation of 2-Ethylhexylcarbamyl-phenazopyridine
[0142]
[0143] A solution of 2.81 mL (2.81 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 13 min at −5° C., to a cooled solution of 0.3 g (1.40 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min. at −5° C., a solution of 0.28 g (0.28 mL, 1.45 mmol) of 2-ethylhexyl chloroformate in 35 mL of THF was added dropwise at −5° C. over a period of 5 min. The reaction was stirred at 0° C. for 1 h and then at room temperature for 24 h. The solvent was concentrated under diminished pressure and the residue was purified by chromatography on a silica gel column (17×3 cm). Elution with a stepwise gradient of EtOAc in heptanes (0→10%) gave the bis-carbamate as an orange syrup: yield 57 mg (7%), followed by the monocarbamate as an orange syrup: yield 309 mg (59%); 1 H NMR (DMSO-d 6 ) δ 0.86 (m, 6H), 1.26-1.40 (m, 8H), 1.56 (m, 1H), 4.01 (d, 2H, J=5.7 Hz), 7.31 (d, 1H, J=8.4 Hz), 7.43 (m, 1H), 7.51 (t, 2H, J=7.5 Hz), 7.85 (d, 2H, J=8.1 Hz), 8.01 (d, 1H, J=8.7 Hz) and 10.09 (s, 1H); mass spectrum (ESI) m/z 370 (M+H) + and 392 (M+Na) + . Anal. calcd for C 20 H 27 N 5 O 2 : C, 65.02; H, 7.37; N, 18.96. Found: C, 65.41; H, 7.43; N, 18.51.
Example 23
Preparation of tert.-Butylcarbamyl-phenazopyridine
[0144]
[0145] A solution of 4.68 mL (4.68 mmol) of lithium hexamethyldisilazide LiHMDS (1M in THF) was added dropwise, over a period of 8 min at 5° C., to a solution of 0.5 g (2.34 mmol) of phenazopyridine in 10 mL of THF. After an additional 10 min. at −5° C., a solution of 0.53 g (2.46 mmol) of (Boc) 2 O in 5 mL of THF was added dropwise at 0° C. over a period of 10 min. The reaction mixture was stirred at 0° C. for 1 h and then at room temperature for 2 h. The solvent was concentrated under diminished pressure and the residue was purified on a silica gel column (18×3 cm). Elution with a stepwise gradient of EtOAc in hexanes (0→10%) gave a mixture of the mono and bis-carbamates. The mixture was purified further on a preparative HPLC column. The mono carbamate (R t 19.9 min.) was obtained as an orange foam: yield 451 mg (61%); 1 H NMR (DMSO-d 6 ) δ 1.60 (s, 9H), 7.40 (d, 1H, J=9 Hz), 7.56 (m, 1H), 7.63 (t, 2H, J=7.6 Hz), 7.97 (d, 2H, J=8.4 Hz), 8.11 (d, 1H, J=9.0 Hz) and 9.89 (s, 1H); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + . Anal. calcd for C 16 H 19 N 5 O 2 : C, 61.33; H, 6.11; N, 22.35. Found: C, 61.37; H, 6.26; N, 22.15. The bis carbamate (R t 22.5 min.) was obtained as an orange syrup: yield 118 mg (12%); mass spectrum (ESI) m/z 414 (M+H) + and 436 (M+Na) + .
Example 24
Preparation of Trichloroethylcarbamyl-phenazopyridine
[0146]
[0147] To a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF was added 0.64 g (4.68 mmol) of oven-dried K 2 CO 3 followed by a solution of 0.5 g (0.32 mL, 2.4 mmol) of trichloroethyl chloroformate in 5 mL of THF (added dropwise at room temperature over a period of 20 min.). The reaction mixture was stirred at room temperature for 4 days. The insoluble material was filtered and the solvent was concentrated under diminished pressure. The residue was purified on a silica gel column (16×3 cm), eluting with a stepwise gradient of EtOAc in hexane (0→8%). The product was obtained as a mixture of mono and bis carbamates. This mixture was fractionated on a preparative HPLC column. The mono carbamate (R t 20.3 min) was obtained as an orange solid: yield 169 mg (18%); 1 H NMR (DMSO-d 6 ) δ 4.97 (s, 2H), 7.26 (d, 1H, J=8.4 Hz), 7.44 (m, 1H), 7.55 (t, 2H, J=7.5 Hz), 7.63 (brs, 2H), 7.87 (d, 2H, J=8.4 Hz), 8.05 (d, 1H, J=9.0 Hz) and 10.69 (s, 1H); mass spectrum (ESI) m/z 390 (M+H) + and 413 (M+Na+H) + . Anal. calcd for C 14 H 12 Cl 3 N 5 O 2 : C, 43.27; H, 3.11; N, 18.02; Cl, 27.56. Found: C, 43.50; H, 3.11; N, 17.78; Cl; 27.56. The bis carbamate (R t 22.9 min) was obtained as an orange solid: yield 58 mg (4%); mass spectrum (ESI) m/z 564 (M) + .
Example 25
Preparation of n-Butylcarbamyl-phenazopyridine
[0148]
[0149] To a solution of 0.50 g (2.34 mmol) of phenazopyridine in 10 mL of THF was added 0.64 g (4.68 mmol) of oven-dried K 2 CO 3 followed by a solution of 0.32 g (0.31 mL, 2.4 mmol) of n-butyl chloroformate in 5 mL of THF (added dropwise at room temperature over a period of 10 min). The reaction mixture was stirred at room temperature for 4 days. The insoluble material was filtered and the solvent was concentrated under diminished pressure. The residue was purified on a short pad of silica, eluting with 20% EtOAc in hexane. The product was purified further on a preparative HPLC column. The mono carbamate (R t 20.1 min) was obtained as an orange solid: yield 252 mg (34%); 1 H NMR (DMSO-d 6 ) δ 0.91 (t, 3H, J=7.2 Hz), 1.38 (m, 2H), 1.60 (m, 2H), 4.11 (t, 2H, J=5.8 Hz), 7.30 (d, 1H, J=8.7 Hz), 7.44 (m, 1H), 7.52 (t, 2H, J=7.2 Hz), 7.86 (d, 2H, J=7.2 Hz), 8.02 (d, 1H, J=8.4 Hz) and 10.09 (s, 1H); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + . Anal. calcd for C 16 H 19 N 5 O 2 : C, 61.33; H, 6.11; N, 22.35. Found: C, 61.23; H, 6.11; N, 22.08.
Example 26
Preparation of N α -Boc-glycine Cyanomethyl Ester
[0150]
[0151] To a solution containing 2.0 g (11.4 mmol) of N α -Boc-glycine in 25 mL of EtOAc was added 1.73 g (2.38 mL, 17.1 mmol) of triethylamine followed by 2.05 g (1.19 mL, 17.1 mmol) of bromoacetonitrile. The reaction mixture was stirred at 60° C. under an argon atmosphere for 16 h. The heterogeneous mixture was cooled to room temperature and filtered through a short pad of silica, washing with EtOAc to remove the precipitated triethylamine hydrobromide. The filtrate was concentrated under diminished pressure to give N α -Boc-glycine cyanomethyl ester as a colorless syrup which solidified upon standing. The crude product was used directly in the next step without further purification: yield 2.12 g (87%); 1 HNMR (500 MHz, CDCl 3 ) δ 1.45 (s, 9H), 4.05 (d, 2H, J=5.5 Hz) and 4.79 (s, 2H).
Example 27
Preparation of 6-N-Boc-phenazopyridine and 2,6-N,N-bis-Boc-phenazopyridine
[0152]
[0153] To a solution of 3.2 g (15 mmol) of phenazopyridine in 20 mL of anhydrous THF under argon atmosphere was added 30 mL (30 mmol) of a 1 M solution of LiHMDS in THF over a period of 15 min. After further 10 min, a solution of 3.27 g (15 mmol) of (Boc) 2 O in 15 mL of anhydrous THF was added slowly over a period of 20 min and the reaction was allowed to proceed for a further 3 h at room temperature. The solvent was concentrated under diminished pressure and the residue was partitioned between 100 mL of dichloromethane and 100 mL of 0.1 N aqueous HCl. The organic layer was washed with two 50-mL portions of water, dried (Na 2 SO 4 ) and concentrated under diminished pressure. Purification by chromatography on a silica gel column (20×4 cm), eluting with hexanes-ethyl acetate (7:1 and 6:1) gave successively 2,6-N,N-bis-Boc-phenazopyridine as an orange foam: yield 1.28 g (20%); silica gel TLC R f 0.44 (5:1 hexanes-ethyl acetate); 1 H NMR (500 MHz, CDCl 3 ) δ 1.51 (s, 9H), 1.57 (s, 9H), 7.47 (d, 1H, J=7.0 Hz), 7.52 (t, 2H, J=7.5 Hz), 7.83 (d, 2H, J=9.5 Hz), 8.15 (t, 2H, J=9.7 Hz) and 10.18 (s, 1H); mass spectrum (ESI) m/z 414 (M+H) + and 436 (M+Na) + , then a mixture of 6-N-Boc-phenazopyridine and 2,6-N,N-bis-Boc-phenazopyridine in 8:1 ratio: yield 1.15 g, and finally 6-N-Boc-phenazopyridine: yield 0.99 g. Another 0.61 g of 6-N-Boc-phenazopyridine was recovered from the mixture by crystallization from 32 mL of 7:1 hexanes-ethyl acetate. 6-N-Boc-phenazopyridine was obtained as an orange solid: yield 1.6 g (34%); silica gel TLC R f 0.34 (5:1 hexanes-ethyl acetate); 1 H NMR (500 MHz, CDCl 3 ) δ 1.53 (s, 9H), 7.39 (m, 1H), 7.48 (m, 3H), 7.79 (d, 2H, J=8.0 Hz) and 8.13 (d, 1H, J=8.5 Hz); mass spectrum (ESI) m/z 314 (M+H) + and 336 (M+Na) + .
Example 28
Preparation of 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine
[0154]
[0155] To a solution of 215 mg (0.68 mmol) of 6-N-Boc-phenazopyridine in 9 mL of anhydrous THF was added dropwise 0.69 mL (0.69 mmol) of a 1 M solution of LiHMDS in THF followed by 147 mg (0.69 mmol) of N α -Boc-glycine cyanomethyl ester. The reaction mixture was stirred at room temperature for 45 min. Another 0.69 mL (0.69 mmol) of a 1 M solution of LiHMDS in THF was added dropwise followed by 147 mg (0.69 mmol) of N α -Boc-glycine cyanomethyl ester. This procedure was repeated four more times every 45 min. and stirring was continued for another 19 h at room temperature. The reaction was quenched by slow addition of 25 mL of water and the reaction mixture was extracted with two 25-mL portions of ethyl acetate. The combined organic layer was dried (Na 2 SO 4 ) and concentrated under diminished pressure. Purification by chromatography on a silica gel column (15×4 cm) eluting with a stepwise gradient of EtOAc in hexanes (10→50%) gave 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine as a brown solid: yield 94 mg (29%); 1 H NMR (500 MHz, CDCl 3 ) δ 1.47 (s, 9H), 1.55 (s, 9H), 4.56 (s, 2H), 7.47-7.53 (m, 3H), 7.83-7.88 (m, 2H), 8.17 (d, 11-1, J=9.0 Hz), 8.35 (s, 1H) and 10.40 (s, 1H); 13 C NMR (125 MHz, CDCl 3 ) δ 47.04, 80.21, 81.68, 107.09, 122.71, 129,24, 129.55, 131.29, 133.06, 145.73, 152.12, 152.81, 156.22 and 169.71; mass spectrum (ESI) m/z 471 (M+H) + and 493 (M+Na) + . Anal. calcd for C 23 H 30 N 6 O 5 .1.2 H 2 O: C, 56.13; H, 6.64; N, 17.08. Found: C, 56.03; H, 6.47; N, 17.02.
Example 29
Preparation of 2-N-Glycyl-phenazopyridine Hydrochloride
[0156]
[0157] To 34 mg (0.07 mmol) of 2-N-(N α -Boc-glycyl)-6-N-Boc-phenazopyridine was added 2.5 mL (2.5 mmol) of a 1 M solution of HCl in EtOAc. The reaction mixture was stirred at 65° C. for 2.5 h. Another 2 mL (2 mmol) of 1 M HCl in EtOAc was added and stirring was continued at 65° C. for another 45 min. The precipitated product was filtered, washed with two 5-mL portions of EtOAc and dried under vacuum for 24 h. 2-N-Glycyl-phenazopyridine hydrochloride was obtained as a brown solid: yield 20.8 mg (84%); 1 H NMR (DMSO-d 6 , 500 MHz) δ 4.16 (d, 2H, J=5.0 Hz), 6.49 (d, 1H, J=9.0 Hz), 7.45 (m, 1H), 7.51 (m, 2H), 7.87 (d, 2H, J=9.0 Hz), 7.96 (d, 1H, J=9.0 Hz) and 8.30 (br s, NH); 13 C NMR (DMSO-d 6 , 125 MHz) δ 42.70, 106.90, 122.88, 128.01, 129.36, 129.66, 130.60, 148.10, 152.62, 160.15 and 167.58; mass spectrum (ESI) m/z 271 (M+H) + , 272 (M+2H) + , 293 (M+Na) + .
Example 30
Oral Bioavailability of PAP Prodrug in Rats
[0158] The oral bioavailability of PAP (phenazopyridine) prodrugs was evaluated in healthy rats. All the PAP amide (amino acid derivatives) bases were dissolved in 0.1N HCl (the same result can be obtained with a lower molarity), while the carbamates were dissolved in PEG-400 due to the very poor aqueous solubility of the PAP-carbamates. The physicochemical properties of various PAP derivatives are shown in Table 1. In general, all of the amino acid amide derivatives of PAP had higher water solubility than those of the PAP-carbamates. In another PK study, PAP.HCl salt, Gly-PAP.HCl salt and Gly-PAP.mesylate salt were dissolved in water, affording a clear solution in each case prior to oral administration.
[0159] The rats were fasted overnight prior to dosing. Appropriate amount of each compound was administered via gastric gavages, and at predetermined time (1, 2, 4, 6, and 24 h) blood samples were withdrawn from the rats. The whole blood was centrifuged immediately, and supernatant (plasma) was collected. The plasma samples were assayed for PAP using LC-MS-MS.
[0000]
TABLE 1
Physicochemical properties of PAP-prodrug
and administered oral dose in rats
Mol.
Solubility in
Oral Dose,
PAP
Compound's
Wt.
0.1 N HCl
mg/kg
free-base
Generic name
(g/mol)
(mg/mL)
prodrug
equivalent
PAP · HCl
249.7
0.5
10.0
8.5
Gly-PAP
270.3
>2
13.4
10.6
Alanyl-PAP
284.3
2
14.2
10.6
Methionyl-PAP
344.4
1
10.0
6.2
Ethylcarbamyl-PAP
285.3
<0.1
13.4
10.0
Benzylcarbamyl-PAP
347.4
<0.1
8.2
5.0
Isobutylcarbamyl-PAP
313.4
<0.1
7.4
5.0
Histidinyl-PAP
350.4
>10
8.2
5.0
Tryptophanyl-PAP
399.0
0.5
9.4
5.0
Valyl-PAP
312.0
>2.5
14.6
10.0
Lysyl-PAP
341.0
>2.5
16.0
10.0
[0000]
TABLE 2
Pharmacokinetic analysis of PAP prodrugs following oral administration in rats
PAP-free
Actual
base
Relative
Dose
equivalent
C max
T max
AUC 0-24
Bioavailability
Compound
(mg/kg)
(mg/kg)
(ng/mL)
(h)
(ng · h/mL)
(%)
PAP•HCl
10
8.5
54
<1
182 ± 12
100
Gly-PAP
13.6
10
344
<1
2235 ± 132
985
Alanyl-PAP
14.4
10
173
<1
511 ± 41
225
Methionyl-PAP
10
5.9
80
<1
193 ± 46
145
Ethylcarbamyl-PAP
13.4
10
BQL
ND
0
0
Isobutylcarbamyl-
7.4
5
8.6
6
136 ± 25
127
PAP
Benzylcarbamyl-PAP
8.2
5
8
<1
65 ± 7
61
Histidinyl-PAP
8.2
5
13.7
<1
172 ± 3.4
161
Tryptophanyl-PAP
9.4
5
17.1
2
145 ± 4.6
135
Valyl-PAP
14.6
10
213
0.5
225 ± 25
105
Lysyl-PAP
16.0
10
249
0.5
821 ± 97
383
AUC: area under curve of plot plasma concentration vs. time, 0-24 hr
Relative Bioavailability (%) = [AUC(prodrug)/AUC(drug) × Dose(drug)/Dose(prodrug)] 100
BQL: below quantitation limit (<0.5 ng/mL)
C max : peak plasma concentration
T max : time to reach peak plasma concentration (C max )
[0160] The pharmacokinetics data is summarized in Table 2. The relative bioavailability of PAP prodrug was in the following order: glycine>lysine>alanine>histidine>methionine>tryptophan>valine>isobutylcarbamyl>benzylcarbamyl>ethylcarbamyl. T max was longer for isobutylcarbamyl-PAP and tryptophanyl-PAP, while the T max for the rest of PAP derivatives were less than an hour.
[0161] The pharmacokinetics data for various salt forms of Gly-PAP is shown in Table 3. The free base of Gly-PAP, as well as the HCl and mesylate salts, have significantly enhanced bioavailability as compared with the HCl salt of PAP.
[0162] The pharmacokinetics data for various salt forms of Gly-PAP is shown in Table 3. The free base of Gly-PAP, as well as the HCl and mesylate salts, have significantly enhanced bioavailability as compared with the HCl salt of PAP.
[0000]
TABLE 3
PAP Pharmacokinetics in rats following oral administration of PAP•HCl
salt, Gly-PAP freebase, Gly-PAP•HCl salt, and Gly-PAP•mesylate salt
Vehicle
used to
Dose
AUC 0-6
dissolve
(mg/kg,
C max
(ng ·
com-
PAP base
(ng/
T max
h/mL)
T 1/2
Compounds
pound
equivalent)
ml)
(h)
(SD)
(h)
PAP•HCl
Water
2.5
58
0.25
105 (20)
0.8
Gly-PAP•HCl
Water
2.5
140
1.0
433 (12)
1.5
Gly-
Water
2.5
102
1.0
237 (51)
1.6
PAP•mesylate
Gly-PAP•free
0.1 N
2.8
211
0.5
378 (57)
1.7
base
HCl
Example 31
Alternative Synthesis of 2-Amino-6-aminoacetamido-3-E-phenazopyridine Dihydrochloride
[0163]
[0000] Chemical formula: C 13 H 16 Cl 2 N 6 O
Molecular Weight: 343.21
[0164] Description of Manufacturing Process depicted in FIG. 16 . Gly-PAP is an amide prodrug of phenazopyridine with the carboxyl group of glycine covalently bound to the nitrogen of the 6-amine of phenazopyridine.
[0165] In the first step of the production of Gly-PAP, phenazopyridine hydrochloride (PAP) was converted to the free base using aqueous potassium carbonate. The free base was extracted into ethyl acetate and isolated by concentration of the solvent in 92% yield. In the second step of the process, phenazopyridine free base was treated with BOC-glycine-OSu in DMF using sodium hydride as the base. The intermediate was isolated by adding water to the reaction mixture which caused the product to precipitate. The product was isolated by filtration, washed with water and recrystallized from isopropyl alcohol to give the intermediate in 34% yield. In the third step BOC-Gly-PAP was deprotected by treatment with HCl in ethyl acetate. The product was isolated in 96% yield by filtration, followed by washing with ethyl acetate and drying at 45° C. under vacuum.
Experimental Procedures
[0166] Preparation of Phenazopyridine Free Base from the HCl Salt
[0167] To a solution of 27.6 grams (200 mmol) of potassium carbonate in 200 mL of water was added 20.0 grams (80 mmol) of phenazopyridine hydrochloride followed by 200 mL of ethyl acetate. The mixture was stirred at room temperature for 30 minutes. The layers were separated and the aqueous layer was extracted one time with 100 mL of ethyl acetate. The ethyl acetate layer was dried over sodium sulfate, and filtered. The filtrate was concentrated under diminished pressure and the product was dried under vacuum at room temperature to give an orange solid: yield 15.1 grams (92%). NMR (300 MHz, CDCl 3 ) δ 4.80 (br s, 4H), 6.06 (d, 1H), 7.34 (m, 1H), 7.48 (m, 2H), 7.76 (m, 2H), and 7.93 (d, 1H).
[0000] Treatment of Phenazopyridine Free Base with N-Boc-Glycine Succinimide Ester
[0168] To a suspension of 5.39 g (224.5 mmol) of NaH in 500 mL DMF maintained at 0-5° C. was added dropwise a solution of 16.0 g (74.40 mmol) of phenazopyridine in 250 mL of DMF and the reaction was stirred at 0-5° C. for 30 min. N-Boc-glycine succinimide ester (25.4 g, 93.50 mmol) in DMF (190 mL) was added dropwise at 0-5° C. then the mixture was warmed to room temperature and stirred for 1.5 h. Isopropyl alcohol (25 mL) was added dropwise and the mixture was stirred at room temperature for 15 min. To the reaction mixture was added 60 grams of Celite™ and it was stirred for 15 minutes. The reaction mixture was filtered and the filter cake was washed two times with 100 mL of DMF. Water (2,500 mL) was added to the DMF solution causing an orange solid to precipitate. The mixture was stirred at room temperature for 30 minutes then the precipitated product was filtered, washed with four 250 mL portion of water and then dried under vacuum over P 2 O 5 at 45° C. for 18 h. The crude product was obtained as an orange powder: yield 12.63 g (46%), purity 95.9% by HPLC.
[0169] The crude product (12.63 grams, 34.1 mmol) was dissolved in 170 mL iPrOH at 80° C. to form a clear dark orange solution. It was cooled slowly to room temperature and then to 0-5° C. The crystallized product was collected by filtration and dried under vacuum over P 2 O 5 at 45° C. for 2 hours. The product, BOC-glycine-phenazopyridine, was obtained as a light orange solid: yield 9.4 g (74%), purity 98.2% by HPLC. Overall yield 34%. 1 H NMR (300 MHz, CDCl 3 ) δ 1.58 (s, 9H), 4.00 (d, 2H, J=4 Hz), 7.47 (m, 4H), 7.80 (m, 2H), 8.17 (d, 1H, J=9 Hz), and 8.29 (br s, 1H).
Deprotection of Boc-Glycine-Phenazopyridine to Form Gly-Pap Dihydrochloride
[0170] To a solution of 9.3 grams (25.1 mmol) of BOC-glycine-phenazopyridine in 236 mL of ethyl acetate was bubbled HCl gas generated by adding concentrated HCl (46 mL, 55.2 grams, 1.53 moles) to 133 mL of concentrated sulfuric acid in a separate flask. After the addition of HCl was complete, the reaction mixture was stirred at room temperature for 3.5 hours. The solid that was formed was isolated by filtration and was washed with 500 mL of ethyl acetate. The product was dried under full vacuum at room temperature to give 8.4 grams of Gly-PAP as an orange solid: yield 98.1%, 98.9% purity by HPLC. 1 H NMR (300 MHz, D 2 O) δ 3.8 (s, 2H), δ 6.5 (d, 1H), δ 7.3 (br s, 3H), δ 7.6 (br s, 2H), δ 8.0 (d, 1H)
Raw Materials and Reagents
[0171]
[0000]
Raw Material/
Supplier
Reactant
Part number (P/N)
Purity
CAS number
Phenazopyridine
Spectrum
>99%
136-40-3
hydrochloride
Chemicals
P/N: P1059
Boc-glycine-OSu
Chem-Impex
99%
3392-07-02
International
P/N: 03793
Sodium hydride
Aldrich
95%
7646-69-7
P/N: 223441
DMF
Sigma-Aldrich
99.8%
68-12-2
P/N: 227056
Isopropanol
EMD Chemicals
99.9%
67-63-0
P/N: PX1834-1
HCl (Conc.)
Fisher Scientific
37.0%
7647-01-1
P/N: A144-212
Ethyl acetate
Fisher Scientific
99.9%
141-78-6
P/N: E195-4
H 2 SO 4 (Conc.)
Fisher Scientific
96.1%
7664-93-9
P/N: A484-212
Example 32
Oral Biovailability of PAP and Gly-PAP (Improved Bioavailability, Limited Gly-PAP Exposure, Sustained Release of PAP from Gly-PAP, Increased Delivery to Site of Action
[0172] Pharmacokinetics for PAP and Gly-PAP (intact prodrug) were assessed in male rats following administration by oral gavage of mg/kg doses. Rats were fasted overnight prior to dosing. Blood samples were withdrawn at 0.25, 0.5, 1, 2, 4, 6, and 24 hours. The whole blood was centrifuged immediately, and supernatant (plasma) was collected. The plasma samples were assayed for PAP and Gly-PAP by LC-MS-MS.
[0173] At a Gly-PAP dose of 4.0 mg/kg (containing 2.5 mg/kg phenazopyridine base approximating 30 mg of a phenazopyridine HCl human equivalent dose (HED*), an increase of roughly 3-fold was observed for phenazopyridine from Gly-PAP compared to the equivalent phenazopyridine hydrochloride dose (2.5 phenazopyridine base content). Plasma levels of Gly-PAP were <5% of those for phenazopyridine from Gly-PAP, illustrating efficient hydrolysis of Gly-PAP with limited systemic exposure to the prodrug. Results are illustrated in FIGS. 1 , 3 , 4 , 11 , and 12 .
[0174] Pharmacokinetics for phenazopyridine for Gly-PAP were determined for a lower dose of 0.9 mg/kg Gly-PAP (0.6 mg/kg phenazopyridine base). When plotted with concentrations of phenazopyridine from an approximately 4-fold higher dose of 2.8 mg/kg phenazopyridine HCl (2.5 mg/kg phenazopyridine base) the lower Gly-PAP dose afforded sustained release of phenazopyridine and approximately equal AUC ( FIGS. 3 and 12 ).
[0175] When compared to levels of phenazopyridine following oral administration of 100, 200 and 300 mg in humans (approximate human equivalent dose (HED) based on 60 kg person (6.2 rat conversion factor)—Guidance for Industry: Estimating the Maximum Safe Starting Dose for Initial Clinical Trials for Therapeutics in Adult Healthy Volunteers), the levels of phenazopyridine where considerably higher in rats at HEDs of approximately 100 mg or less for both Gly-PAP and phenazopyridine hydrochloride. Although the absolute bioavailability of phenazopyridine hydrochloride in humans has not been determined it appears to be poorly absorbed. (Shang E, et al. Determination of phenazopyridine in human plasma via LC - MS and subsequent development of a pharmacokinetic model. Anal Bioanal Chem. 2005 May; 382(1):216-22). Rat pharmacokinetics have been found to be highly correlated with human pharmacokinetics. (See Chiou, W. L, et al., Pharm. Res. 17:135-140 (2000); Chiou, W. L., et al., Pharm. Res. 15:1474-1479 (1998); and Chiou, W. L., et al., J. Clin. Pharmacol. Ther. 38:532-539 (2000).
[0176] Pharmacokinetics for PAP and Gly-PAP (intact prodrug) were assessed in dogs following administration by oral gavage of mg/kg doses. Blood (approximately 2 mL) was collected from a jugular vein into tubes containing lithium heparin anticoagulant predose and at 0.083, 0.25, 0.5, 1, 2, 4, 8, 12, and 24 hours postdose. Urine was collected into plastic containers surrounded by wet ice predose (−18 to 0) and 0 to 24 hours postdose. The volume of each sample was recorded. Plasma and urine samples were assayed for PAP and Gly-PAP by LC-MS-MS.
[0177] In dogs Gly-PAP afforded effective delivery of phenazopyridine following oral administration of 8.1 mg/kg Gly-PAP, approximating a HED (Approximate human equivalent dose (HED) based on 60 kg person (1.8 dog conversion factor—Guidance for Industry: Estimating the Maximum Safe Starting Dose for Initial Clinical Trials for Therapeutics in Adult Healthy Volunteers) of 200 mg of phenazopyridine HCl. Phenazopyridine from phenazopyridine HCl containing an equivalent amount of phenazopyridine resulted in greater plasma bioavailability of phenazopyridine; however, a greater amount of phenazopyridine was delivered to the urine from Gly-PAP. The site of action for phenazopyridine is the bladder and urethra. Plasma T max was increased for phenazopyridine from Gly-PAP as compared to phenazopyridine from phenazopyridine HCl, illustrating sustained release. Exposure (AUC 0-24 ) to Gly-PAP was less than 10% of that for phenazopyridine in dogs following administration of Gly-PAP ( FIGS. 13-15 ).
[0178] The pharmacokinetics of various salts of Gly-PAP were compared following oral administration to rats. All salt forms improved the oral bioavailability of phenazopyridine as compared to bioavailability from phenazopyridine HCl. Gly-PAP HCl afforded the highest bioavailability ( FIG. 17 ).
Example 33
Reduced Emesis in Dogs
[0179] Dogs (1 male/1 female) were dosed by oral gavage 3 times (TID), once every 8 hours, with 40 mg/kg Gly-PAP or 29 mg/kg phenazopyridine HCl (doses contained an equivalent amount of 24.8 mg/kg phenazopyridine base). A single observation of vomitus was observed for Gly-PAP compared to four observations of vomitus for phenazopyridine HCl. Results showing reduction of the GI side effect of emesis are illustrated in FIG. 18 .
[0180] Having now fully described this invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof. All patents, patent applications and publications cited herein are fully incorporated by reference herein in their entirety. | The present invention is directed to substituted phenazopyridines represented by Formula I. The present invention also relates to the discovery that compounds of Formula I have increased bioavailability as compared to unconjugated phenazopyridine. | 2 |
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 60/245,188, filed Nov. 3, 2000, and Canadian patent application Ser. No. 2,345,560, filed Apr. 27, 2001, under the provisions of 35 U.S.C. § 119.
FIELD OF THE INVENTION
[0002] The invention relates to rotary drilling, and more particularly, to steered directional drilling with a rotary drilling tool.
BACKGROUND OF THE INVENTION
[0003] In the earth drilling art, it is well known to use downhole motors to rotate drill bits on the end of a non-rotating drill string. With the increasingly common use of directional drilling, where the well is drilled in an arc to produce a deliberately deviated well, bent subs have been developed for guiding the downhole motors in a desired drilling direction. The bent subs are angled, and thus cannot be used in association with rotating drill strings.
[0004] This invention is directed towards a tool that permits steered directional drilling with a rotary drilling tool.
SUMMARY OF THE INVENTION
[0005] The device contemplated provides a method for positioning the drill bit in a drilling operation to achieve small changes in hole angle or azimuth as drilling proceeds. Two different positions are available to the operator. The first is a straight ahead position where the tool essentially becomes a packed hole stabilizer assembly. The second position tilts the bit across a rotating fulcrum to give a calculated offset at the bit-formation interface. The direction that the bit offset is applied in relation to current hole direction is controlled by positioning the orienting pistons prior to each drilling cycle, through the use of current measurement-while-drilling (MWD) technology.
[0006] In one aspect of the invention, components of the tool comprise a MWD housing, upper steering and drive mandrel, non-rotating position housing, lower drive mandrel splined with the upper mandrel, rotating fulcrum stabilizer and drill bit.
[0007] If, after surveying and orienting during a connection, it is desired to drill with the tool in the oriented position, the rig pumps are activated. The pressure differential created by the bit jets below the tool will cause pistons to open from the ID of the tool into the tool chamber. As the pistons open, they will contact wings that come out into the path of travel of the upper mandrel as it comes down a spline, and bottoms out on the lower drive mandrel. This occurs as the drill string is being lowered to bottom. The extra length provided by the open wings moves a sliding sleeve centered over, but not attached to the upper mandrel, to a new position that in turn forces the orienting pistons to extend out into the borehole annulus. This extrusion pushes the non-rotating sleeve (outer housing) to the opposite side of the hole. When this force is applied across the rotating stabilizer, the stabilizer becomes a fulcrum point, and forces the drill bit against the side of the hole that is lined up with the orienting pistons. The calculated offset at the bit then tends to force the hole in the oriented direction as drilling proceeds. After the drilling cycle is complete, the tool will be picked up off bottom, and as the upper mandrel moves upward on the spline in the lower mandrel, a spring pushes the sliding sleeve back into its normal position, the orienting pistons retract into the outer housing, and the centering pistons come back out into the borehole annulus, thus returning the tool to its normal stabilized position. This cycle may be repeated until the desired result is achieved.
[0008] Once the desired hole angle and azimuth are achieved, the following procedure may be implemented to drill straight ahead. After making a connection and surveying, slowly lower the drill string to bottom and set a small amount of weight on the bit. Then engage the rig pumps. This time, when the activation pistons from the ID attempt to open the wings, they will be behind the sliding sleeve assembly, and the sliding sleeve will remain in its normal or centered position throughout the following drilling cycle.
[0009] Skillful alternating of the two above drilling positions will yield a borehole of minimum tortuosity, when compared to conventional steerable methods.
[0010] These and other aspects of the invention are described in the detailed description of the invention and claimed in the claims that follow.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0011] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0012] [0012]FIG. 1 is a side view of a drill string with rotary steerable tool according to the invention;
[0013] FIGS. 2 A- 2 D are lengthwise connected sections (with some overlap) through a rotary steerable tool according to the invention showing the tool in pulled back position ready to extend the wings used to move the pistons into the offset drilling position;
[0014] [0014]FIG. 3 is a cross section along section line 3 - 3 in FIG. 2C;
[0015] [0015]FIG. 4 is a cross section along section line 4 - 4 in FIGS. 2C and 8C;
[0016] [0016]FIG. 5 is a cross section along section line 5 - 5 in FIGS. 2C and 8C;
[0017] [0017]FIG. 6 is a cross section along section line 6 - 6 in FIGS. 2C and 8C;
[0018] [0018]FIG. 7 is a cross section along section line 7 - 7 in FIGS. 2B and 8B;
[0019] FIGS. 8 A- 8 D are lengthwise connected sections (with some overlap) through a rotary steerable tool according to the invention showing the tool in straight ahead drilling position;
[0020] [0020]FIG. 9 is a cross section along section line 9 - 9 in FIG. 8C;
[0021] [0021]FIG. 10 is a lengthwise section through a rotary steerable tool according to the invention showing the tool in offset drilling position;
[0022] [0022]FIG. 11 is a cross section along section line 11 - 11 in FIG. 10;
[0023] [0023]FIG. 12 is a cross section along section line 12 - 12 in FIG. 10;
[0024] [0024]FIG. 13 is a cross section along section line 13 - 13 in FIG. 10;
[0025] [0025]FIG. 14 is a cross section along section line 14 - 14 in FIG. 10;
[0026] [0026]FIG. 15 is a perspective view of a rotary steerable tool according to the invention showing wings in the extended position with the housing partly broken away to show the mandrel;
[0027] [0027]FIG. 16 is a perspective view of a rotary steerable tool according to the invention with the housing broken away to show wings in the retracted position;
[0028] [0028]FIG. 17 is a close-up view of mating dog clutch faces for use in orienting the rotary steerable tool according to the invention;
[0029] [0029]FIG. 18 is an end view of a rotary steerable tool according to the invention showing pistons set in the offset drilling position; and
[0030] [0030]FIG. 19 is an end view of a rotary steerable tool according to the invention showing pistons set in the straight ahead drilling position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] In this patent document, “comprising” is used in its inclusive sense and does not exclude other elements being present in the device. In addition, a reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the elements is present. MWD means measurement-while-drilling. All seals and bearings described herein and shown in the drawings are conventional seals and bearings.
[0032] Referring to FIG. 1, which shows the overall assembly of a drill string according to the invention, a rotary steerable drilling tool 10 is shown located on a conventional drill string 12 between a conventional MWD tool 14 and a conventional drill bit 16 . As shown more particularly in FIGS. 2A and 2D, rotary steerable drilling tool 10 includes a mandrel 20 having a conventional box connection 22 at an uphole end for connection into drill string 12 and a conventional box connection 24 at a downhole end for connection to a pin connection 26 of a drilling sub 28 . Sub 28 is configured as a rotating stabilizer 17 provided on the drill string between rotary steerable drilling tool 10 and drill bit 16 , and operates as a fulcrum for rotary steerable drilling tool 10 and drill bit 16 to pivot around. Drill bit 16 will conventionally have jets in the bit for egress of fluid from the drill string. At the surface, a conventional rig will include conventional pumps (not shown) for pumping fluid down drill string 12 to drill bit 16 and out the jets in the drill bit.
[0033] The components of rotary steerable drilling tool 10 are best seen in FIGS. 2 A- 2 D, which show the tool in the pulled back off-bottom position, ready to set the tool into either a straight ahead drilling position or an offset drilling position. FIGS. 3 - 7 are sections corresponding to the section lines on FIGS. 2 A- 2 D. FIGS. 15 - 19 provide perspective views of the tool broken away to show the internal workings. FIGS. 3 - 7 are sections corresponding to the section lines on FIGS. 2 A- 2 D. FIGS. 8 A- 8 D show rotary steerable drilling tool 10 in a straight ahead on-bottom drilling position. FIG. 9 is a section corresponding to the section line 9 - 9 on FIG. 8C. The other sections shown on FIG. 8A- 8 D correspond to FIGS. 4 - 7 as well, since the sections do not change in those positions. FIG. 10 shows rotary steerable drilling tool 10 in position for offset drilling, insofar as it is different from the position shown in FIGS. 8 A- 8 D. FIGS. 11 - 14 are sections corresponding to the section lines on FIG. 10.
[0034] Referring to FIGS. 2 A- 2 D, 3 - 7 , 8 A- 8 D, and 15 - 19 , and particularly to FIGS. 2 A- 2 D, a bore 30 is provided within mandrel 20 for communication of fluid from surface to drill bit 16 . A housing 32 is mounted on mandrel 20 for rotation in relation to mandrel 20 . During drilling, housing 32 is held against rotation by frictional engagement with the wellbore and the mandrel rotates, typically at about 120 rpm. Housing 32 is provided with an adjustable offset mechanism that can be adjusted from the surface so that rotary steerable drilling tool 10 can be operated in and changed between a straight ahead drilling position and an offset drilling position. In the straight ahead drilling position, asymmetry of housing 32 , namely thickening 33 of housing 32 on one side, in combination with pistons on the other side of housing 32 yields a tool that is centered in the hole. In an offset drilling position, pistons on the thickened side of housing 32 drive tool 10 to one side of the wellbore, and thus provide a stationary fulcrum in which mandrel 20 rotates to force the drill bit in a chosen direction. Three hole grippers 15 are provided on the exterior surface of housing 32 downhole of thickened section 33 . One of hole grippers 15 is on the opposite side of the thickened section, and the other two are at about 90 degrees to thickened section 33 . Hole grippers 15 are oriented such that when rotary steerable tool 10 is offset in the hole by ½ degree by operation of the adjustable offset mechanism described below, hole grippers 15 will lie parallel to the hole wall, so that hole grippers 15 make maximum contact with the hole wall. Hole grippers 15 grip the wall of the hole and prevent housing 32 from rotating, as well as preventing premature wear of housing 32 against the wellbore.
[0035] Housing 32 has threaded on its uphole end an end cap 34 holding a piston 36 , and on its downhole end another end cap 40 holding a floating piston seal 42 within chamber 44 . Floating piston 42 accommodates pressure changes caused by movement of the housing on mandrel 20 . Housing 32 rotates on mandrel 20 on seven bearings 46 . Mandrel 20 is formed from an upper mandrel 50 and lower mandrel 52 connected by splines 54 . A sleeve 55 , is held in the bore of lower mandrel 52 , and in the downhole end of upper mandrel 50 , by a pin on sub 28 . Appropriate seals are provided as shown to prevent fluid from the mandrel bore from entering between the upper mandrel 50 and lower mandrel 52 at 57 . Downhole movement of upper mandrel 50 in lower mandrel 52 is limited by respective shoulders 59 and 61 . Housing 32 is supported on lower mandrel 52 by thrust bearings 56 on either side of a shoulder 58 on lower mandrel 52 .
[0036] The adjustable offset mechanism may for example be formed using plural pistons 60 , 62 and 64 radially mounted in openings in housing 32 . Pistons 60 and 62 are mounted in openings on thickened side 33 of the sleeve, while pistons 64 are mounted on the opposed side. Thickened side 33 has a larger radius than the opposed side, and pistons 64 are extendable outward to that radius. Pistons 62 are at 120 degrees on either side of piston 60 and extend outward at their maximum extension less than the extension of piston 60 when measured from the center of mandrel 50 . Pistons 60 and 62 extend outward to a radius of a circle that is centered on a point offset from the center of mandrel 50 , as shown in FIG. 18. As shown in FIGS. 4 - 6 and 12 - 14 , hole grippers 65 are also embedded on either side of housing 32 at 90 degrees to piston 60 . Hole grippers 65 are about 5 inches long, and are oriented, as with hole grippers 15 , so that one edge lies furthest outward. Thus, hole grippers 65 assist in preventing housing 32 from rotating by engaging the hole wall with their outermost edge. Hole grippers 15 and 65 should be made of a suitably hard material, and may, for example, be power tong dies since these are readily available and may be easily removed for replacement. Pistons 60 , 62 and 64 should also be made of a similar hard material.
[0037] Pistons 60 , 62 and 64 are radially adjustable by actuation of mandrel 20 as follows. Dog clutch 66 is pinned by pins 68 to mandrel 32 to form a chamber 70 between housing 32 and upper mandrel 50 . Dog clutch 66 has a dog face 67 that bears against dog face 69 on end cap 34 when upper mandrel 50 is raised in the hole. Wings 72 secured on pins 76 in the upper mandrel 50 are operable by fluid pressure in bore 30 of upper mandrel 50 through opening 74 . Fluid pressure in bore 30 urges pistons 71 radially outward and causes wings 72 to swing outward on pins 76 into chamber 70 . Upon reduction of fluid pressure in bore 30 , wave springs 73 surrounding pistons 71 draw pistons 71 back into upper mandrel 50 . A spring (not shown) is also placed around wings 72 seated in groove 77 . Groove 77 is also formed in the outer surface of wings 72 and extends around upper mandrel 50 . The spring retracts wings 72 when the pressure in bore 30 is reduced and wings 72 are not held by frictional engagement with collar 84 .
[0038] Chamber 70 is bounded on its housing side by a sleeve 78 , which acts as a retainer for a piston actuation mechanism held between shoulder 80 on end cap 34 and shoulder 82 on housing 32 . The piston actuation mechanism includes thrust bearing 86 held between collars 84 and 88 , cam sleeve 90 and spring 92 , all mounted in that order on mandrel 32 . Cam sleeve 90 is mounted over a brass bearing sleeve 91 that provides a bearing surface for cam sleeve 90 . Spring 92 provides a sufficient force, for example 1200 lbs, to force cam sleeve 90 uphole to its uphole limit determined by the length of sleeve 78 , yet not so great that downhole pressure on upper mandrel 50 cannot overcome spring 92 . Spring 92 may be held in place by screws in holes 93 after spring 92 is compressed into position during manufacture, and then the screws can be removed and holes 93 sealed, after the remaining parts are in place.
[0039] Cam sleeve 90 is provided with an annular ramped depression in its central portion 94 and thickens uphole to cam surface 96 and downhole to cam surface 98 , with greater thickening uphole. Piston 60 is offset uphole from pistons 64 by an amount L, for example 3-½ inches. Cam surface 96 is long enough and spaced from the center of depression 94 sufficiently, that when cam sleeve 90 moves a distance L downward to the position shown in FIG. 10, piston 60 rides on cam surface 96 , while pistons 64 ride in the center of depression 94 . Cam surface 98 is long enough and spaced from the center of depression 94 sufficiently, that when cam sleeve 90 is urged uphole by spring 92 to the position shown in FIG. 2C or 8 C, pistons 64 ride on cam surface 98 , while piston 60 rides in the center of depression 94 . Thus, when cam sleeve 90 is forced downhole in relation to housing 32 , pistons 60 ride on uphole cam surface 96 , and are pressed outward into the well bore beyond the outer diameter of housing 32 , while pistons 64 may retract into annular depression 94 . When cam sleeve 90 is in the uphole position, pistons 60 are in annular depression 94 , while pistons 64 ride on downhole cam surface 98 . Pistons 62 will also ride on cam sleeve 90 , but are slightly offset downhole from piston 60 and so do not extend as far outward. Since cam surface 98 has a smaller diameter than cam surface 96 , the tool may move more readily in the hole when pistons 64 are extended for the straight ahead drilling position, and piston 64 and housing 32 act as a stabilizer. The stabilizer position or straight ahead drilling position of the pistons is shown in the end view FIG. 19 and the cross sections of FIGS. 5 and 6. The offset drilling position of the pistons is shown in the end view of FIG. 18 and the cross sections of FIGS. 12 - 14 .
[0040] An orientation system is also provided on rotary steerable drilling tool 10 . A sensor 102 , for example a magnetic switch, is set in an opening in upper mandrel 50 . A trigger 104 , for example a magnet, is set in end cap 34 at a location where trigger 104 will trip sensor 102 when mandrel 20 rotates in an on-bottom drilling position (either offset or straight). Snap ring 105 should be non-magnetic. A further sensor 106 is set in upper mandrel 50 at a distance below sensor 102 about equal to the amount upper mandrel 50 is pulled back as shown in FIGS. 2 A- 2 D, which will be slightly greater than the distance L, for example 4 inches when L is 3 ½ inches. Trigger 104 will therefore trip sensor 106 when mandrel 20 is pulled back and jaw clutch faces 67 , 69 are engaged. This position allows the tool to be oriented with the MWD tool face. Sensors 104 and 106 communicate through a communication link, e.g. a conductor, in channel 105 with a MWD package in MWD tool 14 . Sensors 102 and 106 are thus sensitive to the rotary orientation of housing 32 in relation to mandrel 20 , and when trigger 104 trips one of sensors 102 , 106 , sends a signal to the MWD tool 14 that is indicative of the rotary orientation of housing 32 on mandrel 20 .
[0041] For drilling in the straight ahead position shown in FIGS. 8 A- 8 D and 9 , mandrel 50 is set down on lower mandrel 52 so that shoulders 59 and 61 abut. Wings 72 are held in mandrel 50 , and spring 92 urges cam sleeve 90 to the position shown in FIG. 8B, so that pistons 64 are forced outward by cam surface 98 , and piston 60 lies in annular depression 94 . In this position, pistons 64 and thickened portion of housing 32 form a circular stabilizer and mandrel 20 rotates within housing 32 centrally located in the hole.
[0042] For drilling in the offset position, rotary steerable drilling tool 10 is altered in position as shown in FIGS. 10 - 14 . Upper mandrel 50 is lifted off lower mandrel 52 until dog face 67 engages dog face 69 , and rotated at least 360 degrees to ensure engagement of faces 67 and 69 . The orientation of housing 32 in the hole can then be determined by MWD tool 14 if the engaging position of dog faces 67 , 69 is programmed in the MWD package. Housing 32 may then be rotated from surface using mandrel 20 into the desired direction of drilling in the offset drilling position. The drilling direction will conveniently coincide with the direction that piston 60 points. With dog faces 67 , 69 engaged, fluid pressure is applied from surface to bore 30 of mandrel 20 to force wings 72 into a radially extended position. Mandrel 20 , or more specifically upper mandrel 50 , since lower mandrel 52 does not move in this operation, is then moved downward. Upon downward motion of mandrel 20 , wings 72 drive cam sleeve 90 downward and lift piston 60 onto cam surface 96 , thus extending piston 60 outward, while piston 64 moves into annular depression 94 . The action of piston 60 bearing against the wellbore places rotary steerable tool 10 in an offset drilling position using rotary stabilizer 17 as a rotating fulcrum. The ratio of the offset caused by pistons 60 , 62 to the offset at drill bit 16 is equal to the ratio of the distance of pistons 60 , 62 from rotary stabilizer 17 to the distance of drill bit 16 from rotary stabilizer 17 .
[0043] During straight ahead drilling, the location of housing 32 may also be determined by rotating mandrel 20 in housing 32 and taking readings from sensors 106 . The timing of the readings from sensor 106 may be used by the MWD package to indicate the location of housing 32 .
[0044] Immaterial modifications may be made to the invention described here without departing from the essence of the invention. | The device contemplated provides a method for positioning the drill bit in a drilling operation to achieve small changes in hole angle or azimuth as drilling proceeds. Two different positions are available to the operator. The first is a straight ahead position where the tool essentially becomes a packed hole stabilizer assembly. The second position tilts the bit across a rotating fulcrum to give a calculated offset at the bit-formation interface. The direction that the bit offset is applied in relation to current hole direction is controlled by positioning the orienting pistons prior to each drilling cycle, through the use of current measurement-while-drilling (MWD) technology. Components of the tool comprise a MWD housing, upper steering and drive mandrel, non-rotating position housing, lower drive mandrel splined with the upper mandrel, rotating fulcrum stabilizer and drill bit. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to a control device for at least one thread feeding device of a thread processing machine, especially a knitting machine. The invention also relates to a method for positive thread feeding to a textile machine, especially a knitting machine with changing thread requirements.
BACKGROUND OF THE INVENTION
[0002] Circular knitting machines and flat knitting machines are known, which are designed for stitching patterned goods. With respect to patterned goods, different stitching positions must be supplied with thread intermittently rather than continuously.
[0003] One example of a circular knitting machine for creating patterned goods is seen in EP 0 724 033 A1. The circular knitting machine has a cutting device in order to cut away unnecessary thread. If thread of the corresponding color is needed again, the previously cut thread is fed again to the stitching position.
[0004] In addition, a so-called striping attachment for a circular knitting machine and for a circular machine is seen in DE-PS 2024 341. The striping attachment contains devices to lay threads in and out, i.e., to feed the stitching positions selectively.
[0005] Knitting machines that stitch plain-weave goods, i.e., to whose stitching positions continuous thread is fed, are usually supplied with thread by means of so-called positive feed wheel mechanisms, which feed a certain amount of thread to the stitching position for every rotation of the machine cylinder. Thus, the mesh size is uniform independent of tolerances of the stitching positions. Such positive feed wheel mechanisms are usually driven by means of a toothed belt or the like and thus are forced to run in sync with the knitting machine.
[0006] Knitting machines used to create patterned goods cannot be supplied with thread with such positive feed wheel mechanisms. Instead, so-called friction feed wheel mechanisms are usually used, as seen in DE 100 06 599 A1. Such friction feed wheel mechanisms have a thread feed wheel that is driven so that it rotates. The thread contacts this thread feed wheel over a wrapping angle, which changes as a function of the thread tension at the point using thread. For this purpose, a so-called feeder lever is provided, which carries on its end an eyelet through which the thread runs. The lever is mounted so that it can pivot and is biased by a spring in the feeder direction, i.e., away from the thread feed wheel. If the thread tension breaks down, the feeder lever lifts the thread away from the thread feed wheel and drastically reduces at least the wrapping angle.
[0007] Such thread feeding devices have been proven in practice. Unlike positive feeding devices, however, they do not directly create a uniform mesh size.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] The goal of the invention is to present a system, as well as a method, with which thread-processing machines, especially circular knitting machines, can be fed with thread in a way that allows increased stitch quality despite changing thread requirements.
[0009] To control the one or more thread feeding devices the control device according to the invention uses a pattern memory, which is used for controlling the knitting machine or some other textile machine. The pattern memory contains data for turning the thread feeding devices on and off at various positions of thread use, for example, stitching positions. Thus, the pattern memory controls, e.g., the lock of a knitting machine, in order to activate or deactivate individual needles, the thread feeder lever to lay thread in and out, cutting devices and the like. The control device has a pattern interface, by means of which it is connected to the pattern memory. In addition, the control device receives from a position sensor information on the current machine position. For a circular knitting machine, the term “machine position” is understood to be primarily the rotational angle of the needle cylinder. Here, the machine position can be detected either as an absolute position or as a relative position in the form of a pulse sequence or otherwise.
[0010] The central component of the control device is a processing module, which can also be designated as a machine interpreter, especially when it is realized in software. The processing module obtains data from the pattern memory according to the position of the machine and converts this data according to a set of given logic rules into control commands for the one or more thread feeding devices. The “set of given logic rules” can be a delay command in the simplest case. When the position sensor delivers, for example, a pulse sequence specifying the angular steps of the needle cylinder, and when the needle cylinder must rotate by a preset angle between the activation of a stitching position and the resulting thread requirements, there is the logic rule of waiting an appropriate number of pulses of the position sensor until a further request for thread is issued from the pattern memory to the thread feeding device. This can be realized with a gate circuit, which, after counting the relevant pulse number, forward the step pulses of the position sensor of the needle cylinder to the thread feeding device in order to cause the synchronous rotation between the thread feed wheel and needle cylinder with the desired delay.
[0011] The number of angular steps that pass between the activation of a certain point in the pattern and the required start of feeding can be viewed as the lag angle. In other cases, advance angles may also be necessary. This is easier to set when the position sensor is an absolute value sensor. The advance angle and/or lag angle are machine-specific and depend on, for example, the distance between a thread supply and feeder lever and a stitching position. For a given machine, they can be constant or dependent on settings or add-on parts. Preferably, they are stored in a data memory for machine data.
[0012] “Machine data” is, for example, a number of angular steps of the stitch cylinder or a number of other machine cycles that are executed after receiving a pattern command until the thread requirements actually change according to the pattern. Thus, the machine interpreter accesses both the pattern data memory and also the machine data memory and links these together (for example, through addition or subtraction of the advance angle or lag angle from the data of the pattern memory) and ensures that the feed wheel mechanisms are activated or deactivated at the correct point of the rotation of the needle cylinder. Instead of the access to the pattern memory, the machine interpreter can also be connected to a line that carries the pattern switching signals. Such lines are, for example, lines controlling switching elements of the knitting machine for activating or deactivating stitching positions. Thus, easily detectable control signals can be used that are used for controlling switching elements. In addition, signals of sensors that poll switching elements, needles, or other mechanical parts for executing pattern-specific actions can be used.
[0013] While activated thread feeding devices run-in sync with the needle cylinder, deactivated thread feeding devices are stationary. In addition to this switching operation, it can also be necessary to create at least temporary operating states in which the thread feeding devices are run at reduced rotational speed or also at overspeed.
[0014] For a simple embodiment, the advance and lag angles can be determined beforehand and programmed by service personnel or the machine manufacturer or the feed wheel mechanism manufacturer. However, it is also possible to provide an input interface, by means of which corresponding data, for example, screen masks, can be input. It is thus possible to test certain start and stop points relative to the rotation of the machine cylinder, and in this way to optimize the quality of the stitching to be created. It has also been found to be useful to establish positive thread feeding for jacquard circular knitting machines, wherein the thread feeding is not dependent on the current thread tension.
[0015] In addition, it is possible to provide thread tension sensors for simplifying the gathering of the machine data and to monitor the thread tension in a test operating mode as well as to activate the thread feeding devices only when tension appears in the thread. The rotational angle of the needle cylinder at which the thread tension appears can be compared to the associated pattern data. The angle differences between the pattern data and the rotational angles at which tension appears in the thread can be stored as advance angles or lag angles. After completing the test run, the thread tension sensor can be deactivated and pure positive operation can be performed with reference to the obtained data. If necessary, however, thread tension monitoring can be continuous or intermittent, e.g., in order to identify error states.
[0016] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic view of a knitting machine with electronic positive feed wheel mechanisms and an associated control device,
[0018] FIG. 2 is a diagrammatic view of advance and lag angles for controlling the feed wheel mechanism for use in embodiments of the invention,
[0019] FIG. 3 is a symbolic illustration of a section from a pattern data memory usable in an embodiment of the invention;
[0020] FIG. 4 is a schematic view of a jacquard knitting machine with a self-programming positive feed wheel mechanism usable in embodiments of the invention; and
[0021] FIG. 5 is a schematic view of a jacquard knitting machine with a self-programming positive feed wheel mechanism and indirect sampling of pattern data from a line carrying switching signals usable in embodiments of the invention.
[0022] While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions and equivalents falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] In the following description, a number of reference numbers are used to refer to specific elements in the several drawings. These reference numerals correspond to the drawing elements as follows: Knitting machine ( 1 ); Needle cylinder ( 2 ); Needles ( 3 ); Lock ( 4 ); Lock cam ( 5 ); Line ( 7 ); Switching element ( 8 , 8 a ); Actuator ( 8 b ); Branches (v); Points ( 12 ); Stitching positions ( 14 ); Thread ( 15 ); Hold points ( 16 ); Thread guide ( 17 ); Thread feeding devices ( 18 , 19 ); Thread feed wheel ( 21 ); Motor ( 22 ); Control device ( 23 ); Processing module ( 23 a ); Position sensor ( 24 ); Position input ( 25 ); Control unit ( 26 ); Position input ( 27 ); Pattern memory ( 28 ); Data connection ( 29 ); Input device ( 31 ); Display device ( 32 ); Input masks ( 33 ); Data memory ( 34 ); and Thread tension sensor ( 35 ).
[0024] In FIG. 1 , a knitting machine 1 designed for manufacturing patterned goods is shown schematically. The knitting machine 1 has a needle cylinder 2 , which is mounted so that it can rotate about a vertical axis and which is connected to a drive device. On its outer periphery, the needle cylinder 2 has vertical guide channels, in which needles 3 are held so that they can move vertically. A lock 4 , which has a groove-like lock cam 5 , is associated with the needles 3 . Feet 6 of the needles 3 project into the lock cam 5 , such that they may move vertically with the position of the lock cam 5 as the needle cylinder 2 turns. The lock cam 5 can have wave-shaped sections as indicated in FIG. 1 with a dashed line 7 , which rise or fall and thus push the needles 3 out (up) or pull them in (down).
[0025] A switching device 8 can be used to activate or deactivate alternative branches 9 , 11 of the lock cam 5 . Additional switching elements and/or lock cams can be provided, but are omitted from FIG. 1 for the sake of clarity. For example, plates can be provided between the needles 3 to guide the stitched material hanging on the needles 3 and to otherwise affect the stitches.
[0026] Downwardly extending positions 12 of the lock cam 5 guide the needles 3 downward to define stitching positions 14 at which a received thread 15 is formed into a stitch. The stitching positions 14 are preceded by holding points 16 at which the thread 15 is guided to the needles 3 . The needles 3 are driven to the holding points 16 by the cam lock 5 , e.g., by branch 9 . Generally at the holding position 16 , there is preferably a thread guide 17 for guiding the thread 15 toward or away from the needles 3 .
[0027] In addition, the device 1 can also include cutting elements, pull-in devices, and the like, as will be appreciated by those of skill in the art. In order to improve clarity, such additional devices are omitted from FIG. 1 .
[0028] Thread feeding devices 18 , 19 , which may be identically or similarly constructed, are used for guiding the thread. The following description of the thread feeding device 18 applies equally to the thread feeding device 19 in an embodiment of the invention. Additional thread feeding devices (not shown) may also be used in keeping with this description.
[0029] The thread feeding device 18 has a thread feed wheel 21 coupled to a motor 22 to rotate therewith. The thread feed wheel is, for example, a bobbin formed of a barred cage or a one-piece part deep-drawn from sheet metal, and can have extended edges or guides on its ends and a cylindrical ribbed storage or receiving portion between the extended edges or guides. In use, the thread 15 wraps around the thread feed wheel 21 one or more times and thus forms a winding. The winding can contact the entire periphery of the thread feed wheel 21 . In an alternative embodiment, the winding is guided over one or more thread lifting pins oriented approximately parallel to the rotational axis of the thread feed wheel 21 . In this embodiment, the winding may contact only part of the periphery of the thread feed wheel 21 . This technique can be used to allow a certain amount of slippage in the thread 15 on the thread feed wheel 21 , so as to buffer feeding errors. In addition, a winding advance and/or an axial stretching of the winding can be achieved with the thread lifting pin, e.g., adjacent windings can be separated from each other. A high angular resolution position sensor preferably associated with the motor 22 allows the position of the motor 22 to be accurately sensed and controlled. In an embodiment of the invention, the accuracy of the position sensor is such that the feeding deviation of the thread 15 is less than 1 mm. A control device 23 is used to control the motor 22 based on the information provided by the sensor. The control device 23 controls the motor 22 by providing continuously updated angular information to the motor 22 , such that the motor 22 rotates with continuous angular information. The angular information can be transmitted in the form of data, currents, voltages, pulses, i.e., step information, etc.
[0030] A second position sensor 24 is associated with the needle cylinder 2 to detect the current angular position of the cylinder 2 . This position sensor 24 then forwards the angular position information, for example, in the form of increments, i.e., angular steps, to a position input 25 of the control device 23 . In an embodiment of the invention wherein the angular position information is relative to the previous position rather than absolute, the position of the needle cylinder is preferably calibrated, such as once at start up, on each rotation, and/or at certain angular intervals. At the time of calibration, a zeroing signal is generated so that the control device can subsequently determine the absolute position of the needle cylinder 2 by counting the individual step pulses (increments). In an alternative embodiment of the invention, the position sensor 24 is an absolute value sensor that supplies an analog or digital signal characterizing the rotational angle of the needle cylinder 2 to the position input 25 .
[0031] The knitting machine 1 is controlled by a control device 26 , which has a position input 27 connected to the position sensor 24 . The control device 26 controls the switching element 8 and also possibly other units of the knitting machine 1 . For example, the control device 26 may control another switching element 8 a shown schematically, an actuator 8 b for moving the thread guide, cutting devices, and/or other elements.
[0032] The control device 26 is connected to a pattern data memory 28 , which contains suitably prepared data characterizing the pattern of the knitted material to be created. An excerpt of the memory contents for a pattern that is continuous over several cylinder rotations is shown in FIG. 3 . The beginnings of the two first rows Z 1 , Z 2 of the control data are shown for example, for two stitching positions. Angular increments are mapped column by column, which can correspond, for example, to the needle spacing. While the first stitching position for the first cylinder rotation (line 1 ) is active (all 1's) at least in the area considered, the second stitching position is inactive (all 0's). In the second row, the second stitching position is continuously active (all 1's) while the first stitching position operates intermittently (sequence of 0's and 1's). In this way, the pattern memory continues for all rows of the pattern and all stitching positions as well as all angular increments.
[0033] The control device 23 is also connected to this pattern memory 28 . In this way it can retrieve the associated pattern data from the pattern memory 28 according to the position signals received via the position input 25 . In FIG. 1 , this is characterized by a corresponding bi-directional data connection 29 . The control device 23 converts the received pattern data into control data for the thread feeding devices 18 , 19 . The conversion between the received pattern data and control data is executed in an embodiment of the invention according to given logic rules, which can be input, for example, via an input device 31 in the form of a keyboard or other input means and/or with reference to a display device 32 , for example, in the form of a monitor or display. For this purpose, input masks 33 in which count values can be entered are displayed on the display device 32 in an embodiment of the invention. The input masks 33 may assist the user in inputting advance angles or lag angles. These values may be given, for example, by the distance from the holding position 16 to the stitching position 14 , and thus relate to structural details of the knitting machine 1 . In particular, this data relates to advance or delay angles (lag angles) that define the number of increments of the position sensor that the thread requirements actually rise or fall before or after a switching command given to the switching element 8 or 8 a.
[0034] Having discussed the knitting machine 1 generally, the following section discusses the function of the control device 23 in the operation of knitting machine 1 in greater detail. In this embodiment of the invention, the knitting machine 1 is knitting plain-weave goods, although it will be appreciated that the described principles are more broadly applicable. In this case, the needle cylinder 2 runs at an essentially constant rotational speed. The rotational movement is detected in the form of individual increments or in the form of a sequence of absolute position information by the position sensor 24 and is forwarded to the control device 23 and also to the control unit 26 . The stitching positions fed by the thread feeding devices 18 , 19 are both active. Accordingly, the control device 23 controls the motors 22 of the thread feeding devices 18 , 19 via control pulses and/or other appropriate control signals, so that the thread feed wheels 21 rotate with a given speed ratio in sync with the needle cylinder 2 . The thread 15 is thus fed positively, i.e., at a predetermined rate. The needles 3 run through the top branch 9 of the lock cam symbolized by the line 7 and hold the thread, which is then stitched at the stitching position 14 .
[0035] It is now assumed that a knitted material section is reached in which a pattern is to be generated. At this point, the control unit 26 receives the corresponding information by polling the pattern memory 28 and then switches the switching elements 8 , 8 a for the corresponding angular position of the needle cylinder 2 detected by the position sensor 24 , so that the needles are no longer driven in and out and the loops are not sunk any further. For example, the feet 6 of the needles then run through the branch 11 of the lock cam, and also through the horizontal branch at the stitching position 14 . Additionally or alternatively, the thread 15 can be pivoted outward by means of the actuator 8 b and the thread guide 17 , such that the thread 15 is no longer engaged by the needles 3 . This is also a mechanism for interrupting the knitting operation when needed.
[0036] In either case (switching of elements 8 , 8 a or pivoting of the thread 15 ) the feeding operation of the associated thread feeding device 18 needs to be modified since the timing of the feeding lock no longer necessarily coincides with the timing of the switching of the switching element 8 or the actuator 8 b . Instead, generally after the switching of elements 8 , 8 a , a portion of the needles are still located in the upward or downward extending lock cam ( 9 , 12 ), that executes the loop-sinking movement, so that additional thread must still be delivered.
[0037] This phenomenon is shown diagrammatically in FIG. 2 . For a rotational angle α 0 , if the knitting machine 1 is switched according to the pattern data, then the associated thread feeding device 18 can be turned off somewhat later at an angle α N of the needle cylinder 2 . The corresponding angular difference α 0 −α N is referred to as the lag angle. A corresponding lag angle α N1 is needed when turning on the stitching position 14 . The lag angles α N1 and α N for turning the stitching position 14 on and off are usually different. In particular, turning the stitching position on generally involves taking into consideration the distance between the holding point 16 and the stitching position 14 . Thus, α N1 is usually significantly larger than α N .
[0038] In principle, advance angles α v can also be stored and maintained, so that the thread feeding starts shortly before the knitting machine 1 receives a corresponding switching command. Such advance angles are especially easy to maintain when the position sensor 24 is an absolute position sensor as opposed to a relative position sensor.
[0039] The necessary advance and lag angles for turning on and off stitching positions 14 or other measures that require an increase or decrease in the feed rate of the thread feeding devices 18 , 19 , are preferably stored in a data memory 34 which is part of the control device 23 . The data stored in the data memory includes the mentioned advance or lag angles, and is input, for example, via the input device 31 .
[0040] FIG. 4 illustrates an embodiment of a control device 23 and associated components that allows simplified programming of the data memory 34 and thus simplified management of the control device 23 . As in the preceding embodiment, the logic rules with regard to processing of the pattern data of the pattern memory 28 for obtaining control signals for controlling the thread feeding device 18 are composed predominantly of the addition or subtraction of advance angles or lag angles at the individual angular steps α 1 , α 2 , etc., for which pattern switching commands are given to the switching elements 8 , 8 a . This corresponds to zero-one or one-zero transitions in each row in FIG. 3 . For example, in the top sub-row of Z 2 between α 1 and α 2 , if a one-zero transition appears, this indicates that a deactivation command is sent for the switching element 8 . The thread feeding device 18 is then controlled with a corresponding angular offset (α 1 +α N1 ).
[0041] The lag angle α N1 can be obtained in the system of FIG. 4 , for example, by means of a thread tension sensor 35 that detects the thread tension between the thread feed wheel 21 and the knitting machine 1 . The thread tension sensor 35 , when activated, delivers thread tension signals to the control device 23 . The control device 23 then controls the motor 22 such that the thread tension is always kept within a given tolerance range. Thus, if the knitting machine 1 does not take up thread during a certain period, then the thread feed wheel 21 is still during that period (i.e., the tension is maintained). If the knitting machine 1 draws thread, i.e., if the stitching position 14 has been activated, then the thread tension initially increases temporarily. This causes the control device 23 to set the motor 22 into operation, so that thread is again fed positively. The appropriate feeding amount is set to keep the thread tension constant by driving the control device 23 .
[0042] The timing or rotational angle of the needle cylinder 2 at which the thread feed can be adjusted is the rotational angle at which the thread tension increases to an amount outside of the predetermined range. The control device 23 can record this associated rotational angle and it can be assigned to the pattern data of the pattern memory 28 . This is realized, for example, by forming the difference between the angle at which the thread tension peak appeared and the angle at which a corresponding switching command was given to the switching element 8 or to the actuator 17 . The difference is stored in the data memory 34 and may be later used in positive operation without tension monitoring in an embodiment of the invention.
[0043] Alternatively, the rotation of the thread feed wheel 21 can be monitored at the position of the detection of the thread tension peak. This involves the detection of the time or rotational angle of the needle cylinder 2 at which the rotation of the thread feed wheel 21 caused by the tension of thread 15 begins. The angular difference between the beginning of rotation of the thread feed wheel 21 and the angle at which the pattern memory 28 causes switching of the actuators or switching elements of the knitting machine 1 is in turn stored in the data memory 34 .
[0044] In an embodiment of the invention, the advance angle and lag angle data obtained and stored in the data memory is editable. Optionally, a corresponding menu can be provided which can be invoked and operated via the input device 31 and the display device 32 .
[0045] Optionally, certain rotational speed stages of the thread feed wheel 21 can also be monitored and registered in order to differentiate, for example, not only two states, e.g., active and inactive, but also a third state such as a “weak feeding” state involving the feeding of floating thread. During operation, the amount of thread fed is preferably determined according to the pattern information. As discussed above, the monitoring of the rotation of the thread feed wheel 21 or alternatively the thread tension is used to establish the angle of the needle cylinder 2 at which feeding of the thread 15 is to begin or stop, with reference to the pattern data. The data obtained in this way is then taken into account by the software operating the control device 21 , which interprets the pattern data of the pattern memory 28 continuously, and determines the switching commands for the thread feeding devices 18 , 19 with reference to the data stored in the data memory 34 .
[0046] In an embodiment of the invention, the control device 23 is a central control device that is constructed independently of the control unit 26 . Alternatively, the control device 23 is part of the same unit. Furthermore, it is possible to house the control device 23 in a thread feeding device 18 , a separate unit, or in a network formed by the thread feeding devices 18 , 19 .
[0047] FIG. 5 illustrates another modification of the described knitting machine 1 . It concerns the knitting machine according to FIG. 4 , whose description is referred to. For the knitting machine according to FIG. 5 , the data connection 29 to the pattern memory 28 is created by polling switching signals from the line that connects the control unit 26 to the switching elements 8 , 8 a . In this embodiment of the invention, direct access to the pattern memory 28 is not necessary. This embodiment of the invention is especially beneficial for retrofitting solutions. In an alternative embodiment of the invention, sensors on the knitting machine 1 that monitor the lock 4 , the switching elements 8 , 8 a , thread guide 17 , or other elements to be moved according to the pattern, provide pattern information.
[0048] In an embodiment of the invention, the control device 23 is used for processing such secondary pattern signals, and may employ its self-learning mode. The control device 23 takes into account advance or lag angles between the switching signal and change in thread use. The advance and lag angles can be determined by manual input or with learning methods by monitoring the thread tension. Learning methods are especially suited for polling pattern data from switching lines. A point-exact turning on and off of the thread feeding devices can be achieved without manual input, without knowledge of the pattern data, and without knowledge of the machine data.
[0049] It will be appreciated that there has been described herein a novel system and control device for controlling thread feeding devices based on the data of a pattern memory or from pattern or switching data, wherein advance or lag angles which relate to the rotation of the needle cylinder for a specific machine are added to or subtracted from the pattern data. All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0050] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0051] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. 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. | The invention relates to a control unit for thread feeding devices, such as those associated with knitting machines and the like. The control unit generates pattern or switch data control signals based on a pattern memory, or otherwise, for the thread feeding devices. In an embodiment of the invention, the control unit adds to or subtracts from the pattern data any advance or lag angles as necessary to account for the structure of the machine and to thus assure effective thread feeding. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
If Any: None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the art of poppet seats and more particularly to poppet seats useful in air regulating devices. In its most preferred embodiment, the present invention relates to an improved poppet seat in which synthetic or natural rubber seat material is molded around and through an annular carrier. The invention also relates to a method for making a poppet seat of this type.
2. Description of the Prior Art
In the field of air regulating devices, such as those used in underwater diving equipment (more commonly known as scuba equipment) breathable air is provided to the diver from a pressurized air source, e.g. a compressed air cylinder, a surface supply hose, etc.
In most equipment a primary regulator is employed to reduce the air pressure available to the diver from the pressurized source, such as a pressurized air tank, and a demand regulator functions to supply air in accordance with the diver's breathing pattern. In current demand regulators, poppet seats have been commonly manufactured by providing a carrier base made out of plastic or metal material and having a groove about its center. Pliable seat material has been added to the groove and has been held in place by friction and/or by adhesive bonding. In one prior art device, such seats were exposed to pressures in the range of 120-150 pounds/in 2 and made spring loaded contact with a coned orifice member to provide a complete seal of the pressure. Such poppet seats are subjected to widely varying environmental conditions and cyclic use since each time a breath is taken, a spring is relieved thereby allowing movement of the coned orifice member toward and away from the seal and permitting the bypass of breathable air to the scuba diver.
Such poppets have proved to be highly effective over extended periods of time, but several design aspects of the current system make it possible for small leakage to occur. For example, the coned orifice can become damaged or the seating surface itself may be contaminated or deformed. These occurrences are especially likely in situations where the regulator is not maintained properly, e.g. if it is not reused as recommended by most manufacturers. Leakage could also occur if the seat material becomes delaminated from the substrate carrier base, as could happen for example if the adhesive or frictional forces became weakened. If any of these occurrences would take place while the diver was below water, normal emergency procedures, such as the use of a back-up regulator, would be employed to allow a divers safe return to the surface. Repair of this regulator would then be required.
While the first two problems mentioned above may be readily cured by proper maintenance, the later problem is less easy to observe, as it can occur over time. An improvement in design would be desirable to make sure the air supply is not bypassed due to inappropriate separation of the seat material from the carrier component.
SUMMARY OF THE INVENTION
The present invention features a seat for use in air regulating devices, such as second stage regulators in diving equipment, in which pliable material is applied through holes in the carrier to provide a mechanical securing of the seat material to its substrate. In accordance with another feature, the present invention employs such mechanical attachment in combination with chemical bonding to increase, even further, the adherence of the seat material to its substrate.
More specifically, the present invention features a technique for encapsulating a substrate base and anchoring seat material therethrough by means of through-hole molding using holes which are geometrically reversed when compared to the direction from which delamination forces would be most likely to occur.
Yet another feature of the present invention is to provide an encapsulated substrate, wherein the encapsulating seat material forms a seating member that also flows into a v-groove surrounding the periphery of the substrate to enhance attachment thereto. In still another modification of the later feature, the v-groove intersects a plurality of through holes to further enhance the security of the seat and substrate.
The invention also features a method for manufacturing a valve seat of the type including an annular base and an elastomeric seating material affixed to the base. The method includes the steps of forming an annular groove in the base and securing the seating material to the base such that the seating material contacts at least a portion of the groove generally in opposing relation with respect to an upper surface of the base.
How these and other features of the present invention are accomplished will be described in the following detailed description of the preferred embodiment, taken in conjunction with the drawings. Generally, however, they are accomplished by using a synthetic or natural rubber seat material and molding it with a substrate which is preferably of annular form. In the most preferred embodiment, the substrate includes a v-groove around its periphery and a plurality of holes so that the molding material passes through the holes and around the v-groove, most preferably encapsulating the entire periphery of the carrier. In the most preferred embodiment, the holes of the substrate are geometrically reversed to increase the seats ability to withstand any delamination forces. Other ways in which the objects of the invention are accomplished will become apparent from the following detailed description after it is read and understood by those knowledgeable in the art. Such other ways are also deemed to fall within the scope of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom plan view of the poppet seat forming the most preferred embodiment of the present invention;
FIG. 2 is a side elevation showing the seat material lip extending from the upper surface of the seat; and
FIG. 3 is a cross section taken along the line 3--3 of FIG. 1 showing the location of the molding material and the reversed drilled holes and v-groove around the perimeter of the substrate.
In the various FIGURES like reference numerals are used to indicated like components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before proceeding to the detailed description of the preferred embodiment, several general comments should be made about the applicability and the scope of the present invention. First, with regard to the materials to be employed, the carrier or substrate material is most commonly prepared from a metal such as brass or stainless steel, although plastics could also be employed. As to the seat material itself, synthetic or natural rubber materials are preferred, the most typical being silicone rubber which has been used heretofore in preparing such seats for air control devices. A preferred seat material in the present invention is silicon rubber, such as Silastic LCS 755 silicon rubber, manufactured by Dow Corning.
As to the use of the seat described in this section of the specification, it could be employed in a number of devices other than that mentioned in the background section hereof. For example, the article shown in the drawings could be used in a wide variety of air or other fluid control devices wherein it is desired to have structural rigidity and mechanical adherence of a pliable seat material to a substrate. This should be kept in mind as the balance of the specification is read, even though demand regulator poppet seats are mentioned and shown. One familiar with air control devices could readily adapt the teachings of the present invention to other seat design, taking into account such factors as diameter, thickness, applicable durometer, environmental conditions and the like. Furthermore one could refer to the instruction manuals, engineering bulletins and maintenance guides for such regulators as the Scubapro Models D400, D350, D300 and AIRI to learn more about such poppet seats and their interaction with other control device components. Copies of Scubapro Engineering Bulletin Nos. 237 and 238 are submitted with this specification for that purpose.
Proceeding next to a brief description of the prior art, prior art molded seats have been made using annular brass inserts or substrates, much like a washer, having a central through opening and an annular groove in one surface thereof. Rubber was added by a molding process to the groove to provide a seat for the coned orifice mentioned above.
In the present invention, molded rubber in a groove is replaced by rubber which is molded with the insert so that it, in the most preferred embodiment, surrounds the sides and fills various through holes to be described in detail hereafter. A molded seat 10 according to the present invention is show in bottom view in FIG. 1. The molding material 11 encases the periphery 12 of a substrate 14, and the rubber passes through holes 17-20 as shown at 22-25. The central opening of the substrate is shown at 27.
A side view of the molded seat is shown in FIG. 2 where a lip 30 is shown extending from the upper surface 32. The configuration of the lip will become more apparent as the explanation continues with a description of FIG. 3.
FIG. 3 is a sectional view showing that the substrate in the most preferred embodiment, includes a v-groove 33 surrounding its periphery, while a recess 35 extends around its upper surface. FIG. 3 also illustrates that through holes 17-20 are provided, as shown particularly at the bottom of this FIGURE. For hole 19, reverse drilling has occurred so that the hole has a smallest diameter 36 near its upper surface 32 and a larger diameter portion 38 near the bottom surface.
From this description and from FIG. 3 it is evident that the holes 17-20 intersect the bottom of the v-groove 33 so that rubber may flow from the holes 17-20 into the v-groove 33 or vice versa. Note that while the rubber does not extend beyond the bottom surface 40 of the brass substrate 14, it does flow into portion 38 of the holes 17-20 to resist any delamination forces which may exist.
In addition to the mechanical forces used to hold the molded seat material to the substrate, chemical bonding aids may also be employed. In the most preferred embodiment of the invention, chemical bonding is provided by using a bonding agent, and preferably methanol based agents, such as Chemlock Adhesive No. Y1540, available from Lord Chemical Products.
While the preferred embodiment shows two different techniques for increasing the mechanical bonding of the seat material to the insert, each of the techniques, the through holes 17-20 and the v-groove 33, could be employed separately to enhance performance when compared to the prior art devices described above. Optimum results would be obtained by using both, together with a chemical bonding agent.
While the present invention has been described and illustrated in connection with a single preferred embodiment, it is not to be limited thereby but is to be limited solely by the claims which follow. | A poppet seat for air regulating devices, such as underwater diving equipment, includes a metal or plastic substrate around and through which synthetic or rubber seat material is molded. In its preferred form, this seat material surrounds the sides of the substrate and fills holes therein as well as an annular v-groove formed in the periphery of the substrate to further enhance the mechanical bond between the substrate and seat material. | 1 |
DESCRIPTION OF THE INVENTION
This is continuation of Ser. No. 08/025,969, filed Mar. 3, 1993, now abandoned, which is divisional of Ser. No. 07/839,114, filed Feb. 20, 1992, now abandoned.
STATE OF THE ART
Electrolytes containing anionic fluorocomplexes are commonly used in conventional technologies for the electrolytic recovery of metals, such as lead, tin, chromium. In the specific case of lead recovery from batteries scraps, the scraps ape leached with acid solutions containing tetrafluoroborates BF 4 - and hexafluorosilicates SiF 6 = . The electrolysis of these solutions produces lead as a solid deposit; therefore, the electrolytic cells ape diaphragmless and have a very simple design. However, this advantage has been so far counterbalanced by the scarce resistance of the substrates to the aggressive action of anionic fluorocomplexes on the anodes whereat oxygen is evolved. Further a parasitic reaction may take place with formation of lead dioxide which subtracts lead to the galvanic deposition of the metal, thus reducing the overall efficiency of the system
Upon carefully considering the prior art teachings found for example in U.S. Pat. Nos. 3,985,630, 4,135,997, 4,230,545, 4,272,340, 4,460,442, 4,834,851 and in Italian patent application No. 67723 A/82, it may be concluded that:
anodes made of carbon or graphite, as such or coated by lead dioxide, are known in the art but offer a rather limited active lifetime, in tile range of a hundred hours due to the oxidizing action of oxygen evolution. Obviously, this brings forth higher maintenance costs for substituting the anodes and additional costs connected to the consequent production losses;
anodes made of titanium, coated by lead dioxide or platinum or oxides of the platinum group metals, still undergo corrosion, though to a far less extent with respect to carbon or graphite; in any case, insufficient for counterbalancing the higher construction costs;
anodes made of tantalum coated by platinum metal or metal oxides offer a much longer lifetime than titanium, but the production costs are extremely high;
the parasitic reaction of lead dioxide deposition onto any type of anode may be prevented by adding a suitable inhibitor to the leaching solution, for example phosphoric acid, antimony acid or arsenic acid. However, the quantities required may spoil the compactness of tire lead metal deposit. This problem is overcome by resorting to an anode having a coating made of metals or oxides of the platinum group metals and at least one element comprised in the group of arsenic, antimony, bismuth, tin. In this case, a remarkably lower quantity of inhibitor to prevent the anodic deposition of lead dioxide is required, and the deterioration of the produced lead deposit is eliminated.
It is therefore, evident than the prior art does not provide for an anode offering both a long lifetime (higher than 1000 hours) and a limited cost, which are both necessary features for a wide industrial application.
THE INVENTION
It has been surprisingly found that ceramic anodes made of sinterized powders of tin dioxide doped by suitable additives both to facilitate sinterization and to their electrical conductivity show an exceptional resistance to the aggressive action of acid solutions containing anionic fluorocomplexes, even under the severe conditions of oxygen evolution at high current densities 2000 A/m 2 ).
It has been further found that said ceramic anodes can be obtained by production techniques which are more simple and less expensive than those conventionally used to obtain ceramic products (isostatic pressing at 1200-2000 kg/cm 2 and sinterization at 1350°-1450° C. for 50-200 hours indicatively), irrespective of their functional characteristics, in particular of electrical conductivity.
Furthermore, it has been found that the oxygen evolution voltage of said anodes is considerably decreased, with the consequent advantageous decrease of the energy consumption, if the solutions containing metal ions and fluorides and/or anionic fluorocomplexes are added with suitable compounds. The same result is alternatively obtained by applying onto said anodes suitable coatings resistant to corrosion and provided with electrocatalytic activity or oxygen evolution.
Eventually, it has been found that the parasitic reaction of deposition of oxides of high valence metal ions on said anodes is efficaciously controlled by adding suitable inhibitors to the solutions containing the metal ions, fluorides and/or anionic fluorocomplexes.
The attempt to find an alternative technique to the conventional industrial production technique has been pursued with the aim to obtain, in large quantities and at low costs, products with a more complex geometry than the simple cylinder or tile so far available on the market, as for example tubes or hollow prism structures, as required for the anodes of the present invention. The technology illustrated in the following description permits to attain the aforesaid objects and eliminates the isostatic pressing step. It is characterized in that it comprises:
precalcining the tin dioxide powder
mixing the precalcined powder with powders of suitable additives to promote sinterization and improve electrical conductivity
wet casting in molds, fop example in alabaster moulds
drying in forced air
sinterization at remarkably lower temperatures than the destabilization point of tin dioxide (1600° C.) but at the same time within extremely reduced times (4-10 hours)
The products thus obtained are substantially free from mechanical defects which would be dangerous for the structural integrity and are characterized by a density above 6 g/cm 3 , a porosity below 9% and an electrical resistivity below 0.15 ohm.cm at ambient temperature. When these products are used as anodes in acid solutions containing anionic fluorocomplexes, the resistance to the aggressive action of the electrolyte under oxygen evolution at 1000-2000 A/m2 is absolutely satisfactory. At said conditions, the voltage of oxygen evolution is in the range of 2.7-2.8 Volts (NHE), where (NHE) means that a Normal Hydrogen Electrode is taken as a reference for the voltage values. The above mentioned values involve a high energy consumption (kWh/ton of produced metal) which may be considerably reduced, for example to 2.1-2.2 Volts (NHE), by adding to the electrolytic solutions, containing fluorides and/or anionic fluorocomplexes, suitable elements for catalyzing the oxygen evolution reaction by a homogeneous catalytic mechanism. Suitable additives are those capable of releasing into the solutions the ionic couples Ce III /Ce IV and Pr III /Pr IV . A cyclic reaction probably takes place as follows:
2Ce.sup.III -2e.sup.- →2Ce.sup.IV
2Ce.sup.IV +H.sub.2 O→2Ce.sup.III +1/2 O.sub.2 +2H.sup.30
2 Ce.sup.III -2e.sup.- →2Ce.sup.IV
An alternative procedure to obtain the same result, particularly advantageous when, for process reasons, the solution cannot be added with compounds of cerium and/or praseodimium, consists in applying to the ceramic anode, made of doped tin dioxide, an electrocatalytic coating directed to favoring oxygen evolution. This coating does not comprise metal of the platinum group or compounds thereof but is made of oxides of transition elements such as the lanthanides, for example cerium or praseodimium, added with other elements to increase their resistance to corrosion and the electrical conductivity, for example niobium, nickel, copper and manganese. Alternatively, this coating may be made of manganese dioxide, doped by copper and chromium.
In regards the deposition onto the anode surface of oxides of high valence metal ions, such as Pb 2 , SnO 2 formed by oxidation of the metal ions present in the electrolytic solutions Pb ++ , Sn ++ , it must be pointed out that this side-reaction should be hindered as much as possible. In fact, the formation of oxides decreases the cathodic efficiency of metal deposition and, in the long run, brings to the formation of muds which make the regular operation of the electrolysis cell difficult. Technical literature describes the use of additives, such as phosphoric acid, antimonic acid, arsenic acid, which, once added to the solutions, inhibit formation of metal oxides. In order to obtain the best efficiency when used the anodes of the present invention, these additives must be present in suitable concentrations not to spoil the quality of the metal deposited onto the cathode causing embrittlement and pulverization of the same. It has been found that zirconyl phosphate completely inhibits these negative by-side reactions. In fact its compound bars formation of metal oxides at the anode even when present in minimum concentrations. Further, it has been surprisingly found zirconyl phosphate may be applied as an external layer onto the anodes of the invention already provided with an electrocatalytic coating. This external layer can inhibit formation of high valence metal oxides so that the addition of zirconyl phosphate to the solution may be reduced to extremely low levels, thus increasing the quality of the metal obtained at the cathode.
These and other features of the present invention are illustrated in the following Examples which, however, should not be intended as a limitation of the present invention.
EXAMPLE 1
Eleven rods, having a diameter of 10 mm and a length of 100 mm, have been prepared according to the following procedure:
precalcination of tin dioxide powder (800°-1200° C. for eight hours, average final size of the particles: 1-20 microns)
mechanical mixing, in a ball mill, of the tin dioxide powder and additives necessary to favor sinterization, in alternative to CuO, conventionally used in the prior art;
dispersion of the powders in an aqueous medium with the addition of nitrogen bearing surfactants;
casting in an alabaster mold
natural drying followed by drying at 60°-120° in forced air
sinterization at 1250° C. in a gas-fired oven for 8 hours
The density (grams/cubic centimeter) and the electrical resistivity (ohm/centimeter) have been detected on the above samples and the relevant data are reported on Table 1,
TABLE 1______________________________________Sam- Resistivityple Additive Ratio % Density ohm · cmNo. Type by weight g/cc 20° C. 1000° C.______________________________________ 1 -- -- -- -- -- 2 CuO 1.0 6.49 10.sup.5 1.5 3 Nb.sub.2 O.sub.5 0.5 6.05 10.sup.6 5 4 " 1.0 6.07 10.sup.6 5 5 " 5.0 5.97 10.sup.6 5 6 Ta.sub.2 O.sub.5 0.5 6.15 10.sup.6 3.7 7 " 1.0 6.21 10.sup.6 3.7 8 " 5.0 6.26 10.sup.6 5 9 NiO 0.5 6.12 10.sup.6 410 " 1.0 6.15 10.sup.5 3.711 " 5.0 6.17 10.sup.5 6.212 ZnO 0.5 6.03 >10.sup.6 >513 " 1.0 6.02 >10.sup.6 >514 " 5.0 5.97 >10.sup.6 515 CuO + Nb.sub.2 O.sub.5 1.0 + 0.5 6.49 10.sup.5 3.116 CuO + Ta.sub.2 O.sub.5 1.0 + 0.5 6.48 10.sup.5 317 CuO + NiO 1.0 + 0.5 6.54 10.sup.5 318 CuO + ZnO 1.0 + 0.5 6.41 10.sup.5 3.7______________________________________
The results reported in Table 1 lead to the following conclusions:
all the additives exhibit a sinterizing action;
the additives used in admixtures are characterized by a greater efficiency with respect to the same additives used alone (synergism);
when the additives are used alone, at the same concentration and sinterization conditions (temperature and time), the efficiency increases according to the following order:
ZnO<Nb.sub.2 O.sub.5 <NiO<Ta.sub.2 O.sub.5 <CuO;
when the additives are used in admixtures and at the same sinterization conditions, the efficiency increases according to the following order:
CuO+ZnO<CuO+Nb.sub.2 O.sub.5 <CuO+Ta.sub.2 O.sub.5 <CuO+NiO.
The same results have been obtained with tubes having an internal diameter and an external diameter respectively of 22 and 30 mm and a length of 120 nun produced by continuous extrusion. Apart from the extrusion procedure, the other production steps remained unvaried with respect to the above described wet casting procedure, in particular in regard to temperatures and times.
EXAMPLE 2
Thirty eight tubes having internal and external diameter of 22 and 30 mm respectively, and a length of 120 mm have been prepared according to the extrusion and sinterization procedure illustrated in Example 1, utilizing composition no. 2 of Example 1, containing further additives to decrease the electrical resistivity. The density and electrical resistivity have been detected on the tubes thus obtained and the results are reported in Table 2.
TABLE 2______________________________________Sam- Content Resistivityple Additive % by Density ohm · cmNo. Type weight g/cc 20° C. 1000° C.______________________________________ 1 -- -- -- -- -- 2 Sb.sub.2 O.sub.3 1.0 6.50 0.15 0.005 3 " 2.0 6.49 0.15 0.007 4 " 2.5 6.49 0.2 0.005 5 " 3.0 6.49 0.18 0.009 6 Bi.sub.2 O.sub.3 0.5 6.48 0.3 0.045 7 " 1.0 6.48 0.3 0.025 8 " 1.5 6.49 0.3 0.025 9 " 2.0 6.47 0.35 0.02710 Al.sub.2 O.sub.3 0.3 6.47 0.42 0.0311 " 1.0 6.47 0.5 0.0312 " 1.5 6.46 0.4 0.0313 " 2.0 6.45 0.47 0.0314 Fe.sub.2 O.sub.3 0.5 6.48 0.28 0.0215 " 1.0 6.48 0.3 0.00716 " 1.5 6.48 0.3 0.00717 " 2.0 5.40 0.3 0.00718 " 3.0 6.45 0.5 0.00719 " 5.0 6.45 0.7 0.0220 Cr.sub.2 O.sub.3 0.5 6.5 0.15 0.0221 " 1.0 6.5 0.15 0.00722 " 1.5 6.5 0.15 0.00523 " 2.0 6.5 0.15 0.01524 " 3.0 6.47 0.2 0.00725 " 5.0 6.48 0.38 0.02826 Pr.sub.6 O.sub.11 0.5 6.48 0.15 0.00927 " 1.0 6.5 0.18 0.00728 " 1.5 6.5 0.15 0.00729 " 2.0 6.48 0.19 0.0930 La.sub.2 O.sub.3 0.5 6.48 1 1.531 " 1.0 6.5 1 1.232 " 5.0 6.47 2 1.233 Sb.sub.2 O.sub.3 + Bi.sub.2 O.sub.3 2.5 + 1.0 6.48 0.18 0.00734 Sb.sub.2 O.sub.3 + Al.sub.2 O.sub.3 2.5 + 1.0 6.53 0.23 0.00735 Sb.sub.2 O.sub.3 + Fe.sub.2 O.sub.3 2.5 + 1.0 6.49 0.15 0.00736 Sb.sub.2 O.sub.3 + Cr.sub.2 O.sub.3 2.5 + 1.0 6.49 0.19 0.00737 Sb.sub.2 O.sub.3 + Pr.sub.6 O.sub.11 2.5 + 1.0 6.48 0.16 0.0138 Sb.sub.2 O.sub. 3 + La.sub.2 O.sub.3 2.5 + 1.0 6.48 0.23 0.9______________________________________
The results reported in Table 2 lead to the following remarks:
all the additives promote electrical conductivity at low temperatures;
for each additive a threshold concentration has been defined beyond which the promoting action no more increases or even decreases;
when the additives are used alone, the promoting action increases according to the following order:
La2O.sub.3 <Al.sub.2 O.sub.3 <Cr.sub.2 O.sub.3 <Fe.sub.2 O.sub.3 <Bi.sub.2 O.sub.3 <Pr.sub.6 O.sub.11 <Sb.sub.2 O.sub.3
if used in admixtures (binary system), the promoting action is higher than that of the components used alone;
in particular, the promoting action of the couples of additives increases according to the following order:
Sb.sub.2 O.sub.3 +La2O.sub.3 <Sb.sub.2 O.sub.3 +Al.sub.2 O.sub.3 <Sb.sub.2 O.sub.3 +Cr.sub.2 O.sub.3 <Sb.sub.2 O.sub.3 +Bi.sub.2 O.sub.3 <Sb.sub.2 O.sub.3 +Pr.sub.6 O.sub.11 <Sb.sub.2 O.sub.3 +Fe.sub.2 O.sub.3
Further tests directed to decrease the electrical resistivity by keeping the composition unchanged and by modifying the sinterization temperature indicated that the temperature must be maintained in the range of 1250°-1350° C., preferably 1300°-1350° C.
Further tests on the efficiency of other additives, in addition to those described in this Example, slowed that silver as a metal or oxide and oxides of cerium, neodimium, titanium give positive results. it may be concluded that low electrical resistivities may be obtained by adding oxides (or even metals in some cases) of elements of groups VA, IA, IIIA, IIIB, IVB, VB, VIII of the Periodic Table.
EXAMPLE 3
Emispheric caps, having a diameter of 30 mm have been produced by wet casting The composition was the same as that of the tube no. 4 of Example 2. The caps have then be welded to tubes, having internal and external diameter of 22 and 30 mm respectively, a length of 120 mm and a composition as given in Example 2, sample No. 4 using a ceramic enamel having a low melting point comprising tin dioxide added with lead oxide (0.5-5%), antimony, copper and cerium (for a total of 5 to 10%). The tube-cap assemblies have been sinterized at 1250° C. and a current feeder has then been applied thereto, according to the following procedure:
pretreatment of the internal surface of the tubes by corindone blasting and ultrasound cleaning
introduction inside the tubes of a copper rod having a diameter of 18 mm
interposition in the gap between the tube and the copper rod of a conductive filling made of copper powder suspended in an organic medium, or copper (50% and and silver (50%) powders suspended in an organic medium, or scales of Wood alloy, alloy 78 (bismuth 50%, lead 25%, tin 15% indium 10%) or equivalents;
evaporation of the medium or melting to the low melting alloy and subsequent cooling and solidification.
The electrical resistance of the electrical contact has then been determined, resulting in a very high value (15-1000 ohm) for all of the samples made of copper or silver-copper powders. Conversely, the resistance of the samples based on low-melting alloys was extremely lower and quite satisfactory (0.002-0.005 Ohm). The same results have been obtained substituting the copper rod with copper wires or copper strands.
Likewise, satisfactory results have been obtained with the electrical contacts based on low melting alloys, which remain liquid even at the operating temperatures of electrolysis when the samples have been used as anodes. Suitable alloys comprise lead (24%), tin (14%), indium (10%), gallium (2%), bismuth (50%).
EXAMPLE 4
Some tubes, provided with the emispheric caps and current feeders have been prepared as described in Example 3 and used as anodes at the following conditions:
______________________________________electrolytic solution 140-180 g/l fluoroboric acid and 40-80 g/l of leadtemperature ambientanodic current density 2000 A/m.sup.2cathodic current density 1000 A/m.sup.2(lead cathode)______________________________________
The samples, made of tin dioxide containing 1% copper oxide and 2.5% antimony oxide, as already illustrated in Example 3, had been previously sandblasted on the internal surfaces by corindone. The electrolytic solutions were used as such or added with inhibitors of the anodic formation of lead dioxide. Phosphoric acid, known in the art, and zirconyl phosphate were utilized as inhibitors. The solutions containing 2000 ppm of zirconyl phosphate were further added with compounds capable of acting under homogenous phase as catalysts for tile oxygen evolution reaction. In particular, compounds capable of releasing into tile solutions the ionic couples Ce III /Ce IV and Pr III /Pr IV were selected. The results of the tests expressed as anodic voltages, lead dioxide formation as the parasitic reaction and quality of the plated lead are reported in Table 4. The concentrations of the additives in the solutions are expressed as ppm (parts per million).
TABLE 4______________________________________ Anodic voltageAdditive Volts (NHE) Lead dioxide Plated lead(ppm) Init 300 h Formation Quality______________________________________H.sub.3 PO.sub.4-- 2.7 2.6 high compact1000 2.7 2.8 moderate compact3000 2.7 2.8 minimum compact6000 2.7 2.8 absent brittleZrO(H.sub.2 PO.sub.4).sub.2-- 2.7 2.8 high compact500 2.7 2.8 moderate compact1000 2.7 2.8 minimum compact3000 2.8 2.7 absent compactCeO.sub.2-- 2.7 2.7 absent compact1000 2.7 2.7 absent compact5000 2.2 2.2 absent compact10000 2.2 2.1 absent compactCeF.sub.3-- 2.7 2.8 absent compact1000 2.7 2.8 absent compact5000 2.2 2.1 absent compact10000 2.2 2.1 absent compactCeO.sub.2 2.2 2.2 absent compact1000 +CeF.sub.31000CeO.sub.2 2.2 2.1 absent compact5000 +CeF.sub.35000Pr.sub.6 O.sub.11 2.2 2.1 absent compact5000PrF.sub.3 2.2 2.1 absent compact5000Pr.sub.6 O.sub.11 2.2 2.1 absent compact5000 +PrF.sub.35000______________________________________
No appreciable corrosion of the anodes was observed. The data reported on table 4 clearly show that the anodes made of the tubes and caps are compatible with the electrolysis process in solutions containing fluorides and anionic fluorocomplexes as regards the composition, the mechanical stability and the type of electrical contact. The anodic voltages are stable with time and may be further decreased to interesting values for industrial applications by adding to the solutions suitable compounds to catalyze the oxygen evolution reaction. Furthermore, the parasitic reaction of lead dioxide formation, as well as similar parasitic reactions which could take place with different metal ions, is efficiencly prevented by adding to the solutions zirconyl phosphate. This additive, never disclosed in the prior art, requires low concentrations (e.g. 2000 ppm) not to impair the quality of the metal plated to the cathode.
EXAMPLE 5
Tubes provided with caps as described in Example 3, made of tin dioxide added with copper oxide (1%) and antimony oxide (2.5%) were sandblasted with corindone on the internal surface and coated by a a coating based on oxides of cerium, praseodimium, manganese, as such or in combinations thereof, further doped by oxides of the elements of the group of niobium, copper, nickel and chromium.
The coating was directed to catalyze the oxygen evolution reaction avoiding the need to add elements as described in Example 4. The coatings were obtained by applying paints containing precursors salts such as resinates, subsequently thermally decomposed in air at 1250° C., as known in the art, as taught for example in U.S. Pat. No. 3,778,307.
Alternatively, said coatings are obtained by applying paints based on suspensions of preformed powders of the aforementioned oxides, said powders having an average diameter in the range of some microns and the suspensions being stabilized by nitrogen bearing surfactants. The paints were then applied by brush or spray, followed by thermal treatment in air at 1250° C. for three hours. In both cases, the cycle painting-thermal treatment is repeated until a thickness of the coating of about 100 microns is obtained.
The various samples were tested as anodes in the following solutions and at the following conditions:
______________________________________electrolytic solutionHBF.sub.4 (fluoroboric acid) 140-180 g/llead (complex) 40-80 g/lphosphoric acid (inhibitor of theformation of lead dioxide) 6 g/ltemperature: ambientanodic current density: 2000 A/m.sup.2cathodic current density (lead cathode): 1000 A/m.sup.2______________________________________
The samples were then characterized as follows:
__________________________________________________________________________No. 1CeO.sub.2 paint with precursorsNo. 2CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) paint with precursorsNo. 3CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) paint as suspensionNo. 4CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + NiO(2%) paint with precursorsNo. 5CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + NiO(2%) paint as suspensionNo. 6CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) paint with precursorsNo. 7CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) paint as suspensionNo. 8CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + NiO(2%) + CuO(1%) paint with precursorsNo. 9Pr.sub.6 O.sub.11 paint with precursorsNo. 10Pr.sub.6 O.sub.11 + Nb.sub.2 O.sub.5 (5%) paint with precursorsNo. 11Pr.sub.6 O.sub.11 + Nb.sub.2 O.sub.5 (5%) paint as suspensionNo. 12Pr.sub.6 O.sub.11 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) paint with precursorsNo. 13Pr.sub.6 O.sub.11 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) paint as suspensionNo. 14CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) + paint with precursors+ Pr.sub.6 O.sub.11 (2%)No. 15CeO.sub.2 + Nb.sub.2 O.sub.5 (5%) + CuO(2%) + paint with precursors+ MnO.sub.2 (2%)No. 16MnO.sub.2 paint with precursorsNo. 17MnO.sub.2 + CuO(2%) + Cr.sub.2 O.sub.3 (2%) paint with precursors__________________________________________________________________________
The experimental data are collected in Table No. 5.
TABLE 5______________________________________ Anodic VoltageSample Volts (NHE)No. initial 300 hours Behaviour of the Coating______________________________________ 1 2.8 2.8 badly corroded 2 2.7 2.4 slightly corroded 3 2.7 2.4 slight cracking 4 2.2 2.2 not corroded 5 2.0 2.0 not corroded 6 2.1 2.1 not corroded 7 2.1 2.1 not corroded 8 2.1 2.0 not corroded 9 2.9 2.8 erosion10 2.8 2.7 slight erosion11 2.3 2.1 slight cracking12 2.2 2.1 not corroded13 2.1 2.1 not corroded14 2.2 2.3 not corroded15 2.2 2.2 not corroded16 2.3 2.3 not corroded17 2.3 2.3 not corrodedReference: 2.7 2.8 --plain SnO.sub.2 ++ CuO(1%) ++ Sb.sub.2 O.sub.3 (2.5%)______________________________________
No formation of lead dioxide was experienced. The data reported on Table 5 clearly show that the tubes made of tin dioxide added with copper and antimony oxide may be provided with a coating having a strong resistance to the aggressive attack of the electrocatalytic solutions and concurrently having a remarkable electrocatalytic activity for the oxygen evolution reaction. Similar results have been obtained using these samples in a similar solution as the one used to obtain the data reported in Table 5, the only difference being the addition of fluorosilic acid (120-140 g/l) instead of fluoroboric acid.
EXAMPLE 6
Five anodes prepared as sample no. 6 of Example 5 were further coated with a zirconyl phosphate layer, obtaining a thickness varying from 10 to 250 microns, by plasma spray technique. The samples were used as anodes at the same conditions as illustrated in the previous examples, the only difference being that no inhibitors were added to avoid formation of lead dioxide. The tests showed that with layers of zirconyl phosphate above 50 micron, no lead dioxide formation is experienced. However said thickness must be maintained below 250 micron to avoid increasing the anodic voltage. | A process for the electrolytic recovery of metals from solutions containing metal ions and fluorides and/or anionic flurocomplexes in diaphragmless cells wherein the deposition of the metals at the cathodes and the oxygen evolution at the anodes is effected, the improvement comprising the use of insoluble anodes made of sintered powders of doped tin dioxide optionally provided with coating of zirconyl phosphate and metal oxides which prevents the deposition of metal oxides on the anode surface and catalyze the oxygen evolution reaction. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to the use of beta-aminoalcohols in the treatment of inflammatory disorders and pain
BACKGROUND OF THE INVENTION
[0002] Immune-driven inflammatory events are a significant cause of many chronic inflammatory diseases where prolonged inflammation causes tissue destruction and results in extensive damage and eventual failure of the effected organ. The cause of these diseases is unknown, so they are often called autoimmune, as they appear to originate from an individual's immune system turning on itself. Conditions include those involving multiple organs, such as systemic lupus erythematosus (SLE) and scleroderma. Other types of autoimmune disease can involve specific tissues or organs such as the musculoskeletal tissue (rheumatoid arthritis, ankylosing spondylitis), gastro-intestinal tract (Crohn's disease and ulcerative colitis), the central nervous system (Alzheimer's, multiple sclerosis, motor neurone disease, Parkinson's disease and chronic fatigue syndrome), pancreatic beta cells (insulin-dependent diabetes mellitus), the adrenal gland (Addison's disease), the kidney (Goodpasture's syndrome, IgA nephropathy, interstitial nephritis), exocrine glands (Sjogren's syndrome and autoimmune pancreatitis) and skin (psoriasis and atopic dermatitis).
[0003] In addition, there are chronic inflammatory diseases whose aetiology is more or less known but whose inflammation is also chronic and unremitting. These also exhibit massive tissue/organ destruction and include conditions such as osteoarthritis, periodontal disease, diabetic nephropathy, chronic obstructive pulmonary disease, artherosclerosis, graft versus host disease, chronic pelvic inflammatory disease, endometriosis, chronic hepatitis and tuberculosis. In these diseases, the tissue destruction often damages organ function, resulting in progressive reductions in quality of life and organ failure. These conditions are a major cause of illness in the developing world and are poorly treated by current therapies.
[0004] Inflammation of skin structures (dermatitis) is a common set of conditions which include actinic keratosis, acne rosacea, acne vulgaris, allergic contact dermatitis, angioedema, atopic dermatitis, bullous pemiphigoid, cutaneous drug reactions, erythema multiforme, lupus erythrametosus, photodermatitis, psoriasis, psoriatic arthritis, scleroderma and urticaria. These diseases are treated using a wide array of therapies, many of which have very severe side-effects.
[0005] Current disease-modifying treatments (if any) for immune-driven conditions include neutralising antibodies, cytotoxics, corticosteroids, immunosuppressants, antihistamines and antimuscarinics. These treatments are often associated with inconvenient routes of administration and severe side-effects, leading to compliance issues. Moreover, certain drug classes are only effective for certain types of inflammatory diseases, e.g. antihistamines for rhinitis.
[0006] It is known that Beta-aminoalcohols have properties which may be useful in therapy. Other such compounds are known but without any suggestion of therapeutic utility; see, for example, WO2005/069930.
SUMMARY OF THE INVENTION
[0007] Surprisingly, it has been found that certain compounds are inhibitors of cytokines and possess anti-inflammatory properties as well as reducing pain in pain conditions where cytokines are involved. According to the present invention, an inflammatory condition or pain such as acute, chronic or neuropathic pain (including, but not limited to, pain associated with cancer, surgery, arthritis, dental surgery, painful neuropathies, trauma, musculo-skeletal injury or disease, and visceral diseases) and migraine headache in mammals, can be treated by the use of a compound of general formula (I)
[0000]
[0000] wherein
[0008] R 1 is aryl or heteroaryl optionally substituted with R 5 ;
[0009] R 2 is H, alkyl or CH 2 OH or forms a ring with R 4 ;
[0010] R 3 is H, alkyl or CH 2 OH or forms a ring with R 4 ;
[0011] R 4 is H, alkyl or (when forming part of a ring with R 2 or R 3 ) CH 2 ; and
[0012] R 5 is alkyl, CF 3 , OH, Oalkyl, OCOalkyl, CONH 2 , CN, halogen, NH 2 , NO 2 , NHCHO, NHCONH 2 , NHSO 2 Me, CONH 2 or SOMe;
[0000] or a salt thereof.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] Compounds of formula (I) for use in the invention include (but are not limited to) novel compounds such as:
1-(4-amino-3,5-dichlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(3-chlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)propan-1-one 1-(3-chlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(3-chlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-phenyl-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(2-chlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)propan-1-one 1-(2-chlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(2-chlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,4-dichlorophenyl)-2-(1-hydroxy-2-methylpropan-2-γ-amino)propan-1-one 1-(3,4-dichlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(3,4-dichlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 2-(1-hydroxy-2-methylpropan-2-ylamino)-1-(4-hydroxy-3-hydroxymethyl-phenyl)butan-1-one 1-(4-hydroxy-3-hydroxymethyl-phenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino) ethanone 1-(4-amino-phenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)butan-1-one 1-(3,5-dimethylcarbamoyl-phenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)propan-1-one 2-(1-hydroxy-2-methylpropan-2-ylamino)-1-(phenyl)ethanone 1-(3,4-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(2,3-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(2,3,4-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(5,6,7,8-tetrahydro-2-naphthyl)-2-(1-hydroxy-2-butan-2-ylamino)ethanone 1-(2,5-dimethoxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(4-hydroxy-3-ureylphenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(4-amino-3,-cyanophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(2-chlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,4-dihydroxyphenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(4-hydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,4-diacetylphenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,4-dichlorophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,4-dichlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(2,5-dimethoxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(3,4-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)butan-1-one 1-(4-hydroxy-3-methoxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3-hydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(4-nitrophenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3-hydroxyquinolin-5-yl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(4-hydroxy-3-methanesulphonamidephenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(4-methanesulphonamidephenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(2-chloro-4-hydroxyphenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(2-fluorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(3-fluorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(4-fluorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(4-fluorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(4-bromophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)propan-1-one 1-(4-bromophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)propan-1-one 1-(3,5-ditertbutylcarbonyloxyphenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone 1-(3,5-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone 1-(3,5-dihydroxyphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(3-chloro-4-amino-5-trifluoromethylphenyl)-2-(1-hydroxy-2-propan-2-ylamino)propan-1-one 1-(2-naphthalenyl)-2-(1-hydroxy-2-propan-2-ylamino)ethanone
[0063] It is understood that the invention refers to salts, e.g. the hydrochloride of compounds (I). The compounds may also be provided as metabolites and pro-drugs thereof. The compounds are chiral, and the invention includes substantially single diastereomers and enantiomers of (I). Aryl and heteroaryl groups are know, and typically have up to 12 atoms.
[0064] The compounds of formula (I) according to the invention are used to treat inflammatory diseases including, but not exclusive to, autoimmune diseases involving multiple organs, such as systemic lupus erythematosus (SLE) and scleroderma, specific tissues or organs such as the musculoskeletal tissue (rheumatoid arthritis, ankylosing spondylitis), gastro-intestinal tract, (Crohn's disease and ulcerative colitis), the central nervous system (Alzheimers, Multiple sclerosis, motor neurone disease, Parkinson's disease and chronic fatigue syndrome), pancreatic beta cells (insulin dependent diabetes mellitus), the adrenal gland (Addison's disease), the kidney (Goodpasture's syndrome, IgA nephropathy, interstitial nephritis) exocrine glands (Sjogrens syndrome and autoimmune pancreatitis) and skin (psoriasis and atopic dermatitis), chronic inflammatory diseases such as osteoarthritis, periodontal disease, diabetic nephropathy, chronic obstructive pulmonary disease, artherosclerosis, graft versus host disease, chronic pelvic inflammatory disease, endometriosis, chronic hepatitis and tuberculosis, IgE mediated (Type I) hypersensitivities such as rhinitis, asthma, anaphylaxis, dermatitis and ophthalmic conditions. Dermatitis conditions include; actinic keratosis, acne rosacea, acne vulgaris, allergic contact dermatitis, angioedema, atopic dermatitis, bullous pemiphigoid, cutaneous drug reactions, erythema multiforme, lupus erythrametosus, photodermatitis, psoriasis, psoriatic arthritis, scleroderma and urticaria. Opthalmic conditions include age related macular degeneration, diabetic retinopathy, choroidal neovascular membrane, cystoid macular edema, epi-retinal membrane, macular hole, dry eye and uveitis.
[0065] These compounds may be used according to the invention when the patient is also administered or in combination with another therapeutic agent selected from corticosteroids (examples including cortisol, cortisone, hydrocortisone, dihydrocortisone, fludrocortisone, prednisone, prednisolone, deflazacort, flunisolide, beconase, methylprednisolone, triamcinolone, betamethasone, and dexamethasone), disease modifying anti-rheumatic drugs (DMARDs) (examples including, azulfidine, aurothiomalate, bucillamine, chlorambucil, cyclophosphamide, leflunomide, methotrexate, mizoribine, penicillamine and sulphasalazine), immunosuppressants (examples including azathioprine, cyclosporin, mycophenolate,) COX inhibitors (examples including aceclofenac, acemetacin, alcofenac, alminoprofen, aloxipirin, amfenac, aminophenazone, antraphenine, aspirin, azapropazone, benorilate, benoxaprofen, benzydamine, butibufen, celecoxib, chlorthenoxacine, choline salicylate, chlometacin, dexketoprofen, diclofenac, diflunisal, emorfazone, epirizole, etodolac, feclobuzone, felbinac, fenbufen, fenclofenac, flurbiprofen, glafenine, hydroxylethyl salicylate, ibuprofen, indometacin, indoprofen, ketoprofen, ketorolac, lactyl phenetidin, loxoprofen, mefenamic acid, metamizole, mofebutazone, mofezolac, nabumetone, naproxen, nifenazone, oxametacin, phenacetin, pipebuzone, pranoprofen, propyphenazone, proquazone, rofecoxib, salicylamide, salsalate, sulindac, suprofen, tiaramide, tinoridine, tolfenamic acid, zomepirac) neutralising antibodies (examples including, etanercept and infliximab), antibiotics (examples including, doxycycline and minocycline).
[0066] Compounds of formula (I) exhibit analgesic activity in animal models. The activity of these compounds may be determined by the use of the appropriate in vivo assay.
[0067] This invention also relates to a method of treatment for patients (including man and/or mammalian animals raised in the dairy, meat or fur industries or as pets) suffering from chronic, acute or neuropathic pain; and more specifically, a method of treatment involving the administration of the analgesic of formula (I) as the active constituent.
[0068] Accordingly, the compounds of formula (I) can be used among other things in the treatment of pain conditions such as acute and chronic pain (as well as, but not limited to, pain associated with cancer, surgery, arthritis, dental surgery, trauma, musculo-skeletal injury or disease, visceral diseases) and migraine headache. Additionally the painful conditions can be neuropathic (post-herpetic neuralgia, diabetic neuropathy, drug induced neuropathy, HIV mediated neuropathy, sympathetic reflex dystrophy or causalgia, fibromyalgia, myofacial pain, entrapment neuropathy, phantom limb pain, trigeminal neuralgia. Neuropathic conditions include central pain related to stroke, multiple sclerosis, spinal cord injury, arachnoiditis, neoplasms, syringomyelia, Parkinson's and epilepsia.
[0069] It will often be advantageous to use compounds of formula (I) in combination with another drug used for pain therapy. Such another drug may be an opiate or a non-opiate such as baclofen. Especially for the treatment of neuropathic pain, coadministration with gabapentin is preferred. Other compounds that may be used include acetaminophen, a non-steroidal anti-inflammatory drug, a narcotic analgesic, a local anaesthetic, an NMDA antagonist, a neuroleptic agent, an anti-convulsant, an anti-spasmodic, an anti-depressant or a muscle relaxant.
[0070] Any suitable route of administration can be used. For example, any of oral, topical, parenteral, ocular, rectal, vaginal, inhalation, buccal, sublingual and intranasal delivery routes may be suitable. The dose of the active agent will depend on the nature and degree of the condition, the age and condition of the patient and other factors known to those skilled in the art. A typical dose is 1.0-100 mg given one to three times per day.
[0071] The compounds of the invention may be prepared via a multistep synthetic route of a type familiar to those skilled in the art, and it is assumed that functional groups present in the molecules can be protected and deprotected as needed. The synthesis begins with a substituted acetophenone or analogue which is reacted initially with bromine to give the bromo derivative, and then the amino alcohol to generate the target molecule. The final compounds are generally isolated via precipitation which may require purification via a technique such as recrystallisation.
[0072] The following Examples illustrate the preparation of compounds of the invention.
Example 1
1-(4-Amino-3,5-dichlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone (3)
[0073]
Bromo-(-4-amino-3,5-dichloro)acetophenone (2)
[0074] Bromine (63 ml, 1.22 mol) was added to a mixture of 4-amino-3,5-dichloroacetophenone (1) (250 g, 1.22 mol) in CHCl 3 (3 L ml) at room temperature. The mixture was stirred for 1 h then EtOH (500 ml) was added. The mixture was cooled to 0° C. and stirred for 1 h. The precipitate was filtered and air-dried (4.7 g, 67%).
[0075] 1 H NMR (400 MHz, DMSO): 4.77 (2H, s), 6.61 (2H, bs), 7.86 (2H, s); 13 C NMR (100 MHz, DMSO): 63.39, 117.89, 128.57, 129.75, 146.17, 195.99.
1-(4-Amino-3,5-dichlorophenyl)-2-(1-hydroxy-2-methylpropan-2-ylamino)ethanone (3)
[0076] 2-Amino-2-methyl-propan-1-ol (180 ml, 2.49 mol) was added to a mixture of bromo-(-4-amino-3,5-dichloro)acetophenone (2) (237 g, 0.83 mol) in chloroform (650 ml). The mixture was stirred at room temperature for 2 h, then water (380 ml) was added. The mixture was stirred for 1 h, and then the solid was filtered. The solid was triturated with water (1 L) to give the desired compound (3) (223 g, 91%).
[0077] 1 H NMR (400 MHz, DMSO): 0.94 (6H, s), 3.18 (2H, d J=4.4 Hz), 3.93 (2H, s), 4.55 (1H, m), 6.40 (2H, s), 7.84 (2H, s), 13 C NMR (100 MHz, DMSO): 24.21, 48.87, 53.73, 68.52, 117.92, 124.57, 125.79, 128.62, 146.07, 195.30; LC-MS: 291, 292, 293 (M+H + ).
Example 2
2-(1-hydroxy-2-methylpropan-2-ylamino)-1-(3-chlorophenyl)propan-1-one (4)
[0078]
Bromo-3′-chloropropiophenone
[0079] Bromine (6.07 ml, 0.12 mol) was added to a solution of 3′-chloropropiophenone (20 g, 0.12 mol) in chloroform (250 ml) at room temperature. The reaction was followed by TLC in DCM. When all of the starting material was consumed the mixture was washed with a saturated solution of sodium bicarbonate. The organic phase was dried over magnesium sulphate, filtered and evaporated. Recrystallisation from chloroform gives the desired compound in 60% yield as a pale yellow solid (18 g, 73 mmol).
[0080] 1 H NMR (400 MHz, CDCl 3 ): 7.99 (1H, m), 7.89 (1H, m), 7.55 (1H, m), 7.43 (m), 5.21 (1H, q J=6.5 HZ), 1.9 (3H, J=6.5 Hz)
2-(1-hydroxy-2-methylpropan-2-ylamino)-1-(3-chlorophenyl)propan-1-one (4)
[0081] 2-Amino-1-methyl-propan-1-ol (14 ml, 0.15 mol) was added to α-bromo-3′chloro propiophenone (18 g, 73 mmol) in suspension in chloroform (50 ml), with two crystals of sodium iodide. The reaction was heated under reflux overnight. After filtration the organic phase was extracted twice with a 2M HCl solution (2×100 ml). The aqueous phase wash washed with DCM then neutralised with sodium carbonate. The aqueous layer was extracted with DCM. The organic phase was dried over magnesium sulphate, filtered and evaporated. Recrystallisation from chloroform gives the desired compound in 55% yield as a white solid (10.2 g, 40 mmol).
[0082] 1 H NMR (400 MHz, CDCl 3 ): 7.57 (1H, m), 7.27-7.26 (2H, m), 3.77-3.74 (1H, m), 3.37-3.34 (1H, m), 3.14-3.11 (1H, m), 1.37 (3H, s), 1.04 (3H, s), 0.76 (3H, s). 13 C NMR (100 MHz, CHCl 3 ): 16.23, 22.69, 27.06, 49.85, 53.41, 69.33, 95.91, 124.52, 126.62, 128.04, 129.34, 134.05, 144.11. LC-MS: 256 (M+H + ).
[0083] The following Assays illustrate the utility of the invention.
Beta2 Agonism Functional Assay
[0084] Guinea-pig trachea ring preparations were suspended in Kreb's solution containing indomethacin. After 15 minutes stabilisation, the preparations were repeated contracted using carbachol and simultaneously treated with increasing cumulative doses test compounds (0.1 nM to 0.1 μM). Beta2 agonism for each test compound was determined by its dose dependant inhibition of carbachol stimulated tracheal muscle twitch.
[0085] Compound (3) was a very poor beta2 agonist, with an IC50 of 13 μM.
LPS Mouse Assay
[0086] 7 week-old Balb C ByJ mice (24-28 g) were administered, either by i.p. (5 ml/kg) or oral (10 ml/kg) administration, with vehicle or test article. 30 minutes later these animals were challenged with an intraperitoneal injection of 1 mg/kg LPS. 2 hours after LPS challenge blood samples were collected under light isoflurane anaesthesia into normal tubes by retro-orbital puncture. Samples were allowed to clot at room temperature and then spun at 6000 g for 3 min at 4° C. Serum was stored at −20° C. until use. Serum TNFα and IL-10 levels were analysed in duplicate by ELISA technique.
[0087] Compound (3) had strong inhibitory effects on TNFα and potentiating effects on IL-10. These effects are unlikely to be due to beta2 agonism.
Carrageenan Paw Assay
[0088] Fasted (18 hour) male Wistar rats (105-130 g) were weighed and a basal mercury plethysmometer reading was taken of the right hind paw by submerging the paw in the mercury up to the tibiotarsal joint. Subsequently, vehicles, reference items and test articles were administered by oral gavage (10 ml/kg). Half an hour after treatment 0.1 ml of 2% carrageenan in 0.9% saline was injected into the subplanatar area of the right hind paw. The right paw was measured again with the plethysmometer at 1, 2, 3, 4 and 5 hours after carrageenan administration.
[0089] Compound (3) had a dose-dependant inhibitory effect on inflammation induced by carrageenan paw injection. | A compound for therapeutic use, of the formula (I), wherein R 1 is aryl or heteroaryl optionally substituted with R 5 ; R 2 is H, alkyl or CH 2 OH or forms part of a ring with R 4 ; R 3 is H, alkyl or CH 2 OH or forms part of a ring with R 4 ; R 4 is H, alkyl or (when forming part of a ring with R 2 or R 3 ) CH 2 ; and R 5 is alkyl, CF 3 , OH, Oalkyl, OCOalkyl, CONH 2 , CN, halogen, NH 2 , NO 2 , NHCHO, NHCONH 2 , NHSO 2 Me, CONH 2 , or SOMe; or a salt thereof. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention generally relates to chairs, particularly to elbows of chairs.
[0003] 2. Related Art
[0004] General chairs are usually equipped with fixed elbows whose height and position can not be adjusted for matching various users. Latterly, chairs with rotary elbows appear in the market. The rotary elbows allow horizontal rotation for satisfying various requirements of users. Such an elbow can provide better support to users to avoid aches and pains of hands and ill posture of bodies. However, because conventional rotary elbows adopt a single rotating shaft, the elongated elbows rotating around a single bearing can not maintain a stably planar rotation, and the bearing is easily damaged by unbalanced pressure.
SUMMARY OF THE INVENTION
[0005] An object of the invention is to provide a rotary elbow with double shaft, which can stably support an armrest to rotate and enhance fixation strength of the armrest to avoid damage resulting from unbalanced pressure.
[0006] To accomplish the above object, the invention disposes two bearings on a mount board fixed on a chair. Each of the bearings connects one end of each of two rotating plates, while the other ends thereof are pivotally connected in a linear slot of a seat plate used for securing an armrest. The length of the slot is longer than the distance between the two bearings, and the latter is longer than the length of the rotating plates. Thus, the armrest on the seat plate can rotate against the mount board with 360 degree and move forward and backward.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective exploded view of the invention;
[0008] FIG. 2 is a perspective assembled view of the invention;
[0009] FIG. 3 shows the rotation of the armrest;
[0010] FIG. 4 shows the forward and backward move of the armrest;
[0011] FIG. 5 shows the deflective move of the armrest;
[0012] FIG. 6 is an exploded view of the positionable bearing;
[0013] FIG. 7 is a sectional view of the positionable bearing in a positioned status; and
[0014] FIG. 8 is a sectional view of the positionable bearing in a rotating status.
DETAILED DESCRIPTION OF THE INVENTION
[0015] FIG. 1 is an exploded perspective view of the invention. Two bearings 2 are disposed on an elongated mount board 1 . The two bearings 2 are provided with two pivot seats 231 , 213 axially aligning with each other (please further refer to FIG. 6 ). The mount board 1 is fixed on a chair for supporting an armrest 5 . Each of the bearings 2 is embedded in a mounting hole 11 of the mount board 1 with one pivot seat 213 thereof, while the other pivot seat 231 is embedded in a connecting hole 31 in one end of an elongated rotating plate 3 . A fastening rod 24 penetrates the mounting hole 11 , bearing 2 and connecting hole 31 for pivotally connecting the rotating plate 3 with the mount board 1 . Thus the rotating plates 3 can separately rotate on the mount board 1 by means of the bearings 2 . And the length of the rotating plate 3 is shorter than the distance of the two bearings 2 thereby the rotating plates 3 can freely rotate not to be blocked by the bearings 2 .
[0016] The other end of the rotating plate is provided with a pivot hole 32 . A seat board 4 having a linear slot 41 is used for fixing an armrest. Two pivot shafts 42 separately penetrate the slot 41 and pivot holes 32 to form a pivotal connection. The length of the slot 41 is longer than the distance of the two bearings 2 , thereby the seat board 4 can linearly move forward and backward under orientation of the pivot shafts 42 and slot 41 .
[0017] FIG. 2 shows an assembled status of the invention. As can be seen in this figure, the mount board 1 is mounted on an elbow 6 and an armrest 5 is mounted on the seat board 4 . Thus, the armrest 5 can rotate by means of the bearings 2 and move forward and backward by means of the slot 41 and pivot shafts 42 as shown in FIGS. 3 and 4 . When the two rotating plates 3 are parallel, the armrest 5 also can maintain a direction parallel to the mount board 1 . However, the armrest 5 can be deflected by asymmetrically rotating the two rotating plates 3 , i.e., the rotating plates 3 are not parallel as shown in FIG. 5 . Thus, the armrest 5 can be both radially 360-degree rotated and linearly move forward and backward. And the double shaft structure further provides firm support.
[0018] Preferredly, the bearings 2 are positionable ball bearings with a multiple positioning function. As can be seen in FIG. 6 , the positionable ball bearing 2 is composed of a round seat 21 , a flexible depressor 22 and a cap 23 . The round seat 21 is provided with a plurality of rolling balls 211 . The rolling balls 211 are disposed in an annular arrangement with an identical pitch. The rolling balls 211 are rotarily disposed on the round seat 21 with exposure of about one second of volume. A first shaft base 213 is protrudent from a center of the round seat 21 . The first shaft base 213 , whose outline may be a cuboid or many-sided body, has a first shaft hole 212 therein. The flexible depressor 22 is a round disk. And a through hole 222 is provided at its center. The flexible depressor 22 is provided with circular holes 221 corresponding to the rolling balls 211 . The circular holes are the same as or an integer multiple of the rolling balls 211 in number. As can be seen in FIG. 6 , the quantity of the circular holes 221 is two times of the rolling balls 211 for forming more compact positioning points. That is to say, the pitch of any two adjacent positioning points is one second of that of the rolling balls 211 . The pitch of any two adjacent positioning points is just the same as that of the rolling balls 211 if the circular holes 221 are the same as the rolling balls 211 in number. Besides, the inner diameter of the circular hole 221 is slightly smaller than the outer diameter of the rolling ball 211 so that the rolling balls can be embedded in the circular holes 221 to make positioned.
[0019] The flexible depressor 22 is disposed on the rolling balls 211 to press them. The cap 23 covers the round seat 21 to accommodate the flexible depressor 22 therein. A second shaft base 231 , whose outline may be a cuboid or many-sided body, is disposed at the center of the cap 23 and extends inwards and outwards. The inward part of the second shaft base 231 penetrates into the through hole 222 of the flexible depressor 22 to secure the flexible depressor 22 . The cap 23 and flexible 22 can be integrated because of the non-round shape of the second shaft base 231 . The second shaft base 231 is provided with a second shaft hole 232 therein. The first shaft hole 212 , through hole 222 and second shaft hole 232 directly communicate with each other to be penetrated by a fastening rod 24 . Bending edges 223 extend from margins of the through hole 222 of the flexible depressor 22 to lean against the cap 23 for supporting the deformed flexible depressor 22 .
[0020] FIG. 7 is a cross-sectional view of the ball bearing 2 in the positioned status. The flexible depressor 22 presses the round seat 21 . A positioned status is made once the rolling balls are embedded into the circular holes 221 . When the cap 23 is forced to rotate with the flexible depressor 22 against the round seat 21 , as shown in FIG. 8 , the rolling balls 211 diverge from the circular holes to rotate. And the flexible depressor 22 is deformed by being leaned by the rolling balls 211 (the central portion of the flexible depressor 22 is leaned by the bending edges 223 so it is not deformed). At this time, though the rolling balls 211 are pressed by the flexible depressor 22 , they still can rotate. This makes the flexible depressor 22 also can rotate smoothly. When the rolling balls 211 move to the position of the circular holes 221 again, they will be automatically embedded into the circular holes 221 to make another positioned status by means of pressure from the flexible depressor 22 . Meanwhile the flexible depressor 22 restores its original shape.
[0021] By employing the above positionable ball bearing, the armrest 5 can be automatically positioned at several positions. Thus the armrest 5 can maintain a specific position without arbitrarily rotation. It is much more convenient than before.
[0022] It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims. | A chair elbow capable of rotating with double shaft is disclosed. Two bearings are disposed on a mount board fixed on a chair. Each of the bearings connects one end of each of two rotating plates, while the other ends thereof are pivotally connected in a linear slot of a seat plate used for securing an armrest. The length of the slot is longer than the distance between the two bearings, and the latter is longer than the length of the rotating plates. Thus, the armrest on the seat plate can rotate against the mount board with 360 degrees and move forward and backward. | 5 |
This is U.S. National phase under 35 U.S.C. § 371 of International Application PCT/EP98/02465, filed Apr. 23, 1998, which claims priority of the Netherlands application 1005884, filed April 1997.
FIELD OF THE INVENTION
The present invention relates to a new regulatory system for inducible expression of genes based on lambdoid promoters. The invention further relates to a regulatory replicon and a method for producing heterologous proteins.
BACKGROUND OF THE INVENTION
In order to enable production of human or animal proteins in sufficient quantities, the gene which codes for the protein is usually cloned in the bacteria Escherichia coli . This bacteria has a high synthesis capacity and is well characterized at molecular level. Bacterial regulation signals are also required for expression of the cloned gene in the bacterial host.
It has been found that the strongest regulation signals for E. coli do not originate from the bacteria itself but from the bacteria-challenging bacteriophages. There exist so-called non-temperate and temperate phages.
The first type are the phages with unregulated promoters. Genes under the control of such promoters are continuously expressed. This results in a high protein production, which can be detrimental or even lethal to the host bacteria.
The other type, the so-called temperate phages, can insert their DNA in a non-active form in the host genome and therefore co-replicate passively with this host genome. By induction of particular promoters the host is stimulated to produce phage protein or, in the case of expression vectors based on phage promoters, to produce the heterologous protein. As long as there is no induction, expression from the promoter is shut off by means of repressor molecules binding cooperatively to the promoter. The promoters of temperate phages are among the strongest, but also the best expressed and controllable promoters from E. coli known (Lanzer & Bujard (1988); Knaus & Bujard (1988)).
The combination of intrinsic strength and superior regulation make these promoters preferable to other regulated or non-regulated E. coli promoters for obtaining heterologous expression on industrial scale.
The best known and prototype phage from the group of temperate phages is the E. coli phage λ. There are many λ-related or lambdoid phages such as 21, φ80, φ81, 82, 424, 434, P22, etc. These phages usually have a different immunity, inter alia through the use of different promoter sequences, repressor molecules and operator sequences.
Many expression plasmids for heterologous protein production which are used in E. coli based on the λP L promoter. The λP L promoter is very strong and can be well regulated. The best known and most controllable regulation mechanism makes use of a thermosensitive mutant of the original repressor molecule. Induction of protein synthesis from the promoter can in this case be started by increasing the temperature from 28° C. to 42° C. The repressor molecule is deactivated by this temperature increase. However, this higher temperature can also be unfavorable for production of many proteins because the protein, instead of remaining soluble, then precipitates for the greater part in the form of so-called inclusion bodies, wherein it loses its activity.
Inclusion bodies are in fact an aggregate of incorrectly folded polypeptide chains. It is a phenomenon which is observed on both laboratory scale and industrial scale when an attempt is made to produce large quantities of a specific protein in E. coli . Inclusion bodies can per se be separated quite easily from the other cellular proteins in one step. However, after isolation of the inclusion bodies the protein must first be denatured by means of for instance urea or guanidine hydrochloride and then slowly refolded into the natural spatial structure. This refolding of the protein from inclusion bodies is not always successful and generally results in a considerable loss of material and entails extra costs in the scale-up process due to an increase in the number of steps in the final processing. The frequent occurrence of inclusion bodies has resulted in it not always being possible to fully utilize the potential of an economically advantageous expression host for heterologous protein production.
It has been found that the formation of inclusion bodies can sometimes be prevented by reducing the fermentation temperature. The reason therefor may be either that the lower temperature has a different effect on the folding of the overproduced protein or that there are fewer newly synthesized protein molecules per unit of time and volume.
When protein synthesis at a lower temperature is desired, it is no longer possible to use the currently existing and much used temperature induction in combination with the strong and well regulated promoters derived from phage lambda and related promoters.
BRIEF SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a simple, well controllable regulation system for strong and highly repressible promoters derived from lambdoid phages, with which induction at a lower temperature becomes possible.
This is achieved by the invention with a regulation system for expression vectors, comprising a lambdoid promoter, a gene coding for a repressor for the lambdoid promoter and a gene coding for an antirepressor of the repressor, which antirepressor gene is under the control of an inducible promoter. This promoter can originate from a. gene other than the antirepressor gene itself and is preferably inducible at lower temperatures.
The regulation of the heterologous protein expression can now be controlled by the expression of the antirepressor. The absence or presence of the antirepressor determines the suppression or activation, respectively, of the promoter of the protein to be produced. The presence or absence of the antirepressor is in turn regulated by whether or not the promoter of the antirepressor is induced.
Regulation of the antirepressor gene can occur in different ways. Use can thus be made for instance of a promoter regulatable by lactose, arabinose or the absence of amino acids or of any other regulatable promoter.
The different components of the regulation system according to the invention can be located on the chromosome of the host as well as on one or more individual replicons, such as plasmids. In a particular embodiment the antirepressor gene can lie on a regulatory plasmid together with the gene coding for the repressor of the promoter of the antirepressor gene. Such a regulatory plasmid can then be combined with any random expression vehicle containing the heterologous gene and its promoter and repression system. Optionally the repression system of the promoter of the heterologous gene can also be situated on the regulatory vehicle. All components can also lie on different replicons.
In a preferred embodiment of the invention the antirepressor is the ant of the lambdoid phage P22. Ant is coded in the immI region of phage P22 from Salmonella typhimurium and engages in a non-covalent interaction with the C-terminal part of the P22c2 repressor and thereby prevents the dimerization of the c2 repressor required for repressor activity and thereby binding to the operator.
In a preferred embodiment of the regulation system according to the invention the expression of this anti-repressor is under the control of an inducible promoter such as P N25/O2 . Repression of the P N25/O2 promoter takes place for instance by means of the lacI repressor of E. coli . The induction of this promoter is based on derepression and preferably takes place by means of administering IPTG.
The regulation system according to the invention is a flexible system wherein according to a preferred embodiment the induction of the desired heterologous protein synthesis can take place in two ways. On the one hand the production of the antirepressor can already be initiated at low temperature by adding IPTG, which leads to derepression of the lambdoid promoter. It is also possible to use the same bacterial culture, wherein the conventional temperature-dependent induction can still be applied.
The regulation system can be applied with any expression vector derived from lambda. As regulatable promoter of the heterologous gene the λP L promoter is particularly recommended, but the invention is certainly not limited thereto. The λP R promoter or any lambdoid promoter which can be repressed by a repressor with sufficient homology in the C-terminal region to P22c2 to be recognized by ant can also be used.
The principle of the invention, i.e. regulating a promoter inducible by a repression system by means of an antirepressor to be expressed in regulated manner, can of course also be applied within the scope of the present invention in configurations other than those specifically described herein.
The invention further relates to a regulatory replicon, comprising a gene coding for an antirepressor, which antirepressor gene is under the control of an inducible promoter. The replicon can further comprise a gene coding for a repressor of the inducible promoter of the antirepressor gene. A gene which codes for a repressor for a lambdoid promoter can moreover also be present in the replicon.
In a preferred embodiment a replicon according to the invention comprises the gene coding for the P22ant protein of S. tyohimurium , under the control of the P N25/O2 promoter, the lacI q gene under the control of the pLacI q promoter and the gene coding for the cI857 repressor.
A preferred embodiment of a regulatory replicon according to the invention is shown in FIGS. 1 and 3. Both figures show the plasmid, designated herein pICA2. FIG. 3 shows the general structure and FIG. 1 the restriction map. The construction of this plasmid is described in the examples.
In an alternative embodiment of the replicon according to the invention the replicon can further comprise the regulation signals, including the lambdoid promoter, required for expression of a heterologous gene.
In such an embodiment there are not therefore two separate vectors for expression and regulation, but only one.
The invention moreover relates to an expression system, comprising a regulatory replicon and an expression vector derived from phage lambda. Examples of expression vectors derived from phage lambda are pLT10T or pLR10T.
Finally, the invention relates to a method for producing a gene product in a heterologous host, comprising providing a culture of a host comprising a heterologous sequence which codes for the gene product, wherein the expression of the heterologous sequence is under the control of a regulation system which at least consists of a lambdoid promoter operably linked to the heterologous sequence, a gene coding for a repressor for the lambdoid promoter and a gene coding for an antirepressor, which antirepressor gene is operably linked to an inducible promoter, and of inducing the promoter of the antirepressor gene. If the inducible promoter of the antirepressor gene is the P N25/O2 promoter, it can be induced by adding IPTG to the culture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A: Schematic drawing of the pICA2 plasmid comprising the lactose repressor gene (lacI) controlled by the lacIq promoter, the thermosensitive lambda repressor gene (cI857) controlled by the lambda PM promoter (overlapping the opposite oriented PR promoter), and the P22 antirepressor gene (ant) fused to a promoter that is controlled by the lactose repressor (PN25/O2). The plasmid further comprises the low-copy replication origin derived from pLG339, and a neomycin phosphotransferase gene (npt) for kanamycin resistance. Some restriction enzyme recognition sites are indicated.
FIG. 1 B: Schematic drawing of a typical expression plasmid that can be used in combination with the ant-regulatory system. The pLT10T3 plasmid comprises the lambda PL promoter, a T7 promoter, an antisense T3 promoter, a suitable ribosomal binding site (s10) derived from phage T7 gene 10 (T7g10), a multiple cloning site, a tandem transcription terminator for the T7 RNA polymerase (TT) and a tandem transcription terminator for the E. coli RNA polymerase (tt). The plasmid further comprises an f1 replication origin, a plasmid replication origin derived from the high-copy number plasmid ColE1, and a β-lactamase encoding gene for ampicilin resistance.
FIG. 1 C: Schematic drawing of a derivative of the expression vector pLT10T3, where the heterologous gene is to be fused to a first translated cistron, instead of fusing to the T7g10 ribosomal binding site (s10).
FIG. 2 : Schematic drawing of the pDMI,1 regulatory plasmid, comprising the lactose repressor gene controlled by the PlacIq promoter. The plasmid further comprises a neomycin resistance gene (neo) and a plasmid replication origin of the P15A replication origin classification, allowing an intermediate copy number.
FIG. 3 A. Construction scheme of the pICA2 plasmid. The P22ant gene was cloned in pDS12 digested with the restriction enzymes SmaI and BamHI, giving rise to pDS12ant.
FIG. 3 B: In a next step the vector fragments indicated with a bold line derived from pBR322 (SalI, AatII), pATcI857 (EcoRI, BamHI) and pUC18lacIq (AatII, EcoRI) were combined and ligated to give rise to pICA1.
FIG. 3 C: The fragment indicated with a bold line in pICA1 was isolated with the restriction enzymes PstI and EagI and combined with the vector fragments indicated in bold from pLG339 (EagI, Xhol) and pUC18kan1 (PstI, XhoI) to give rise to pICA2.
FIG. 4 A: Kinetics of β-galactosidase production at different growth temperatures from λP L by induction of ant from pICA2 following addition of 1 mM IPTG. All cultures eventually reach the same plateau-value of maximal enzyme expression. Due to the use of the thermo-sensitive cI857 repressor, temperatures above 28° C. also result in thermo-induction. At temperatures below 37° C., E. coli metabolism and growth rate are dramatically reduced.
FIG. 4 B: A represents the proteins of MC1061[pICA2][pLR10βGal] before (−) and after (+) the addition of IPTG at 28° C. B compares protein extracts from induced (−) and non-induced (+) MC1061[pDMI,1][pDS12ant], also by the addition of IPTG. The positions of the Ant protein and of β-galactosidase are indicated by arrows. Lane M represents the marker proteins with a molecular mass of 94; 67; 43 and 30 kDa.
FIG. 5 A: Coomassie Brillant Blue stained protein gel comparing the total protein content of cells induced by thermo-induction at 42° C. (A) or IPTG induction at 28° C. (B). In the first two lanes the induction of human interferon gamma is compared, the two following lanes compare the induction of murine interleukin 2. The fifth lane contain a non-induced protein extract and the last lane contains marker proteins to calibrate the gel.
FIG. 5 B: Coomassie Brillant Blue stained protein gel comparing the total protein content of cells induced by thermo-induction at 42° C. (A) or IPTG induction at 28° C. (B). In the first two lanes the induction of T7 gene 10 is compared, the two following lanes compare the induction of E. coli thioredoxin. The fifth lane contains a non-induced protein extract and the last lane contains marker proteins to calibrate the gel.
FIG. 6 A: Coomassie Brillant Blue stained protein gel comparing the soluble and non-soluble fractions from E. coli expression strains producing human interferon gamma (hIFNγ) or murine interleukin 2 (mIL2). The presence of both induced proteins is indicated by arrow points. The bottom row indicated the biological activity found in the cell extracts as titrated with a specific assay for the respective protein.
FIG. 6 B: Coomassie Brillant Blue stained protein gel comparing only the soluble phase of protein extracts from expression strains induced to produce human interferon gamma (hIFNγ) at different temperature (18° C., 28° C., 37° C. and 42° C.) for either 6 h or 16 h. The with M contains calibrating marker proteins. The position of hIFNγ is indicated wit arrow heads. The bottom table contains the number of biologically active units that was found in the respective fractions.
FIG. 7 A: Schematic drawing of the pICA1 plasmid comprising the lactose repressor gene (lacI) controlled by the laclq promoter, the thermosensitive lambda repressor gene (cI857) controlled by the lambda PM promoter (overlapping the opposite oriented PR promoter), and the P22 antirepressor gene (ant) fused to a promoter that is controlled by the lactose repressor (PN25/O2). The plasmid further comprises the high-copy replication origin derived from ColE1, and a gene for γ-lactamase (bla) for ampicilin resistance. Some restriction enzyme recognition sites are indicated.
FIG. 7 B: Schematic drawing of the pPLGN1hIL2 plasmid comprising the lambda PL promoter functionally coupled to the gene encoding human interleukin 2 (hIL2). The plasmid further comprises the lambda repressor cI857 gene, a broad host range replication origin derived from PRSF1010, and a gene for neomycin phosphotransferase, for kanamycin resistance. Some restriction enzyme recognition sites are indicated.
FIG. 7 C: Coomassie Brillant Blue stained protein gel comparing protein extracts from MC1061 [pICA1][pPLGN1hIL2] at 28° C. after the addition of 0, 0.1 or 1 mM IPTG, or after shifting the bacteria to 42° C. The position of ant and hIL2 is indicated with an arrow head.
FIG. 8 A: Schematic drawing of the pICA3 plasmid comprising the lactose repressor gene (lacI) controlled by the laclq promoter, the P22 repressor gene c2 controlled by the P22 PM promoter (overlapping the opposite oriented P22PR promoter), and the P22 antirepressor gene (ant) fused to a promoter that is controlled by the lactose repressor (PN25/O2). The plasmid further comprises the low-copy replication origin derived from pLG339, and a neomycin phosphotransferase gene (npt) for kanamycin resistance. Some restriction enzyme recognition sites are indicated.
FIG. 8 B: Schematic drawing of a typical expression plasmid that can be combined wit pICA3. The plasmid contains the same features as pLT10T3 (FIG. 1 B), but now contains the P22 PL promoter instead of the lambda PL promoter.
FIG. 8 C: Schematic drawing of a typical expression plasmid that can be combined wit pICA3. The plasmid contains the same features as pLT10T3 (FIG. 1 B), but now contains the P22 PR promoter instead of the lambda PL promoter.
FIG. 9 : Schematic drawing of the pICA5 plasmid comprising the lactose repressor gene (lacI) controlled by the laclq promoter, the thermosensitive lambda repressor gene (cI857) controlled by the lambda PM promoter (overlapping the opposite oriented PR promoter), and the P22 antirepressor gene (ant) fused to a promoter that is controlled by the arabinose repressor (ParaBAD), and the repressor gene for the arabinose promoter (araC). The plasmid further comprises the low-copy replication origin derived from pLG339, and a neomiycin phosphotransferase gene (npt) for kanamycin resistance.
FIG. 10 A: Coomassie Brillant Blue stained protein gel comparing soluble (S) and non-soluble (pellet) (P) protein extracts from MC1061[pT7POL26][pLT10mIL2T], MC1061[pT7POL26][pLT10hIFNGT], MC1061[pICA2][pLT 10mIL2T] and MC1061[pICA2][pLT10hIFNGT], all induced with 1 mM IPTG at 28° C. The position of murine interleukin 2 (mIL2) and human interferon gamma (hIFNγ) is indicated with an arrow head.
FIG. 10 B: Coomassie Brillant Blue stained protein gel comparing soluble (S) and non-soluble (pellet) (P) protein extracts from MC1061 strains containing the hIFNγ expression module on a pRK2 replicon, controlled by the T7 polymerase promoter (PT7), the PN25/O2 promoter (PN25), the trc promoter (Ptrc) and an ant-controlled lambda PL promoter (PL/ant). Bacteria were grown at 28° C. and induced with 1 mM IPTG. The position of human interferon gamma (hIFNγ) is indicated with an arrow head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Following below is a summary of the definitions used in this application.
Antirepressor: protein which can neutralize a repressor and thus activates the repressed promoter.
Phage: (bacteriophage) a virus whose host is a bacteria.
Phage λ: (bacteriophage lambda) temperate bacteriophage which infects Escherichia coli , belongs to the Styloviridae family.
Phage P22: (bacteriophage P22) temperate phage which infects Salmonella typhimurium , belongs to the Podoviridae family.
Gene Expression: expression of a gene by transcription and translation to a polypeptide or a protein (functional protein).
Temperate Phage: phage which can pass on its genetic information through infection as well as via the cell division of the host after insertion in the genome.
Immunity: (phage immunity) superinfection resistance for phages with the same or homologous regulatory elements.
Inclusion Bodies: discrete structures consisting of non-native folded, coagulated protein.
LMBP: Laboratory of Molecular Biology Plasmid collection, recognized deposit body for plasmids, part of the Belgian Coordinated Collection of Micro-organisms (BCCM).
Plasmid: extra-genomic replication unit.
Promoter: DNA sequence which allows transcription to initiate.
Replicon: a unit of DNA replication.
Repressor: protein which prevents transcription initiation on one or more determined promoters.
Vector: a biological entity which can ensure the multiplication of genetic information.
In the examples below the invention is illustrated on the basis of the prokaryote lacZ gene and the eukaryote genes coding for human interferon-γ (hIFN γ ), murine Interleukin 2 (mIL2) and human Interleukin 2 (hIL2) as model system for protein synthesis. It will be apparent to a person skilled in the art that in an analogous manner other genes can be expressed in a regulated manner with the system described here without any inventive work having to be performed for this purpose.
EXAMPLES
The materials and methods used are first elucidated hereinbelow. Thereafter the invention is illustrated in the examples. In support of most of the methods reference is further made to Sambrook et al. (1989) Molecular cloning: a Laboratory Manual, 2nd ed. Cold Spring Harbor Laboratory Press, Cold Spring Harbor, USA, and Miller, J. (1972) Experiments in Molecular Genetics, Cold Spring Harbor Laboratory, New york.
MATERIALS AND METHODS
1. Bacteria Strains, Phages and Plasmids
All cloning experiments were carried out in E. coli MC1061 (hsdR mcrB araD139 Δ(araABC-leu)7697 ΔlacX74 galU galK rpsL thi) (Casadaban and Cohen, 1980) lysogenized with λ when multiplying λP L -containing plasmids. Expression experiments were carried out in MCI061 transformed with a regulatory plasmid (for instance pcI857 or pICA2).
The repressor came from pcI857 (LMBP537), a vector with a high copy number (P15A replicon), which carries an autogenously regulated cI857 gene coding for a thermosensitive cI mutant (Remaut et al., 1983).
S. typhimurium LT2 (ATCC 19 585) was grown in Nutrient Broth (Difco 0001) supplemented with 0.5% NaCl. Phage P22 (ATCC 19 585-B1) stocks were obtained from confluent lysis plates prepared by using an excess of plaque-forming units with freshly prepared nutrient agar plates. The macerated soft agar was cleared by centrifugation to isolate the phage particles. P22 DNA was prepared by phenol extraction of purified phage particles.
pLR10T is a vector derived from pLt10T (Mertens et al., 1995 B) in which the actual translation initiation site is preceded by a small, well-translated cistron which resulted from a fusion of the N-terminal region of T7g10 and the C-terminal piece of the E. coli trpB gene (FIG. 1 ).
pDMI,1 (LMEP1594) was obtained from Dr. Dietrich Stüber (Hoffman-La Roche, Basel, Switzerland). (See FIG. 2)
2. Plasmid Construction (FIG. 3)
Plasmid DNA purification was carried out as described in Sambrook et al., 1989. All enzymes used for plasmid cloning were obtained from New England Biolabs or Boehringer Mannheim and used according to the recommendations of the supplier.
The P22 ant region was amplified by means of PCR with Vent DNA polymerase (New England Biolabs) using 5′-ATCAGAATTCGCGGTAACAGTCAGGGCTTCGG-3′ (SEQ. ID NO: 1) and forward and 5′-TTAAGGATCCGAAGCTGGGTCGTTGCGTTGG-3′ (SEQ. ID NO: 2) as backward primer. This amplifies a 1054 bp DNA region spanning the coordinates 498-1531 of the POP22IMM Genbank sequence (Sauer et al., 1983). This includes the ant coding region with its own ribosomal binding site and adds a BamHI restriction site to the 3′ end.
The amplified fragment was trimmed with BamHI and ligated in a pDS12 vector opened with SMaI and BamHI (Stüber et al., 1984). An XhoI-BamHI fragment from pDS12ant (with the PN 25/O2 -ant combination) was combined with the cI857 gene on an EcoRI-BamHI fragment derived from pAT153cI857 (Mertens et al., 1995 A), (LMBP1065), a lacI q -containing fragment from pUC181acI q (LMBP3259) trimmed with AatII and EcoRI, and an AatII-SalI pBR322 (LMBP140) vector part. The resulting pICAl is a multi-copy number plasmid which contains a combination of lacI q , cI857 and P N25/O2 ant which is useful according to the invention. From this plasmid an EagI-PstI fragment was combined with a pUC18Kan (Pharmacia, Sweden) trimmed with PstI and XhoI and containing an npt gene (Km R (kanamycin resistance)) and an XhoI-EagI vector fragment from pLG339 (Stoker et al., 1982) in order to obtain the plasmid pICA2 according to the invention. pICA2 (FIG. 1) is a low copy number plasmid compatible with all current expression vectors in respect of replication origin (pSC101) and antibiotic selection.
3. Gene Induction and Protein Analysis
Expression strains containing pCI857, pICA1 or pICA2 were kept at a non-permissive temperature (28° C.). during manipulations preceding induction. λP L -dependent temperature induction was carried out in MC1061 with either pICA2 according to the invention or the known pcI857 by raising the culture temperature from 28° C. to 42° C. MC1061 (pICA1) and MC1061 (pICA2) were induced at temperatures of 28° C. or lower by adding IPTG to a final concentration of 1 mM. The cells were harvested, resuspended in sonication buffer (SB, 10 mM Tris-Cl pH 7.5; 0.1 M NaCl; 5 mM DTT; 10% glycerol) and frozen at −20° C. Aliquots (usually 200 μl) were thawed at 37° C. and cooled on ice. The cells were subsequently opened by sonication on ice using a Sonics & Materials (Danbury Conn., USA) sonicator with a microtip. Lysates were then cleared by centrifugation at 15 000 G for 15 minutes.
Prior to cytokine assay the lysates were diluted in SB and filtered over a cellulose-acetate 0.22 μm pore-size filter.
β-Galactosidase was assayed using ONPG as substrate (Miller, 1972).
mIL2 titers were determined by a proliferation assay using the IL2-dependent cytotoxic T-cell line CTLL-2 (Guisez et al., 1993).
Human interferon-γ activity was determined on human FS4 cells by a cytopathic effect reduction assay using encephalomyocarditis virus as challenge virus (Devos et al., 1982).
Example 1
Construction of a Regulatory Plasmid for IPTG Induction of λP L
The ant gene of phage P22 of S. typhimurium was amplified from purified P22 DNA and cloned in the pDS12 expression vector, as described in Materials and Methods. In this manner the gene was under the control of the P N25/O2 promoter (Strueber et al., 1984) inducible by means of IPTG. Induction of the resulting expression plasmid pDS12 ant resulted in a high production of the repressor P22 ant (FIG. 4 B).
The ant gene was subsequently combined with lacI q and λcI857 in a manner such that the different promoters did not interfere with the expression of each individual gene. The resulting combination (pICA1) was transferred to a low copy number replicon which is ColE1-compatible and derived from pSC101 and also carried a kanamycin resistance selection marker (Stoker et al., 1982). The resulting plasmid pICA2 contains all necessary information for repression of λP L or λP R (by means of cI857) and repression (by means of lacI q ) and induction (from the P N25/O2 -ant promoter) of the antirepressor, and can therefore be used as a suitable expression regulatory plasmid for IPTG-induced λP L or λP R expression when it is combined with an expression plasmid containing a gene under the transcriptional control of the λP L or λP R promoter.
Example 2
Tight Regulation and Expression at Low Temperatures with the P22 Ant-based Expression System
In order to quantify the characteristics of the new expression system an expression vector was used containing as model gene a λP L -driven lacZ gene for protein synthesis. This vector is capable of inducing high levels of functional B-galactosidase by means of translationally-coupled translation initiation (Mertens et al., 1995 A; Mertens et al., 1997).
The non-induced levels of B-galactosidase, which could be influenced by a possible continuous presence of low non-induced levels of antirepressor protein, were comparably low when pICA2 or pcI857 (without antirepressor) plasmid were used. This means therefore that low, non-induced levels of antirepressor protein are probably not present, since if this were indeed the case a higher expression of lacZ would be expected.
Investigation of the induction kinetics of the lacZ gene was carried out in MC1061[pICA2] at 18° C., 24° C., 28° C., 37° C. or 42° C. after adding 1 mM IPTG (FIG. 4 A). Temperatures above 28° C. likewise denature the temperature-sensitive cI857 λ-repressor and are an indication of the level of expression obtainable with this vector by thermo-induction. From FIG. 4A can be concluded that maximum B-galactosidase levels can be obtained by adding IPTG at lower temperatures. As expected, the induction kinetics were slower at temperatures under 28° C., because under these sub-optimal growth conditions a lower growth rate and a lower metabolism are obtained.
FIG. 4B compares the level of the induced proteins in MC1061[pICA2] [pLR10βgal] and MC1061[pDMI,1][pDS12 ant], which shows that the high expression level of P22 ant obtained using the high copy number expression vector pDS12 ant disappears by transferring the P N25/O2 -ant combination to a low copy number plasmid (6-10 copies/cell), while still retaining the ability to induce the lambdoid promoter by induction of ant.
Decreasing the synthesis of the repressor antagonist to <1% of the total protein synthesis is advantageous because the ultimate concern is to obtain a large quantity of a particular protein—the gene of which has been inserted behind the strong lambdoid promoter—and the ultimate yield of this target protein can be adversely affected if the repressor antagonist must be produced in large quantities.
Example 3
Induction at Low Temperature can Improve the Production of Soluble Heterologous Proteins
Induction resulting in a high expression level, particularly at increased temperatures where the E. coli metabolism is high, often results, as already indicated above, in the production of inclusion bodies, while at the same time further cell growth is often inhibited. For reasons which are still not entirely clear, induction at low temperatures is more favourable when production of correctly folded, soluble protein is required. (Lin et al., 1990; Shirano & Shibata, 1990; Schein and Noteborn, 1988; Bishia et al., 1987; Mizukami et al., 1986).
This example therefore investigates whether the different methods of induction (temperature increase or IPTG) result in different quantities of soluble protein.
Used for this purpose were expression vectors derived from pLt10T (Mertens et al., 1995) containing one of the following genes: prokaryotic T7g10 or thioredoxin, two proteins which can be readily expressed in E. coli ); human interferon-γ (hIFNγ) and murine interleukin-2 (mIL2).
FIG. 5 compares production levels obtained either after thermo-induction or after low temperature IPTG induction. It can be clearly inferred from the prokaryotic examples, T7g10 and thioredoxin, that in the same time-span the same quantity of heterologous protein can be induced. The strains induced by means of IPTG continued to grow and eventually synthesized a larger quantity of host proteins (FIG. 5B, lane B). This resulted in a lower yield in comparison with the total protein content (% of the total protein), but gave practically the same absolute yield (mg protein per liter culture). In the figure equivalent quantities of bacterial cultures are compared to each other.
FIG. 6 shows the activities of mIL2 and hIFNγ obtained after induction by temperature increase or by IPTG induction.
In these experiments with the eukaryotic proteins human interferon-γ and murine interleukin-2, two proteins which do aggregate readily in E. coli , less heterologous protein is formed after the IPTG induction at low temperature (FIG. 5 A). However, the high expression at 42° C. results exclusively in the forming of inclusion bodies, while after IPTG induction at 28° C. a significant quantity of soluble protein is produced (FIGS. 6 A and 6 B). The soluble protein fraction visible on gel corresponds with the obtained amount of activity after a biological titration.
Example 4
Use of the Ant-based Induction System from Different Replicons
In a preferred embodiment of the invention the synthesis of the repressor, the antirepressor and the repressor of the promoter controlling the gene of the antirepressor takes place from a low copy number plasmid. This example illustrates the use of the ant system from other replicons.
As the case arises, the regulatory genes (repressor cI857 controlled by the auto-regulatory promoter P M , antirepressor ant controlled by the P N25/O2 promoter and the lacI gene controlled by the constitutive P lacI q -promoter) were induced from a high copy number plasmid and a ColE1/pMB1 replication origin (FIG. 7 A). The gene for expressing (human interleukin 2, hIL2) was linked on a plasmid with a high copy number and a broad host range to the λP L promoter and a prokaryote ribosome binding site (originating from the ner gene of phage Mu). This plasmid also contains an extra copy of the λP L repressor gene cI857. The pPLGNIhIL2 plasmid also contains the required functions also enabling replication in other bacteria (FIG. 7 B).
Induction was investigated after adding 0, 0.1 or 1 mM of the inducer IPTG, which provides induction of ant from the P N25/O2 promoter, which in turn brings about inhibition of the λP L , repressor cI857 and thus activates the λP L which results in overexpression of, in this case, hIL2 (FIG. 7 C). These inductions were carried out at 28° C. and compared with the classic temperature deactivation of cI857 by growing the bacteria further at 42° C.
In this example the relative production of hIL2 using the ant system and by temperature induction are roughly equal. The temperature induction at 42° C. was however found to cause a greater growth-inhibiting effect (the gel shows equivalent samples of culture medium).
Example 5
An Ant-based Expression System for the Lambdoid Promoters P22P L and P22P R
Induction of a repressor antagonist in order to induce a promoter can in principle also be applied to promoters other than the λP L . In this example a vector system is described which makes use of the P22 ant gene to deactivate the homologous P22c2 repressor and thus obtain induction of the P22P L or the P22P R .
Constructed first for this purpose was the pICA3 plasmid which is a derivative of pICA2 but which contains the P22c2 repressor gene instead of the λcI857 repressor gene. The λP L promoter in pLt10T3 was further replaced by both the P22P L (pLT22T3) and the P22P R (pRT22T3). Both pICA3 and pLT22T3 and pRT22T3 are shown in FIG. 8 .
Example 6
An Ant-based Regulatory System for λP L and λP R that is Inducible with L-arabinose
In the pICA2 regulatory plasmid, the induction of ant is controlled by the IPTG-inducible P T5 N25/O2 . Control of ant-gene expression can in principle come from any inducible promoter. It is preferred that the promoter of choice is inducible also at lower temperatures (28° C. or lower). It is also preferred that the promoter of choice be well regulated. If this would not be the case, the level of expression of the uninduced culture can be sufficient to initiate continuous expression. Uncontrolled expression is likely to result in eventual loss of the functional expression strain.
In this example a regulatory plasmid was constructed containing the promoter region of the E. coli arabinose operon (P araBAD ) and the gene encoding the araC repressor of this promoter. The ant-gene is in this way controlled by a promoter which is inducible by the addition of L-arabinose.
The ParaBAD promoter and the araC repressor gene encoding the repressor for this promoter were amplified from a wild type E. coli K12 bacterial strain, using the PCR primers NM73 (ATATATCCAAGGTTATGCAATCGCCATCGTTTCACTCC) (SEQ. ID NO: 3) and NM72 ATATCGGCCGTTATGACAACTTGACGGCTACATC (SEQ. ID NO: 4). PCR amplification was performed with Vent DNA polymerase (New England Biolabs) and the resulting fragment was cloned between the XmaIII and the Styl restriction sites present in pICA2. The resulting pICA5 plasmid was characterized by restriction site mapping, PCR analysis and the PCR amplified insert was sequenced. FIG. 9 shows the pICA5 plasmid.
Example 7
Comparison of the λP L -ant Induction System with Other IPTG Inducible Expression Systems
Although the λP L promoter is amongst the strongest promoters recognized by the E. coli transcriptional machinery, the T7 promoter, which is recognized by the extremely active T7 RNA-polymerase (T7RNAP), allows for a far greater amount of mRNA to be formed (Studier and Moffatt, 1986). A well-controlled, IPTG-based induction system for the T7RNAP that also resides on a pSC101-derived low-copy number plasmid system was previously described (Mertens et al., 1995b). The pLT10mIL2T and the pLT10hIFNγT expression plasmids were used, which contain both the λPL and the P T7 promoters (Mertens et al., 1995a), to compare the expression obtained from either the P T7 and the λP L induction system upon addition of IPTG (FIG. 10 A).
Strikingly, cells containing the T7-based induction system stopped growing almost immediately after induction, while those induced by the λP L -ant system continued to proliferate. This resulted in an almost 10-fold higher biomass after 4 h of induction at 28° C. Remarkably, after induction of the P T7 T7RNAP system all of the mIL2 and almost all of the hIFNγ were in the insoluble phase, while when using the λP L -ant system about 50% of the heterologous protein was found in the soluble phase.
The coding sequence of hIFNγ combined with the strong RBST7g10 resulted in a favorable translation initiation region (Mertens et al., 1995a). When combined with a strong promoter on a high-copy number plasmid, abundant expression was obtained after induction. To emphasize the difference in promoter strength between various IPTG-inducible promoters such as P trc (Amann et al., 1988), P T5 N25/O2 (Stüber et al., 1984) and P T7 (Mertens et al., 1995b; Studier et al., 1990) and the λP L -ant system, the RBS-gene-terminator combination combined with the aforementioned promoters was transferred to an RK2 replicon (Blatny et al., 1997). This resulted in expression plasmids with a much lower copy-number than the normally used ColE1-derived vectors. Subsequently the induction of hIFNγ was then compared using these vectors. Using the stronger P T7 resulted in a higher level of production, but all of the hIFNγ produced was insoluble. Employing the P trc and P T5 N25/O2 promoters did not result in visually detectable levels of induced protein from this low-copy number vector after SDS-PAGE staining with Coomassie Brilliant Blue. However, when the λP L -ant system was used a clearly detectable level of huIFNγ was synthesized, while the protein remained completely soluble (FIG. 10 B).
FIG. 10 shows that induction at 28° C. using the λP L /ant system is more efficient in producing functional protein than other IPTG-inducible expression systems. FIG. 10A demonstrates the SDS-PAGE analysis of soluble (S) and pelleted (P) proteins after induction of pLT10mIL2T or pLT10hIFNγT in either MC1061 [pT7POL26] (inducing the T7 promoter) or MC1061 [pICA2] (inducing the λP L -promoter). Induction was obtained by growing for 5 h at 28° C. in the presence of IPTG. Clearly, more soluble mIL2 was obtained by using the λP L /ant induction system. Unlike the T7-system, the latter system also allowed the cultures to continue growing, and thus resulted in a higher biomass accumulation.
FIG. 10B is a comparison of expression of the RBS T7g10 -hFNγ-T7Tφ module combined with some different IPTG-inducible promoters on an RK2-derived low-copy number plasmid. (S=soluble, P=pelleted fraction). Arrow points indicate the position of the induced proteins. Protein markers (M) are 94; 67; 43; 30; 21 and 14 kDa.
REFERENCES
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Bishia, W. R., Rappuoli, R., and Murphy, J. R. (1987). High-level expression of a proteolytically sensitive diphtheria toxin fragment in Escherichia coli . J. Bacteriol. 169, 5140-5151.
Blatny et al. (1997) Improved broad-host-range RK2 vectors useful for high and low regulated gene expression levels in gram-negative bacteria. Plasmid 38, 35-51.
Casadaban, M. J. and Cohen, S. N. (1980). Analysis of gene control signals by DNA fusion and cloning in Escherichia coli . J. Mol. Biol. 138, 179-207.
Devos, R., Cheroutre, H., Taya, Y., and Fiers, W. (1982). Isolation and characterisation of IFN-gamma MRNA derived from mitogen-induced human spienocytes. J. Interferon Res. 2, 409-420.
Guisez, Y., Demolder, J., Mertens, N., Raeymaekers, A., Plaetinck, G., Robbens, J., Vandekerckhove, J., Remaut, E., and Fiers, W. (1993). Highlevel expression, purification, and renaturation of recombinant murine interleukin-2 from Escherichia coli . Protein Expr. Purif 4, 240-246.
Knaus, R. and Bujard, H. (1988). PL of coliphage lambda: an alternative solution foran efficient promoter. EMBO J. 7, 2919-2923.
Lanzer, M. and Bujard, H. (1988). Promoters largely determine the efficiency of repressor action. Proc. Natl. Acad. Sci. U.S.A. 85, 8973-8977.
Lin, K., Kurland, I., Xu, L. Z., Lange, A. J., Pilkis, J., el Maghrabi, M. R., and Pilkis, S. J. (1990). Expression of mammalian liver glycolyticlgiuconeogenic enzymes in Escherichia coli : recovery of active enzyme is strain and temperature dependent. Protein Expr. Purif 1, 169-176.
Mertens, N., Remaut, E., and Fiers, W. (1995a). A tight transcriptional control ensures stable high-level expression from T7 promoter-based expression plasmids. Bio/Technology 13, 175-179.
Mertens, N., Remaut, E., and Fiers, W. (1995b). Versatile, multi-featured vectors for high-level expression of heterologous genes in E. coli : overproduction of human and murine cytokines. Gene 164, 9-15.
Miller, J. (1972). Experiments in Molecular Genetics (NY: Cold Spring Harbor Laboratory).
Mizukami, T., Komatsu, Y., Hosoi, N., Ito, S., and Oka, T. (1986). Production of active human interferon-γ in E. coli , 1. Preferential production by lower culture temperature. Biotechnol. Letters 8, 605-610.
Remaut, E., Tsao, H., and Fiers, W. (1983b). Improved plasmid vectors with a thermoinducible expression and temperature-regulated runaway replication. Gene 22, 103-113.
Sambrook, J., Fritsch, E. F., and Maniatis, T. (1989). Molecular Cloning: a Laboratory Manual. Cold Spring Harbor Laboratory Press, Cold Spring Harbor.
Sauer, R. T., Krovatin, W., DeAnda, J., Youderian, P., and Susskind, M. M. (1983). Primary structure of the immI immunity region of bacteriophage P22.
Sauer, R. T., Krovatin, W., DeAnda, J., Youderian, P., and Susskind, M. M. (1983). Primary structure of the immI immunity region of bacteriophage P22. J. Mol. Biol. 168, 699-713.
Schein, C. H. and Noteborn, M. H. M. (1988). Formation of soluble recombinant proteins in E. coli is favored by lower growth temperature. Bio/Technology 6, 291-294.
Shirano, Y. and Shibata, D. (1990). Low temperature cultivation of Escherichia coli carrying a rice lipoxygenase L-2 CDNA produces a soluble and active enzyme at a high level. Febs. Lett. 271, 128-130.
Stoker, N. G., Fairweather, N. F., and Spratt, B. G. (1982). Versatile low copy-number vectors for cloning in E. coli . Gene 18, 335-341.
Stueber, D., Ibrahimi, I., Cutler, D., Dobberstein, B., and Bujard, H. (1984). A novel in vitro transcription-translation system: accurate and efficient synthesis of single proteins from cloned DNA sequences. EMBO J. 3, 3143-3148.
Studier and Moffatt (1986) Use of bacteriophage T7RNA polymerase to direct selective high level expression of cloned genes. J. Mol. Biol. 189, 113-130.
Studier et al. (1990) Use of T7RNA polymerase to direct expression of cloned genes. Methods Enzymol. 185, 60-89. | The invention relates to a regulation system for inducible expression of genes, comprising a lambdoid promoter, a gene coding for a repressor for the lambdoid promoter and a gene coding for an antirepressor of the repressor, which antirepressor is under the influence of an inducible promoter. The invention further relates to a regulatory replicon, comprising said gene coding for an antirepressor, an expression system, comprising said regulatory replicon, and an expression vector based on a lambdoid promoter, and also to a method for producing a gene product in a heterologous host, by providing a culture of a host comprising a heterologous sequence which codes for the gene product. Providing a culture of a host comprising a heterologous sequence is obtained by putting the expression of the heterologous sequence under the control of a regulation system, a gene coding for a repressor for the lambdoid promoter and a gene coding for an antirepressor, and by inducing the promoter of the antirepressor gene. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a muffled hydrostatic displacement machine.
A muffled hydrostatic displacement machine of this type is known from DE-OS 39 21 790. The core of this hydrostatic displacement machine consists in sealing--based on the displacement ring--the radially outer area relative to the radially inner area in such a way and having such a varying pressure act upon it that the noise level caused by the position of the displacement ring will be reduced.
The known conception, or design, has uniquely proved itself in conjunction with the basic idea--it is somewhat problematic only insofar as relatively close tolerances must be observed so as to avoid, because of the axially one-sided seal, an insufficient or excessive contact force. Insufficient contact pressure leads to a lacking sealing effect; excessive contact pressure entails problems in the adjustment or setting of the displacement ring, particularly with low adjustment pressures. On the end away from the seal, moreover, leakages may occur as well, due to pump housing deformations depending on operating pressure.
The German utility patent 84 07 367 shows displacement elements (FIG. 1, part 17, or FIG. 1, part 16) which, viewed axially, are attached to the displacement ring (14 or 20) by way of two retaining rings (33, 34 or 26, 27).
The German patent publication 24 30 119 shows a radial seal (grooves in the displacement ring) between displacement ring and retaining ring (FIG. 1).
The problem underlying the invention is to provide a hydrostatic displacement machine where, despite close tolerances, the necessary tightness is achievable between the radially outer and radially inner areas.
SUMMARY OF THE INVENTION
This problem is solved by the features of the present invention. A hydrostatic displacement machine, for instance a radial piston machine or a vane cell machine, is provided in a revolving cylinder block with several displacement elements which are movable in a guideway and whose radial position during the rotation of the cylinder block is determined by a nonrotating displacement ring. Resting in a housing, the displacement ring is movable transverse to the axis of rotation of the cylinder block by means of diametrically arranged adjustment pistons, so that the space (eccentricity "e") between the axis of the displacement ring and the axis of rotation of the cylinder block, and thus the stroke of the displacement elements is variable. Situated at least predominantly radially outside the displacement ring, the (outer) area of the housing interior is relative to the (inner) area of the housing interior, which at least predominantly is situated radially within the displacement ring sealed in such a way that within the radially outer area a pressure will build up which ranges slightly above atmospheric pressure. Only the radially inner area of the housing interior is connected to a low-pressure area [leakage oil line, suction channel] while the radially outer area of the housing interior is connected to a pressure supply (line 33). The displacement elements, viewed axially, are retained on the displacement ring by two retaining rings, with the retaining rings featuring relative to the displacement ring a radial seal (O-ring), and the axial seal of the retaining rings being effected in standstill, relative to the housing or housing lid, by way of spring elements, and during the pumping operation, by a contact force which is indirectly dependent on the operating pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully explained hereafter with the aid of the drawing, in which:
FIG. 1 illustrates a radial piston pump in longitudinal section;
FIG. 2 illustrates the radial piston pump according to FIG. 1 in cross section, along line II--II;
FIG. 3 illustrates a section of the radial piston pump according to FIG. 1, for detail illustration of the axial seal between displacement ring and housing;
FIG. 4 illustrates the section relative to FIG. 3 for illustration of the forces acting on the retaining ring.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 and 2 illustrate the details and mechanical elements of the illustrated radial piston machine (for instance radial piston pump).
A housing 10 into which a fixed control pin 11 is inserted is sealed by a housing lid 12. Mounted in this lid is a drive shaft 13. Refer also to antifriction bearing 14 and drive shaft seal 15. The drive shaft 13 is by means of a clutch 16 hooked to a cylinder block 17 which, in turn, is rotatably mounted on the control pin 11. Contained in the cylinder block 17, in a spider type arrangement, are a plurality of pistons 18, shown in the embodiment of FIG. 2 as seven pistons. Each of these pistons 18, in turn, is hinged to a piston shoe 19. These assemblies comprised of piston 18 and piston shoe 19 form so-called displacement elements by way of whose revolution the pumping action proper is effected.
Arranged in the housing 10 is a displacement ring 20 which relative to the control pin 11 assumes an eccentric position (compare eccentricity "e"). As the cylinder block 17 rotates, the piston shoes 19 slide along the inner shell surface of said displacement ring 20. The magnitude of the eccentricity "e" between the control pin 11 and the displacement ring 20 is variable, by shifting the displacement ring 20 with the aid of adjustment pistons 21 and 22. Adjustment pistons 21,22 are adjusted according to the demanded pump output, by way of pressure action exerted by means of fluid.
A low-pressure channel 23 and a high-pressure channel 24 extend through the housing 10 and through the control pin 11.
The area 25 of the housing interior radially within the displacement ring 20, includes rotating drive shaft 13, antifriction bearing 14, clutch 16, cylinder block 17 and piston 18 with the piston shoe 19, and communicates by way of a leakage channel 29 with a low-pressure area, for instance with a--symbolically illustrated--pressureless oil tank 9. Thus, a pressure adjusting itself between 0 and 1 bar prevails in this radially inner area 25.
According to the prior radial piston pump, the area 26 of the housing interior contained radially outside the displacement ring 20 is sealed relative to the remaining housing interior, i.e., from the radially inner area 25, in that in one of the end faces of the displacement ring 20 there is an annular groove provided in which an axially movable ring seal is fitted. The displacement ring and the ring seal are spread apart in axial direction with the aid of at least one elastic element (for instance an O-ring). The displacement ring 20, therefore, bears with its one end face always, in sealing fashion, on the surface 40 of the housing 10, while on the opposite end face of the displacement ring 20 the ring seal bears in sealing fashion constantly on the surface 41 of the housing lid 12. It is essential here that a "medium" pressure of about 2 to 4 bars builds up in the radially outer area 26 of the interior, which can come about, e.g., in that leakage fluid penetrates out of a pressure space into the outer area 26, along the adjustment piston 21. The outer area 26, as a further design feature, communicates by way of a channel 33 with a selective pressure supply, so that the buildup of the "medium" pressure in the said area 26 can take place as quickly as possible.
Basically, it is suitable to always maintain a certain pressure difference between the radially outer area 26 and the pressure in the radially inner area 25. To maintain this pressure difference, of for instance 2 to 4 bars, the outer area 26 connects via bores with the leakage oil channel 29. In addition, as illustrated in FIG. 1, a check valve 37 is arranged in the connection between the outer area 26 and the leakage oil channel 29, which check valve opens only if the said pressure difference exceeds the desired value. Instead of the check valve 37, any other suitable pressure valve, for instance a pressure relief valve, may be provided.
The housing 10 features on its inside in known fashion two guide surfaces 42 which provide guidance to the displacement ring 20. This guide surface 42 subdivides the radially outer area 26 of the housing interior in two chambers which, however, are interconnected via channels 45. In the illustrated example, the connecting channels 45 are machined into the housing 10; similar connecting channels could be provided, however, also in the displacement ring 20.
Also illustrated in FIG. 1, by dash-dot lines, is a connecting channel 33' extending from the low-pressure channel 23 to one of the connecting channels 45. This arrangement should be regarded as an alternative to the aforementioned channel 33 (refer to FIG. 2) and applies when in the low-pressure channel 23 a "medium" fluid pressure prevails, which now propagates into the area 26 of the housing interior situated outside the displacement ring.
The radial piston pump depicted and described so far pertains to the prior art. The object of the present invention relates to the seal between the inner and outer areas 25, 26, based as such on the displacement ring 20.
The inventional conception, or design, regarding the improved seal over the prior art, is illustrated in FIG. 3, which shows a section of the longitudinal section relative to FIG. 1. In this respect it should be noted that--different from the prior art--a seal is integrated between the inner area 25 and the outer area 26 on both ends of the displacement ring 20. That is, the seal illustrated with the aid of FIG. 3, between the displacement ring 20 and the housing 10, is provided in mirror-inverted fashion equally between the displacement ring 20 and the housing lid 12.
Consequently, a basic consideration is that in addition to the displacement ring 20, which separates the inner area 25 and the outer area 26 from each other, there is on both ends of the displacement ring 20 a flange type, so-called retaining ring 30 each (reference 30') provided, which two retaining rings--relative to the displacement ring 20--can be spread apart axially in relation to each other. Viewed in terms of design, the seal by means of the retaining rings 30 is fashioned as follows: the displacement ring 20 features on both ends a first recess each into which the retaining rings 30 are fitted by way of their flange type projection 30'. Moreover, the displacement ring 20 features a second recess each, so that between the displacement ring 20 and the retaining ring 30 there is a radial space 31 created into which an elastic seal is inserted, for instance in the form of an O-ring.
Due to this specific design., the deformation of the O-ring in the radial space 31 occurs now radially and no longer--as with the prior art--axially, so that in the manufacture there is no longer any excessive expense required in view of the tolerances of the longitudinal dimensions. The installation of two retaining rings 30, and thus two sealing washers, has the advantage that not only the longitudinal tolerances can be balanced, but that also angular deviations between the displacement ring 20 and the housing 10, or housing lid 12, as well as angular variations of the displacement ring 20 due to load-dependent deformations can be compensated for. The retaining rings are needed in any event for the basic function of the pump; they hold the pistons 18 on the running surface of the displacement ring 20.
The above functional description presupposes that the pump is operating. In this case--analogous to the prior art--the inner area 25 and outer area 26 are being sealed relative to each other in accordance with the pressure difference establishing itself between both. In order to assure the axial hold-down of the retaining rings 30, i.e., of the sealing washers, at any operating condition, including also at the start of the pumping operation, spring elements 32 are additionally installed in the displacement ring, opposite the flange type projection 30' of the retaining rings 30.
The inventional configuration will hereafter be illustrated once more with the aid of FIG. 4, by way of a review of the pressure, or force, conditions which are effective in the area of the retaining ring 30. In FIG. 4, the displacement ring 20 with the retaining ring 30 representing the seal are illustrated as a pairing of elements opposite to the housing 10.
The specific pairing of displacement ring 20/retaining ring 30 is so designed, or conceived, that the slightly elevated interior pressure P 1 (in the space above the displacement ring 20) is fully effective on the retaining ring 30 up to the seal (O-ring) in the radial space 31, while on the side of the retaining ring 30 facing the housing 10 the conjugated pressure Pi diminishes down to the level of the interior space. The appropriate contact forces F1, F2 thus produce a resultant defined contact force Fan for forcing the retaining ring 30 on the housing 10 (or housing lid 12).
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A hydrostatic displacement machine has in a revolving cylinder block several displacement elements movable in a guideway and having a radial position during the rotation of the cylinder block determined by a nonrotating displacement ring. The displacement elements, viewed axially, are retained on the displacement ring by two retaining rings. The retaining rings feature relative to the displacement ring a radial seal. The axial seal of the retaining rings is effected in standstill, relative to the housing or housing lid, by way of spring elements, and during the pumping operation, by a contact force which is indirectly dependent on the operating pressure. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to means for recirculation of exhaust gas of an internal combustion engine in an automotive vehicle. More particularly, the invention relates to an exhaust gas recirculation means in which the amount of recirculated exhaust gas is varied or is made zero in accordance with engine operating conditions.
A known technique for reduction of emission of pollutants, particularly nitrogen oxides, in the exhaust gases of an internal combustion engine which are discharged to the atmosphere is to recycle a portion of the exhaust gases to a stage preceding the combustion stage, usually to the carburetor.
In a means according to one conventional approach, the air-fuel mixture is made leaner or richer than the theoretical air-fuel ratio of 15, at which nitrogen oxide emission is maximum, and a comparatively small amount of exhaust gas is recirculated. However, there are definite limits to the amount of reduction of NO x emission that can be achieved by such a means.
To provide increased control of NO x emission in order to meet the requirements of government or other regulations without having an excessively adverse effect on average engine operating conditions, it has therefore been proposed to set the air-fuel ratio at the theoretical ratio and to greatly increase the amount of recirculated exhaust gas.
To achieve recirculation of the desired large amounts of exhaust gas it has been proposed to introduce the recirculated gas into a carburetor via separate ducts which are upstream and downstream of the throttle valve in the carburetor, i.e., upstream and downstream in terms of air flowing through the carburetor, and, in order to maintain the ratio of recirculated exhaust gas to the air-fuel intake more or less constant over the range of moderately low to moderately high load conditions for the engine, to make the upstream supply of recirculated exhaust gas proportional to the air intake and the downstream supply proportional to the pressure downstream of the venturi section of the carburetor. In conventional means, control of the flow rates of recirculated exhaust gas is effected simply by orifices, and the large amount of exhaust gas recirculated by conventional means is very disadvantageous in certain operating conditions. In particular, when a vehicle transmission is set to operation in a high speed range, recirculation of a large amount of exhaust gas inevitably leads to reduced engine output and/or increased fuel consumption rates. Alternatively, depending on ambient temperature conditions and relative humidity of the intake air, recirculated exhaust gas, which has a high moisture content, is liable to cause icing in the carburetor. These points, however, are largely ignored in conventional recirculation means which concentrate on achieving recirculation of requisite amounts of exhaust gas based on average operating conditions of an engine.
SUMMARY OF THE INVENTION
It is accordingly a principal object of the present invention to provide an improved exhaust gas recirculation means which permits recirculation of desired large amounts of exhaust gas during average operating conditions, but causes the supply of recirculated exhaust gas to be reduced or cut off as necessary during special engine operating conditions.
It is another object of the invention to provide an exhaust gas recirculation means which is easily adjustable to change the amount of recirculated exhaust gas for different sets of conditions, to meet requirements of vehicles or other means driven by an internal combustion engine.
It is a further object of the invention to provide an exhaust gas recirculation means which has a simple construction and is easily associated with a conventional carburetor.
In accomplishing these and other objects, there is provided according to the present invention an exhaust gas recirculation means in which exhaust gas is recirculated into the carburetor of an internal combustion engine via two ports, one upstream of and the other downstream of the throttle valve in the carburetor, and in which recirculation lines leading to these ports are closed by the action of valve elements controlled by a control unit which receives an input signal which indicates that the vehicle transmission is set to operation in a high speed range and in response to which the control unit causes only the upstream recirculation in line to be closed.
In a preferred embodiment, the control unit receives an input signal indicative of conditions under which icing is liable to be caused by the recirculation of the exhaust gas into the upstream portion of the carburetor, and/or an input signal which indicates that the engine is being warmed up, and in response to which the control unit causes both recirculation lines to be closed.
In conditions in which icing is liable to occur, only the upstream supply of the recirculated exhaust gas is stopped. In this manner, the means of the invention ensures that the desired large amount of exhaust gas is recirculated during operation of the engine in standard conditions while avoiding adverse effects liable to be caused by the recirculated exhaust gas in more unusual or extreme sets of conditions.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the invention may be had from the following full description of several preferred embodiments thereof when read in reference to the attached drawings, in which like numbers, refer to like parts, and in which
FIG. 1 is a schematic cross-sectional view showing the main features of an exhaust gas recirculation means according to a first embodiment of the invention;
FIG. 2 is a graph showing the relation of exhaust gas recirculation ratio to vehicle speed in the means of FIG. 1;
FIG. 3 is a graph showing the relation of specific fuel consumption to the exhaust gas recirculation ratio in the means of FIG. 1;
FIG. 4 is a view similar to FIG. 1 and showing another embodiment of the invention;
FIG. 5 is a graph showing the relation of icing in a carburetor to intake air temperature and relative humidity of the air in a carburetor, and
FIG. 6 is a view similar to FIG. 1 and showing another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, there is shown a carburetor 1 comprising an air intake circuit 1a which leads to a venturi section 5, a main nozzle 3a providing communication between a fuel float system 3b and the venturi section 5, and a throttle valve 4 downstream of the venturi section 5, i.e., on the opposite side of venturi section 5 from the air intake circuit 1a, and which produces an air-fuel mixture in a conventionally known manner and supplies the mixture to be burned in one or more combustion chambers of an engine, indicated schematically at E. The carburetor 1 may include other conventionally known elements such as a choke valve, an idle port, and a low speed port, not shown. In terms of air flow into the carburetor 1, the air intake circuit 1a is preferably preceded by an air cleaner 2 comprising a filter 2a. Gases produced by combustion of the mixture are exhausted from engine E through an exhaust pipe 8 and a portion thereof is taken off from the exhaust pipe 8 by a take-off line 9 and supplied by line schematically indicated at 9 into the intake ends 6c and 7c of a first recirculation line 6 and a second recirculation line 7, respectively, lines 6 and 7 being separate from each other and connected to separate branch lines of take-off line 9.
The first recirculation line 6 forms part of a first exhaust gas recirculation means and has a delivery end 6a which opens into a portion of carburetor 1 which is upstream of throttle valve 4 and, in this embodiment, is upstream of venturi section 5 also. Flow of exhaust gas through the recirculation line 6 can be throttled or completely stopped by a first flow control valve 10 which is seated on a valve seat 6b defined by wall portions of the recirculation line 6 and the degree of opening of which is controlled by a diaphragm 13 through a rod 12 having one end attached to the first flow control valve 10 and the opposite end connected to one side of the diaphragm 13 extending across a first diaphragm unit 11. The portion of the diaphragm unit 11 which is in part bounded by the side of the diaphragm 13 to which the rod 12 is connected is sealed or connected to a constant pressure source and constitutes a constant pressure chamber 11c. The portion of the diaphragm unit 11 which is on the opposite side of the diaphragm 13 constitutes a negative pressure chamber 11a which is connected through a first control fluid duct 14 to a suitable negative pressure source, for example, a portion of the intake air flow to carburetor 1 which is at reduced pressure. In the control fluid duct 14 there is provided a first stop valve 15 which is controlled in a manner described below by a control unit 23. In the negative pressure chamber 11a there is provided a coil spring 11b which acts on the flow control valve 10 via the diaphragm 13 and the rod 12 and constantly exerts a force on the control valve 10 urging it toward the valve seat 6b. Assuming that the top valve 15 is open, the diaphragm 13 moves against the force of spring 11b, due to the force exerted as a result of the difference of pressures in chambers 11a and 11c, and the control valve 10 is opened to a degree dependent on the amount of movement of the diaphragm 13, and exhaust gas is allowed to flow through the recirculation line 6 into the carburetor 1. By connecting the control fluid duct 14 to a source the pressure of which is proportional to the air flow in the carburetor 1, the movement of the diaphragm 13, and, hence the opening of the flow control valve 10 and the rate of flow of the exhaust gas into the carburetor 1, are varied in accordance with conditions in the carburetor 1, i.e., in accordance with engine operating conditions. When the stop valve 15 is closed, the difference between the pressure in the chamber 11a and the pressure in the chamber 11c of the diaphragm unit 11 becomes insufficient to counter the force of the spring 11b, which therefore seats the flow control valve 10 on the valve seat 6b, thereby interrupting the supply of the exhaust gas to the delivery end 6a of the recirculation line 6.
Still in FIG. 1, the exhaust gas supplied into the second recirculation line 7 is supplied via the delivery end 7a of the line 7 into a portion of the carburetor 1 which is downstream of the throttle valve 4. The recirculation line 7 forms part of a second recirculation system that has basically the same construction and manner of functioning as the above-described first exhaust gas recirculation system and comprises a second flow control valve 16 which is seatable on a valve seat 7b defined by wall portions of the line 7 and which controls the flow of the exhaust gas in the line 7, a second diaphragm unit 20 divided into a negative pressure chamber 20a and a constant pressure chamber 20c by a diaphragm 19 which acts through a rod 18 to control the position of the flow control valve 16, a coil spring 20b provided in the negative pressure chamber 20a and exerting a constant force tending to cause the diaphragm 19 to seat the flow control valve 16 on the valve seat 7b, whereby the flow of the exhaust gas in the line 7 is stopped, a second control fluid duct 21 which connects the negative pressure chamber 20a of the diaphragm unit 20 to a suitable negative pressure source, and a second stop valve 22 which is controlled by the control unit 23 and is actuable to open and close the control fluid duct 21 selectively.
Needless to say, instead of being connected to a negative pressure source, the control fluid duct 14 and/or the control fluid duct 21 may be connected to a positive pressure source, in which case the spring llb and/or the spring 20b is provided on the other side of the diaphragm of the corresponding diaphragm unit.
The control unit 23 is suitably an electrical or electronic unit, which is not necessarily positioned adjacent to the carburetor 1 in the manner shown in FIG. 1, and which receives input signals s and M. The input signal s indicates that the engine E is warming up, and may be supplied, for example, from a switch actuated by a device which detects the temperature of cooling water in the engine E. The input M is supplied by a transmission switch 24a connected to and actuated by the means for shifting the transmission when the shift means is shifted to the high speed range, of a transmission speed change gear 24.
In response to these input signals the control unit 23 supplies as an output a signal p causing the stop valve 15 and the stop valve 22 to close when the warm-up signal s is received, and a signal q to close only the stop valve 15 when only the signal M is received, the stop valve 22 otherwise being left open. This action is achieved by providing in the control unit 23 an output terminal which is connected directly to an input terminal for signal s and supplies an output to the stop valve 22, and an OR circuit the output terminal of which is connected to the stop valve 15 and which receives both signals s and M as an input, for example. The stop valves 15 and 22 may be any type of valve that is actuable by electrical signals, for example, solenoid-controlled valves.
By this action, therefore, recirculation of the exhaust gas is completely stopped during warm-up of engine E and, when suitable running conditions have been achieved, the exhaust gas is recirculated via both lines 6 and 7, but recirculation of excessive amounts of exhaust gas when the vehicle transmission is set to operate in the high speed range is avoided by closure of the recirculation line 6 when these conditions are attained.
Results obtained by the means of the invention are illustrated in the graph of FIG. 2 to which reference is now had, and in which the abscissa shows values of vehicle speed, determined directly or on the basis of engine speed, and the ordinate shows values of the exhaust gas recirculation ratio, defined as the amount of recirculated exhaust gas divided by the intake fuel-air mixture and multiplied by 100. The curve a shows the overall recirculation ratio, the curve b the recirculation ratio of the exhaust gas supplied to the upstream portion of the carburetor 1 by the recirculation line 6, and the curve c the recirculation ratio of the exhaust gas supplied to the downstream portion of the carburetor 1 by the recirculation line 7.
Because of the respective locations of the delivery ends 6a and 7a of the first and second recirculation line 6 and 7, the upstream supply of recirculated exhaust gas tends to increase proportionally to the increased air intake which accompanies increased vehicle or engine speed, whereas the flow of the recirculated exhaust gas via the recirculation line 7 is greatly influenced by the negative pressure downstream of the throttle valve 4 and, therefore, tends to decrease as the vehicle speed increases. The net result is that, in the range of speed of about 30-70 km/h the recirculation ratio of the total amount of exhaust gas supplied into the carburetor 1 via the recirculation lines 6 and 7 remains generally constant at a value somewhat higher than 15%. When the vehicle speed reaches about 70 km/h, the signal M is supplied to operation in the control unit 23 since the vehicle transmission is set to the high speed range in this condition and, consequently, the recirculation ratio drops rapidly to a value of about 4 to 6%. This lowering of recirculation ratio is effected to prevent engine output from falling and to reduce the fuel consumption rates.
Reference is now had to FIG. 3, which shows the relation achieved by the means of the invention between the exhaust gas recirculation ratio and the specific fuel consumption when the air-fuel ratio of the mixture produced in the carburetor 1 is 14, 15, and 16 and the engine speed and the mean effective output pressure Pe are maintained constant at 1,500 rpm and 3 kg/cm 2 , respectively. It is seen that, for all three air-fuel ratios, the fuel consumption is minimum when the recirculation ratio is in the vicinity of 5%.
It is thought that the reason for minimum fuel consumption for the recirculation ratio of about 5% is as follows. In an engine in which an Otto cycle is repeatedly effected, the thermal efficiency is influenced by the ratio of specific heat of the components of a mixed gas, in this case, the air-fuel mixture and recirculated exhaust gas, and the pressure inside of cylinder defining a combustion chamber at the start of the compression stroke. However, since a change in the ratio of the specific heat of the gas mixture components between times when the exhaust gas is recirculated and the exhaust gas is not recirculated is very small, for example, on the order of 1.38:1.40, which may be ignored for practical purposes, the thermal efficiency is directly governed by the pressure in the cylinder, that is, by the amount of recirculated gas and, theoretically, from this point of view, the thermal efficiency should improve as the amount of recirculated exhaust gas is increased. However, since the recirculated exhaust gas is comparatively inert, it tends to lower the speed of combustion, which off-sets the advantages of the increased pressure in the cylinder due to the gas. The net result of these mutually cancelling factors is that maximum thermal efficiency is achieved when the exhaust gas recirculation ratio is in the range of 5 to 10%.
Comparing FIG. 2 and FIG. 3, it is seen that the system of the invention offers the considerable advantage that a minimum specific fuel consumption is achieved when high vehicle speeds are reached, that is, the vehicle transmission is set to operate in the high speed range.
Referring now to FIG. 4, there is shown another embodiment of the invention in which a control unit 23 further receives, in addition to the signals received in the embodiment in FIG. 1, a signal T indicating that the temperature of the air in the air intake portion of the carburetor 1 is below a certain temperature, and other parts are the same as in FIG. 1. The signal T may be supplied, for example, by a bimetallic element or other suitable means constituting a temperature detector 26 which is mounted on the filter 2a adjacent to the inlet of the carburetor 1, and has associated therewith a suitable circuit (not shown) for transmission of signals to the control unit 23.
Referring to the graph of FIG. 5, the abscissa represents values of relative humidity of intake air and the ordinate represents values of the temperature thereof. In the absence of the recirculated exhaust gas admixed therewith, the intake air is practically never in a super-saturated state in which the relative humidity is greater than 100%. The region in which icing is liable to occur is that bounded by the generally-parabolic curve (a) in the drawing, in which the relative humidity is in the range 50-100% and temperature centers on a value of 3°-5° C. and extends up to an upper limit of 20° C. and to a lower limit of close to -15° C. These temperatures noted for the intake air are, of course, influenced to a considerable extent by the temperature of the engine as a whole, and are somewhat higher than the external ambient air temperature. The reason for the upper limit of 20° C. is that, even supposing a certain amount of lowering of temperature of air subsequent to intake thereof due to the latent heat of vaporization, temperatures reached are not such as to permit icing. On the other hand, if the temperature of the intake air is in the vicinity of or lower than about -15° C., although air temperature is favourable into icing, the absolute moisture content of the air is so low that the quantity of ice which may form is insufficient to have any practical effect on the functions of the carburetor. The system of the invention makes no contribution to avoidance of icing in the region bounded by the curve (a) of FIG. 5.
With the addition of the upstream recirculated exhaust gas, however, the relative humidity of the air-fuel mixture in the intake portion of the carburetor readily becomes higher than 100% and icing may occur over the whole range of intake air temperature from below -20° C. to +20° C. In this respect, the system of the invention offers a definite advantage since the supply of the recirculated exhaust gas via the recirculation line 6 is interrupted when the temperature of the intake air is in the range in which admixture of the exhaust gas therewith is liable to cause icing. For the above noted reason, 20° C. is the upper limit of this range, and the temperature detector is therefore preferably made such that a signal T is supplied continuously to the control unit 23 while the intake air temperature is lower than 20° C., but is not supplied when air intake temperature is 20° C. or higher.
Referring now to FIG. 6, there is shown another embodiment of the invention in which the delivery end 6a of the recirculation line 6 opens into a portion of the carburetor 1 which is intermediate the venturi section 5 and throttle valve 4 and is also in communication with the delivery end of a supplementary air duct 25, the intake end of which opens into a portion of the carburetor 1 upstream of the venturi section 5. In this embodiment of the invention, the flow rate of air which is delivered via the duct 25 into the carburetor 1 is inversely proportional to the flow rate of the exhaust gas delivered into the carburetor 1 via the recirculation line 6, since the recirculated exhaust gas is at a generally higher pressure than that of the air in the supplementary air duct 25, delivery of air from the duct 25 into the carburetor 1 being completely or almost completely stopped at high flow rates of the exhaust gas in the recirculation line 6, whereby there is automatic enrichment of the air-fuel mixture produced in the carburetor 1 as the exhaust gas recirculation ratio is increased. To ensure a correct supply of the exhaust gas into the carburetor 1, there is suitably provided in the supplementary air duct 25 an orifice element 25a which has a smaller cross-sectional area than that of the delivery end 6a of the recirculation line 6, whereby the duct 25 presents a greater resistance to flow.
In all of the above described embodiments of the invention, the stop valves 15 and 22 may, of course, be directly positioned in the recirculation lines 6 and 7, respectively. The diaphragm units 11 and 20 are preferably included, however, since, as noted earlier, by the connection of the ducts 14 and 21 to a source in which the value of pressure is related to the intake air pressure in the carburetor 1, the rate of exhaust gas recirculation can be varied in relation to operating conditions of the engine E.
Although the present invention has fully been described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Such changes and modifications are to be construed as being included within the true scope of the present invention unless they depart therefrom. | An exhaust gas recirculation system has at least two recirculation lines to permit recirculation of a large quantity of exhaust gas when required and in which recirculation of exhaust gas is reduced or completely cut off in accordance with particular engine operating conditions. | 5 |
BACKGROUND OF THE INVENTION
The present applicant has previously proposed various ways to focus solar rays or artificial light rays by the use of lenses or the like and to guide the same into an optical conductor cable, and thereby to transmit them onto an optional desired place. The solar rays or the artificial light rays transmitted and emitted in such a way are employed for photo-synthesis and for use in illumination or for other like purposes, as for example, to promote the cultivation of plants.
However, in the case of utilizng the light energy for cultivating plants as mentioned above, the light rays transmitted through the optical conductor cable have directional characteristics. Supposing that the end portion of the optical conductor cable is cut off and the light rays are emitted therefrom, the radiation angle for the focused light rays is, in general, equal to approximately 46°. That is quite a narrow field. In the case of utilizing the light energy as described above, it is impossible to perform a desirable amount of illumination by simply cutting off the end portion of the optical conductor cable and by letting the light rays emit therefrom.
Therefore, the present applicant has already proposed various kinds of radiators capable of effectively diffusing the light rays which have been transmitted through an optical conductor cable and for radiating the same for the purpose of illuminating a desired area. The present invention extends the idea and, in particular aims at applying intensified light rays to a desired place and to keep the light source at a distance to plants and to move the light source back and forth in order to supply light rays over a wider area.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a light radiator capable of effectively emitting solar rays or artificial light rays which were transmitted through an optical conductor cable outside the same for nurturing plants.
It is another object of the present invention to provide a light radiator capable of effectively moving the optical means installed in a transparent cylinder.
It is another object of the present invention to provide a light radiator of which the light energy of good quality and suitable for nurturing the plants can be effectively supplied to the plants.
The above-mentioned features and other advantages of the present invention will be apparent from the following detailed description which goes with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a construction view for explaining an embodiment of a light radiator proposed in another way by the present applicant;
FIG. 2 is a construction view showing an embodiment of the optical means;
FIG. 3 is a construction view for explaining an embodiment of a light source device according to the present invention;
FIG. 4 is a construction view for explaining another embodiment of the present invention;
FIG. 5 is a view showing an embodiment of the optical, oil-supplying method for arranging a large number of cylinders parallel to each other; and
FIG. 6 is a construction view for explaining another embodiment of a light filter;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective construction view for explaining an embodiment of a light radiator proposed in another way by the present applicant. In FIG. 1, 10 1 and 10 2 are transparent cylinders, 20 1 and 20 2 optical conductors, 30 1 and 30 2 optical means, and 40 1 and 40 2 liquid pumps. The cylinders 10 1 and 10 2 are filled with optical oil. The liquid pumps 40 1 and 40 2 consist of, respectively, cylinders 40a 1 , 40a 2 and pistons 40b 1 , 40b 2 . The pistons 40b 1 , 40b 2 are connected with each other through a connecting member 50 which can be reciprocally moved in the direction of A and the direction of B by means of a driving means which acts like a motor.
Consequently, when the connecting member 50 is moved in the direction shown by arrow A, optical oil in the liquid pump 40 1 is pushed out in the direction of A by the piston 40b 1 and thereby supplied to the cylinder 10 1 . As a result, the optical means 30 1 in the cylinder 10 1 moves in the direction of A and, at the same time, the piston 40b 2 in the liquid pump 40 2 moves also in the direction of A. In such a manner, the optical oil in the cylinder 10 2 is sucked up by the liquid pump 40 2 so that the optical means 30 2 in the cylinder 10 2 moves in the direction of A. When the connecting member 50 is moved in a direction shown by arrow B, the liquid pumps 40 1 and 40 2 operate in a way that is completely opposite to that mentioned above so that the optical means 30 1 and 30 2 move in the direction of B.
Moreover, 70 1 and 70 2 are transparent pipes for protecting, respectively, cylinders 10 1 and 10 2 . Actually, the cylinders 10 1 and 10 2 are fine and made of a hard and fragile substance like quartz or the like, while the protective pipes 70 1 and 70 2 , etc. are constructed of a comparatively strong substance like acrylic, etc. In such a construction, it may be possible to prevent the cylinder 10 1 or 10 2 from being injured or destroyed when an object directly hits the cylinder 10 1 or 10 2 .
FIG. 2 is a cross-sectional view showing an embodiment of the optical means preferably employed in the light radiator as mentioned above. In FIG. 2, 30 is an optical means consisting of a cylindrical optical conductor 31 having one end surface 31a formed on a plane surface and another end surface 31b formed on an inclined plane surface and a cover member 32 for forming an air chamber at the side of the inclined plane surface 31b by closing the side thereof. In relation to the optical means 30, the longer side 31c of the cylinder 31 is always lowered by the action of gravity in the case of employing the cylinders 10 1 and 10 2 both of which are set horizontally.
The present invention intend to provide a light source device capable of effectively supplying light rays to plants etc. by utilizing the light radiator as mentioned above. However, the present invention is not limited to the afore-mentioned light radiator. Other various kinds of light radiators, which have been previously proposed by the present applicant, can also be employed according to the present invention.
FIG. 3 is a perspective construction view for explaining an embodiment of a light source device according to the present invention. In FIG. 3, 10x 1 , 10x 2 , . . . , 10xn are cylinders arranged in a lateral direction and parallel to each other, 10y 1 , 10y 2 , . . . , 10ym cylinders are arranged in a longitudinal direction perpendicular thereto and parallel to each other, 20x 1 , 20x 2 , . . . , 20xn, 20y 1 , 20y 2 , . . . , 20ym optical conductors for supplying the light rays into those optical conductors (cylinders), add 30x 1 , 30x 2 , . . . , 30xn, 30y 1 , 30y 2 , . . . , 30ym optical means which are movably arranged inside the respective cylinders.
Those optical means are moved inside the cylinders in such a manner as mentioned before and discharge the light rays downward which have been guided from the optical conductor into the cylinder. The plants to be cultivated are planted under the light radiator and arranged crosswise in parallel fashion as mentioned above. When the plants are small, the light radiator is lowered so as to set the light source near the plants. In such a manner, the plants can be nurtured much more effectively.
In FIG. 3, 80 is a cable for hanging down the aforementioned light radiator. The cable 80 is moved up and down by winding the same forward and backward by use of a drum (not shown in FIG. 3). When the plants are small the light radiator is lowered so as to put the light source at a position near the plants. When the plants grow up the light radiator is wound up for controlling the position of the light source in order to always supply light rays to the plants at a position near them.
Furthermore, the movement area of the optical means can be regulated by controlling the movement area of the movement member 50 shown in FIG. 1. When the plants are small, in other words, the square measure occupied by the plants is small, the movement area of the optical means is decreased. On the contrary, when the plants grow up the movement area thereof is increased. In such a manner, the light energy can be more and more effectively supplied to the plants. Also, the ultraviolet rays, the infrared rays or the like tend to disturb the development of plants. Those ultraviolet rays and infrared rays are not contained in the light rays transmitted through the optical conductor. However, in the case of cultivating the plants indoors by use of the light radiator as mentioned above, it follows that the ultraviolet rays or the infrared rays are supplied to the plants from a light source such as a fluorescent lamp for illuminating the inside of a room or otherwise through a light-receiving window. For this reason, it is necessary to cut out ultraviolet rays and infrared rays.
FIG. 4 is a cross-sectional side view showing an embodiment for cutting out the afore-mentioned harmful ultraviolet and infrared rays. In FIG. 4, 90 is a filter for cutting out ultraviolet and infrared rays. If such a filter 90 is put above the light radiator, as mentioned above, the ultraviolet or infrared rays supplied by means of a fluorescent lamp and a light receiving window are cut off by the filter 90 so that the plants can be more effectively nurtured.
FIG. 5 is a view showing an embodiment for arranging a large number of cylinders as mentioned above in parallel with each other. In the embodiment shown in FIG. 5, one end portion of the cylinders; 10 1 , 10 3 , . . . , 10n 1 is connected with a common optical, oil-supplying pipe 100, while the other end portion of the cylinders; 10 2 , 10 4 , . . . , 10n is connected with another common optical, oil-supplying pipe 110. The optical means 30 1 through 30n in all of those cylinders 10 1 through 10n are moved at the same time through the common optical oil supplying pipes 100 and 110.
On that occasion, the amount of optical oil flowing through the optical, oil-supplying pipes 100 and 110, is equal to that of the optical oil flowing through the cylinders 10 1 ˜10n. For this reason, when the number of cylinders 10 1 ˜10n becomes large, the amount of optical oil flowing through the optical, oil-supplying pipes 100 and 110 has to be increased.
In FIG. 5, pumps P 1 ˜P 4 are provided in order to satisfy the requirements as mentioned above. When the optical oil needs to be moved in a direction shown by the arrows, the pumps P 1 and P 3 are driven in an operative state while the other pumps P 2 and P 4 stop the operation thereof. On the contrary, when the optical oil needs to be moved in another direction i.e. opposite to that shown by the arrows, the pumps P 2 and P 4 are operatinonal while the other pumps P 1 and P 3 stop working. In such a manner, since each pump is allowed to move in only one direction, it becomes easy to control those pumps so that optical oil can be effectively supplied.
Furthermore, in the case of supplying the optical oil to a large number of cylinders through the common optical, oil-supplying pipes, as mentioned above, the optical oil is not always uniformly supplied to the respective cylinders. Consequently, if the fluid-resisting, value adjusting devices 11 1 ˜11n are installed at the end portions of the respective cylinders 10 1 ˜10n, the optical oil can be uniformly supplied to the cylinders 10 1 ˜10n by adjusting the fluid-resistance, value-adjusting devices 11 1 ˜11n. Otherwise, the movement area of the respective optical means 30 1 ˜30n can be optionally adjusted by adjusting the amount of optical oil to be supplied to the respective cylinders to a desired value.
FIG. 6 is a side view showing another embodiment of the light filter. In FIG. 6, a plurality of light filters 90 1 ˜90n are arranged, for instance, in zigzag fashion for the purpose of providing air passages. By the use of such a construction, the plants under the light radiator can be easily supplied with air. Furthermore such air passages as shown in FIG. 6 represent only one example. It can be easily understood that other various air passages are possible for the purpose.
As is apparent from the foregoing description, according to the present invention, it is possible to provide a light source device in which light energy of good quality which is suitable for nurturing plants can be effectively supplied to plants. | A light source device for effectively diffusing and radiating light rays which have been transmitted through an optical conductor cable or the like, to the outside of the optical conductor cable. The light source device contains a light radiator comprising a transparent cylinder, an optical conductor for guiding light rays into the cylinder through one end of it, optical means movably accommodated in the cylinder for reflecting the light rays guided into the cylinder from the optical conductor and radiating the light rays outside of the cylinder, and driving means for moving the optical means along an axis direction of the cylinder, a large number of the cylinders being arranged crosswise in a state of grille. | 0 |
SUMMARY OF THE INVENTION
The invention provides a dental syringe having a handle portion, a valve body portion and a tip portion rotatably supported on the valve body portion to an adjusted position. A modular button-actuated valve assembly for each fluid passage system controls the "on" and "off" flow functions of the syringe. A metering valve in the handle portion upstream from a respective valve assembly is adjustable to limit the maximum rate flow in the associated passage means or system while maintaining the effectiveness of the fluid stream. A valve assembly includes a valve member that is movable to a seated position in part by the fluid pressure in a passage means so as to require a reduced spring force for closing and, in turn, a reduced operator force for opening. The interconnection of the valve assembly and actuator means therefor to provide a negative pressure at the liquid discharge orifice of the syringe, when the liquid flow is interrupted, permits the liquid and air discharge ports to be located in a common plane or surface of the discharge nozzle. A valve assembly is constructed as a module unit for convenient assembly and maintenance purposes and the metering valves in the handle portion are easily accessible. The syringe is thus readily manipulated and adjusted so as to quickly and efficiently meet the work requirements of a dentist.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the syringe of this invention;
FIG. 2 is a fragmentary exploded perspective view of the syringe showing the air and liquid control valve assemblies and their respective metering valves;
FIG. 3 is an enlarged top plan view of the syringe with the tip portion foreshortened;
FIG. 4 is a fragmentary longitudinal sectional view of the syringe as seen along the line 4--4 in FIG. 3;
FIG. 5 is an enlarged longitudinal sectional view of a modular valve assembly illustrated in the closed position therefor;
FIG. 6 is illustrated similarly to FIG. 5 and shows a valve assembly in the open position therefor;
FIG. 7 is an enlarged sectional detail view showing the assembly of the tip portion with the valve body portion of the syringe;
FIG. 8 is a perspective view of a tip or cap member for the free end of the syringe tip portion;
FIG. 9 is an enlarged longitudinal sectional view of the cap member of FIG. 8;
FIG. 10 is an enlarged showing of the free end of the tip portion, shown in FIG. 7, showing a water globule that may form at the liquid discharge orifice when the water flow is interrupted; and
FIG. 11 is illustrated similarly to FIG. 10, showing the pull back of the water globule of FIG. 10, as a result of the negative back pressure effected in the valve assembly on interruption of the water flow.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a three-way dental syringe 15 which is comprised of a hand portion 16 and a tip portion 17 interconnected by a valve body portion 18. The handle portion is of a hollow tubular construction formed to be conveniently gripped in the hand of a user. A pair of flexible tubes or hoses 19 and 21 extend through the hollow handle 16 and are connected to barbs 22 and 23 (FIG. 2) on the valve body portion 18. The tube 19 is connected to a source of air under pressure (not shown) and the tube 21 is connected to a source of water under pressure (not shown).
The tip portion 17 of the syringe 15 (FIG. 7) is comprised of a pair of rigid coaxial tubes which are mounted at one end on the valve body portion 18 and extend generally transversely of the axis of the hollow handle portion 16. The outer tube 24 of the coaxial tubes of the tip portion 17 provides a conduit section for air under pressure and the inner coaxial tube 26 a conduit section for water under pressure.
As shown in FIGS. 3 and 4, a valve assembly or mechanism 27 is installed in a cavity 28 in the valve body portion 18 and includes an actuator means 29 that has a control button 31 projecting from the valve body portion 18. Passageways 32 and 33 formed in the valve body 18 communicate with the cavity 28 at longitudinally spaced ports 52 and 51, respectively, and interconnect the inner water tube 26 of the tip portion 17 with the barb 23 and liquid hose 21 through the cavity 28 to form a continuous water passage means between the ends of which the valve mechanism 27 is interposed. Referring to FIGS. 2 and 3, it will be seen that a second valve mechanism, indicated as 27a, is installed in a second cavity 28a of the valve body 18 with the control button 31a thereof projecting from the valve body at a position adjacent the control button 31. Appropriate passageways formed in the valve body 18 and communicating with the second cavity 28a interconnects the outer conduit section 24 of the tip portion 17 with the barb 22 through the second cavity 28a to form a second continuous passage means with the valve mechanism 27a interposed between the ends thereof. This second passage means constitutes the air passage system in the syringe 15, the air to which is introduced through the air hose 19 and through the valve assembly 27a and into the tip portion 17 through a passageway indicated at 34 in FIG. 4.
In use the handle portion 16 (FIG. 1) of the syringe 15 may be held in the palm of a dentist's hand, with the tip portion 17 pointing away much in the manner of gripping a pistol. The thumb of the hand is conveniently positioned to operate either one or both of the actuator buttons 31 and 31a which project outwardly from the valve body portion 18.
When the button 31 is depressed, a solid stream of water is projected from the nozzle head 36 at the free end of the tip portion 17. Likewise, when the button 31a is depressed, a jet of air will be projected from the nozzle head 36. Since both of the control buttons 31 and 31a are located adjacent to each other, a dentist may press both buttons simultaneously in which case both water and air will be projected or discharged from the nozzle head 36 in the form of a spray. To control the maximum rate flow of fluid from the nozzle head 36, each of the fluid passage means is provided with a metering valve. The metering valve for the liquid passage means is indicated generally at 37 in FIG. 4, it being understood that the air passage means is provided with a similar metering valve (not shown). Since the valve assemblies and metering valves are carried in a dual manner within the hollow handle portion 16 and valve body 18, respectively, and are identical in construction and operation, only the metering valve and valve assembly for the liquid passage means will be described in detail with like parts in the air passage means being indicated with like numbers bearing the suffix a.
The metering valves (FIGS. 2 and 4) include a cylindrical bushing 38 fitted within a bore 39 of reduced diameter formed in the upper end of the hollow handle portion 16. The bushing is formed with a pair of adjacent longitudinally extended holes 41 and 42 for receiving the air hose 19 and liquid hose 21, respectively. Extended transversely of the bushing 38 for registration with corresponding ones of the longitudinally extended holes 41 and 42 are a pair of tapped holes 43 and 44. The hoses 19 and 21 are extended through their associated holes 41 and 42, respectively, in the bushing 38 for connection with associated barbs 23 and 22, also respectively, with the holes 41 and 42 being of a size to receive the barb connections therein.
With further reference to FIGS. 2 and 4, it is seen that the valve body portion 18 is formed with an externally threaded reduced neck section 46 for reception in and threaded connection with an internally threaded portion of the bore 39. To adjust the metering valve 37, the valve body portion 18 is disconnected from the handle portion 16 and the bushing 38 with the hoses 19 and 21 therein removed from the bore 39 to provide access to adjustment screws 45 received in the tapped holes 43 and 44 for direct engagement with the hoses. On movement of the adjustment screws 45 of the metering valve 37 inwardly of the tapped hole 44, a side portion of the hose 21 is deflected or squeezed inwardly to adjustably collapse the cross sectional area of the hose. At all adjusted positions therefor the adjustment screws 45 are within the confines of the bushing 38. On completion of the rate flow metering adjustment, the bushing 38 is replaced within the bore 39 and the valve body and handle connected together at the coacting threaded portions thereof. The maximum rate flow in a fluid passage means is thus adjusted upstream from a corresponding valve assembly 27 or 27a.
As shown for the valve assembly 27, the cavity 28 therefor (FIGS. 4 and 5) is of a cylindrical shape having an inner bore section 47 of small diameter, an outer bore section 48 of a large diameter and a central bore section 49 of an intermediate diameter. The valve assembly 27 (FIG. 5) includes a seat member comprised of an O-ring 53 extended transversely of the inner bore section 47 and in engagement with the side wall thereof at a position intermediate the ports 51 and 52. Coacting with the valve seat 53 is a valve member 54 having a head member 56 and a stem member 57. The valve head 56 is located within the inner bore section 47 with the stem member 57 projected through the valve seat and the central bore section 49 and into the outer bore section 48. Interposed between the seat 53 and an O-ring 58, extended transversely of the central bore section 49 at its junction with the outer bore section 48, is a tubular spool or spacer member 59 having an outer diameter slightly less than the diameter of the inner bore section 47. The end of the spacer member 59 adjacent the O-ring 58 is formed with a bearing portion 61 for guided engagement with the side wall of the central bore section 49.
Mounted within the outer bore section 48 is a tubular retaining bushing 62 formed at its inner end with an inwardly extended annular flange 63 for bearing engagement with the O-ring 58. Movable within the retainer bushing 62 for movement axially of the valve stem member 54 is a tubular or liquid displacement sleeve member 64. When the valve assembly 27 is in the closed position therefor of FIG. 5, the outer end of the sleeve member projects outwardly from the cavity 28 and its inner end inwardly into the central bore section 49. The projected outer end of the sleeve 64 is covered by the button 31 which is engageable with a plug 66 inserted in the outer end of the sleeve member 64. The inner end of the button 31 is formed with an outwardly extended annular flange 67 for bearing engagement with the side wall of the outer bore section 48. A snap ring 68 in the retaining bushing 62 limits the outward movement of the button 31 and in turn the outward movement of the sleeve member 64 when the valve assembly 27 is in the closed position therefor.
The sleeve member 64 is mounted about the valve stem member 57 in liquid sealed engagement with the O-ring 58 and is formed at the inner end thereof with an inwardly extended annular shoulder 69. A coil spring 71 within the sleeve member 64 is mounted about the valve stem member 54 and placed in compression between the sleeve shoulder 69 and a snap ring 72 carried at the free end of the stem member 57. A second coil spring 73, mounted about the sleeve member 64 within the outer bore section 48, is arranged in compression between the flange 63 on the retaining bushing 62 and a shoulder 74 formed at the outer end of the sleeve 64.
The springs 71 and 73 are of a relative strength such that the spring 73 exerts a compressive force greater than the compressive force of the spring 71. As shown in FIG. 5, for a closed position of the valve assembly 27, the outer end of the sleeve member 64 is in a spaced axial relation with the free end of the valve stem member 57 to provide a lost motion connection therebetween on initial depression of the button 31. Thus, the button, when initially depressed, is axially moved relative to the valve member 54 until abutting engagement takes place between the plug 66 in the outer end of the sleeve member 64 and the free end of the valve stem member 57. This initial movement of the button 31 takes place against the action of the spring 73 as reduced by an extension of the spring 71. However, such extension is without effect in unseating the valve head 56 due to the pressure of the liquid in the inner bore section 47 acting to hold the valve head 56 seated. Following the engagement of the valve stem member 57 and sleeve member 64, the continued depression of the button 31 unseats the valve head 56 to permit a flow of water under pressure from the port 51 (FIG. 6), into the inner bore section 48 and through the valve seat 53 and port 52 into the passage 33 for discharge from the nozzle head 36.
On a release of the push button 31, the valve head 56 is moved against the seat 53 by the sole action of the spring 71 to interrupt the flow of water between the cavity ports 51 and 52. With the valve head seated, the movement of the sleeve 64 is continued by the action of the spring 73 until the shoulder 67 on the button 31 is engaged by the snap ring 68.
By virtue of the projection of the sleeve member 64 within the central bore section 49, when the button 31 is fully depressed, the delayed retraction of the sleeve member outwardly from such central bore section, after seating of the valve head 56, creates a negative pressure within the passage 33 tending to pull back or withdraw water from the passage 33 into the central bore section 49.
Stated otherwise, that portion of the cavity 28 between the O-ring 53 and the cavity bottom wall 76 defines what may be called a water receiving chamber 77 and the cavity portion between the O-rings 53 and 58 a water discharge cavity 78. When the valve head 56 is in the unseated position of FIG. 6, the liquid volume of the chamber 78 is reduced by an amount corresponding to the liquid therein displaced by the extension of the sleeve member 64 therein. On a seating of the valve head 56, prior to the retraction of the sleeve 64, the subsequent retraction of the sleeve member increases the volume of the discharge chamber 78. The volume of water pulled back into the discharge chamber 78 from the passage means 33 is thus equal to the volume displacement therein by the sleeve member 64.
It will also be noted that when the valve member 54 is retained in the closed position therefor by the spring 71, and the button 31 locked within the retaining bushing 62 by the snap ring 68, the complete valve assembly 27 constitutes a module assembly which is removable from and placed within the cavity 28 as a unit package. The valve assemblies 27 and 27a (FIGS. 2 and 4) are locked against removal from their associated cavities 28 and 28a by a single lock screw 79 threadable within the valve body 18 at a position between the retaining bushings 62 and 62a for reception within a peripheral grove 81 formed in each of the bushings 62 and 62a. As clearly shown in FIG. 4, the screw 79 is accessible on disconnection of the valve body 18 from the handle 16.
The valve body 18 and tip portion 17 are assembled by means including a tubular connector member 82 (FIG. 7) having a threaded neck section 83 of a reduced diameter for threaded reception within a threaded cavity 84 formed in the valve body 18. The outer end of the connector member 82 is formed with an inwardly extended annular clamping or retaining flange 86 which defines a central opening 87. Arranged in a concentrically spaced relation within the tubular connector 82, is a cylindrical spool 88 having axially aligned bores 91 and 92.
The water conduit section 26 at the base or inner end of the tip portion 17 projects axially outwardly from the air conduit section 24 (FIG. 7). In the assembly of the tip portion with the spool member 88, the water conduit section 26 is received within the bore 91 of reduced diameter and the air conduit section 24 within the bore 92. A diametric passage 89 is in registration with the bore 92 so that fluid passing therethrough is permitted to flow about that portion of the water conduit section 26 which intersects the passage 89.
A first O-ring 93 is positioned about the air conduit section 24 between the spool 88 and the retaining flange 86 on the connection member 82. A second O-ring 94 is positioned in a seat 96 extended about the inner end of the water conduit section 26. The outlet port 98 of the discharge passage 33 from the valve assembly 27 is arranged centrally of the bottom wall 97 of the cavity 84 in axial alignment with the water conduit section 26. The outlet port 99 of the air passage 34 from the valve assembly 27a is located in the cavity bottom wall 97 adjacent the periphery thereof for communication with the annular passage 101 formed between the spool 88 and the side wall of the connector 82.
As a result of the relative arrangement of the port 98 with the water conduit section 26 and the air port 99 with the inner peripheral surface of the connector 82, the threaded engagement of the connector 82 within the cavity 84 effects a clamping of the O-ring 94 between the cavity bottom wall 97 and spool 88 concurrently with the clamping of the O-ring 93 to close the annular air passage 101 at the flange end of the connector 82. On loosening of the connector member 82 the tip portion 17 is rotatable relative to the valve body 18 to a desired adjusted position. At any adjusted position of the tip portion 17, the O-ring 94 functions to separate the water flow from the air flow at the cavity bottom wall 97 so that water from the passage 33 travels directly into the water conduit section 26 for discharge from the nozzle head 36. The air from the passage 34 is directed into the annular passage 101 and through the diametric opening 89 for travel within the air conduit section 24 and about the water conduit section 26 for discharge at the nozzle head 36.
The nozzle head 36 (FIGS. 8 and 9) is of a tubular construction and is formed with a shank 103 and a head 104. The nozzle head has an enlarged bore section 106 and a reduced bore section 107 with the side wall of the bore section 107 being slotted to provide air distributing wings 108. With the shank 103 inserted within the space formed between the coaxial conduit sections 24 and 26 until the head 104 engages the terminal face 109 of the air conduit section 24, the air flowing about the water conduit section 26 is dispersed by the wings 108 for uniform distribution about the water discharge orifice 110 of the nozzle head 36. The terminal end of the water conduit section 26 projects outwardly from the terminal face 109 of the air conduit section 24 a distance such that when the nozzle head 36 is assembled, the orifice 110 and the concentrically arranged annular air discharge port 111 are arranged in a common plane or surface of the nozzle head.
As illustrated in FIG. 10, when the water flow through the water conduit section 26 is interrupted by closing of the valve assembly 27, a globule of water, indicated at 113, may form on the nozzle 36 in a covering relation with the orifice 110 and port 111. If the air system is then actuated the globule 113 can be picked up in the jet of air issuing from the port 111. This condition is eliminated by the previously described pull back action of the sleeve member 64 relative to the water discharge chamber 78 on interruption of water flow by the valve assembly 27. As a result, and as shown in FIG. 11, the globule 113 is withdrawn back into the water conduit section 26 so that when the air system is actuated the jet of dry air, indicated by the arrows 114, is discharged without any water being present at the orifice 110. It is seen, therefore, that the extent of the sleeve projection within the water discharge chamber 78 need only be such as to withdraw the amount of water necessary to insure the issuance of the dry jet of air following an interruption of water flow.
Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited since changes and modifications can be made therein which are within the full intended scope of this invention as defined by the appended claims. | A dental syringe is connectible to sources of air and water under pressure for selectively providing a solid stream of water, a jet of air or a spray of water and air. The maximum rate flow of air and/or water to be used is independently metered in the handle portion of the syringe to limit the flow as required by the dental work being performed. Valve assemblies in the valve body porton of the syringe for independently controlling the air and water flow have respective actuator means each of which is interconnected with the valve assembly therefor to pull back into the water passage system downstream of the valve assembly any wafter that may be adjacent to the orifice of the syringe when the water flow is interrupted. | 0 |
The present invention relates to a support apparatus and more particularly relates to a support and gripping apparatus for securing a traffic control sign to a base member such as a concrete abutment.
BACKGROUND OF THE INVENTION
Temporary concrete abutments are used to mark and delineate vehicle traffic lanes. Concrete abutments of this type are commonly used in road construction areas to define temporary roadway or vehicle lanes. Because of space restrictions in construction areas, use of conventional roadside traffic control signs is not often practical. Accordingly, a problem arises as to the placement of traffic control signs such as signs advising motorists of legal speed limits, narrowing lanes, lane restrictions, curves, no stopping areas and the like. Accordingly, it has become a common practice to position traffic control signs on the top of concrete abutments which align the roadway. Traffic control signs are customarily clamped to the top of abutments using conventional clamping devices. However, conventional clamps such as C-clamps and the like do not provide adequate retention and gripping force, particularly when signs are located in close proximity to traffic lanes where passing vehicles, particularly, large trucks exert considerable vacuum or draft forces against the surface of the sign which may cause it to become loosened or to become dislodged from the abutment. Obviously, dislodgement of a traffic control sign poses an immediate and hazardous condition to both traffic and personnel in the area.
SUMMARY OF THE INVENTION
Briefly, the present invention relates to a support or retention device which mounts to the abutment securing traffic control members such as traffic signs to the top of the concrete abutment. Traffic abutments of this type are generally preformed temporarily positioned along the roadway such as through construction areas. The top surface of the abutment is planar and may be of varying width. Abutments may diverge outwardly toward a base.
The device of the present invention has a base plate which is elongated having a depending flange along one edge. The base plate is adapted to rest on the upper surface of the abutment with the flange engaging a vertical side wall of the abutment. One or more adjustable slider or gripping clamps mounted on the base can be adjusted to grip the vertical side of the abutment opposite the flange. C-clamps are secured to the base by a flexible chain or cable and at the time of installation are positioned with the body of the clamp engaging the base and with the opposite jaws of the clamps engaging the opposite vertical walls of the abutment to restrain the base plate against both lateral and lifting movement. Handles may also be provided extending from the base to facilitate lifting the device when transporting, installing and removing the apparatus.
Traffic control signs for temporary installation will generally include a panel portion which may be of various shapes and which carries an appropriate legend or graphic. The sign is mounted on a shaft which is attached to a spring at its lower end. The lower end of the spring is secured to an adaptor which has a pair of oppositely extending flanges. The adaptor is releasably retained on the base. One flange of the adaptor is received within a slot or groove and a hold down releasable engages the opposite flange. The adaptor may also include a leg which extends downwardly and has fixed or adjustable stops that engages the vertical side-wall of the abutment to stabilize the support.
In another embodiment of the invention, the adaptor is elongated and extends laterally from the vertical side-wall of the abutment. A stand has a ground engaging pad and an upright tubular member which may be selectively secured to the adaptor by spring loaded detent pin or other retainer member.
The invention also comprehends a tool which may be used to assist the installer in positioning the apparatus on the upper surface of an abutment in installations where the abutment supports a vertical anti-glare screen. The installation tool is a wedge-type device which may be inserted to lift the lower edge of the screen to accommodate the placement of the support apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will be more fully appreciated from the following description, claims and the drawings in which;
FIG. 1 is a perspective view of the support apparatus of the present invention shown installed on a traffic abutment;
FIG. 2 is a side view of the retention apparatus shown in FIG. 1;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 2;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 2;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 2;
FIG. 8 is a plan view of the support apparatus;
FIG. 9 is a perspective view of a alternate embodiment of the adaptor component of the retention device;
FIG. 10 is a sectional view taken along lines 10--10 of FIG. 9;
FIG. 11 is a perspective view of the installation tool which may be used to assist in the installation of the support of the present invention;
FIG. 12 is a end view showing the use of the installation tool in FIG. 11;
FIG. 13 is a top view showing use of the installation tool in FIG. 11;
FIG. 14 is a perspective view showing an alternate embodiment of the apparatus of the present invention which includes a supporting leg;
FIG. 15 is a side view of the embodiment of FIG. 14; and
FIG. 16 is a sectional view taken along lines 16--16 of FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, particularly FIGS. 1-8, the support apparatus of the present invention is generally designated by the numeral 10. As indicated above, the support 10 is intended for installation on structures such as concrete abutment 12. Concrete abutments 12 are generally provided sections and are temporarily positioned in medians and along traffic lanes. Abutments of this type are constructed of concrete having opposite side-walls 14 and 16 and are generally flat or planar upper surface 18. Side-walls 14 and 16 may flare or extend outwardly toward a base, not shown, which rests on the ground surface.
The support 10 is intended to support a traffic control sign such as sign 20. Sign 20 may be in any shape or square, rectangular, round carrying information for motorists such as speed limits, cautionary notices and other conventional signs. The sign 20 is supported on a tube 22 which at its lower end is secured to a pair of oppositely positioned and generally L-shaped brackets 24 by fasteners 25. The horizontal legs 28 of the L-shaped brackets are secured to a spring 30. The lower end of each of the springs is secured by a fastener 33 to adaptor 32. The springs 30 provide a resilient mounting so that impact or wind forces, either natural or imparted due to draft created by passing traffic, will cause the springs to deflect absorbing energy preventing damage to the sign. Rigid retention of signage would be unsatisfactory as the sign or its mounting tube would tend to fail over a period of prolonged use. Also, the resilient mounting of the sign 20 is safer in the event of impact with a vehicle.
The adaptor 32 is in the form of an inverted C-shaped channel having an overall length approximately, corresponding to the width of the abutment. The adaptor 32 has a pair of oppositely extending flanges 34 and 36 which, in the installed position, rest on the upper surface of the abutment as seen in FIGS. 1 and 2. One end of the adaptor may carry a depending leg member 40 which may have one or more inwardly disposed stop members 42 which may be either fixed as shown in FIG. 1 or adjustable as described hereafter with respect to FIGS. 9 and 10.
The support includes a base plate 50 which has a planar upper surface 52. A flange 54 extends downwardly along one edge of the plate. A pair of studs 56 and 58 are welded to the upper surface 52 of the plate adjacent the ends and the studs project upwardly. Each of the studs carries adjustable gripping means in the form of sliders 60, 61 each of which have a flat strap portion 62 extending transversely across the base. A slot 64 is provided each of the sliders and receives the associated upstanding stud.
As seen in FIG. 7, nut 70 may be loosened to provide for lateral adjustment of the slider and tightened once the appropriate adjustment is made. One end of the slider has an upwardly extending flange 72 and the opposite end of the strap has a downwardly depending flange 74. The flange 72 provides a gripping surface for the installer when installing the device and flange 74 engages a side wall of the abutment when tightened.
A pair of U-shaped handles 75 and 76 are welded or otherwise secured to the base at spaced-apart locations convenient for the installer to grasp when lifting or transporting the device. These are seen in FIGS. 1 and 4.
Clamps, 80 and 82, which are shown as C-clamps are also provided to secure and hold down the device against dislodgement. The C-clamps are shown as conventional C-clamps having an elongated body with each having an adjustment screw 85 which may be extended or retracted to bring the jaws 87 into engagement with the abutment. Each of the C-clamps 80 and 82 is permanently secured near the ends of the base by a flexible cable or chain 88 to prevent theft and to maintain the clamps with the base. A pair of eyelets 89 project from each clamp as best seen in FIG. 3.
A pair of hooks 90 and 91 are provided extending from the flange of the base at spaced-apart locations so that the C-clamps may be suspended from the hooks at eyelets 89 when the device is stored or being transported to or from a use location.
In use, the support 10 is positioned on the upper surface 18 of the abutment wall. The installer may conveniently lift the device from the bed of a truck by grasping the handles 74 and 76 and manually transporting the device to the installation location. During the manual transportation of the device, the C-clamps 80, 82 will normally be supported in a suspended position on hooks 90 and 91. Once the support is in position on the wall, it is manually moved to a position so that the lip or flange 54 tightly abuts the vertical edge of the abutment adjacent to the installer. The nuts 60 or studs 58, 60 may be loosened and the sliders 60, 61 can be moved to position the associated depending flange 74 engaging the opposite vertical surface 14 of the abutment. The nuts 70 then are tightened so that the support is secured against lateral movement. Vertical movement is resisted by securing the C-clamps 80 and 82 in the position shown in FIGS. 1 and 3 and the installer tightens screws 85 associated with each of the clamps. Note the clamps are tethered to the support by chain or cable 81 so that they cannot become separated.
The sign 20 is then positioned on the support by inserting flange 34 of the adaptor beneath the L-shaped lip 86. The opposite flange 36 of the adaptor is secured by a hold down 55. Hold down 55 is an elongated member having a C-shaped cross section and is positioned by adjusting it relative to stud 66 at nut 68 along slot 69 as seen in FIG. 8. The lip 86 and the hold down provide a receiver for detachably securing the adaptor to the upper surface of the support 10.
In the installed position, the sign is supported on the upper surface of the abutment in a stable position by the support. Lateral displacement of the sign and support is resisted by the base and the sliders at the opposite end of the base. Transverse movement along the upper surface of the abutment is resisted by the C-clamps although some limited movement may be allowed to assist in dissipating energy.
The forces imposed against the sign 20 are absorbed by the springs 30 and will also be absorbed by the base and the abutment as both lateral and longitudinal forces will be transferred to the abutment through the support.
FIGS. 9 and 10 show an alternate embodiment of the present invention in which the adaptor is provided with adjustability on the depending legs. The adaptor 32 as been described above and supports springs 30 which are secured to the tubular support posts of the sign. The generally U-shaped depending leg member 100 may be laterally adjusted along the adaptor at slot 102. The upper or bight section 104 of leg member 100 has an upstanding stud 106 which receives nut 108 which will clamp retaining plate 110 tightly against the adaptor. The lower ends of legs 100 member have internally threaded ends 115 which each receive a screw 116 which may be extended or retracted by means of rotation of handle 118. The other end of the screw carries a bearing member 120 which may be brought into engagement with the abutment wall.
In some installations it is necessary to install anti-glare screen along the upper surface of the abutment as shown in FIG. 1. The glare screen 150 reduces the glare of headlights from the oncoming traffic lane. Often the glare screen is positioned so that minimal space 152 exists below the lower edges of glare screen and the upper surface of the abutment.
Accordingly, it is helpful in installing the support apparatus in this situation to have the assistance of tool 200 as shown in FIGS. 11, 12 and 13. The tool 200 has a blade 220 with a wedge shaped or inclined forward edge 204. The bottom edge of the blade 220 carries a transversely extending flat base 208. The rear edge of the plate carries a strap 210 which extends beyond the upper and lower edges of the blade. A handle 215 extends transversely across the blade 210 and is welded to the staple.
The tool 200 assists in lifting or compressing the glare screen 150 to provide clearance so that the support device may be more easily installed. As shown in FIGS. 12 and 13, the wedge like tool may be inserted by engaging the flat base 208 with the upper surface 18 of the abutment and manually forcing the tool forwardly in the direction F as seen in FIG. 12. This movement will cause the bottom edge of the screen 130 to ride up the inclined surface 204 lifting the bottom edge of the screen well above the surface 18 of the abutment. The tool is left in place providing clearance so the support may be installed. Once installed, the tool 200 is removed.
Another embodiment of the invention shown in FIGS. 14 through 16. In this embodiment, the support base plate 50 is substantially as has been described above is secured in place by adjustable sliders and C-clamps in the manner described above. A lip 86 defines a transverse slot and an adjustable hold down member 55 is positioned opposite the lip.
The adaptor 232 is similar to the adaptor 32 having an inverted body and opposite extending flanges 234, 236. Adaptor 232 has a length greater than the width of the abutment 12. The width of the abutment is represented by the letter W in FIG. 14. Sign supporting springs 30 are secured to the adaptor 232 at a location outward of the vertical wall 16. This allows the supported sign to be displayed or positioned adjacent to the rear side of the abutment 12. However, since mounting in this fashion creates a substantial overhanging or cantilever load, a stand 250 is provided to assist in supporting the sign. The stand 250 has a ground engaging base plate 252 and an upstanding tubular member 254. The tubular member 254 defines a plurality of spaced-apart holes 256. A tubular receiver 260 is secured at the outer end of the adaptor 240. The receiver 260 slidingly receives the tubular member 254. The adaptor and the stand can be secured at a desired position by registering one of the selected holes 256 with spring loaded retainer member 270 which is located on the outer end of the adaptor.
Hook 275 is secured to the outer end of the adaptor and provides a location at which one or more weights such as sandbags 280 may be secured to provide additional stability.
It will be seen from the foregoing that the present invention provides a simple yet highly effective mounting support for traffic control signage and the like. The support has the advantage that it can easily be installed or removed by workers having no special training or skill. The device may be manually transported or positioned by use of the integrally formed handles. The device is one piece construction so that there are not loose components that can become lost or subject to theft. The relatively large base surface provides security and stability for safety of both workers in the area and passing motorists. No special tools are needed for installation or removal of the device and installation can be accomplished by use of a single wrench for tightening the nuts and tightening and loosening the C-clamps.
While the principles of the invention have been made clear in the illustrative embodiments set forth above, it will be obvious to those skilled in the art to make various modifications to the structure, arrangement, proportion, elements, materials and components used in the practice of the invention. To the extent that these various modifications do not depart from the spirit and scope of the appended claims, they are intended to be encompassed therein. | A support and gripping apparatus for supporting traffic control signs to a concrete roadway abutment. The support has a plate which rests on the top of the abutment and which is held in place by a flange and adjustable grips which engage the abutment side wall. C-clamps are positioned along the plate. An adaptor is detachably securable to the plate and has a spring and vertically extending tube which carries the sign. Handles may be provided on the base to assist in moving and positioning the support. The adaptor may extend horizontally in cantilever fashion past the abutment side wall and having a group supported leg for additional stability. A wedge may be used by the installer to lift a glare screen if one is mounted on the abutment. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 10/330,914, filed Dec. 27, 2002, which is a continuation-in-part of U.S. application Ser. No. 09/949,071, filed Sep. 7, 2001, which is a continuation-in-part of U.S. application Ser. No. 09/109,454, filed Jul. 2, 1998 now U.S. Pat. No. 6,402,734 (all of the above-identified applications are incorporated by reference). This invention was disclosed in the Disclosure Documents Program of the U.S. Patent and Trademark Office on May 4, 1998, Disclosure Document No. 435938.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to medical diagnostic and therapeutic methods and, in particular, to a method for cannulating blood vessels, including, but not limited to retinal blood vessels, such that a medication may be injected or a quantity of fluid removed from the blood vessel. Alternatively, a catheter, wire or stent may be placed through the cannula to treat or diagnose an area remote from the insertion site.
2. Description of Related Art
The cannulation of a retinal blood vessel is difficult as the lumen of the blood vessels is less than 200 microns in size. The present day ocular instruments are too large to cannulate the vessel and the dexterity required to maintain the cannula within the blood vessel for several minutes is not commonly available. The piercing of a blood vessel elsewhere in the body to inject medications, perform surgical procedures or remove blood for analysis and treatment is commonly performed. It is therefore, to the effective resolution of the aforementioned problems and shortcomings that the present invention is directed.
Furthermore, perforating a blood vessel or other structure to withdraw blood, inject or infuse a substance into the blood vessel, thread a catheter, wire, fiber or other device into a blood vessel are established procedures in medicine. It is common practice to apply pressure for a variable length of time to the perforation or cannulation site once the needle, cannula, catheter, wire, etc. is withdrawn. Generally if the perforation site is in a small blood vessel near the skin surface and/or a small gauge needle is used the application of pressure should minimize the extravasation of blood from the puncture site. However, in situations where the blood vessel or structure is large or deep to the skin surface, or a large bore needle is used, or the patient has a bleeding proclivity from a blood abnormality or uses a medication that delays blood clotting, significant hemorrhaging may occur once the device is removed from the blood vessel or structure. This may happen despite the application of pressure for a limited amount of time or despite the application of a pressure bandage.
Accordingly, it is an object of this invention to provide a microcannula or micropipette whose lumen is small enough to be safely placed within the lumen of a retinal blood vessel and by its configuration is parallel to the lumen when placed through a standard sclerotomy site, as commonly used in vitreoretinal surgery.
It is another object of this invention to provide, by its configuration and method of attachment, a stable support such that the micropipette may be securely held within the blood vessel so that subsequent maneuvers may be safely accomplished.
It is still another object of this invention to provide a micromanipulator such that the micropipette may be remotely advanced to perforate the retinal blood vessel.
It is yet another object of this invention to provide a portable device that may be easily attached to a standard operating surgical wrist rest and is stable in its “X”, “Y” and “Z” planes.
It is a further object of this invention to provide a device that, by its configuration and method of attachment, does not inhibit the surgeon's view when using an operating microscope or otherwise interfere with the use of the operating microscope.
It is yet another object of this invention to provide a safe method such that the surgical procedure may be performed.
Another object of the invention is to provide a device that by the nature of its design will lessen or eliminate the amount of hemorrhage that occurs when a needle, cannula, catheter, wire, stent, fiber or other device is removed from a blood vessel or other structure.
Another object of this invention is to provide a device that can easily perforate a designated blood vessel.
Another object of this invention is to provide a device that by its nature and design is compatible with existing syringes, cannulas, catheters, etc.
Another object of this invention is to provide an ocular implant needle.
BRIEF SUMMARY OF THE INVENTION
The foregoing objects are achieved and the foregoing problems are solved in the embodiments of the invention in which a retinal blood vessel is cannulated using a micropipette (microcannula) attached to a micromanipulator which is connected to a positioner or stabilization system attached to a standard surgical wrist rest.
More particularly, a sclerotomy can be made at the standard distance from the limbus and an illuminated infusion cannula can be placed through the sclera at this point. A pars plana vitrectomy may or may not be necessary with further experience. Another sclerotomy can be made at the standard distance from the limbus such that the micropipette/microcannula is substantially parallel to the retinal blood vessel chosen to be cannulated. The micropipette is then placed through the sclerotomy overlying the selected retinal blood vessel. The intraocular pressure can be lowered to approximately 5 mm of Mercury to allow dilation of the vessel. Once the blood vessel is perforated, it may be advantageous to raise the intraocular pressure to minimize bleeding. The retinal blood vessel may be cannulated manually or the micromanipulator used to advance the micropipette into the retinal blood vessel.
The micropipette tip is preferably at an approximately 135-degree angle to the shaft such that it is parallel to the lumen of the blood vessel in the posterior retina when placed through a standard sclerotomy site. The tip of the micropipette is preferably approximately 100 microns in diameter or smaller so it may safely enter the lumen of the retinal blood vessel. The opposite end of the micropipette can be connected to and in fluid communication with a standard surgical tubing and/or syringe such that fluid may be withdrawn or injected into the retinal vessel. Alternatively, a catheter or wire may be advanced through the microcannula for diagnosing, testing or treatment of an area located at a distance from the insertion site.
In certain situations medication such as Tissue Plasminogen Activator (“t-PA”) made by Genetech, Inc. and sold under the trademark ACTIVASE can be injected into the retinal vessel. Alternatively, a dye can be injected into the retinal vessel for diagnosing purposes.
The micromanipulator is preferably attached to a positioner or stabilization system that is freely mobile and stable in the “X”, “Y” and “Z” directions. In the preferred embodiment, the positioner or stabilization system is securely attached to a standard ophthalmic surgery wrist rest by conventional means. The positioner or stabilization system is easy to attach to the wrist rest and may be removed when the device is not needed. At the conclusion of the maneuver, the intraocular pressure may be raised in order to minimize retinal hemorrhaging and the micropipette removed from the blood vessel. The operation is then concluded in standard fashion.
If the illumination is incorporated within the infusion line and infusion cannula then the illumination/infusion line may be placed into a illumination positioner that can be mounted on the stabilization post attached to the surgical wrist-rest. The illumination positioner may be adjustable in the x, y and z planes such that the angle of the fiber optic illumination relative to the eye may be set. This is beneficial in directing the light to the area of the retina that the surgeon is working on.
In another embodiment of the microcannula, a sheath protects the shaft of the microcannula and/or a cover protects the tip of the microcannula during insertion into the eye. Once the microcannula is within the eye the cover is retracted thus exposing the tip. The cover may be slid over the microcannula tip prior to removing the device from the eye in order to minimize tip breakage. A barbed fitting may be attached to the end of the microcannula to aid in attaching the tube that is attached to the syringe.
In an alternate embodiment of the microcannula, the protective tube, needle or larger cannula protects the shaft and the tip of the microcannula and is retracted into the handle to expose the tip. The handle will also protect an otherwise exposed/unprotected portion of the shaft of the microcannula when the protective member is in an extended/outward position over the beveled tip.
If the illumination is incorporated with the microcannula then the illumination component of the infusion cannula may not be necessary. It is also apparent that if an infusion line is required, it may also be incorporated into the microcannula device which may obviate the need for a separate infusion line and/or separate sclerotomy site.
The microcannula may be used to cannulate the retinal vessel manually or alternatively be placed within a holder that aids the surgeon in steadying the device. Another option is to place the microcannula within a micromanipulator such that the microcannula may be manually advanced or automatically advanced into the retinal vessel.
If the retinal vessel chosen for cannulation is in the posterior retina then the microcannula tip is preferably at an approximately 135 degree angle to the shaft such that the tip will be parallel to the lumen of the blood vessel when it is placed through a standard pars plana sclerotomy site. It is apparent that if the blood vessel chosen to be cannulated is in the equatorial or in the peripheral retina than the angle to the shaft would be different so that the microcannula tip will be parallel to the vessel when it is placed through a pars plana sclerotomy site. The location of the sclerotomy site in the eye and its relation to the location of the blood vessel chosen for cannulation affects the tip angle in relation to the shaft. If the microcannula is used to place or remove fluid or material from on top of or underneath the retina than other tip angles are possible.
Fluid may be withdrawn or injected into the retinal vessel or alternatively a catheter, wire, laser fiber, stent, etc. may be advanced through the microcannula for diagnosing, testing or treating an area at or at a distance from the cannulation site. Many other uses of this technology will be apparent to those skilled in the art.
Thus, the present invention provides a device that may safely advance the micropipette into the retinal blood vessel while securely holding it in a stable fashion and allowing rotation in the “X”, “Y” and “Z” planes for ease of maneuverability. The apparatus can be easily attached and removed from the operating field, and, is thus portable. The apparatus can be attached by conventional means to the a wrist rest, the operating table, the operating microscope or any other convenient and stable location in the operating room. Additionally, the apparatus is constructed so not to encumber the surgeon's view through the operating microscope, or otherwise interfere with the use of the operating microscope.
Additionally, a self-sealing needle can be provided and can be made of stainless steel, plastic or other biocompatible materials compatible with manufacturing and sterilization requirements. The self-sealing needle tip is at an angle to the shaft such that it can be substantially parallel to the lumen of the blood vessel chosen for perforation. The diameter of the tip and length of the parallel portion of the needle can be dependent on the blood vessel chosen for perforation. The terms perforation and cannulation and the terms blood vessel or structure are used interchangeably throughout this application.
The self-sealing needle comprises an elongated relatively rigid hollow body member having a single angled first end to define a relatively sharp beveled end and a second end, said second end may be attached to a syringe, tubing member, etc. The first body portion can be substantially smaller in size than the second body portion. The outer diameter of the first body portion may be of a smaller diameter than the outer diameter of the second body portion. The first body portion can be permanently disposed at an angular relationship with said second body portion such that the beveled tip will be positioned substantially parallel to the blood vessel to be perforated. The angular relationship can be chosen based on the blood vessel targeted for perforation. The first body member can be sized such that the beveled tip can safely enter the structure. The length of said first body portion and said beveled tip causes a shelved incision in the targeted structure which is self-sealing upon removal of said first body portion and said beveled tip from the perforation site.
Another embodiment of the present invention provides an ocular implant needle. Advances in the diagnosis and pathophysiology of eye diseases have allowed advances in therapy. Delivering therapeutic levels of drugs to the eye has resulted in the development of reservoir and biodegradable ocular implants that are filled with drugs to treat the ocular condition. One such reservoir ocular implant is manufactured by Controlled Delivery Systems of Watertown, Mass.; one such biodegradable ocular implant is manufactured by Oculex Pharmaceuticals of Sunnyvale, Calif. The present invention ocular implant needle is used to lessen the surgical trauma associated with the placement of ocular implants. The ocular implant needle can easily perforate the eye while making a self-sealing perforation site. The needle can also be used for the injection of a drug implant or other device or pharmaceutical agent at a precise location within the eye.
For purposes of the disclosure and claims the terms micropipette, microcannula, cannula and needle are used interchangeably. To the extent that such terms differ in any way in meaning, if any, then the broadest definition for any of the terms is considered to be the definition for all terms for purposes of the instant invention disclosure. It should also be noted that with some uses the size of the device may not be in micron sizes (i.e. drawing blood from a human's arm as opposed to cannulating a human retinal blood vessel).
In accordance with the objects noted above, which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention may be better understood by reference to the drawings in which:
FIG. 1 is a front view of a first embodiment for the micropipette (microcannula) of the present invention;
FIG. 2 is a front view of a second embodiment of the micropipette in which an illumination member such as a fiber optic light source is attached to the side of the micropipette to provide illumination during the operation;
FIG. 3 is a front view of a third embodiment of the micropipette wherein the micropipette and fiber optic are enclosed within a protective sheath or tube to minimize breakage when placed into the eye, the protective sheath or tube can also be used for a microcannula without a fiber optic;
FIG. 4 is a perspective view of the preferred embodiment for the micropipette, micromanipulator, positioner and base of the present invention attached to a conventional wrist rest;
FIG. 5 is another perspective view of the preferred embodiment for the micropipette, micromanipulator, positioner and base of the present invention;
FIG. 6 illustrates a view of the micropipette when placed through the sclerotomy site into the eye;
FIG. 7 illustrates the tip of the micropipette overlying and parallel to the retinal blood vessel to be cannulated;
FIG. 8 is a perspective view of the micropipette when placed through the sclerotomy site into the eye;
FIGS. 9A–9B illustrate a front view of the fourth embodiment of the microcannula in which the shaft of the microcannula is enclosed by a protective sheath;
FIGS. 10A–10B illustrate a front view of the fifth embodiment of the microcannula in which the shaft of the microcannula is enclosed within a protective sheath with a cover that retracts and exposes the tip of the microcannula;
FIG. 11 illustrates a front view of the sixth embodiment of the microcannula in which the protective sheath may be retracted thus exposing the microcannula tip;
FIG. 12 illustrates a front view of the seventh embodiment of the microcannula in which the device is encased in a case. The protective sheath may be retracted thus exposing the microcannula tip. An illumination member, such as a fiber optic or other light source may be attached to the microcannula assembly such that the tip of the microcannula or the area surrounding the tip of the microcannula may be illuminated;
FIG. 13 illustrates a front view of the eighth embodiment of the microcannula where the protective sheath may also be substantially sharp;
FIG. 14 is a perspective view of the preferred embodiment for the microcannula, clamp with stabilization post, stabilization arm and illumination positioner attached to a conventional surgeons wrist-rest;
FIGS. 15A–15B illustrate the illumination positioning arm that attaches to the stabilization post and an accessory arm that contains a series of openings in which to place a fiber optic thus directing the angle of the illumination within the eye;
FIG. 16 illustrates a self sealing needle embodiment of the present invention;
FIG. 17 illustrates the self sealing needle of FIG. 16 having a curved portion; and
FIG. 18 illustrates a substantially straight ocular implant needle embodiment of the present invention having a flange and hole.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a first embodiment for the micropipette/microcannula ( 1 ) showing the opening ( 2 ) that is preferably connected to a surgical tubing and the tip ( 3 ) of the micropipette oriented at an approximately 135 degree angle, although other ranges are possible. Tip ( 3 ) can be angled so that it may safely cannulate the retinal vessel when micropipette ( 1 ) is placed through a standard retinal surgical sclerotomy site. While glass is suggested for the material because of its ease of fashioning, strength, transparency, etc., other materials may be used. It is essential, however, that the materials maintain substantial strength when fashioned to perform retinal vessel cannulation. A handle ( 1 a ) is shown attached to the body member of micropipette ( 1 ). Handle ( 1 a ) fits securely within a micropipette holder ( 10 ) by inserting the end of micropipette ( 1 ) associated with handle ( 1 a ) and handle ( 1 a ) into the front opening of holder ( 10 ). Once inserted micropipette ( 1 ) is held in place by a setscrew associated with the holder ( 10 ).
As seen in FIG. 2 , an alternative embodiment of the micropipette/microcannula is illustrated. In this embodiment, a fiber optic ( 8 ) is attached to the micropipette body ( 7 ) to provide illumination such that an illuminated infusion cannula is not required. If a vitrectomy is not performed then one sclerotomy for the micropipette and fiber optic is all that is necessary. A handle ( 8 a ) is provided and fits securely within the holder ( 10 ) and is held in place by a set screw within the holder ( 10 ), similar to as described for micropipette ( 1 ).
FIG. 3 illustrates a further alternative embodiment for the micropipette ( 4 ) where a fiber optic for illumination is included ( 5 ) and both items are placed within a tube or needle ( 6 ). The purpose of the tube or needle is to protect the enclosed instruments such that they may be safely inserted through the sclerotomy site without breakage. Both the fiber optic and the micropipette ends are at the end or protrude from the end of the tube or needle. The micropipette and fiber optic may be advanced through the end of the tube or needle once it has been placed within the eye. A handle ( 6 a ) is illustrated that fits securely within the holder ( 10 ) and may be firmly held in place by a set screw or locking mechanism within the holder ( 10 ), as previously described above. If a vitrectomy is not performed then one sclerotomy for this device is all that is necessary.
FIG. 4 illustrates the micropipette ( 9 ) attached to the holder ( 10 ). A screw handle ( 14 b ), which controls the position of the holder ( 10 ), is attached to a flexible tube ( 13 ) so the micromanipulator may remotely advance the micropipette. Screw handle ( 14 b ) is associated with a micromanipulator ( 14 ). Preferably, screw handle ( 14 b ) is connected to micromanipulator ( 14 ). Holder ( 10 ) is attached to the micromanipulator. In one embodiment, the micromanipulator is a miniature translation stage, using dual dowel pin bearings. One such micromanipulator is made by the Newport Corporation located in Irvine, Calif. The Newport micromanipulator has a stage, which has a range of travel of approximately four (4 mm) millimeters, though such measurement is not considered limiting.
In one embodiment ( FIG. 4 ), the non-tip end of the micropipette is preferably attached to standard surgical tubing ( 11 ). The tubing ( 11 ) is attached to a connector ( 11 a ), which is connected to a syringe ( 12 ) that is used to inject medication or withdraw fluid from the retinal blood vessel. In certain situations medication such as t-PA can be injected into the retinal vessel. Alternatively, a dye can be injected into the retinal vessel for diagnosing purposes. Alternatively, a catheter, wire or stent ( 27 ) may be advanced through the microcannula for diagnosing, testing or treatment of an area located at a distance from the insertion site ( FIG. 5 ).
A foot pedal or other switch may also be provided to control (i.e. electrically, pneumatically, mechanically, etc.) the micromanipulator and injector or withdrawing device so it may be activated by the surgeon. These alternative embodiments are considered within the scope of the invention.
The micromanipulator ( 14 ) is attached to a base ( 14 a ) which is attached to a positioner ( 15 ) that is freely mobile in the “X”, “Y” and “Z” planes due to the multiplicity of joints ( 16 ), connected by elongated members ( 15 a and 16 a ). The positioner may also be electrically controlled by servo-motors and activated by the surgeon with a foot pedal or other switch. Such alternatives are also considered within the scope of the invention. Positioner ( 15 ) is not limited to any specific amount of elongated members.
The positioner can be attached to a base ( 17 ). In one embodiment, an attachment post ( 18 ) fits into a hole within another base ( 19 ). Preferably, set screws or wing nuts ( 20 ), are provided, on either side of the base which is used to secure the post to the base. In order to make the base secure, base ( 19 ) attaches to another base ( 22 ) by two screws ( 23 ). Base ( 19 ) fits above the standard ophthalmic surgical wrist rest ( 30 ) which is oriented perpendicular to bases ( 19 ) and ( 22 ). The wrist rest fits within the hole ( 21 ) that exists between bases ( 19 ) and ( 22 ). Base portion ( 22 ) completes the base and is located underneath the wrist rest. Alternatively, the positioner may be attached directly to the wrist rest or connected to the operating microscope or operating table. Additionally, the bases can be sized to fit other objects in the operating room. Changes in modifications within the spirit and scope of the invention will be apparent to those skilled in the art. Such modifications and changes are intended to be covered by the claims herein.
As seen in FIGS. 6 through 8 , a sclerotomy can be made at the standard distance from the limbus and an illuminated infusion cannula can be placed through the sclera at this point. A pars plana vitrectomy may or may not be necessary with further experience. Another or second sclerotomy can be made at the standard distance from the limbus such that the micropipette/microcannula is substantially parallel to the retinal blood vessel chosen to be cannulated. The micropipette is then placed through the sclerotomy overlying the selected retinal blood vessel. The intraocular pressure can be lowered to approximately 5 mm of Mercury to allow dilation of the vessel. Once the blood vessel is perforated, it may be advantageous to raise the intraocular pressure to minimize bleeding. The retinal blood vessel may be cannulated manually or the micromanipulator used to advance the micropipette into the retinal blood vessel.
FIGS. 9A and 9B illustrate a front view of the fourth embodiment of the microcannula in which the shaft ( 7 ) of the microcannula is enclosed by a protective sheath ( 6 ).
FIGS. 10A and 10B illustrate a fifth embodiment for the microcannula showing the microcannula ( 7 ) within a protective sheath ( 6 ) that protects the shaft of the microcannula and protective cover ( 31 ) that protects the tip of the microcannula ( FIG. 10A ). The protective sheath and cover may be made of metal, plastic, or other materials that protects the shaft and tip of the microcannula. As seen in FIG. 10B , the cover may be retracted once the microcannula is within the eye and is replaced or extended outwards once the procedure is complete and the microcannula is ready for removal from the eye, such that tip breakage is minimized.
FIGS. 11A and 11B illustrate a front view of the sixth embodiment of the microcannula in which the protective sheath ( 6 ) may be retracted into the handle ( 32 ) thus exposing the microcannula tip ( FIG. 11A ). Handle ( 32 ) also protects an otherwise exposed/unprotected portion of the shaft ( 7 ) of the microcannula when the protective member is in an extended/outward position over the beveled tip ( FIG. 11B ). The handle attached to the various microcannulas of the invention, including but not limited to handle ( 32 ) can be constructed from various materials such as nylon, plastic, delfin, etc.
FIG. 12 illustrates a seventh embodiment for the microcannula, wherein a portion of the shaft of the microcannula is encased in a hard case ( 33 ) which may be made from plastic, metal, or another robust material. An illumination member, such as a fiber optic ( 34 ) traditionally used in retinal surgery, or another illumination member or light source, may be attached to the case and secured in place by a gasket assembly ( 35 ). The type of light source and method of attachment will determine the size and degree of illumination provided. Alternatively, the light member may be attached within or outside the protective cover. The side port ( 36 ) is in communication with a device or tubing that is connected to a syringe or other device that will allow the injection or egress of fluid or other material through the microcannula.
FIG. 13 illustrates an alternate embodiment for the microcannula assembly where the tip ( 33 ) of the sheath ( 6 ) surrounding the microcannula may be sharp enough to perforate the sclera. This embodiment obviates the need for the traditional knife or MVR blade that is generally used by the surgeon to make a hole in the sclera, or sclerotomy, through which the surgeon places instruments into the eye. Once the device is inside the eye, the sheath ( 6 ) is retracted exposing the tip of the microcannula and the procedure is performed.
FIG. 14 illustrates a microcannula (i.e. any of the microcannulas disclosed herein) which can be attached to a stabilization arm ( 42 ) by a holder ( 43 ) and set screw assembly ( 44 ) or similar device. The holder ( 43 ) includes a clamp mechanism that allows for different sizes of microcannulas to be retained. The stabilization arm ( 42 ) is preferably maneuverable in the x-y-z positions and may be connected by another set screw assembly ( 35 ) with clamp mechanism ( 36 ) or similar device to a stabilization post ( 38 ) which can be attached to a clamp ( 39 ) that can be attached to a standard surgical wrist-rest ( 30 ) or other object. The tension within the stabilization arm is controlled by a tension control assembly ( 45 ). The tension along the stabilization arm controls the flexibility of the arm. The stabilization arm may be loosely tightened such that it is sufficiently flexible along its length and allows the microcannula to be easily placed into the eye. Prior to the cannulation of the retinal blood vessel, the tightening of the stabilization arm by the tension control assembly is performed such that the microcannula is steady within the eye, but where small movements are still possible with mild force by the surgeon, if desired. This allows the surgeon to place the microcannula within the blood vessel and allows it to maintain its position within the blood vessel during an infusion of medication, withdrawal of a sample, placement of an instrument, etc. The force required by the surgeon against the stabilization arm dampens any unintended movement by the surgeon such as tremor which may occur during the procedure.
FIGS. 15A and 15B illustrate the illumination positioning arm ( 37 ). As seen in FIG. 14 , illumination positioning arm ( 37 ) attaches to the stabilization post ( 38 ) through circular member ( 39 ). The arm is held in place by a set screw ( 39 a ). One or more, and preferably a series of, openings ( 40 ) are placed within an accessory arm ( 41 ) that is secured to the illumination positioning arm by a set screw ( 41 a ). By setting the angle of the illumination positioning arm in relation to the patient's head, the location of the accessory arm, and the opening in which the fiber optic ( 49 ) is placed, the desired location/intensity of illumination within the eye is achieved.
The stabilization arm, stabilization post and illumination positioning arm and accessory arm are preferably made from an easily sterilizable material, such as stainless steel or rubber, though other materials may be used and are considered within the scope of the invention.
In all embodiments, where the micropipette/microcannula is used for cannulating a retinal blood vessel it can be preferably designed to fit a eighteen (18) through twenty (20) gauge sclerotomy site. However, such is not limiting and other gauge sclerotomy sites can be chosen, and the micropipette designed accordingly, and are considered within the scope of the invention.
Though not to be considered limiting, the dimension ranges for the micropipette/microcannula for all embodiments when used for cannulating retinal blood vessels, can preferably consist of the following:
(a) first body portion associated with beveled tip end having a length range of between approximately 500 microns to approximately 1000 microns; (b) tip end beveled at a range of between approximately twenty (20°) degrees to approximately thirty (30°) degrees; (c) second body portion associated with handle having a length range of between approximately 60 millimeters to approximately 100 millimeters; (d) beveled tip end having an outer diameter range of between approximately 50 microns to approximately 100 microns and an inner diameter range of between approximately 40 microns to approximately 70 microns; and (e) angle between first body portion and second body portion having a range of between approximately 100° degrees to approximately 180° degrees, depending on area in which it is used for.
As seen in FIG. 16 a self-sealing needle 100 is provided and can be made of stainless steel, plastic or other biocompatible materials compatible with manufacturing and sterilization requirements. A self-sealing needle tip 102 can be provided at an angle to the shaft such that when used properly it can be substantially parallel to the lumen of the blood vessel chosen for perforation. The diameter of tip 102 and length of the parallel portion of the needle can be dependent on the blood vessel chosen for perforation. The terms perforation and cannulation and the terms blood vessel or structure are used interchangeably throughout this application.
The self-sealing needle comprises an elongated relatively rigid hollow body member having a single angled first end to define a relatively sharp beveled end and a second end, said second end may be attached to a syringe, tubing member, etc., directly or through a conventional attachment mechanism 104 . A first body portion 106 can be substantially smaller in size than a second body portion 108 . The outer diameter of first body portion 106 may be of a smaller diameter than the outer diameter of second body portion 108 . First body portion 106 can be permanently disposed at an angular relationship 110 with second body portion 108 such that beveled tip 102 can be positioned substantially parallel to the blood vessel to be perforated when used properly. Angular relationship 100 can be chosen based on the blood vessel targeted for perforation. First body portion 106 can be sized such that beveled tip 102 can safely enter the structure. The length of first body portion 106 and beveled tip 102 causes a shelved incision in the targeted structure which is self-sealing upon removal of first body portion 106 and beveled tip 102 from the perforation site.
As an example only, a self-sealing needle 100 that could be used to perforate the brachial vein in a normal, healthy 40-year-old male might consist of a 21 gauge tip 102 that can be beveled at an angle of approximately 20 degrees. The length of first body portion 106 can be approximately 4 mm and angular relationship 100 between the first and second body portions can be approximately 135 degrees.
Additionally, second body portion 108 of self-sealing needle 100 can be curved (See FIG. 17 ). Another variation is where a portion of the shaft is curved. An additional variation is where the shaft has multiple different curves. You can use this device is situations where a needle or cannula is required, to perforate or cannulate a blood vessel or other structure.
The length of second body portion 108 is appropriate for the structure chosen for perforation. A deeper structure may require a longer second body portion than a more superficial structure. Second body portion 108 may be straight, curved with the same or different curves along its length, or only a portion of second body portion 108 may be curved to facilitate perforation of the chosen structure. Though not limiting in range, the curve or curves of second body portion 108 may be between approximately 0 degrees to approximately 50 degrees.
FIG. 18 illustrates an ocular implant needle embodiment of the present invention which is generally referenced as needle 120 . In order to facilitate the placement into the eye of a drug implant, ocular prosthesis, sensor or other device or pharmaceutical agent a flange or other marking device (e.g. protrusion, bump depth mark, etc. all collectively referred to as “marking device”) 122 may be placed at a desired location from the extreme tip 124 of needle 120 along its length. The position of flange or marking device 122 depends on the length of the object or substance to be inserted in the eye and the properties of the item to remain in the desired location and not migrate.
Straight needles approximately 25 gauge and smaller will generally make self-sealing perforation sites when placed through the sclera of the eye. However, other gauge needles could be used as an ocular implant needle if provided in a curved or bent configuration, such as, but not limited to, the needles illustrated in FIGS. 16 and 17 herein. Preferably, needle 120 can fall within this gauge range to permit a self-sealing perforation site to be achieved. Though no limitation to the invention is implied by the following example, an ocular implant that is 2 mm in length and sized to fit within a 30 gauge needle that is to be placed through and remain at the pars plana of the eye might have a flange 122 that prevents needle 120 from being further introduced deeper into the eye at end 124 of the bevel of needle 120 , approximately 1 mm from tip 124 of needle 120 . A hole or holes 128 in the shaft 121 of needle 120 at some distance above or from flange 122 may be provided depending on the length, the stability properties, the location of placement and other properties of the item to be injected into the eye. Needle 120 preferably comprises a relatively rigid hollow body member 121 , which can be elongated or substantially straight, having a relatively sharp beveled first end 124 and a second end 125 . Second end 125 may be attached to a syringe, tubing member, etc., directly or through conventional attachment mechanism 130 .
As the surgeon slowly injects, the injectable item passes hole 128 in shaft 121 thus releasing the pressure within shaft 121 of needle 120 and slowing the rate of injection as the item nears needle tip 124 . The release of pressure within needle 120 , the visualization of escaping fluid, gas or the displacement of the surrounding fluid, hemorrhage or other objects near hole or holes 128 in needle shaft 121 alerts the surgeon to be more careful as the injectable item is reaching end 124 of needle 120 and its desired location. Once the injection is complete, the surgeon withdraws needle 120 from the eye in standard fashion.
In an alternative embodiment for needle 120 , a portion or all of shaft 121 can be transparent and provided with or without one or more holes 128 . Any percentage amount of transparent portion is considered within the scope of the invention. As being at least partially transparent, any device or liquid traveling through shaft 121 can be seen by the surgeon who can determine how much pressure to exert based on the location of the device or liquid within shaft 121 . Preferably, flange 122 or other marking device can be provided with this alternative needle 120 embodiment, and the other alternative needle 120 embodiments discussed below.
In an another needle 120 embodiment, shaft 121 is either opaque or transparent. One or more holes 128 is either covered with a membrane like material or plastic or like material. Where a membrane like material is provided, if too much pressure is applied by the surgeon, the membrane is designed to burst or pop, similar to a balloon popping. Where a plastic or other transparent like material is provided, the item can be seen traveling through shaft 121 at the location of one or more holes 128 .
In a further needle 120 embodiment, at least one slit in a side area of shaft 121 can be provided for monitoring the travel of the item within shaft 121 . Similar to the preceding paragraph, a membrane like material or plastic/transparent like material can be provided to cover the at least one slits.
The membrane like material or plastic/transparent like material can be disposed over or within holes 128 or the slits by any conventional attachment method. It is also within the scope of the invention that only a portion of the membrane like material or plastic or like material is transparent. For example, though not considered limiting, the portion of the membrane, plastic or like materials could be transparent at the portion which is aligned with holes 128 or slits, to permit visibility within shaft 121 , with other portions of the material not required to be transparent.
It is also within the scope of the invention to provide a needle 120 having any combination of features chosen from all of the features discussed above for the needle 120 embodiments.
Needle 120 may also be used to place implants, prosthesis, drugs, devices, etc. elsewhere in the eye, i.e. the choroid, the subretinal space, etc. in a desired area within the eye, i.e. anteriorly, posteriorly, etc. The injected implant or device may contain barbs or other aids to assist in the implantation and help prevent the migration of the device. Needle 120 can be constructed from materials or combination of materials similar to those described above for the embodiments illustrated in FIGS. 16 and 17 .
The angle of entry for needle 120 into the eye and the location of the flange or other marking device 122 may allow the placement of the injectable device or substance at various locations within the eye. If a mm scale along the side of shaft 121 of needle 120 is used as a marking device then the same needle 120 may be used to place the item at different locations within the eye. As an example only and not considered limiting, perforating the sclera at the 4 o'clock position and angling needle 120 toward the opposite pars plana may allow the placement of the device or substance in the pars plana at the 8 o'clock position. In this situation the surgeon would “feel” needle 120 touching the opposite internal side of the eye and would then inject. It is also apparent that the plunger on the syringe may be connected to a rod or other device that physically pushes the device to be injected out of the end of needle 120 .
Similar to earlier embodiments of the invention discussed above, shaft 121 can be provided in a bent or angled configuration to allow needle 120 to create a shelved incision at its point of entry in the eye.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. | An apparatus and method for safely cannulating a blood vessels, including but not limited retinal blood vessels, is described. In one embodiment, the apparatus can consist of a micropipette/microcannula, micromanipulator and positioner mounted to a base, which is attached to a wrist rest commonly used in eye surgery. The micropipette/microcannula is connected to tubing such that a medication may be injected through the micropipette/microcannula into the blood vessel or conversely, a small quantity of material may be removed from a blood vessel. Alternatively, a catheter, wire or stent may be placed through the micropipette/microcannula to treat or diagnose an area remote from the insertion site. The ability to cannulate a retinal blood vessel should be efficacious in the treatment of vein and artery occlusion, ocular tumors and other retinal, vascular and optic nerve disorders that would benefit from diagnosis and/or treatment. In another embodiment, a self-sealing needle is provided which allows the perforation of a blood vessel or other structure and the minimization of hemorrhaging when the needle is withdrawn from the blood vessel/structure. Another embodiment discloses an ocular implant needle. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a copier, printer, facsimile transceiver or similar equipment for copying or printing an image by an electrophotographic procedure and, more particularly, to an electrophotographic process control device capable of controlling an electrophotographic process on a step basis.
A traditional method of controlling an electrophotographic process consists in measuring the surface potential of a photoconductive drum and the image density, i.e., the amount of toner deposition by an electrometer and a photosensor, respectively, and selecting optimal manipulation amounts matching the respective measured values by referencing a look-up table which is prepared beforehand by experiments. Another conventional method is to change manipulation amounts of various sections of equipment and determine, by a PID (Proportional Integrated Difference) or similar scheme, optimal manipulation amounts while feeding back the resulting states of the equipment sensed by sensors. Still another and more advanced method uses a computing unit implemented with a fuzzy estimation algorithm and manipulates various subjects of control on the basis of the total decision of numerous parameters entangled in a complicated way. Such conventional control methods have various problems left unsolved, as enumerated below.
(1) Causes of the fluctuation of developing ability are too complicated to be presented as a model for control.
(2) Many of the parameters cannot be directly measured, e.g., the charging ability of a toner and the come-off of the coating of a developer as well as the spent condition of a developer.
(3) Since the response of toner supply delays a period of time associated with several copies, the consumption of toner which is continuous and great in amount cannot be readily dealt with.
(4) A huge amount of experimental data is needed in the event of the design and development of a developing unit.
(5) When a reference image pattern is formed to measure the density thereof, the copying speed is lowered and, in addition, the load acting on a cleaning unit is increased.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an electrophotographic process control device capable of controlling the supply of a toner in such a manner as to stabilize images against changes in the characteristics of a photoconductor and in the concentration of toner.
In accordance with the present invention, an electrophotographic image process control device has an image density sensor for measuring the density of an image formed on a photoconductive drum, a scanner for writing read image data representative of a document on the photoconductive drum, and a determining section responsive to the image density from the image density sensor and write image data from the scanner and representative of the area of an image for executing a predetermined fuzzy combination operation which uses fuzzy rules registered beforehand, and converting a membership function resulted from the operation to a non-fuzzy value to thereby determine a toner supply manipulation value.
Also, in accordance with the present invention, a process control device for electrophotographic apparatus has an image density sensor for measuring the density of an image formed on a photoconductive element, a scanner for writing read image data representative of a document image on the photoconductive element, a neural network responsive to data from sensors including a toner density sensor, a surface electrometer, a drum ammeter, a drum rotation counter, an exposure duration counter, a copy counter, a temperature sensor and a humidity sensor positioned within and in peripheral portions of the electrophotographic equipment for outputting image density data by using image density data from the image density sensor as learning data, and a determining section responsive to the image density data from the neural network and write image data from the scanner for performing a predetermined fuzzy combination operation by using fuzzy rules registered beforehand, and converting a membership function resulted from the operation to a non-fuzzy value to thereby determine a toner supply manipulation value.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken with the accompanying drawings in which:
FIG. 1 is a block diagram schematically showing an electrophotographic process control device embodying the present invention;
FIG. 2 is a block diagram schematically showing an alternative embodiment of the present invention;
FIG. 3 is an electrophotographic copier to which the present invention is applicable;
FIG. 4 shows a specific construction of a neural network incorporated in the electrophotographic process control device of the present invention;
FIG. 5 shows specific fuzzy rules applicable to toner supply control to be executed by the control device of the invention; and
FIG. 6 shows a procedure in which a toner supply manipulation value is detrermined by fuzzy estimation based on fuzzy rules.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, an electrophotographic process control device embodying the present invention has an image density sensor 109 for outputting image density data, a scanner 200 for outputting image data to be written, a toner supply value determining section 300 for determining a toner supply manipulation value, and a toner supply controller 400 for supplying a toner on the basis of the determined manipulation value.
In the scanner 200, a document image is read by a CCD (Charge Coupled Device) image sensor 201, then digitized by an analog-to-digital converter (ADC) 202, and then subjected to various kinds of image processing including correction by an image processor 203. The resulting image data from the scanner 200 and the image density data from the image density sensor 109 are applied to the toner supply value determining section 300. In response, the determining section 300 determines a toner supply manipulation value which stabilizes the image density at a predetermined value. For example, assume that the image density level is 25% and the image data to be written is 53%. Then, as shown in FIG. 5, the membership functions (indicated by hatching) of the toner supply manipulation value (posterior) are determined by respective rules. Thereafter, all the membership functions of the posterior are subjected to MAX combination to produce the final membership function indicated by hatching in FIG. 6. The final membership function is converted to a non-fuzzy value to thereby determine a toner supply manipulation value. While some different methods are available for the conversion of the membership function to a non-fuzzy value, one of them is to calculate the center of gravity of the membership function (hatched portion).
To control the supply of a toner in an electrophotographic process, a reference image pattern is formed on a photoconductive element for the measurement of image density. The amount of toner deposition on the reference image pattern is measured by a photosensor, or P sensor as sometimes referred to hereinafter, so that the toner supply is controlled in matching relation to image density which is based on the amount of toner deposition. Generally, the toner supply is effected when the image density is low or interrupted when it is high. Since forming the reference toner image pattern on the photoconductive element lowers the overall copying speed and increases the load of a cleaning unit, the number of times that such a pattern is formed should be as small as possible. However, when the reference pattern is formed and, therefore, image density is measured, for example, every predetermined number of copies for the above purpose, sharp changes in the amount of toner consumption cannot be dealt with immediately, resulting in poor image quality.
FIG. 2 shows an electrophotographic process control device embodying the present invention which eliminates the above-discussed drawbacks. Briefly, the control device of the invention causes a neural network to learn a relation between the various factors effecting image density and the actual image density and thereby controls the toner supply without forming any reference image pattern for measurement. In FIG. 2, the same or similar blocks as the blocks of FIG. 1 are designated by like reference numerals, and redundant description thereof will be avoided for simplicity. As shown in FIG. 2, the control device has sensors 100 for measuring parameters relating to toner consumption, a neural network 500 for determining an image density in response to the outputs of the sensors 100, the scanner 200, the supply value determining section 300, and the toner supply controller 400. As shown in FIGS. 2 and 3, the sensors 100 are comprised of a toner densitometer 101 responsive of toner density, an electrometer 102 responsive to the surface potential of a photoconductive drum 1, a rotation counter 103 for counting the rotations of the drum 1, an exposure duration counter 105, a copy counter 106, a temperature sensor 107, a humidity sensor 108, and the image density sensor 109.
As shown in FIG. 3, a light source, e.g., a halogen lamp 4 illuminates the image surface of a document 3 existing between a glass platen 5 and a cover plate 6. The resulting reflection from the document 3 is read by the CCD image sensor 201 via optical members including mirrors. The output of the CCD image sensor 201 is digitized by the ADC 202, then processed by the image processor 203, and then applied to the exposure manipulation value determining section 500. In response, this section 500 determines a manipulation amount meant for the exposing section and sends it to an exposure controller 601. On the other hand, a charge manipulation value determining section 700 determines a manipulation value meant for the charging section and sends it to a charge controller 701.
The operation of the control device of the invention will be described with respect to the learning stage and the decision stage of the neural network 500.
At a learning stage, the neural network 500 obtains various sensor data from the sensors 100 while a reference pattern for determining image density is formed on the drum 1. Among the sensor output data, parameters effecting the image density are applied to the input layer of the neural network 500. Applied to the output layer of the neural network is the output of the P sensor which is an instruction value or learning data.
The parameters effecting the image density include the concentration of a toner stored in a toner box 2, FIG. 3, the charge potential on the drum 1, the current flow into the drum 1 from a charging section, the wear and fatigue of the drum 1 which influences the long-term deterioration of the drum 1, the degree of continuous use representative of the frequency of operation of the equipment (copier), and the temperature and humidity having influence on the electrostatic capacity of the drum 1 and the frictional charge to be deposited on the toner.
Examples of parameters having influence on the image density and methods of calculating them will be described.
The toner density which is a first parameter is measured, in the case of a two-component type developer, in terms of a weight ratio of the toner in the toner box to the developer by the toner densitometer 101.
The surface potential of the drum 1 which is a second parameter is determined by forming a predetermined latent image pattern on the drum 1 and then measuring the surface potentials of the resulting image area and white background of the drum 1 by the electrometer 102. Here, stabilizing the surface potentials to target values is the object of latent image control. A third parameter is an amount of charge passed through the drum 1 and is determined by measuring a current fed from a charger 8 to the drum 1 by the ammeter 103 and then integrating the currents by the duration of use of the drum 1. Specifically, since the sensitivity of the drum 1 sequentially falls due to the long-term repetition of charging and discharging, the amount of charge passed through the drum 1 is represented by percentage to the usable limit (maximum rating) of the drum 1.
An amount of wear of the drum 1 which is a fourth parameter is substantially proportional to the total number of rotations of the drum 1. Specifically, the surface of the drum 1 is sequentially shaved off in contact with a cleaning section and a blade while in rotation, so that the electrostatic capacity of the drum 1 sequentially decreases. Therefore, the amount of wear of the drum 1 is determined in terms of the count of the rotation counter 104 and is represented by percentage to the usable limit (maximum rating) of the drum 1. An amount of fatigue of the drum 1 which is a fifth parameter is substantially proportional to the total duration of exposure of the drum 1. Specifically, the sensitivity of the drum 1 also changes and decreases due to short-term repetition of exposure. Hence, the amount of fatigue is determined in terms of the count of the exposure duration counter 105 and is represented by percentage to the usable limit (maximum rating) of the drum 1.
A degree of continuous use which is a sixth parameter shows how many copies have been produced in the past up to the present time by, for example, a copier. The degree of continuous use means a ratio of a short-term duration of use of, for example, a copier, and a duration of suspension. Further, as the drum 1 is continuously used, the sensitivity thereof falls and potentials undesirably remain thereon. In light of this, the degree of continuous use is determined in terms of the count of the copy counter 106. Temperature and humidity which are a seventh and an eighth parameter are represented by the outputs of temperature sensor 107 and humidity sensor 108, respectively. The sensitivity of the drum 1 is extremely susceptible to changes in temperature and humidity. While this is ascribable to changes in the electrostatic capacity of a photoconductor and leakage currents occurring during and after charging, it is difficult to grasp a direct relation in practice.
Regarding the image density which is a ninth parameter, use is made of the image density sensor 109 which may be implemented as a P sensor made up of a laser diode 9a and a photosensor 9b. The amount of toner deposition on the image area of the drum 1 is calculated in response to the output of the image density sensor 109 and on the basis of a difference of reflectances. The output of the image density sensor 109 is used as learning data by the neural network and is also used as data for determining an amount of toner supply by the toner supply value determining section 300. The prerequisite is that the toner supply value determining section 300 be adjusted beforehand in such a manner as to output an optimal toner supply manipulation value in response to the image density. The adjustment of this determining section may be executed in parallel with the operation for obtaining the learning data for the neural network 500.
To measure, among the above various parameters, the image density, a predetermined reference image pattern has to be formed on the drum 1. This lowers the copying speed of, for example, a copier and increases the load on a cleaning unit, as stated earlier. Hence, the number of times that such a reference pattern is formed should be as small as possible.
In light of the above, when the control device of the present invention executes control, the reference image pattern for measurement is formed every time more than a predetermined copies are produced and, therefore, a minimum number of times. Stated another way, the image density is not measured until a predetermined number of copies have been produced. For this reason, the control device of the invention causes the neural network 500 to estimate an image density at any suitable time and controls the toner supply in matching relation to the estimated image density. Specifically, the process control device of the invention is capable of feeding a toner in an optimal amount copy by copy by obtaining charge potential, drum current and other sensor data copy by copy and combining them with the image data from the scanner to estimate image density data.
In summary, it will be seen that the present invention provides an electrophotographic process control device capable of effecting optimal control with respect to each of various definite factors which cause a photoconductive element to deteriorate. Such a control device, therefore, achieves a broad range of control and prevents equipment in which it is incorporated from running out of control. Since the control device estimates image density without forming a reference density pattern on a photoconductive element, it prevents the copying speed from being lowered and reduces the load on a cleaning unit. Moreover, the control device makes it needles to assume a model for the control of a developing system, immediately adapts itself to sharp changes in the amount of toner consumption, and reduces the amount of experiments and, therefore, the term and costs for design and development.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof. | An electrophotographic process control device for controlling the supply of a toner in such a manner as to stabilize images against changes in the characteristics of a photoconductive element and in the concentration of the toner. An image density sensor measures the density of an image formed on a photoconductive drum. A scanner writes read image data representative of a document on the photoconductive drum. A determining section is responsive to the image density from the image density sensor and write image data from the scanner and representative of the area of an image for executing a predetermined fuzzy combination operation by using fuzzy rules registered beforehand and converts a membership function resulted from the operation to a non-fuzzy value to thereby determine a toner supply manipulation value. | 6 |
FIELD
[0001] The present invention relates to containers for holding, storing and dispensing liquids, such as sauce, dressing or other items.
BACKGROUND
[0002] Food items served with sauces or other condiments (such as ketchup, mustard, dressings, or the like) for dipping are common (generically, the foregoing referred to herein as condiments). Typically, the condiment is provided in a small round plastic container which may or may not have a lid. A problem with such a container is that it is not convenient or efficient to remove excess condiment on the container rim after the food item is dipped therein, resulting in excess condiment remaining on the food item. Also, round containers are difficult to grasp when a user's fingers may be slippery from condiment, grease, or the like which may accumulate during eating.
[0003] It would be desirable to have a condiment container which would provide a more effective and efficient means to remove excess condiment on a dipped food item. It would also be desirable to have a condiment container which could be easily grasped in a user's fingers even if the fingers are slippery.
SUMMARY
[0004] Generally described, the present invention provides in a first exemplary embodiment a container for holding and storing sauces and other liquids, comprising a base having a generally flat base bottom, a generally frusto-conical wall extending upward from the bottom and having a rim, the wall having a first section, a second section opposing the first section, the first section having a height greater than the second section, a third section, and a fourth section opposing the third section, the third and fourth sections each having an inwardly curved gripping section, the gripping section having at least one gripping surface a lip extending substantially around the rim of the wall.
[0005] The wall first section has at least one and preferably a plurality of fluid retention devices for retaining fluid when a food item is wiped across the retention devices. The retention devices can be ribs, grooves, bumps, other protrusions, combinations and mixtures of the foregoing or the like.
[0006] The container may have a lid adapted to snap fit over the lip, the lid having a generally flat lid bottom, a lid wall extending upward from the lid bottom, the lid wall having a first section and a second section, the first section having a height greater than the second section, a seal portion comprising a first flange extending generally outward and generally perpendicular to the lid wall and a second flange extending generally downward from the first flange, the seal portion being adapted to mate with the lid and form a seal therewith, whereby the lid wall first section is generally aligned with the base wall first section.
[0007] The gripping section may include a plurality of retention devices to facilitate gripping. The retention devices can be grooves, ribs, bumps, combinations of the foregoing or the like.
[0008] The container is preferably constructed to allow a number of containers to nest and stack to minimize storage space. The lid is similarly constructed. When the lid is attached to the container a number of lid-container units can be stacked to permit storage of pre-filled containers.
[0009] Other features of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:
[0011] FIG. 1 is a perspective view of a container base according to one exemplary embodiment of the present invention.
[0012] FIG. 2 is a bottom plan view of the base of FIG. 1 .
[0013] FIG. 3 is a side elevation view of the base of FIG. 1 .
[0014] FIG. 4 is a top plan view of the base of FIG. 1 .
[0015] FIG. 5 is a perspective view of a lid according to one exemplary embodiment of the present invention.
[0016] FIG. 6 is a perspective view of the base of FIG. 1 and the lid of FIG. 5 in which the lid is in position over the base.
[0017] FIG. 7 is a perspective view of the lid attached to the base.
[0018] FIG. 8 is a perspective view of a first alternative embodiment of a base, including a plurality of retention devices.
[0019] FIG. 9 is a perspective view of a second alternative of a lid including a tab.
[0020] FIG. 10 is a perspective view of a container base with condiment showing a food item being wiped across the lip and retention devices.
DETAILED DESCRIPTION
[0021] FIGS. 1-7 show one exemplary embodiment of a container 10 having a base 20 and a lid 22 . FIGS. 1-4 show the details of the base 20 , which generally has a bottom 24 , a wall 28 and a lip 30 .
[0022] The wall 28 has a first section 32 , second section 34 , third section 36 and fourth section 38 . The first and second sections 32 , 34 oppose each other and the first section 32 has a height greater than that of the second section 34 so that the lip 30 is angled with respect to the base 20 . The wall 28 may flare outward in a generally frusto-conical shape. The general relationship between the diameter of the base 20 and the lip 30 is such that a container is created which, when placed on a flat surface, is generally resistant to tipping when a condiment is placed therein.
[0023] The third and fourth sections 36 , 38 oppose each other and each has a recessed area which serves as a gripping area 40 . Each recessed gripping area 40 may curve inward slightly so that a user can grip the gripping areas 40 with a thumb and opposing finger. Each gripping area 40 may optionally have one or more gripping surfaces 42 , which may take the form of protrusions, grooves, recesses, ribs, ridges, steps, bumps, spikes, domes, fingers, nibs, and combinations of the foregoing. The gripping area 40 may extend to the base 20 (as shown in FIG. 1 ) or may extend only toward the base 20 . If the former, the gripping area 40 may optionally create a curved notched out area 44 in the base 20 .
[0024] The lip 30 may extend outward from the wall 28 . Alternatively, the lip 30 may have a flange which extends both outward and inward.
[0025] Turning to FIG. 5 , the lid 22 includes a bottom 60 and a sidewall 62 . The sidewall 62 has a first section 64 that is greater in height than a second section 66 . A rim 68 has a seal 70 comprising a first flange 72 and a second flange 74 , the seal 70 being adapted to mate over the lip 30 by a friction or snap fit to seal the container base 10 , as shown in FIGS. 6-7 . The seal 70 can be one which is removable and resealable, or, the seal 70 can be a seal which is formed so that in use, a container 10 filled with condiment has the lid 22 and seal 70 formed to provide a seal which can be unsealed only once (such as a milk jug cap seal). In such an embodiment the seal 70 may have a weakened or frangible area which a user can separate or remove by pulling on a tab 90 (see FIG. 9 and as described hereinbelow).
[0026] The container 10 may be made of any suitable material, such as, but not limited to, polymer plastic, stainless steel, aluminum, paper/cellulose, wood, recycled or recyclable material, edible materials, mixtures and combinations of the foregoing or the like and may be formed by any suitable manufacturing process, such as, but not limited to, vacuum forming, blow molding, or the like.
[0027] The lid bottom 60 can be marked with a pen, pencil or marker with the contents, or can have a sticker adhered to or a stamp placed on the bottom 60 as advertising.
[0028] In one use, a server can place a quantity of liquid, such as a condiment 78 (e.g., ketchup or mustard), sauce (e.g., barbeque) or dressing (e.g., ranch, blue cheese) (the foregoing referred to generically as “condiment(s)”, but is intended to include such items as can be contained in the container), in the base 20 and attach the lid 22 to the base 20 to prevent spilling. The container 10 can be served with various food items suitable for dipping, such as, but not limited to, chicken wings, vegetable sticks, fried cheese sticks, spring rolls or the like. The user can then remove the lid 22 and dip the food item into the condiment and wipe the excess condiment on the lip 30 , such as proximate the wall first section 32 . As the food item is raked across the lip 30 the excess condiment is retained by the lip 30 and flows down the wall 28 and back into the container base 20 . The angle and diameter of the wall first section 32 is such that the condiment is retained in the base 20 .
[0029] A user can pick the base 20 up and hold it between his or her fingers, using the gripping areas 40 to hold the base 20 . The gripping surfaces 42 help to maintain the user's grip, particularly when the user's fingers may be slippery, wet or greasy or have excess condiment on them.
[0030] In a first alternative embodiment, shown in FIG. 8 , the base 20 can have at least one, and preferably a plurality of fluid retention devices 80 , such as, but not limited to, protrusions, grooves, recesses, ridges, steps, bumps, spikes, domes, fingers, nibs, combinations and mixtures of the foregoing or the like formed as part of the wall 28 , such as part of the first section 34 (it being understood that other portions of the wall can include such retention devices 80 ). The condiment retention device 80 helps to retain excess 79 condiment 78 (see FIG. 10 ) when the user wipes the food item across the lip 30 and the wall 32 .
[0031] The base 20 can be nestably stacked with multiple bases 20 to minimize the area needed for storage. Similarly, the lid 22 can be nestably stacked with a plurality of other lids 22 . The base bottom 24 and lid bottom 60 are generally the same diameter so that multiple containers 10 (in which the lid 22 is fitted on the base 20 ) with or without condiments, can be stacked. In this manner, a set of different condiments can be conveniently carried from kitchen to table by stacking several containers 10 on top of each other without fear of spilling or inadvertently mixing the contents. Containers 10 can be filled with condiments, sealed, and stacked and stored, such as in a refrigerator, until used.
[0032] The lid 22 can optionally have a tab 90 (as shown in FIG. 9 ) to aid in removal of the lid 22 .
[0033] In one exemplary embodiment, the container base 20 can be a 2, 3 or 4 ounce capacity size. It is to be understood that the size and proportions can be adapted for different uses. Similarly, the angle of the wall 28 can be modified as the use requires. For example, the container 10 can be adapted for use as a paint container such that a user can hold the container in one hand and dip a small brush in to reservoir of paint, wiping the excess paint off using the lip 30 or the retention devices 80 (see FIG. 8 ).
[0034] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
[0035] 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. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[0036] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
[0037] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.
[0038] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following inventive concepts. It should further be noted that any patents, applications and publications referred to herein are incorporated by reference in their entirety. | A container for holding a dipping condiment or sauce and allowing a user to wipe a food item to remove excess condiment or sauce. The container has a base and a side wall having one portion higher than an opposing portion, the wall including at least one ridge, groove or other fluid retention device. The wall also includes a pair of opposing inwardly curved gripping surfaces for facilitating gripping by a user's fingers, the gripping surfaces including ribs or grooves. The container may also include a lid which snap fits onto the lip of the container. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2009-071736 filed on Mar. 24, 2009.
BACKGROUND
Technical Field
[0002] The present invention relates to an image processing apparatus and an image processing control method and a computer readable medium.
SUMMARY
[0003] According to an aspect of the invention, an image processing apparatus includes: an image processing unit; a processing unit that performs predetermined processing under the control of the information processing unit; a reading unit that performs an operation of reading authentication information at intervals of a predetermined time under the control of the information processing unit; an authentication unit that authenticates a user based on the authentication information read by the reading unit under the control of the information processing unit; a permission unit that permits the predetermined processing to be performed by the processing unit on the condition that the authentication is completed by the authentication unit; and a change unit that changes the time interval for the reading unit to perform the reading operation in accordance with the status of processing to be executed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Exemplary embodiment(s) of the present invention will be described in detail based on the following figures, wherein:
[0005] FIG. 1 is a block diagram for explaining the overall configuration of a system according to a first exemplary embodiment of the invention;
[0006] FIG. 2 is an electric connection block diagram of a digital copying machine according to the first exemplary embodiment of the invention;
[0007] FIG. 3 is a functional block diagram of the digital copying machine according to the first exemplary embodiment of the invention;
[0008] FIG. 4 is a flow chart of the digital copying machine according to the first exemplary embodiment of the invention;
[0009] FIG. 5 is a flow chart of a digital copying machine according to a second exemplary embodiment of the invention; and
[0010] FIG. 6 is a flow chart of a digital copying machine according to a third exemplary embodiment of the invention.
DETAILED DESCRIPTION
[0011] Exemplary embodiments of the invention will be described below.
[0012] A first exemplary embodiment of the invention will be described first.
[0013] FIG. 1 is a block diagram for explaining the overall configuration of a system according to the first exemplary embodiment.
[0014] In this system, a digital copying machine 1 placed in an office or the like for performing an image processing apparatus according to the invention is connected to respective user's personal computers (PCs) 2 for the digital copying machine 1 via a network 3 such as an LAN. One of the PCs 2 is an administrative PC 4 used by an administrator of the digital copying machine 1 .
[0015] FIG. 2 is an electric connection block diagram of the digital copying machine 1 .
[0016] The digital copying machine 1 has a control portion 11 which controls the whole of the digital copying machine 1 . The control portion 11 has a CPU 12 which controls respective parts in a centralized manner, an ROM 14 which is connected to the CPU 12 and in which various types of control programs 13 to be executed by the CPU 12 and stationary data are stored, and an RAM 15 which is connected to the CPU 12 and which serves as a working area of the CPU 12 .
[0017] The control programs 13 may be set up initially in production of the digital copying machine 1 . Alternatively, the control programs 13 may be stored in a recording medium so that the control programs 13 can be read from the recording medium and set up on a nonvolatile memory, a magnetic recording device or the like later. Alternatively, the control programs 13 may be downloaded in the form of carrier waves through a communication unit such as the Internet and set up on nonvolatile memory, a magnetic recording device or the like later.
[0018] A card reader 22 , a scanner 23 , a printer engine 24 , a facsimile controller 26 , a magnetic recording device (HDD) 27 , a communication interface (I/F) 28 and an operation panel 29 are connected to the control portion 11 . The card reader 22 reads a card 21 . The scanner 23 reads an image of an original. The printer engine 24 forms an image on a medium such as a sheet of paper by electrophotography or another method. The facsimile controller 26 is connected to a public phone line 25 or the like and performs facsimile transmission and reception. The magnetic recording device (HDD) 27 stores image data, etc. The communication I/F 28 communicates with the outside via a network 3 . The operation panel 29 accepts various kinds of operations. The communication I/F 28 may be connected to the Internet 30 via the network 3 .
[0019] For example, the card 21 is an IC card on which a password or personal identification number is recorded for authenticating a user who possesses the card 21 . The password or personal identification number is read by the card reader 22 to authenticate the user about a license to use the digital copying machine 1 . The means for authenticating the user is not limited thereto. For example, a password or personal identification number may be input through the operation panel 29 or biometrics authentication such as fingerprint authentication may be used. When biometrics authentication is used, a reader for reading biometric information such as fingerprint information is used in place of the card reader 22 so that the reader is connected to the digital copying machine 1 .
[0020] Processing executed by the control portion 11 based on the control programs 13 will be described next.
[0021] FIG. 3 is a functional block diagram of processing executed by the control portion 11 based on the control programs 13 .
[0022] An information processing unit 41 controls respective units shown in FIG. 3 in a centralized manner. The information processing unit 41 is implemented by the control portion 11 . A reader 42 is implemented by the card reader 22 or a reader for reading biometric information such as fingerprint information. An authentication information reading unit 43 uses the reader 42 for reading a password or personal identification number or authentication information such as biometric information.
[0023] An access control list 44 is stored in a storage device such as an HDD 27 . Passwords, personal identification numbers, biometric information, etc. are registered in the access control list 44 so that authentication information read by the authentication information reading unit 43 can be collated when user authentication is performed. An authentication unit 45 collates the authentication information read by the authentication information reading unit 43 with information registered in the access control list 44 to thereby authenticate the user about a license to use the digital copying machine 1 .
[0024] A processing status determination unit 46 determines the processing status operated in the digital copying machine 1 . A reading interval control unit 47 changes a time interval for the reader 42 to read authentication information in accordance with the processing status determined by the processing status determination unit 46 . That is, the reader 42 performs an authentication information reading operation at intervals of a predetermined time. This time interval can be changed. An operation unit 48 accepts various kinds of operations from the user through the operation panel 29 .
[0025] FIG. 4 is a flow chart of processing executed by the control portion 11 based on the control programs 13 .
[0026] Processing in FIG. 4 starts when a main power supply of the digital copying machine 1 is turned on. First, the time interval for the reader 42 to read authentication information is set to be short by the authentication information reading unit 43 (step S 1 ).
[0027] That is, the time interval for the reader 42 to read authentication information is set to be a short time interval predetermined as a default value. Accordingly, the reader 42 can read authentication information rapidly compared with the case where setting in step S 6 which will be described later has been performed.
[0028] Then, when the user makes the reader 42 read the card 21 or biometric information such as fingerprint information so that authentication information is read (Y in step S 2 ), the authentication unit 45 refers to the access control list 44 (step S 3 ) and determines whether the user is allowed to use the digital copying machine 1 or not (step S 4 ). When the authentication unit 45 determines that the user is allowed to use the digital copying machine 1 (Y in step S 4 ), the user is permitted to use (log in) the digital copying machine 1 because the user has been authenticated about a license to use the digital copying machine 1 . As a result, the user can operate the operation unit 48 freely to perform various kinds of processing allowed to be executed by the digital copying machine 1 , that is, to perform copying, printing, scanning, facsimile processing, etc. On this occasion, the processing status of the digital copying machine 1 is changed to ‘active’ (step S 5 ).
[0029] In response to the processing status of the digital copying machine 1 changed to ‘active’, a reading interval control unit 47 sets the reading interval for the reader 42 to read authentication information to be longer than that in the step S 1 through the authentication information reading unit 43 (step S 6 ).
[0030] Accordingly, because the information processing unit 41 need not devote a large throughput capacity to controlling the authentication information reading unit 43 , the information processing unit 41 can devote a relatively large throughput capacity to controlling a job of the digital copying machine 1 operated by the user compared with the situation where processing in the step S 6 has not been performed yet.
[0031] When the card 21 for authentication is removed from the reader 42 or a predetermined operation is accepted by the operation unit 48 , the user's use of the digital copying machine 1 is terminated (logged out) (Y in step S 7 ). Then, the time interval for the reader 42 to read authentication information is set to be shorter again than that in the step S 6 by the authentication information reading unit 43 (step S 8 ) and the situation of processing goes back to the step S 2 .
[0032] Accordingly, after the user's use of the digital copying machine 1 is terminated, the reader 42 can read authentication information rapidly compared with the case where setting in the step S 6 has been performed.
[0033] A second exemplary embodiment of the invention will be described next.
[0034] The hardware configuration of a digital copying machine 1 according to this exemplary embodiment is the same as that of the digital copying machine 1 according to the first exemplary embodiment as described above with reference to FIGS. 1 and 2 . The functional block diagram of the digital copying machine 1 according to this exemplary embodiment is the same as that of the digital copying machine 1 according to the first exemplary embodiment as described above with reference to FIG. 3 . The same numerals in FIGS. 1 to 3 are used in the following description for the sake of omission of detailed description. In this exemplary embodiment, processing in FIG. 5 is performed in place of processing in FIG. 4 .
[0035] Processing in FIG. 5 starts when the main power supply of the digital copying machine 1 is turned on. First, the authentication information reading unit 43 sets the time interval for the reader 42 to read authentication information to be shorter than that in step S 17 which will be described later (step S 11 ).
[0036] That is, the time interval for the reader 42 to read authentication information is set to be a short time interval predetermined as a default value. Accordingly, the reader 42 can read authentication information rapidly compared with the case where setting in step S 17 which will be described later has been performed.
[0037] Then, when the user makes the reader 42 read the card 21 or biometric information such as fingerprint information so that authentication information is read (Y in step S 12 ), the authentication unit 45 refers to the access control list 44 (step S 13 ) and determines whether the user is allowed to use the digital copying machine 1 or not (step S 14 ). When the authentication unit 45 determines that the user is allowed to use the digital copying machine 1 (Y in step S 14 ), the user is permitted to use (log in) the digital copying machine 1 because the user has been authenticated about a license to use the digital copying machine 1 . As a result, the user can operate the operation unit 48 freely to perform various kinds of processing allowed to be executed by the digital copying machine 1 , that is, to perform copying, printing, scanning, facsimile processing, etc.
[0038] When there is any job running in the digital copying machine 1 (Y in step S 15 ), determination is made as to whether the job is a job (such as copying, printing, scanning, facsimile transmission, etc.) executed based on the user's operation of the operation unit 38 (or PC 2 ) or whether the job is a job (such as facsimile reception, etc.) executed based on the determination of the information processing unit 41 without the user's operation of the operation unit 48 (step S 16 ). When the job is a job executed based on the user's operation of the operation unit 48 (Y in step S 16 ), the authentication information reading unit 43 sets the time interval of a reading operation for the reader 42 to read authentication information to be longer than that in the step S 11 (step S 17 ).
[0039] As a result, because the information processing unit 41 need not devote a large throughput capacity to controlling the authentication information reading unit 43 when a job executed based on the user's operation of the operation unit 48 is performed, the information processing unit 41 can devote a relatively large throughput capacity to controlling the processing of the digital copying machine 1 operated by the user. Accordingly, the job executed based on the user's operation of the operation unit 48 can be performed rapidly compared with the job executed based on the determination of the information processing unit 41 without the user's operation of the operation unit 48 .
[0040] On the other hand, when a job executed based on the determination of the information processing unit 41 without the user's operation of the operation unit 48 is performed (N in step S 16 ), the reader 42 can read authentication information rapidly compared with the case where a job executed based on the user's operation of the operation unit 48 is performed.
[0041] When the card 21 for authentication is removed from the reader 42 or a predetermined operation is accepted by the operation unit 48 , the user's use of the digital copying machine 1 is terminated (logged out) (Y in step S 18 ). Then, the time interval for the reader 42 to read authentication information is set to be shorter again than that in the step S 17 by the authentication information reading unit 43 (step S 19 ). In this case, the situation of processing goes back to the step S 12 .
[0042] Accordingly, after the user's use of the digital copying machine 1 is terminated, the reader 42 can read authentication information rapidly compared with the case where a job executed based on the user's operation of the operation unit 48 is performed.
[0043] When the user's use of the digital copying machine 1 is not terminated (logged out) (N in step S 18 ), the situation of processing goes back to the step S 15 .
[0044] A third exemplary embodiment of the invention will be described next.
[0045] The hardware configuration of a digital copying machine 1 according to this exemplary embodiment is the same as that of the digital copying machine 1 according to the first exemplary embodiment as described above with reference to FIGS. 1 and 2 . The functional block diagram of the digital copying machine 1 according to this exemplary embodiment is the same as that of the digital copying machine 1 according to the first exemplary embodiment as described above with reference to FIG. 3 . The same numerals in FIGS. 1 to 3 are used in the following description for the sake of omission of detailed description. In this exemplary embodiment, processing in FIG. 6 is performed in place of processing in FIG. 4 .
[0046] Processing in FIG. 6 starts when the main power supply of the digital copying machine 1 is turned on. First, the authentication information reading unit 43 sets the time interval for the reader 42 to read authentication information to be shorter than that in step S 23 which will be described later (step S 21 ).
[0047] That is, the time interval for the reader 42 to read authentication information is set to be a short time interval predetermined as a default value. Accordingly, the reader 42 can read authentication information rapidly compared with the case where setting in step S 23 which will be described later has been performed.
[0048] Then, when the user makes the reader 42 read the card 21 or biometric information such as fingerprint information so that authentication information is read (Y in step S 22 ), the authentication information reading unit 43 sets the time interval of a reading operation for the reader 42 to read authentication information to be longer than that in the step S 21 (step S 23 ). Then, the authentication unit 45 refers to the access control list 44 (step S 24 ) and determines whether the user is allowed to use the digital copying machine 1 or not (step S 25 ) When the authentication unit 45 determines that the user is allowed to use the digital copying machine 1 (Y in step S 25 ), the user is permitted to use (log in) the digital copying machine 1 because the user has been authenticated about a license to use the digital copying machine 1 . As a result, the user can operate the operation unit 48 freely to perform various kinds of processing allowed to be executed by the digital copying machine 1 , that is, to perform copying, printing, scanning, facsimile processing, etc.
[0049] As described above, when authentication information is read (Y in step S 22 ), the authentication information reading unit 43 sets the time interval of a reading operation for the reader 42 to read authentication information to be longer than that in the step S 21 (step S 23 ). As a result, because the information processing unit 41 need not devote a large throughput capacity to controlling the authentication information reading unit 43 , the information processing unit 41 can devote a relatively large throughput capacity to controlling processing of jobs such as copying, printing, scanning, facsimile processing, etc. Accordingly, these jobs can be executed rapidly.
[0050] Moreover, because processing in steps S 24 and S 25 is performed after the authentication information reading unit 43 sets the time interval of a reading operation for the reader 42 to read authentication information to be longer than that in the step S 21 , the user authentication process can be performed rapidly compared with the case according to the first or second exemplary embodiment.
[0051] When the card 21 for authentication is removed from the reader 42 or a predetermined operation is accepted by the operation unit 48 so that the user's use of the digital copying machine 1 is terminated (logged out) (Y in step S 26 ), the situation of processing goes back to the step S 21 in which the time interval for the reader 42 to read authentication information is set to be shorter again than that in the step S 23 by the authentication information reading unit 43 .
[0052] Accordingly, after the user's use of the digital copying machine 1 is terminated, the reader 42 can read authentication information rapidly compared with the case where setting in the step S 23 has been performed.
[0053] The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | An image processing apparatus includes: an image processing unit; a processing unit that performs predetermined processing under the control of the information processing unit; a reading unit that performs an operation of reading authentication information at intervals of a predetermined time under the control of the information processing unit; an authentication unit that authenticates a user based on the authentication information read by the reading unit under the control of the information processing unit; a permission unit that permits the predetermined processing to be performed by the processing unit on the condition that the authentication is completed by the authentication unit; and a change unit that changes the time interval for the reading unit to perform the reading operation in accordance with the status of processing to be executed. | 7 |
[0001] This invention relates to operating systems. More particularly, this invention relates to systems, methods and computer programs for running multiple operating systems concurrently.
[0002] For some computer programs, it is critical that steps in the program are performed within defined time periods, or at defined times. Examples of such programs are control programs for operating mobile telephones, or for operating private branch exchanges (PBXs) or cellular base stations. Typically, the program must respond to external events or changes of state in a consistent way, at or within a certain time after the event. This is referred to as operating in “real time”.
[0003] For many other programs, however, the time taken to execute the program is not critical. This applies to most common computer programs, including spreadsheet program, word processing programs, pay roll packages, and general reporting or analysis programs. On the other hand, whilst the exact time taken by such programs is not critical, in most cases, users would prefer quicker execution where this is possible.
[0004] Applications programs interact with the computers on which they run through operating systems. By using the applications programming interface (API) of the operating system, the applications program can be written in a portable fashion, so that it can execute on different computers with different hardware resources. Additionally, common operating systems such as Linux or Windows provide multi-tasking; in other words, they allow several program to operate concurrently. To do so, they provide scheduling; in other words, they share the usage of the resources of the computer between the different programs, allocating time to each in accordance with a scheduling algorithm. Operating systems of the this kind are very widely used, but they generally make no provision for running real time applications, and they therefore are unsuitable for many control or communications tasks.
[0005] For such tasks, therefore, real time operating systems have been developed; one example is ChorusOS (also know as Chorus) and its derivatives. Chorus is available as open source software from: http://www.experimentalstuff.com/Technologies/ChorusOS/index.html and Jaluna at http://www.jaluna.com/
[0006] It is described in “ChorusOS Features and Architecture overview” Francois Armand, Sun Technical Report, August 2001, 222p, available from: http://www.jaluna.com/developer/papers/COSDESPERF.pdf
[0007] These operating systems could also be used to run other types of programs. However, users understandably wish to be able to run the vast number of “legacy” programs which are written for general purpose operating systems such as Windows or Linux, without having to rewrite them to run on a real time operating system.
[0008] In U.S. Pat. No. 5,903,752 and U.S. Pat. No. 5,721,922, an attempt is made to incorporate a real time environment into a non real time operating system by providing a real time multi-tasking kernel in the interrupt handling environment of the non real time operating system (such as Windows).
[0009] It would be possible to provide a “dual boot” system, allowing the user to run either one operating system or the other, but there are many cases where it would be desirable to be able to run a “legacy” program at the same time as running a real time program. For example, telecommunications network infrastructure equipment, third generation mobile phones and other advanced phones, and advanced electronic gaming equipment may require both realtime applications (e.g. game playing graphics) and non-realtime applications (game download).
[0010] One approach which has been widely used is “emulation”. Typically, an emulator program is written, to run under the real time operating system, which interprets each instruction of a program written for a general purpose operating system, and performs a corresponding series of instructions under the real time operating system. However, since one instruction is always replaced by many, emulation places a heavier load on the computer, and results in slower performance. Similar problems arise from the approach based on providing a virtual machine (e.g. a Java™ virtual machine).
[0011] A further similar technique is described in U.S. Pat. No. 5,995,745 (Yodaiken). Yodaiken describes a system in which a multi tasking real time operating system runs a general purpose operating system as one of its tasks, pre-empting it as necessary to perform real time tasks.
[0012] A more similar approach is that of ADEOS (Adaptive Domain Environment for Operating Systems), described in a White Paper at http://opersys.com/ftp/pub/Adeos/adeos.pdf
[0013] ADEOS provides a nanokernel which is intended, amongst other things, for running multiple operating systems although it appears only to have been implemented with Linux. One proposed use of ADEOS was to allow ADEOS to distribute interrupts to RTAI (Realtime Application Interface for Linux) for which see:
[0014] http://www.aero.polimi.it/˜rtai/applications/.
[0015] An object of the present invention is to provide an improved system, method and computer program for running multiple operating systems simultaneously, even when the systems are designed for different purposes. In particular, the present invention aims to allow one of the operating systems (for example, a real time operating systems) to perform without disturbance, and the other (for example, a general purpose operating system) to perform as well as possible using the remaining resources of the computer.
[0016] Accordingly, in one aspect, the present invention provides a system in which multiple operating systems are slightly modified and provided with a common program which schedules between them, in which one of the operating systems (the “primary” or “critical” operating system) is favoured over another (the “secondary” or non-critical operating system). Preferably, the invention allocates hardware preferentially to the critical operating system, and it denies the secondary operating system or systems access which would interfere with that of the critical operating system. Preferably, the present invention uses the critical operating system drivers to access shared resources, even if the access is requested by the secondary operating system. However, in no sense is the critical operating system “running” the secondary operating system, as in U.S. Pat. No. 5,995,745; each system ignores the others running alongside it and only communicates with the common program (corresponding to a nanokernel of the prior art) which brokers the access to the drivers of the critical operating system.
[0017] Other aspects, embodiments and preferred features, with corresponding advantages, will be apparent from the following description, claims and drawings.
[0018] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0019] [0019]FIG. 1 is a block diagram showing the elements of a computer system on which the present invention can execute;
[0020] [0020]FIG. 2 a is a diagram illustrating the arrangement of software in the prior art; and
[0021] [0021]FIG. 2 b is the corresponding diagram illustrating the arrangement of software according to the present embodiment;
[0022] [0022]FIG. 3 is a flow diagram showing the stages in creating the software of FIG. 2 b for the computer of FIG. 1;
[0023] [0023]FIG. 4 show the components of a hardware resource dispatcher forming part of FIG. 2 b;
[0024] [0024]FIG. 5 illustrates the program used in a boot and initialisation sequence;
[0025] [0025]FIG. 6 illustrates the system memory image used in the boot or initialisation process;
[0026] [0026]FIG. 7 illustrates the transition from a primary operating system to a secondary operating system;
[0027] [0027]FIG. 8 illustrates the transition from a secondary operating system to a primary operating system;
[0028] [0028]FIG. 9 a illustrates the communication between applications running on different operating systems according to the invention; and
[0029] [0029]FIG. 9 b illustrates the communication between applications running on different operating systems on different computers according to the invention.
INTRODUCTION
System Hardware
[0030] A computer system to which the system is applicable 100 comprises a central processing unit (CPU) 102 , such as a Pentium 4™ CPU available from Intel Corporation, or PowerPC CPU available from Motorola (the embodiment has been implemented on both), coupled via a system bus 104 (comprising control, data and address buses) to a read-only memory (ROM) chip 106 ; one or more banks of random access memory (RAM) chips ( 108 ); disk controller devices 110 (for example IDE or SCSI controllers, connected to a floppy disk drive, a hard disk drive, and additional removable media drives such as DVD drives); one or more input/output ports ( 112 ) (for example, one or more USB port controllers, and/or parallel port controllers for connection to printer and so on); an expansion bus 114 for bus connection to external or internal peripheral devices (for example the PCI bus); and other system chips 116 (for example, graphics and sound devices). Examples of computers of this type are personal computers (PCs) and workstations. However, the application of the invention to other computing devices such as mainframes, embedded microcomputers in control systems, and PDAs (in which case some of the indicated devices such as disk drive controllers may be absent) is also disclosed herein.
Management of Software
[0031] Referring to FIG. 2 a, in use, the computer 100 of FIG. 1 runs resident programs comprising operating system kernel 202 (which provides the output routines allowing access by the CPU to the other devices shown in FIG. 1); an operating system user interface or presentation layer 204 (such as X Windows); a middleware layer 206 (providing networking software and protocols such as, for instance, a TCP/IP stack) and applications 208 a , 208 b , which run by making calls to the API routines forming the operating system kernel 202 .
[0032] The operating system kernel has a number of tasks, in particular:
[0033] scheduling (i.e., sharing the CPU and associated resources between different applications which are running);
[0034] memory management (i.e. allocating memory to each task, and, where necessary, swapping data and programs out of memory add on to disk drives);
[0035] providing a file system;
[0036] providing access to devices (typically, through drivers);
[0037] interrupt handling;
[0038] providing an applications programming interface enabling the applications to interact with system resources and users.
[0039] The kernel may be a so-called “monolithic kernel” as for Unix, in which case the device drivers form part of the kernel itself. Alternatively, it may be a “microkernel” as for Chorus, in which case the device drivers are separate of the kernel.
[0040] In use, then, when the computer 100 is started, a bootstrap program stored in ROM 106 accesses the disk controllers 110 to read the file handling part of the operating system from permanent storage on disk into RAM 108 , then loads the remainder of the operating system into an area of RAM 108 . The operating system then reads any applications from the disk drives via the disk controllers 110 , allocates space in RAM 108 for each, and stores each application in its allocated memory space.
[0041] During operation of the applications, the scheduler part of the operating system divides the use of the CPU between the different applications, allowing each a share of the time on the processor according to a scheduling policy. It also manages use of the memory resources, by “swapping out” infrequently used applications or data (i.e. removing them from RAM 108 to free up space, and storing them on disk).
[0042] Finally the routines making up the applications programming interface (API) are called from the applications, to execute functions such as input and output, and the interrupt handling routines of the operating system respond to interrupt and events.
Summary of Principles of the Preferred Embodiment
[0043] In the preferred embodiment, each operating system 201 , 202 to be used on the computer 100 is slightly re-written, and a new low-level program 400 (termed here the “hardware resource dispatcher”, and sometimes known as a “nanokernel” although it is not the kernel of an operating system) is created. The hardware resource dispatcher 400 is specific to the particular type of CPU 102 , since it interacts with the processor. The versions of the operating systems which are modified 201 , 202 are also those which are specific to the hardware, for reasons which will become apparent.
[0044] The hardware resource dispatcher 400 is not itself an operating system. It does not interact with the applications programs at all, and has very limited functionality. Nor is it a virtual machine or emulator; it requires the operating systems to be modified in order to cooperate, even though it leaves most of the processing to the operating systems themselves, running their native code on the processor.
[0045] It performs the following basic functions:
[0046] loading and starting each of the multiple operating systems;
[0047] allocating memory and other system resources to each of the operating systems;
[0048] scheduling the operation of the different operating systems (i.e. dividing CPU time between them, and managing the change over between them);
[0049] providing a “virtualised device” method of indirect access to those system devices which need to be shared by the operating systems (“virtualising” the devices);
[0050] providing a communications link between the operating systems, to allow applications running on different operating systems to communicate with each other.
[0051] The operating systems are not treated equally by the embodiment. Instead, one of the operating systems is selected as the “critical” operating systems (this will be the real time operating system), and the or each other operating system is treated as a “non critical” or “secondary” operating systems (this will be the or each general purpose operating system such as Linux).
[0052] When the hardware resource dispatcher is designed, it is provided with a data structure (e.g. a table) listing the available system resources (i.e. devices and memory), to enable as many system devices as possible to be statically allocated exclusively to one or other of the operating systems.
[0053] For example, a parallel printer port might be statically allocated to the general purpose operating system 202 , which will often run applications which will need to produce printer output. On the other hand, an ISDN digital line adapter port may be permanently allocated to the real time operating system 201 for communications. This static allocation of devices wherever possible means that each operating system can use its existing drivers to access statically allocated devices without needing to call the hardware resource dispatcher. Thus, there is no loss in execution speed in accessing such devices (as there would be if it acted as a virtual machine or emulator).
[0054] In the case of system devices which must be shared, the hardware resource dispatcher virtualises uses of the devices by the non-critical operating systems, and makes use of the drivers supplied with the critical operating system to perform the access. Likewise, for interrupt handling, the interrupts pass to the critical operating system interrupt handling routines, which either deal with the interrupt (if it was intended for the critical operating system) or pass it back through the hardware resource dispatcher for forwarding to a non critical operating system (if that was where it was destined).
[0055] On boot, the hardware resource dispatcher is first loaded, and it then loads each of the operating systems in a predetermined sequence, starting with the critical operating system, then following with the or each secondary operating system in turn. The critical operating system is allocated the resources it requires from the table, and has a fixed memory space to operate in. Then each secondary operating system in turn is allocated the resources and memory space it requires from the available remaining resources.
[0056] Thus, according to the embodiment, the resources used by the operating systems are separated as much as physically possible, by allocating each its own memory space, and by providing a static allocation of devices exclusively to the operating systems; only devices for which sharing is essential are shared.
[0057] In operation, the hardware resource dispatcher scheduler allows the critical operating system to operate until it has concluded its tasks, and then passes control back to each non critical operating system in turn, until the next interrupt or event occurs.
[0058] The embodiment thus allows a multi operating system environment in which the operation of the critical operating system is virtually unchanged (since it uses its original drivers, and has first access to any interrupt and event handling). The secondary operating systems are able to operate efficiently, within the remaining processor time, since in most cases they will be using their own native drivers, and will have exclusive access to many of the system devices. Finally, the hardware resource dispatcher itself can be a small program, since it handles only limited functions, so that system resources are conserved.
[0059] The preferred embodiment is also economic to create and maintain, because it involves only limited changes to standard commercial operating systems which will already have been adapted to the particular computer 100 . Further, since the changes to the operating systems are confined to architecture specific files handling matters such as interrupt handling, and configuration at initialising time, which interface with the particular type of computer 100 , and which are unlikely to change as frequently as the rest of the operating system, there may be little or no work to do in adapting new versions of the same operating system to work in a multiple operating system fashion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0060] In this embodiment, the computer 100 was an Intel 386 family processor (e.g. a Pentium processor) and a Motorola PowerPC 750 (Reduced Instruction Set Computer or “RISC”) computer (step 302 ). The critical operating system 201 was the C5 operating system (the real time microkernel of Jaluna-1, an open-source version of the fifth generation of the ChorusOS system, available for open source, free download from http://www.jaluna.com).
[0061] In step 306 , the ChorusOS operating system kernel 201 is modified for operating in multiple operating system mode, which is treated in the same way s porting to a new platform (i.e. writing a new Board Support Package to allow execution on a new computer with the same CPU but different system devices). The booting and initialisation sequences are modified to allow the real time operating system to be started by the hardware resource dispatcher, in its allocated memory space, rather than starting itself. The hardware-probing stage of the initialisation sequence is modified, to prevent the critical operating system from accessing the hardware resources which are assigned to other secondary systems. It reads the static hardware allocation table from the hardware resource dispatcher to detect the devices available to it.
[0062] Trap calls 2012 are added to the critical operating system, to detect states and request some actions in response. A trap call here means a call which causes the processor to save the current context (e.g. state of registers) and load a new context. Thus, where virtual memory addressing is used, the address pointers are changed.
[0063] For example, when the real time operating system 201 reaches an end point (and ceases to require processor resources) control can be passed back to the hardware resource dispatcher, issuing the “idle” trap call, to start the secondary operating system. Many processors have a “halt” instruction. In some cases, only supervisor-level code (e.g. operating systems, not applications) can include such a “halt” instruction. In this embodiment, all the operating systems are rewritten to remove “halt” instructions and replace them with an “idle” routine (e.g. an execution thread) which, when called, issues the “idle” trap call.
[0064] Some drivers of the Board Support Package are specially adapted to assist the hardware resource dispatcher in virtualizing the shared devices for secondary operating systems.
[0065] Additional “virtual” drivers 2014 are added which, to the operating system, appear to provide access to an input/output (I/O) bus, allowing data to be written to the bus. In fact, the virtual bus driver 2014 uses memory as a communications medium; it exports some private memory (for input data) and imports memory exported by other systems (for output data). In this way, the operating system 201 (or an application running on the operating system) can pass data to another operating system (or application running on it) as if they were two operating systems running on separate machines connected by a real I/O bus.
[0066] The secondary operating system 202 was selected (step 308 ) as Linux, having a kernel version 2.4.18 (step 308 ).
[0067] In step 310 , the secondary operating system kernel 202 is modified to allow it to function in a multiple operating system environment, which is treated as a new hardware architecture. As in step 306 , the boot and initialisation sequences are modified, to allow the secondary operating system to be started by the hardware resource dispatcher, and to prevent it from accessing the hardware resources assigned to the other systems, as specified in the hardware resource dispatcher table. As in step 306 , trap calls 2022 are added, to pass control to the hardware resource dispatcher.
[0068] Native drivers for shared system devices are replaced by new drivers 2028 dealing with devices which have been virtualized by the hardware resource dispatcher (interrupt controller, I/O bus bridges, the system timer and the real time clock). These drivers execute a call to virtual device handlers 416 of the hardware resource dispatcher in order to perform some operations on a respective device of the computer 100 . Each such virtual device handler 416 of the hardware resource dispatcher is paired with a “peer” driver routine in the critical operating system, which is arranged to directly interact with the system device. Thus, a call to a virtual device handler is relayed up to a peer driver in the critical system for that virtualized device, in order to make real device access. As in step 306 , read and write drivers 2024 for the virtual I/O bus are provided, to allow inter-operating system communications.
[0069] The interrupt service routines of the secondary operating system are modified, to provide virtual interrupt service routines 2026 each of which responds to a respective virtual interrupt (in the form of a call issued by an interrupt handler routine 412 of the hardware resource dispatcher), and not to respond to real interrupts or events. Routines of the secondary operating system (including interrupt service routines) are also modified to remove masking of hardware interrupts (at least in all except critical operations). In that way, the secondary operating systems 202 , . . . are therefore pre-emptable by the critical operating system 201 ; in other words, the secondary operating system response to a virtual interrupt can itself be interrupted by a real interrupt for the critical operating system 201 . This typically includes:
[0070] masking/unmasking events (interrupts at processor level);
[0071] saving/restoring events mask status;
[0072] identifying the interrupt source (interrupt controller devices);
[0073] masking/unmasking interrupts at source level (interrupt controller devices).
[0074] New virtual device drivers 2028 are added, for accessing the shared hardware devices (the I/O bus bridges, the system console, the system timer and the real time clock). These drivers execute a call to virtual device handlers 416 of the hardware resource dispatcher in order to write data to, or read data from, a respective device of the computer 100 .
[0075] To effect this, the Linux kernel 207 is modified in this embodiment by adding new virtual hardware resource dispatcher architecture sub trees (nk-i386 and nk-ppc for the I-386 and PowerPC variants) with a small number of modified files. Unchanged files are reused in their existing form. The original sub-trees are retained, but not used.
[0076] In step 312 , the hardware resource dispatcher 400 is written. The hardware resource dispatcher comprises code which provides routines for the following functions as (as shown in FIG. 4):
[0077] booting and initialising itself ( 402 );
[0078] storing a table ( 403 ) which stores a list of hardware resources (devices such as ports) and an allocation entry indicating to which operating system each resource is uniquely assigned;
[0079] booting and initialising the critical operating system that completes the hardware resource dispatcher allocation tables ( 404 );
[0080] booting and initialising secondary operating systems ( 406 )
[0081] switching between operating systems ( 408 );
[0082] scheduling between operating systems ( 410 );
[0083] handling interrupts (using the real time operating system interrupt service routines, and supplying data where necessary to the virtual interrupt service routines of the secondary operating systems) ( 412 );
[0084] handling trap calls from each of the operating systems ( 414 );
[0085] handling access to shared devices from the secondary operating systems ( 416 );
[0086] handling inter-operating system communications on the virtual I/O bus ( 418 ).
[0087] In further embodiments (described below), it may also provide a system debugging framework.
Operating System Switcher 408
[0088] In order to switch from an operating system to another, the operating system switcher 408 is arranged to save the “context”—the current values of the set of state variables, such as register values—of the currently executing operating system; restore the stored context of another operating system; and call that other operating system to recommence execution where it left off. Where the processor uses segments of memory, and virtual or indirect addressing techniques, the registers or data structures storing the pointers to the current memory spaces are thus swapped. For example, the operating systems each operate in different such memory spaces, defined by the context including the pointer values to those spaces.
[0089] In detail, the switcher provides:
[0090] explicit switches (e.g. trap calls) from the currently running to the next scheduled operating systems, when the current becomes idle; and
[0091] implicit switches from a secondary operating system to the critical operating system, when a hardware interrupt occurs.
[0092] The switches may occur on a trap call or a real or virtual interrupt, as described below.
Scheduler 410
[0093] The scheduler 410 allocates each operating system some of the available processing time, by selecting which secondary operating system (if more than one is present) will be switched to next, after exiting another operating system. In this embodiment, each is selected based on fixed priority scheduling. Other embodiments allowing specification based on time sharing, or guaranteed minimum percentage of processor time, are also contemplated herein. In each case, however, the critical operating system is pre-empted only when in the idle state.
[0094] In further embodiments, the critical operating system may explicitly inform the scheduler 410 when it may be pre-empted, so as to allow all secondary operating systems some access to the CPU to perform tasks with higher priority then the tasks still running in critical system. Thus, in one example, the interrupt service routines of the critical operating system cannot be pre-empted, so that the critical operating system can always respond to external events or timing signals from the realtime clock, maintaining realtime operation.
Handling Virtualised Processor Exceptions
[0095] The hardware resource dispatcher is arranged to provide mechanisms to handle processor exceptions (e.g. CPU interrupts or co-processor interrupts) as follows:
[0096] firstly, to intercept processor exceptions through the critical operating system;
[0097] secondly, to post a corresponding virtual exception to one or more secondary operating systems; to store that data and, when the scheduler next calls that secondary operating system, to call the corresponding virtual interrupt service routine 2026 in the secondary operating system;
[0098] thirdly, to mask or unmask any pending virtual exceptions from within secondary operating systems.
[0099] Virtualised exceptions are typically used for two different purposes;
[0100] Firstly, to forward hardware device interrupts (which are delivered as asynchronous processor exceptions) to secondary operating systems;
[0101] Secondly, to implement inter-operating system cross-interrupts—i.e. interrupts generated by one system for another interrupts (which are delivered as synchronous exceptions).
Trap Call Handler 414
[0102] The operation of the trap call handler will become apparent from the following description. Its primary purpose is to allow the scheduler and switcher to change to another operating system when a first one halts (and hence does not require CPU resources). An additional role is to invoke hardware resource dispatcher services such as a system console for use in debugging as discussed in relation to later embodiments.
Virtualised Devices 416
[0103] As indicated above, for each shared device (e.g. interrupt controller, bus bridges, system timer, realtime clock) each operating system provides a device driver, forming a set of peer-level drivers for that device. The realtime operating system provides the driver used to actually access the device, and the others provide virtual device drivers.
[0104] The shared device handler 416 of the hardware resource dispatcher provides a stored data structure for each device, for access by all peer device drivers of that device. When the device is to be accessed, or has been accessed, the device drivers update the data stored in the corresponding data structure with the details of the access. The peer drivers use cross-interrupts (as discussed above) to signal an event to notify other peer drivers that that the data structure has just been updated.
[0105] The drivers which are for accessing interrupt controller devices use the virtualised exception mechanisms discussed above to handle hardware interrupts as follows:
[0106] The critical operating system device driver handles hardware interrupts and forwards them as virtualised exceptions to the secondary peer drivers;
[0107] The secondary operating system enables and disables interrupts by using the virtualised exception masking and unmasking routines discussed above.
[0108] I/O buses and their bridges only have to be shared if the devices connected to them are not all allocated to the same operating system. Thus, in allocating devices, to the extent possible, devices connected to the same I/O bus are allocated to the same operating system. Where sharing is necessary, the resource allocation table 404 stores descriptor data indicating the allocation of the resources on the bus (address spaces, interrupt lines and I/O ports) to indicate which operating system has which resources.
Implementation of the Embodiment
[0109] Finally, in step 314 , the code for the hardware resource dispatcher and operating systems is compiled as a distributable binary computer program product for supply with the computer 100 .
[0110] A product which may be supplied in accordance with an aspect of the invention is a development environment product, comprising a computer program which enables the user to select different operating systems to be used, build and select different applications for each operating system, embed the application and operating systems into a deliverable product, and provide for booting of the operating system and launch of executable binaries of the applications. This is based on, and similar to, the C5 development environment, available from www.jaluna.com.
Operation of the Embodiment During Booting and Initialisation
[0111] Referring to FIG. 5, the boot and initialisation processes according to this embodiment are performed as follows.
[0112] A bootstrapping program (“trampoline”) 4022 stored in the ROM 106 is executed when power is first supplied, which starts a program 4024 which installs the rest of the hardware resource dispatcher program 400 into memory, and starts it, passing as an argument a data structure (as described below) describing the system image configuration.
[0113] The hardware resource dispatcher initialises a serial line which may be used for a system console. It then allocates memory space (an operating system environment) for each operating system in turn, starting with the critical operating system. The hardware resource dispatcher therefore acts as a second level system kernel boot loader.
[0114] Each operating system kernel then goes through its own initialisation phase, selecting the resources to be exclusive to that operating system within those remaining in the resource allocation table 404 , and starting its initial services and applications.
[0115] [0115]FIG. 6 illustrates an example of a memory address allocation forming the system image. A position within memory is allocated when the hardware resource dispatcher and operating systems are compiled. The set of these positions in memory defines the system image, shown in FIG. 6. The system image comprises a first bank of memory 602 where the hardware resource dispatcher is located; a second bank of memory 604 where the real time operating system is located; a third bank of memory 606 where the secondary operating system is located; and, in this embodiment, a fourth bank of memory 608 where the RAM disk containing a root file system of the secondary operating system (Linux) is located.
[0116] This system image is stored in persistent storage (e.g. read only memory for a typical real time device such as a mobile telephone or PBX). The remaining banks of memory are available to be allocated to each operating system as its environment, within which it can load and run applications.
Allocation of Memory for Operating System Context
[0117] Whilst being booted, each operating system then allocates a complementary piece of memory in order to meet the total size required by its own configuration. Once allocated to an operating system, banks of memory are managed using the physical memory management scheme of the operating system itself. All other memory is ignored by the operating system.
Virtual Memory Allocation
[0118] Each operating system is allocated separate virtual memory spaces, to make sure that operating systems cannot interfere with each other or with the hardware resource dispatcher. The User address spaces (i.e. ranges) and Supervisor address space (i.e. range) of each of the operating systems is each allocated a different memory management unit (MMU) context identifier (ID), which allow the differentiation of different virtual memory spaces having overlapping addresses. The MMUs context IDs are assigned to each operating system at the time it is compiled (step 314 of FIG. 3).
[0119] This solution avoids the need to flush translation cashes (TLBs) when the hardware resource dispatcher switches between different operating systems, which would take additional time. Instead, the switch over between different operating systems is accomplished by storing the MMU context IDs of the currently function operating system, and recalling the previously stored MMU context IDs of the switched two operating system.
Allocation of Input/Output Devices
[0120] As indicated above, the allocation table 404 indicates which devices are allocated uniquely to each operating system. In addition, table 404 indicates which input/output resources (Direct Memory Access (DMA) devices, input/output ports, interrupts and so on) are allocated exclusively to such devices, thus allowing a direct use of these resources without any conflict. Typically, many devices are duplicated, so it is possible to reduce potential conflicts substantially in this way.
[0121] The distribution is based on the operating system configuration scheme (for example, in the case of C5, the devices specified in the device tree). They are allocated to operating systems at boot time, and in order of booting, so that the critical operating system has first choice of the available devices in the table 404 and the secondary operating systems in turn receive their allocation in what remains. As each operating system initialised, it detects the presence of these devices and uses its native drivers for them without interaction from the hardware resource dispatcher.
“Hot” Reboot of Secondary Operating System
[0122] According to the present embodiments, it is possible to reboot a secondary operating system (for example because of a crash) whilst other operating systems continue to run. Because of the separation of system resources, a crash in the secondary operating system does not interfere with the ongoing operation of the critical operating system (or other secondary operating systems) and the rebooting of that secondary operating system does not do so either.
[0123] In the embodiment, the system “stop” and “start” trap calls to the hardware resource dispatcher assist in shutting down and restarting the secondary operating systems from within the critical operating system. Additionally, the hardware resource dispatcher saves a copy of the original system image, at boot time, in persistent memory within the hardware resource dispatcher allocated memory. As an example, hot restart in this embodiment is managed as follows:
[0124] At the time of initially booting up, the hardware resource dispatcher saves a copy of the secondary operating systems memory image.
[0125] The critical operating system includes a software watchdog driver routine for periodically monitoring the functioning of the secondary operating systems (for example, by setting a timeout and waiting for an event triggered by a peer driver running in the secondary operating systems so as to check for their continued operation).
[0126] If the critical operating system detects that the secondary operating system has failed or stopped, it triggers “stop” and then “start” trap calls (of the secondary operating system) to the hardware resource dispatcher.
[0127] The hardware resource dispatcher then restores the saved copy of the secondary operating system image, and reboots it from memory to restart. It was found that, on tests of an embodiment, the Linux secondary operating system could be rebooted within a few seconds from locking up. In other respects, the hot restart builds upon that available in the Chorus operating system, as described for example in:
[0128] “Fast Error Recovery in CHORUS/OS. The Hot-Restart Technology”. Abrossimov, F. Hermann. J. C. Hugly, et al, Chorus Systems Inc. Technical Report, August 1996, 14p. available from:
[0129] http://www.jaluna.com/developer/papers/CSI-TR-96-34.pdf
Run-time Operation
[0130] The operation of the embodiment after installation and booting will now be described in greater detail.
[0131] Having been booted and initialised, the real time operating system is running one or more applications 207 (for example a UDP/IP stack—UDP/IP stands for Universal Datagram Protocol/Internet Protocol) and the secondary operating system is running several applications 208 a , 208 b (for example a word processor and a spreadsheet). The real time operating system microkernel 201 and the secondary operating system kernel 202 communicate with the hardware resource dispatcher through the hardware resource dispatcher interface which comprises:
[0132] a data structure representing the operating system context (i.e. the set of state variables which need to be saved and restored in order to switch to the operating system), and the hardware repository;
[0133] the set of functions which execute in the operating system environment; and
[0134] the set of trap call routines which execute in the hardware resource dispatcher environment.
[0135] If neither operating system requires processor time (for example, both have reached “wait” states) then the hardware resource dispatcher 400 switches to the critical operating system's idle thread, in which it waits an interrupt or event. Thus, interrupts can be processed immediately by the critical operating system's servicing routines, without needing to switch to the critical operating system first.
[0136] At some point, an interrupt or event will occur. For example, a packet may be received at a data port, causing an interrupt to allow it to be processed by the real time operating system executing the UDP/IP stack. Alternatively, a user may manipulate a keyboard or mouse, causing an interrupt to operate the GUI of the second operating system 202 for interaction with the word processing application 208 . Alternatively, the system clock may indicate that a predetermined time has elapsed, and that an application should commence re-execution, or an operating system function should execute.
[0137] The critical operating system servicing routine then services the interrupt, as described below.
Interrupt and Event Handling
[0138] If not already in the critical operating system, the hardware resource dispatcher interrupt handler 412 calls the operating system switcher 408 to switch to the critical operating system, and then the interrupt handler routine 412 to call an interrupt service routine (ISR) in the critical operating system 201 . If the interrupt is intended for the critical operating system, either because it is from a device uniquely assigned to the critical operating system or because it is from a shared device and has a certain predetermined value, the critical operating system ISR takes the action necessary to handle the interrupt. If not, control is passed back to the hardware resource dispatcher.
Critical to Secondary Operating Systems Switch
[0139] Referring to FIG. 7, for this example, the system is executing a thread 702 of an application 207 a running on the critical operating system 201 .
[0140] If an interrupt occurs, a critical operating system interrupt service routine 704 performs interrupt servicing. On termination, control passes back to the thread 702 and any others executed by the scheduler of the critical operating system 201 . When processing of all threads is complete, the critical operating system has finished executing, it schedules its “idle” thread. Accordingly the “idle” trap routine in the critical operating system issues an “idle” trap call to the hardware resource dispatcher 400 . The hardware resource dispatcher then executes a routine which does the following:
[0141] If the interrupt handler 412 currently has some stored virtual interrupts, these are forwarded by the interrupt handler 412 to the secondary operating system.
[0142] The hardware resource dispatcher operating system scheduler 410 selects the secondary operating system 202 to execute. The OS switcher 408 then saves the current context (typically, processor MMU and status registers, instruction and stack pointers) in the critical OS context storage area 706 . It then retrieves the stored execution context 708 for the secondary operating system 202 , and writes them to the registers concerned.
[0143] If there are virtual interrupts for the secondary OS concerned, the interrupt handler 412 calls the relevant interrupt service routine 710 within the secondary operating system, which services the interrupt and then, on completion, reverts to the execution of a thread 712 of the secondary operating system where it left off.
[0144] If the interrupt handler 412 currently has no pending interrupts, then the hardware resource dispatcher operating switcher 408 causes the secondary operating system to recommence execution where it left off, using the stored program counter value within the restored operating system context, in this case at the thread 712 .
[0145] Thus, after the critical operating system 201 has performed some function (either servicing its own applications or services, or servicing an interrupt intended for another operating system), the hardware resource dispatcher passes control back to the next secondary operating system 202 , as determined by the scheduler 410 .
Secondary to Critical Operating System Switch on Interrupt
[0146] Referring to FIG. 8, the process of transferring from the secondary operating system to the critical operating system will now be disclosed. In this case, the system is executing a thread 712 of an application 208 a running on the critical operating system 202 .
[0147] When a hardware interrupt occurs, the hardware resource dispatcher starts the OS switcher, to save the secondary operating system context in the context storage area 708 . It then switches to the primary operating system 201 , restoring the values of state variables from the context storage area 706 , and calls the interrupt service routine 704 of the primary operating system 201 . After servicing the interrupt, the scheduler of the primary operating system 201 may pass control back from the ISR 704 to any thread 704 which was previously executing (or thread to be executed).
[0148] When the ISR and all threads are processed, the primary operating system 201 passes control back to the hardware resource dispatcher, which switches from the primary operating system 201 (saving the state variables in the context storage 706 ) and switches to a selected secondary operating system 201 (retrieving the state variables from the context storage 708 ), in the manner discussed with reference to FIG. 7 above.
Inter-operating System Communications—Virtual bus 418
[0149] The virtual bus routine cooperates with the virtual bus drivers in each operating system. It emulates a physical bus connecting the operating systems, similar to Compact PCI (cPCI) boards plugged into a cPCI backplane. Each operating system is provided with a driver routine for the virtual bus bridge device on this virtual bus, allowing the operating systems and their applications to communicate by any desired protocol, from raw data transfer to a full IP protocol stack.
[0150] The hardware resource dispatcher virtual bus is based on shared memory and system cross interrupts principles already discussed above. In detail, the virtual bus routine 418 emulates the C5 buscom DDI: syscom which defines virtual bus bridge shared devices, allowing the export (sharing) of memory across the virtual bus and triggering of cross-interrupts into other operating systems.
[0151] Each virtual bus driver, in each secondary operating system, creates such a virtual bus bridge in the hardware resource dispatcher hardware repository at startup time. By doing so, it exports (shares) a region of its private memory, and provides a way to raise interrupts within its hosting system.
[0152] Thus, a virtual bus driver of a first operating system sends data to a second operating system by:
[0153] writing into the memory exported by a peer virtual bus driver of the second operating system, and then;
[0154] triggering a cross-interrupt to notify that data are available to the peer bus driver in the second operating system.
[0155] In the reverse (incoming) direction, the virtual bus driver propagates incoming data up-stream (for use by the application or routine for which it is intended) when receiving a cross-interrupt indicating that such data have been stored in its own exported memory region.
[0156] Referring to FIG. 9 a, an application 208 a which is to communicate with another 208 b running on the same operating system 202 can do so through that operating system. An application 207 b running on one operating system 201 which is to communicate with another 208 b running on a different operating system 202 does so by writing data to the virtual bus using the API of its operating system, which uses the virtual bus driver routine to pass the data to the other operating system 202 , which propagates it from its virtual bus driver to the application 208 b.
[0157] Referring to FIG. 9 b , the changes necessary to migrate this arrangement to one in which the first and second operating systems run on different computers 100 , 101 are small; it is merely necessary to change the drivers used by the operating systems, so that they use drivers for a real bus 103 rather than the virtual bus drivers. The system is therefore made more independent of the hardware on which it operates.
[0158] Communication across the hardware resource dispatcher virtual bus is available to applications, but can also be used internally by the operating system kernels, so that they can cooperate in the implementation of services distributed among multiple operating systems. “Smart” distributed services of this kind include software watchdog used for system hot restart (discussed above), or a distributed network protocol stack.
Debugging
[0159] In a preferred embodiment, the hardware resource dispatcher has a second mode of operation, in which it acts as a debugging agent.
[0160] According to this embodiment, in the second mode, the hardware resource dispatcher can communicate via a serial communications line with debugging software tools running on another machine (the “host” machine).
[0161] Such debugging tools provide a high level graphical user interface (GUI) to remotely control the hardware resource dispatcher. The hardware resource dispatcher virtualised exception mechanism is used to intercept defined exceptions. The user can then configure and control how the hardware resource dispatcher behaves in case of processor exceptions, and also display machine and system states, to enable diagnosis of code or other system errors or problems.
[0162] The user can select one or more such processor exceptions as the basis for a trap call from an operating system to the hardware resource dispatcher. On the basis of the selected exception, when the or each exception occurs during execution, the operating system is stopped, and executes the trap call to the hardware resource dispatcher, which then saves the current context and enables interaction with the debugging tools on the host. The user can then cause the display of the current states of the state variables (such as the stack pointers, program and address counters) and/or the content of selected block of memory. The user can specify either that a given type of exception should be trapped in a specific operating system to be debugged, or that they should be trapped whenever they occur, in any operating system. In response, the trap call is implemented in just one, or in all, operating systems. The user can also specify if a given type of exception is to be normally forwarded to the system when restarting execution or simply ignored.
[0163] Because the hardware resource dispatcher executes in its own environment, it is able to debug much more of an operating system than could be done from within that system. Importantly, no code is shared between the hardware resource dispatcher acting as a debug agent and the sytems being debugged. This allows, for example, the debugging of even kernel low level code such as exception vectors or interrupt service routines.
[0164] Some other aspects of the overall (host/target) debugging architecture according to this embodiment are similar to those for the Chorus and C5 debugging systems, described in the document “C5 1.0 Debugging Guide” published by Jaluna, and available at:
[0165] http://www.jaluna.com/doc/c5/html/DebugGuide/book1.html
Secure Architecture
[0166] It will be clear that the embodiments described above give a firm basis for a secure architecture. This is because the secondary operating system, on which a user will typically run insecure applications, is insulated from specified system resources, and accesses them only through the hardware resource despatcher (and the drivers of the primary operating system). Thus, security applications can be run on the primary operating system which, for example, perform encryption/decryption; allow access to encrypted files; manage, store and supply passwords and other access information; manage and log access and reproduction of copyright material. Applications running on the secondary operating system cannot access system resources which are not allocated to that operating system, and where the operating systems run in different memory contexts (i.e. use different addressing pointers to different spaces) applications running on the secondary operating system cannot be used to interfere with those operating on the primary system so as to weaken the security of its operations.
Other Aspects and Embodiments
[0167] It will be clear from the forgoing that the above-described embodiments are only examples, and that many other embodiments are possible. The operating systems, platforms and programming techniques mentioned may all be freely varied. Any other modifications, substitutions and variants which would be apparent to the skilled person are to be considered within the scope of the invention, whether or not covered by the claims which follow. For the avoidance of doubt, protection is sought for any and all novel subject matter and combinations thereof disclosed herein. | A method of enabling multiple different operating systems to run concurrently on the same computer, comprising selecting a first operating system to have a relatively high priority (the realtime operating system, such as C5); selecting at least one secondary operating system to have a relatively lower priority (the general purpose operating system, such as Linux); providing a common program (a hardware resource dispatcher similar to a nanokernel) arranged to switch between said operating systems under predetermined conditions; and providing modifications to said first and second operating systems to allow them to be controlled by said common program. | 6 |
PRIORITY CLAIM
This is a U.S. national stage of application No. PCT/CA2006/001114, filed on 7 Jul. 2006. Priority is claimed on the following application: Country: US, application Ser. No.: 11/181,592, Filed: 14 Jul. 2005; the content of which is incorporated here by reference.
FIELD OF THE INVENTION
This invention relates to equipment for generating a force in a wellbore and more particularly but not limited to setting and retrieving tools for use in oil and gas wells.
BACKGROUND OF THE INVENTION
The structure of a wellbore of an oil or gas well generally consists of an outer production casing and an inner production tubing installed inside the production casing. The production tubing extends from the surface to the required depth in the wellbore for production of the oil or gas. Various tools such as plugs, chokes, safety valves, check valves, etc. can be placed in landing nipples in the production tubing to allow for different production operations or the downhole control of fluid flow. Also, tools like bridge plugs, packers and flow control equipment are placed in the production casing to control production or stimulation operations. Force generating tools are needed both to exert a pushing force to set tools in the production tubing or casing and to provide a pulling force to retrieve these tools. It is preferable to have the force generating tools wellbore pressure balanced so that the same force may be applied both in pulling and in pushing operations, irrespective of the pressure in the wellbore.
A downhole force generator is disclosed in U.S. Pat. No. 6,199,628. A downhole force generator is disclosed in U.S. Pat. No. 5,070,941. A locator and setting tool is disclosed in Canadian Patent No. 2,170,711. These 3 patents describe virtually the same technology, in different variations. None of these prior art tools are pressure balanced to provide equal force in pulling and pushing operations. As detailed in the article published by Halliburton Energy Services in the June 1996 edition of the SPE Drilling & Completion magazine, “Any pressure differential increases the available force with the DPU in tension and decreases the setting force in the extension mode. This is because (1) the DPU is sealed to the well pressure through redundant sealing elements maintaining internal parts at near-atmospheric pressure, and (2) the well pressure acts on the power rod's sealed diameter.” This is a disadvantage, especially in high-pressure wells. A high enough downhole pressure will render these tools unusable. Additionally, none of these tools provide a simple mechanical tool, particularly for the retrieving of downhole tools.
SUMMARY OF THE INVENTION
According to one broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) a drive mandrel; b) an engaging mandrel; c) an actuation means; d) a housing sealing a portion of the drive mandrel and a portion of the engaging mandrel within an interior space, the drive mandrel and the engaging mandrel extending from opposite ends of the housing; e) a drive mandrel piston area defined at a drive mandrel end portion of the housing between an outside diameter of the housing and a sealed diameter of the drive mandrel; and f) an engaging mandrel piston area defined at an engaging mandrel end portion of the housing between the outside diameter of the housing and a sealed diameter of the engaging mandrel; wherein the actuation means is adapted to reversibly move the housing longitudinally relative to the drive mandrel and the engaging mandrel and wherein the drive mandrel piston area and the engaging mandrel piston area are substantially equal and external pressure acting on these two piston areas, generates two opposing forces that are substantially balanced during relative movement.
According to another broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner elongated member; b) an outer elongated member; c) a sealed interior defined between the inner elongated member and the outer elongated member; and d) an actuation means defined at least partially within the sealed interior; wherein the actuation means is adapted to reversibly move the outer elongated member longitudinally over the inner elongated member and wherein the inner elongated member and the outer elongated member are arranged such that a volume of the sealed interior occupied by the inner elongated member remains substantially constant as the inner elongated member and the outer elongated member move relative to each other.
According to a further broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner elongated member; b) an outer elongated member encircling an intermediate segment of and longitudinally moveably engaged with the inner elongated member; c) a screw component of the inner elongated member, the screw component being coupled for rotation about a longitudinal axis; and d) a threaded component of the outer elongated member engaged with the screw component; wherein rotation of the screw component reversibly moves the outer elongated member relative to the inner elongated member.
According to a still further broad aspect, the invention provides a well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner member comprising a first elongated member, a second elongated member and an actuation means axially interconnecting the first elongated member and the second elongated member; b) an outer elongated member longitudinally moveably engaged with the inner member; c) a first seal defined between the first elongated member and the outer elongated member; d) a second seal defined between the second elongated member and the outer elongated member; e) a first piston area defined at a first end portion of the outer elongated member between an outer diameter of the outer elongated member and a sealed outer diameter of the first elongated member; f) a second piston area defined at a second end portion of the outer elongated member between the outer diameter of the outer elongated member and a sealed outer diameter of the second elongated member; and g) a sealed chamber defined between the first seal and the second seal, the sealed chamber including a fluid at a fluid pressure; wherein operation of the actuation means axially reversibly moves the outer elongated member relative the inner member while the fluid pressure remains constant; and wherein the first piston area and the second piston area are substantially equal and external pressure acting on these two pistons areas, generates two opposing forces that are substantially balanced during relative movement.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the attached drawings in which:
FIGS. 1A , 1 B and 1 C are partial schematic cross-sectional views of a first embodiment of the invention;
FIGS. 2A , 2 B and 2 C are detailed upper, middle and lower cross-sectional views, respectively, of the first embodiment of the invention in a first position;
FIGS. 3A , 3 B and 3 C are detailed upper, middle and lower cross-sectional views, respectively, of the embodiment of FIGS. 2A , 2 B and 2 C in a second position;
FIGS. 4A , 4 B and 4 C are detailed upper, middle and lower cross-sectional views, respectively, of the embodiment of FIGS. 2A , 2 B and 2 C in a third position;
FIGS. 5A , 5 B and 5 C are detailed upper, middle and lower cross-sectional views, respectively, of a second embodiment of the invention;
FIGS. 6A , 6 B and 6 C are detailed upper, middle and lower cross-sectional views, respectively, of a third embodiment of the invention; and
FIGS. 7A , 7 B and 7 C are partial cross-sectional views of a forth embodiment of the invention in first, second and third positions, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows cross-sectional view of a simplified embodiment of the invention. A tool 10 has an inner elongated member which includes a drive mandrel 50 , a screw 62 and an engaging mandrel 66 . The engaging mandrel may be a setting or a retrieving mandrel. The drive mandrel 50 and the screw 62 are axially coupled for both rotational and longitudinal movement. The engaging mandrel 66 and the screw 62 are preferably coupled for longitudinal movement only. The cross-sectional area of the drive mandrel 50 is substantially equal to the cross-sectional area of the engaging mandrel 66 .
The tool 10 also includes an outer elongated member or main housing 64 . The outside diameter of the main housing 64 is preferably constant. Fixed to the interior of the main housing 64 is a threaded component or nut 58 . The nut 58 is threaded on the screw 62 . One end of the main housing 64 is sealed to the drive mandrel 50 by a seal 48 . The other end of the main housing 64 is sealed to the engaging mandrel 66 by a seal 70 . The sealed interior of the main housing 64 is preferably equalized with the wellbore pressure. The connection between the screw 62 and the nut 58 is not fluid tight, i.e. chambers 65 and 67 on either side of the nut 58 are enclosed by the main housing 64 and are in fluid communication through gaps between the screw 62 and nut 58 and/or channels milled on the outside of the nut 58 .
The drive mandrel 50 is coupled at its other end to a motor 24 . The motor 24 is contained within a motor housing 14 . A connector 12 is provided at the other end of the motor for electrically and mechanically connecting the tool 10 . Cap screws 44 are provided in a guide sleeve 38 formed at the end of the motor housing 14 which encircles the drive mandrel 50 and an electronics seal 46 is provided around the drive mandrel 50 which seals the guide sleeve to the mandrel 50 to protect the inside of the motor housing 14 from the environment. A guide housing extension 40 of the main housing 64 slidably encompasses a portion of the guide sleeve 38 . The cap screws 44 travel in slots in the guide housing extension 40 and prevent rotation of the main housing 64 .
In operation, the connector 12 is electrically and mechanically connected to a wireline. The motor 24 rotates the drive mandrel 50 . Rotation of the drive mandrel 50 causes the screw 62 to rotate. The main housing 64 is held against rotation so that rotation of the screw 62 causes the main housing 64 to move longitudinally over the inner elongated member. At all times, the volume of the drive mandrel entering/exiting the interior space is the same as the volume of the engaging mandrel exiting/entering the interior space so that the free volume, and therefore also the pressure, in the interior space remains constant. The seals 48 and 70 , define two hydraulic pistons between the outside diameter of the main housing 64 and the outside diameter of the drive mandrel 50 and the outside diameter of the engaging mandrel 66 respectively. The two piston areas, shown schematically in FIGS. 1B and 1C , have the same area. Any outside well pressure P acting on these two hydraulic piston areas will create two equal opposing forces that cancel each other. The constant volume in the interior and the matched piston areas enable the same force to be applied by the tool in both the pushing and the pulling operations. The main housing 64 and/or the engaging mandrel 66 are coupled to engaging tools for setting or retrieving of downhole tools.
In greater detail, FIGS. 2A to 4C depict a well tool, in particular a wireline retrieving tool for applying a pulling force to an object in the interior of a wellbore. The wireline retrieving tool 110 is generally tubular in shape. A connector 112 is located at the proximal end of the wireline retrieving tool 110 . The proximal end is the upper or trailing end when the wireline retrieving tool 110 is inserted into a wellbore. The connector 112 allows for mechanical and electrical connection of the wireline retrieving tool 110 to a wireline. The connector 112 connects to a proximal end of a tubular electronics housing 114 . Seals 116 are provided at the interface between the connector 112 and the electronics housing 114 to seal the interior of the electronics housing 114 from the environment. The electronics housing 114 houses an electronics carrier 118 , a printed circuit board 120 , a digital positioning encoder 122 and a gear motor 124 . The electronics carrier provides mechanical support for the printed circuit board 120 . The connector 112 is connected to the printed circuit board 120 to provide power to the printed circuit board from the wireline. The printed circuit board 120 provides control for the operation of the digital positioning encoder 122 and the gear motor 124 . The digital positioning encoder 122 is connected at one end of the gear motor 124 . The digital positioning encoder 122 counts the rotation of the gear motor 124 to allow precise calculation and control of the movement of the distal end, i.e. lower or leading end, of the wireline retrieving tool 110 .
A distal end of the electronics housing 114 is connected to a guide sleeve 138 . The guide sleeve is generally tubular. Seals 116 are provided between the guide sleeve 138 and the electronics housing 114 to seal the interior from the environment. A drive mandrel 150 extends at least partially through the guide sleeve 138 . The drive mandrel 150 is generally an elongated solid member with a circular cross-section. The drive mandrel 150 is interconnected to the gear motor 124 through a spline adapter 130 . The spline adapter 130 interconnects the gear motor 124 to the drive mandrel 150 through axial splines so that rotation of an output of the gear motor 124 results in rotation of the drive mandrel 150 at the same speed. The spline adaptor 130 is threaded to the drive mandrel 150 . Set screws 136 hold the drive mandrel 150 in position relative to the spline adaptor 130 .
Thrust bearings 134 are provided at support ends of the spline adapter 130 to facilitate smooth rotation of the drive mandrel 150 relative to the guide sleeve and the electronics housing. A drive mandrel lock nut 132 is provided to retain the bearings 134 and the spline adaptor in the guide sleeve 138 and cap screws 128 are provided to fasten the gear motor to the distal end of the electronics housing 114 .
Cap screws 144 are provided at a distal end of the guide sleeve 138 . The heads of the cap screws 144 project outward from the surface of the guide sleeve 138 . An upper guide housing 140 slidably encompasses a portion of the guide sleeve 138 . Longitudinal slots are defined in the upper guide housing 140 . The cap screws 144 travel within the longitudinal slots in the upper guide housing 140 when the upper guide housing 140 slides relative to the guide sleeve 138 . The cap screws 144 rest against the ends of the longitudinal slots to retain the upper guide housing 140 in contact with the guide sleeve 138 at the limits of relative travel and prevent relative rotation between the guide housing 138 and the upper guide housing 140 .
A glide ring 142 is also provided adjacent the cap screws 144 between the guide sleeve 138 and the drive mandrel 150 to facilitate the smooth rotation of the drive mandrel 150 . An electronics seal 146 is provided around the drive mandrel 150 at the distal end of the guide sleeve 138 . The electronics seal 146 seals the electronic section from external contaminants and keeps it at atmospheric pressure.
The distal end of the upper guide housing 140 mates with a proximal end of an upper housing 152 . The upper housing 152 is also generally tubular. The upper guide housing 140 and the upper housing 152 are retained relative to one another by a threaded connection. An upper interior area seal 148 is provided at a proximal end of the upper housing 152 and seals the upper housing 152 to the drive mandrel 150 . The upper internal area seal 148 seals the interior of the upper housing 152 . The electronics seal 146 and the upper internal area seal 148 allow for rotation of the drive mandrel 150 .
A distal end of the upper housing 152 is coupled to a proximal end of an actuator housing 160 . The actuator housing 160 is generally tubular. An actuator nut 158 is non-rotatably held within the actuator housing 160 . An actuator screw 162 extends through the actuator nut 158 . The actuator screw 162 is coupled to a distal end of the drive mandrel 150 . The coupling is provided by an anti-rotational lug so that the actuator screw 162 rotates with the drive mandrel 150 . A drive mandrel retainer 154 is provided within the upper housing 152 which maintains the drive mandrel 150 in contact with the actuator screw 162 . Glide rings 156 are provided around the circumference of the drive mandrel retainer 154 to allow smooth rotation of the drive mandrel retainer 154 within the upper housing 152 .
Upper chambers 165 A and 165 B ( FIGS. 3B and 3C ) are defined within the upper housing 152 which accommodate the drive mandrel retainer 154 when the upper housing 152 moves longitudinally relative to the drive mandrel 150 . Upper chambers 165 A and 165 B are in permanent communication.
Seals 116 are provided at the interface of the upper housing 152 and the actuator housing 160 to protect the interior of the upper chambers from the environment. A bottom housing 164 connects to the distal end of the actuator housing 160 . Seals 116 are provided between bottom housing 164 and the actuator housing 160 to protect the interior from the environment.
The actuator screw 162 extends through the bottom housing 164 . The actuator nut 158 is engaged with the actuator screw 162 such that rotation of the actuator screw 162 moves the actuator nut 158 relative to the actuator screw 162 . Other screw components and threaded components may be utilized.
The distal end of the actuator screw 162 is coupled to a retrieving mandrel 166 . The retrieving mandrel 166 is generally an elongated solid member with a circular cross-section of substantially the same diameter as the drive mandrel 150 . The actuator screw 162 is coupled to the retrieving mandrel 166 by a retrieving mandrel retainer 168 . The proximal end of the retrieving mandrel 166 adjacent to the actuator screw 162 has a shoulder 177 . On either sides of the shoulder 177 are thrust bearings 134 . The thrust bearings 134 allow longitudinal movement of the actuator screw 162 to be transmitted to the retrieving mandrel 166 but rotational movement of the actuator 162 is not transmitted to the retrieving mandrel 166 such that retrieving mandrel 166 moves longitudinally but does not rotate. Glide rings 156 are positioned between the retrieving mandrel retainer 168 and the bottom housing 164 to allow smooth longitudinal and rotational movement of the retrieving mandrel retainer 168 relative to the bottom housing 164 .
Bottom chambers 167 A and 167 B ( FIGS. 3B and 3C ) are defined within the bottom housing 164 which accommodate the retrieving mandrel retainer 168 when the bottom housing 164 moves longitudinally relative to the retrieving mandrel 166 . The bottom chambers 167 A and 167 B are in permanent communication.
A distal end of the bottom housing 164 is coupled to a setting cone 174 . Seals 116 are provided between the bottom housing 164 and the setting cone 174 . A lower internal area seal 170 is provided between the setting cone 174 and the retrieving mandrel 166 . A lower secondary interior area seal 172 is provided between the bottom housing 164 and the retrieving mandrel 166 . The lower internal seal 170 provides a primary seal to seal the interior of the bottom housing 164 from the external environment. The lower secondary interior seal 172 provides a backup seal.
A slip cage 178 holds a set of slips 180 on the setting cone 174 . Cap screws 176 connect the slip cage 178 to the setting cone 174 . The slip cage 178 is moveable relative to the setting cone 174 by movement of the cap screws 176 in slots defined in the slip cage 178 . The slips 180 are biased inward by springs 182 .
A C-ring 190 is provided which sits in a circumferential recess in the retrieving mandrel 166 . The C-ring 190 sits inside a C-ring housing 186 which is connected to the setting cone 174 by cap screws 184 . The C-ring 190 is retained within the C-ring housing 186 by a C-ring retainer 192 . A segment of the production tubing or casing 188 is shown to facilitate the explanation of the operation of the wireline retrieving tool 110 .
The drive mandrel 150 and the retrieving mandrel 166 are of substantially the same diameter so that the volume of either mandrel entering the sealed interior defined by the upper housing 152 , the actuator housing 160 , and the bottom housing 164 is substantially the same as the volume of the other mandrel exiting the sealed interior so that the free volume within the sealed interior remains substantially constant. A hydraulic piston defined between the outside diameter of the upper housing 152 and the outside diameter of the drive mandrel 150 and a hydraulic piston defined between the outside diameter of the bottom housing 164 and the outside diameter of the retrieving mandrel 166 are equal in area. Any outside well pressure acting on these two hydraulic piston areas will create two equal opposing forces that cancel each other. This provides the same power availability for pushing and pulling.
The operation of the wireline retrieving tool 110 is explained with reference to FIGS. 2A to 2C , 3 A to 3 C and 4 A to 4 C which show the wireline retrieving tool 110 in three different positions. The same reference characters are used in all three figures to refer to the same elements. In operation, the wireline retrieving tool 110 is connected by connector 112 to a wireline, both electrically and mechanically. The wireline retrieving tool is lowered into a segment of the production tubing or casing 188 to a desired location. At that location, the gear motor 124 is operated via the printed circuit board 120 . The digital positioning encoder 122 counts the rotations of the gear motor 124 so that an exact position of the retrieving mandrel 166 can be obtained. Rotation of the gear motor 124 is translated to the drive mandrel 150 to provide rotation of the drive mandrel 150 .
In the initial position depicted in FIGS. 2A to 2C , only chambers 165 A and 167 A are open. The drive mandrel 150 is coupled to the actuator screw 162 as noted above so that rotation of the drive mandrel 150 provides rotation of the actuator screw 162 at the same rate of rotation. Rotation of the actuator screw 162 moves the actuator nut 158 downward along the actuator screw 162 as seen in FIGS. 3A to 3C . This opens up chambers 165 B and 167 B at the same rate that chambers 165 A and 167 A are closed. The movement of the actuator nut 158 in turn moves the upper guide housing 140 , the upper housing 152 , the actuator housing 160 and the bottom housing 164 downward. The bottom housing 164 in turn pushes the setting cone 174 downward.
The C-ring housing 186 is held against downward movement by the C-ring 190 seated in the recess on the retrieving mandrel 166 . This also holds the slips 180 stationary relative to the retrieving mandrel 166 . The setting cone 174 slides relative to the slips 180 . The setting cone 174 has a narrower end initially within the slips 180 and expands along a shoulder 181 to a wider section. As the shoulder 181 is forced through the slips 180 , the slips are moved outward, the springs 182 are compressed and the slips bite into the segment of production tubing or casing 188 and hold the slips stationary relative to the production tubing or casing 188 (see FIGS. 3A to 3C ). Further rotation of the actuator screw 162 no longer moves the housing downwardly, instead, further rotation of the actuator screw 162 will force the expansion and release the C-ring 190 from the retrieving mandrel 166 and the proximal end of the wireline retrieving tool 110 moves upwardly to the upper limit of travel shown in FIGS. 4A to 4C . In this final position, chambers 165 A and 167 A are completely closed and chambers 165 B and 167 B are completely open.
All of chambers 165 A, 165 B, 167 A and 167 B are in fluid communication through gaps between the actuator screw 162 and the actuator nut 158 and gaps between the coupling assemblies interconnecting the actuator screw 152 to the mandrels 150 and 166 and the housings 152 and 164 . The mandrels 150 and 166 have substantially the same cross section. As a result, the combined free volume of the chambers 165 A, 165 B, 167 A and 167 B remains substantially constant throughout the relative movement of the housings so that the pressure within the sealed interior of the tool 110 remains constant. Also, because the mandrels 150 and 166 have the same cross section, any outside well pressure acting on the two opposing hydraulic pistons defined by the outside diameters of the housings 152 and 164 and the outside diameters of the mandrels 150 and 166 , would generate two equal opposing forces that would cancel each other and would not affect the function of the tool in pushing or pulling operations.
In operation, a fishing tool is attached to the distal end of the wireline retrieving tool 110 . The further rotation of the actuator screw 162 pulls the fishing tool upward against the holding force of the slips against the segment of production tubing or casing 188 . Thus, the pulling force is not provided by the wireline but instead by the action of the retrieving mandrel 166 against the slips 180 .
To reset the tool, the actuator screw 162 is rotated in the opposite direction causing the upper guide housing 140 , the upper housing 152 , the actuator nut 158 , the actuator housing 160 , the bottom housing 164 and the setting cone 174 to move upward. The withdrawal of the shoulder 181 of the setting cone 174 from the slip 180 results in the springs 182 retracting the slips 180 from contact with the segment of production tubing or casing 188 . The wireline retrieving tool 110 can then be withdrawn from the production tubing or casing. Alternatively, if the object to be retrieved is not completely free, the wireline retrieving tool 110 can be partially withdrawn up the production tubing or casing 188 and reset to perform a second or other subsequent pulling operations in the same manner as described above.
FIGS. 5A to 5C depicts a wireline setting tool 198 . The same reference characters are used in FIGS. 5A to 5C for the same components as identified in FIGS. 2A to 4C . It can be seen that the only difference between the wireline retrieving tool 110 of FIGS. 2A to 4C and the wireline setting tool 198 of FIGS. 5A to 5C is the assembly at the distal end. In particular, the wireline setting tool 198 does not contain a slip assembly. Instead, a setting housing 194 is connected at the distal end of the bottom housing 164 . As with the wireline retrieving tool 110 , a lower internal area seal 170 seals against a mandrel, in this case a setting mandrel 169 , of substantially the same diameter as the upper interior seal 148 which seals against the drive mandrel 150 . A setting adapter 196 is fixed to the distal end of the setting mandrel 169 . A tool to be set is fixed to the end of the setting housing 194 and the setting adapter 196 . When the wireline setting tool 198 is actuated in the manner as described with regard to the wireline retrieving tool 110 , the housings 140 , 152 , 160 , 164 and 194 move downward over the setting mandrel 169 and the force thus exerted is used to set a tool to be placed in the production tubing or casing (not shown). In FIGS. 5A to 5C , the wireline setting tool 198 is shown with the actuator nut 158 in an intermediate position such that the housings are partly but not fully extended.
The tools depicted in FIGS. 1A to 5C are intended to be deployed by a wireline. A wireline is flexible and uses gravity to lower a tool into position. For horizontal or highly deviated wells, a wireline alone may not allow a tool to be properly positioned in the well. Instead coiled tubing with a wireline installed inside it, also known as stiff wireline, is used. Coiled tubing consists of a hollow tube that surrounds the wireline and can be used to push a tool into a horizontal well. Coiled tubing is typically relatively thin walled. As a result, to prevent the tubing from collapsing under well pressure and mechanical forces, it is necessary to allow pressurized completion fluids to flow through the coiled tubing and through the tool.
FIGS. 6A to 6C depict an embodiment of a retrieving tool that has been adapted for use with coiled tubing. FIGS. 6A to 6C use the same reference characters that are used in FIGS. 2A to 4C for the same components. FIGS. 6A to 6C will be described only in respect to how they differ from FIGS. 2A to 4C . FIGS. 6A to 6C depict a retrieving tool 200 . A flow path is defined through the retrieving tool 200 to allow fluid to flow through the coiled tubing as detailed in the following description.
At a proximal end of the retrieving tool 200 there is the connector 112 for connecting to a wireline as explained above. FIG. 6A depicts additional components at a proximal end of the connector 112 , not shown in FIGS. 2A to 4C . In particular, an electrical contact sub 208 and a rubber boot 204 are shown as interconnecting between a segment of wireline 202 and the connector 112 . The electrical contact sub 208 and the rubber boot 204 do not form part of the retrieval tool 200 . They serve to mechanically and electrically interconnect the connector 112 to the wireline 202 .
The connector 112 is connected at its distal end to the electronics housing 114 as in FIGS. 2A to 4C . However, in FIG. 6A , the electronics housing 114 is surrounded by a bypass sleeve 218 . A proximal end of the bypass sleeve 218 is connected to a coiled tubing connector 206 . The bypass sleeve 218 and the coiled tubing connector 206 are both hollow, and may be tubular. The coiled tubing connector 206 is adapted to connect to the coiled tubing at its free end so that the coiled tubing can be used to position the retrieving tool 200 in the well.
As can be seen in FIG. 6A , the combination of the coiled tubing connector 206 and the bypass sleeve 218 define an outer hollow member in fluid connection with the coiled tubing. The wireline 202 , the rubber boot 204 , the electrical contact sub 208 , the connector 112 , and the electronics housing 114 define an inner member surrounded by the outer hollow member. An elongated fluid chamber or conduit 212 is defined between the inner member and the outer member which allows fluid to flow down the coiled tubing and around the electronics. The electronics remain sealed from the fluid chamber 212 .
FIGS. 6A to 6C also depict an inner elongated member comprised of a drive mandrel 250 , an actuator screw 262 and a retrieving mandrel 266 comparable the drive mandrel 150 , the actuator screw 162 and the retrieving mandrel 166 . The difference between the inner elongated member of FIGS. 6A to 6C , from the inner elongated member of FIGS. 2A to 4C , is that the inner elongated member of FIGS. 6A to 6C has a fluid flow port or conduit 224 defined longitudinally therethrough. The drive mandrel 250 the actuator screw 262 and the retrieving mandrel 266 are connected to each other in a fluid tight manner by the seals 234 at either end of the actuator screw 262 . This prevents any fluid exchange between the fluid flow port 224 and the chambers 165 A, 165 B, 167 A and 167 B.
The elongated fluid chamber 212 is in fluid communication with the fluid flow port 224 such that fluid entering the coiled tubing can exit through the distal end of the retrieving mandrel 266 . In particular, the distal end of the bypass sleeve 218 is attached to the proximal end of the guide sleeve 138 through a threaded connection and the connection is sealed with the seals 116 . Interconnection ports 244 are defined between where the elongated fluid chamber 212 ends adjacent to the end of the bypass sleeve 218 and where the fluid flow port 224 begins at the proximal end of the drive mandrel 250 . These interconnection ports extend through the guide sleeve 138 and the drive mandrel 250 generally perpendicular to the direction of the elongated fluid chamber 212 and the fluid flow port 224 . Fluids pumped through the coiled tubing will flow through the space (i.e. chamber 212 ) between the bypass sleeve 218 and the outside diameter of the tool (i.e. electronics housing 114 ) then it will cross over to the inside of the tool through the ports 244 in the guide sleeve 138 and the drive mandrel 250 to the fluid flow port 224 . Although the coiled tubing connector 206 and the bypass sleeve 218 are depicted as separate from the electronics housing 114 , it will be appreciated that they may be interconnected such that flow passages, rather than a complete chamber 212 , may be defined.
The flow path through the tool may be used for other purposes. For example, fluids may be pumped through to perform clean-outs for fishing jobs or for formation stimulation. Another option is to pump fluids, particularly cold fluids, around the electronics. If the tool is being run into a hot well whose temperature exceeds the temperature rating of the tool, by pumping cold fluids through the tool, the electronics section will be cooled thereby enabling the tool to perform.
FIGS. 2A to 4C and 6 A to 6 C depict the slips 180 as the means of fixing the tool 110 in place. Other means may also be used. FIG. 7 provides an example of a portion of a retrieving tool 300 . The tool 300 is shown within three segments of tubing or casing 388 , 386 and 384 . The middle segment of tubing or casing 386 is a landing nipple which has a profile 390 defined around the interior surface.
The tool 300 comprises a bottom housing 364 comparable to bottom housing 164 previously described. The bottom housing 364 is connected to a retrieving housing 374 which in turn connects to a locking lug holder 326 . Locking lugs 350 are movably held within the locking lug holder 326 . The outer contour of the locking lugs 350 matches the profile 390 so that the locking lugs 350 fit into the profile 390 .
A retrieving mandrel 366 extends axially through the centre of the bottom housing 364 , the retrieving housing 374 , the locking lug holder 326 , and the locking lugs 350 . The retrieving mandrel 366 has an essentially constant circular diameter. However, the retrieving mandrel 366 has two necked down portions 327 and 328 which are used to position and release the locking lugs. Springs or other biasing means 352 are positioned between the retrieving mandrel 366 and the locking lugs 350 . The locking lugs 350 are movable inwards and outwards perpendicular to the direction of travel of the retrieving mandrel 366 . The springs 352 bias or push the locking lugs 350 in the outwards direction.
In use, the springs 352 are initially positioned in the necked down portion 327 of the retrieving mandrel 366 . The tool 300 is inserted into the well with the mandrel 366 held in this position until the locking lugs 350 reach the profile 390 of the landing nipple 386 . The locking lugs 350 are forced outward and locked in position in the profile 390 as shown in FIG. 7A . Actuation of the tool 300 will cause the retrieving mandrel 366 to move upward (to the left in the FIGS. 7A to 7C ) relative to the locking lugs 350 and the housings 364 and 374 to perform its retrieving function. A larger diameter portion of the mandrel 366 , as shown in FIG. 7B will come between the locking lugs 350 and further compress the spring 352 . The larger diameter portion of the mandrel 366 will lock the locking lugs 350 in place. As the retrieving function is performed, the retrieving mandrel 366 is moved upwards relative to the locking lugs 350 until the second necked down portion 328 of the mandrel is positioned under the lugs 350 and the springs 352 . The locking lugs 350 can now be forced inward in the second necked down portion 328 of the retrieving mandrel 366 so that the locking lugs 350 are drawn out of the landing nipple 386 and the tool 300 can be withdrawn from the well. Other locking means may also be used.
In addition to the setting and retrieving applications already described, the tools described herein can also be used for other applications such as shifting of sleeves and measuring the location of an object in the well. For example, if the tool is locked in a known position in the well, the mandrel can be extended and the positioning encoder 122 or other counter can be used to precisely determine the location of the end of the tool and therefore the location of an object contacted by the tool.
Extended reach slip assemblies can be used to perform retrieving, shifting or measuring operations in through tubing applications.
The number of housings and configurations depicted in FIGS. 2A to 7C is based, at least in part, on manufacturing concerns. The invention encompasses tools having more or fewer housings. The tubular shape of the housings is preferred but not essential.
Although seals are depicted throughout the figures, seals may be unnecessary between the relatively stationary parts if a sufficiently tight fit is present.
The mechanical means of interconnecting the various components of the tool shown in the figures are exemplary only. Other known mechanical means of interconnecting the various components are contemplated by the invention.
Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A well tool for applying a pulling or a pushing force to an object in an interior of a well bore comprising: a) an inner member comprising a first elongated member, a second elongated member and an actuation means axially interconnecting the first elongated member and the second elongated member; b) an outer elongated member longitudinally moveably engaged with the inner member; c) a first seal defined between the first elongated member and the outer elongated member; d) a second seal defined between the second elongated member and the outer elongated member; e) a first piston area defined at a first end portion of the outer elongated member between an outer diameter of the outer elongated member and a sealed outer diameter of the first elongated member; f) a second piston area defined at a second end portion of the outer elongated member between the outer diameter of the outer elongated member and a sealed outer diameter of the second elongated member; and g) a sealed chamber defined between the first seal and the second seal, the sealed chamber including a fluid at a fluid pressure; wherein operation of the actuation means axially reversibly moves the outer elongated member relative the inner member while the fluid pressure remains constant; and wherein the first piston area and the second piston area are substantially equal and external pressure acting on these two piston areas, generates two opposing forces substantially balanced during relative movement. | 4 |
BACKGROUND OF THE INVENTION
This invention concerns to improvements in or relating to tillage. In particular, the invention relates to a method and apparatus for controlling a width adjustable tillage implement such as a plough operatively combined with a powered vehicle such as a tractor or other multi-purpose agricultural vehicle.
Conventionally a plough is secured to the three point hitch at the rear of a tractor. An operator of the tractor may use controls in the tractor cab to set the ploughing depth of the implement. This results in raising or lowering of the members of the three point hitch until the desired ploughing depth is obtained. Most ploughs are invertible by means of actuators also conventionally controlled from within the tractor cab. Inversion of a plough at the end of a first pass along a field ensures that the furrows ploughed during the next succeeding pass (during which the tractor travels in a direction opposite its direction during the first pass) face in the same direction as those ploughed during the first pass.
The width of many ploughs is adjustable, by means of powered actuators mounted on the plough that are, conventionally, controllable from within the tractor cab. When a plough is adjusted to a wide setting the width of tillage increases correspondingly. Thus the workrate of the tractor/plough combination is potentially increased commensurately if the tractor maintains a constant forward speed. However, increasing the plough width increases the draught experienced by the tractor, ie. the force needed to pull the plough through the soil. This tends to increase the tractor's fuel consumption rate at a given speed, because of a need to fuel the tractor engine at a higher rate; or because of a need to shift transmission to a lower ratio; or both. In the alternative, the tractor may be driven at a lower speed to try and maintain a constant fuel consumption rate, but then the workrate improvement from the wider plough setting may be offset. There may in any event be an increase in fuel consumption, through running of the tractor engine at an inefficient speed.
Any attempt to achieve compromise settings for the plough width, ploughing depth and engine governor that give rise to acceptable work rates without increasing the tractor's fuel consumption rate excessively are virtually impossible for a tractor operator alone to achieve in practice. This is primarily because the strength of soil (ie. its resistance to cultivation) varies over typically a range of eg. 30 kNm -2 to 60 kNm -2 from place to place in a field. The tractor operator is often unable to prevent wheel slip, over revving of the tractor engine or stalling of the engine when the plough encounters sudden changes in the soil strength.
Patent application GB 9622087.6 discloses an automatic control apparatus and a control method for operating a tractor/implement combination in order to maintain a constant ploughing depth whilst simultaneously optimizing a performance parameter of the vehicle/implement combination. Typical such performance parameters include the workrate of the vehicle/implement combination; and the fuel consumption rate of the vehicle.
SUMMARY OF THE INVENTION
This invention provides a method and apparatus suitable for use in conjunction with the method of GB 9622087.6; and suitable for use in conjunction with other vehicle/implement automatic and semi-automatic control arrangements.
According to a first aspect of the invention, there is provided a method of controlling a width adjustable tillage implement operatively combined with a powered vehicle, the method comprising:
i. tilling with the implement for a first period;
ii. obtaining a plurality of measured values of the strength of the soil tilled during the first period;
iii. at the end of the first period, analyzing the measured soil strength values and selecting a first soil strength value characteristic of the soil strength values encountered during the first period; and
iv. adjusting the width of the implement, in dependence on the first soil strength value, to a width for use during a subsequent tilling period.
This method advantageously provides a width adjustment technique suitable for use with the apparatus of GB 9622087.6. The method of the invention also advantageously makes use of the headland turn of a tractor/implement combination for determining and, as necessary, adjusting the plough width setting for a subsequent pass along a field.
Preferably during the subsequent period, tilling occurs in generally the same direction as in the first tilling period. Thus, the method of the invention may be used to determine at the end of a first pass an optimal width setting for a subsequent pass along the field in the same direction. This is advantageous because (i) the strength of a given area of soil encountered by a plough may differ depending on the direction of approach of the plough; and also, of course, because (ii) many fields are inclined and hence give rise to different loadings on the vehicle/implement combination, depending on its direction of travel. Thus it is desirable that the method of the invention includes the sub-step of storing of an optimal value of the width setting determined from the average soil strength, until the vehicle/implement combination next tills in the same general direction.
Conveniently the method includes:
v. tilling with the implement for a second period;
vi. obtaining a plurality of measured values of the strength of the soil tilled during the second period;
vii. at the end of the second period, analyzing the measured soil strength values and selecting a second characteristic soil strength value characteristic of the soil strength values encountered during the second period; and
viii. adjusting the width of the implement, in dependence on the second characteristic soil strength value, to a width for use during a further, subsequent tilling period.
Thus the method permits optimization of the implement width, in dependence of average soil strength values, for a plurality of directions of travel in a field.
Most fields are generally rectangular, so the number of different tilling directions to be accommodated in this way is usually limited to two (ie. representing passes in opposite directions along a field).
Therefore, in preferred forms of the invention, in the further, subsequent period tilling occurs in generally the same direction as in the second period; and tilling in the first period occurs in generally the opposition direction to that of tilling in the second period.
Nonetheless, it may be desirable to allow for more than two directions of travel during tilling.
The method preferably includes:
ix. inverting the tilling implement between consecutive tilling periods; and encoding of the measured soil strength values in dependence on the orientation of the tilling implement. This provides an advantageously simple method of ensuring that each width adjustment of the implement is determined from soil strength values detected during a previous pass along the field in the same direction.
Conveniently the or each step of obtaining a plurality of measured soil strength values includes:
xi. periodically measuring a variable of the vehicle/implement combination, the variable being proportional to the draft between the implement and the vehicle. This is particularly advantageous when the method is employed in a vehicle/implement combination including control apparatus as disclosed in GB 9622087.6.
An advantageous frequency for measuring of the said variable of the vehicle/implement combination has been found to be equal to or greater than 4 Hz.
Preferably the measured values of the variable are converted to values of soil strength and stored in a memory means as a histogram. Thus the inventive method is suitable for implementation by a microprocessor that may be installed in the vehicle.
Preferably the soil strength values are rounded to the nearest 5 kNm -2 . This confers acceptable accuracy on the method without requiring lengthy processing times when the method of the invention is implemented by a microprocessor or other computing device.
Conveniently the measured variable is or includes a static draft measurement. In particular, the measured value of the variable may be converted to a soil strength value using the formula:
D=(C1+C2.gs.sup.2)·d·w·n.
in which:
D=draught (kN)
C1=soil strength (kN/m 2 )
C2=dynamic draught coefficient ([kN/m 2 ]/[km/h] 2 )
gs=ground speed of the vehicle/implement combination (km/h)
d=working depth of implement (m)
w=width of implement (m)
n=number of furrows
The dynamic draft coefficient C2 may be derived from the measured draft value and the ground speed (gs) value.
The method of the invention may incorporate capturing data from a plurality of sensors located on or in the vehicle/implement combination in order to permit use of the above-identified formula.
Conveniently the method includes tilling for one or more further tilling periods in which tilling occurs in directions generally parallel to that of the first and second periods, the number of periods of tilling being equivalent to the tilling of a predetermined area of land, the method including the step of mapping and storing in a memory the soil strength values occurring over the predetermined area.
This advantageously permits subsequent analysis and/or manipulation of the soil strength data, for example in order to generate for a farmer a plot showing areas of a field requiring extra cultivation or the application of specialized chemicals in order to aid subsequent cultivation.
The following definitions of optimal features of the invention relate to aspects thereof particularly suitable for when the method is practiced using the apparatus, or in conjunction with the method, of GB 9622087.6.
When, as is usually the case, the tilling depth of the implement is adjustable, the method may optionally include:
xii. adjusting one or more performance parameters of the vehicle during tilling, whereby to permit maintenance of a constant value of the tilling depth and to optimize a performance characteristic of the vehicle/implement combination.
Preferably the one or more performance parameters are selected from:
workrate;
fuel consumption.
Conveniently the step of adjusting the width of the implement in dependence on the average soil strength value includes the sub-steps of:
xiii. measuring the value of the performance characteristic of the vehicle/implement combination;
comparing the said measured value and a steady state reference model of the performance characteristic; and
adjusting the implement width so as to minimize any difference between the said performance characteristic and the steady state reference model.
This aspect of the method may include the further sub-steps:
xiv. adjusting the implement width to a value predicted to minimize the difference between the measured value and the steady state reference model;
xv. further tilling with the implement and measuring a further value of the said performance characteristic;
xvi. comparing the further performance characteristic value and the steady state reference model;
xvii. if necessary, further adjusting the implement width to minimize the difference between the performance characteristic and the steady state reference model;
as necessary
xviii. repeating steps xiv. to xvii. further to minimize the said difference; and, optionally,
xviii. detecting one or more characteristics of the tilth; and
xix. modifying the steady state reference model in dependence on the said detected tilth characteristics.
For the avoidance of doubt, a "steady state" reference model is herein taken to mean a reference model in which the physical characteristics of the tractor/implement assembly are regarded as fixed with respect to any particular instant in time. Thus, for example, parameters such as the mass of the vehicle and the moments of inertia of various sub-components thereof are taken to be constant, even though such parameters will in reality vary during operation of the tractor.
The method normally includes the steps of automatically adjusting the implement width to a value expected to be an optimal value for the prevailing values of the measured draft and for the prevailing setting of a variable performance parameter of the vehicle/implement combination.
Under some circumstances the width of the implement may instead be adjusted to a predetermined value chosen by an operator of the vehicle/implement combination. A further, optional feature of the method may then include:
xx. comparing a first performance characteristic of the vehicle/implement combination, when the implement width is adjusted to the predetermined value, against a further performance characteristic of the vehicle/implement combination when the implement width is adjusted to a value expected to be optimal for the prevailing values of the measured draft and for the prevailing settings of one or more variable performance parameters of the vehicle/implement combination and, if the difference between the first and further performance characteristics exceeds a predetermined maximum;
xxi. transmitting a warning signal to an operator of the vehicle/implement combination.
Thus if the setting selected by an operator of the vehicle/implement combination is too far removed from an optimal width setting that would normally be achieved under prevailing conditions by use of the method, the vehicle operator can be warned.
In preferred embodiments, the tilling of the method is or includes ploughing, although other forms of tilling such as harrowing or operating a rotary cultivator are theoretically within the scope of the method of the invention.
Conveniently the first and second characteristic soil strength values, for example, may be obtained by identifying the most frequently occurring soil strength value from a range of possible values during a said period of tilling. This step may advantageously employ storing of a histogram of soil strength values in eg. a microprocessor. When two soil strength values are encountered with equal frequency during a tilling period, the method may include the step of selecting the larger of the values as the characteristic soil strength value.
According to a second aspect of the invention, there is provided a method of controlling a width-adjustable tillage implement operatively combined with a powered vehicle, the method comprising:
i. tilling with the implement in a first direction for a first period;
ii. obtaining a plurality of measured values of the strength of soil tilled during the first period;
iii. subsequently tilling with the implement in a second direction for a second period;
iv. subsequently adjusting the width of the implement in dependence on a first soil strength value characteristic of the soil strength values obtained during the first period;
v. subsequently tilling, for a further period, in the first direction.
This method may advantageously be used with many of the optional, preferred features of the first aspect of the invention defined herein.
Alternatively, the step of selecting the characteristic soil strength value may include averaging of the soil strength values encountered during a said tilling period.
According to a third aspect of the invention, there is provided an apparatus for controlling the width of a width-adjustable tillage implement operatively combined with a powered vehicle, the apparatus comprising one or more actuators for adjusting the width of the implement; one or more sensors for detecting the strength of soil previously tilled by the implement; and a processor for controlling the or each actuator in dependence on the detected soil strength values, wherein the processor stores detected soil strength values during a period of tilling and at the end of said period averages the stored values to obtain an average soil strength value, the processor subsequently controlling the or each actuator to adjust the width of the implement in dependence on the average soil strength value.
Such an apparatus is advantageously suited for practicing of the method of the invention.
In preferred embodiments the processor includes means for ensuring that such width adjustment of the implement occurs before subsequent tilling in generally the same direction as the direction of tilling during the first tilling period. Such means may for example include one or more means for receiving and recognizing sensor signals indicative of the orientation of an invertible plough, the orientation of which is uniquely associated with a chosen direction of travel of the vehicle/plough combination.
Preferably the processor includes a memory for storing a histogram of soil strength values and means for comparing the most frequently occurring soil strength value against said histogram whereby to obtain the average soil strength value associated with the period of tilling.
Alternatively, the apparatus may include means for averaging the soil strength values encountered during a said tilling period.
Conveniently the apparatus may include one or more sensors for:
detecting the width adjustment of the tillage implement and generating a width signal indicative thereof; and/or
detecting the depth setting of the tillage implement and generating a depth signal indicative thereof, said signals being input to the processor.
Preferably the implement is invertible and the apparatus includes one or more sensors for generating an orientation signal indicative of the orientation of the implement, the orientation signal being input to the processor.
The processor may advantageously receive the width and depth signals in analogue form and the orientation signal in digital form.
In preferred embodiments, the processor may include an interface for communicating with a CAN for controlling the actuators adjusting the or each performance parameter of the vehicle/implement combination; and/or maintaining a constant depth setting of the implement.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic representation of a tractor/implement combination according to the invention;
FIG. 2 is a flow chart showing the steps of the method of the invention; and
FIG. 3 is a block diagram representation of a control apparatus, incorporated in the FIG. 1 apparatus, for implementing the method of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is shown an agricultural tractor denoted by the reference numeral 10. In common with such vehicles in general, tractor 10 has front 11 and rear 12 pairs of driven wheels. Tractor 10 also has an engine (not shown in the drawings), a transmission system including a gearbox, transfer box and appropriate differentials for the driven wheels; an operator cab 13 and a three point hitch 15 at the rear of the vehicle between the rear wheels for attachment of an adjustable implement, which in the embodiment shown is a plough 60.
The ploughing width of reversible plough 60 shown is adjustable.
Thus the tractor/implement combination 10 may be regarded as comprising a plurality of controllable sub-systems, each of which influences the performance of the tractor in dependence on the prevailing conditions. The sub-systems include the engine (adjustable in one of two ways, ie. by means of a throttle setting or by means of an engine governor setting, depending on the engine type); the transmission (adjustable by virtue of selection of gear ratios); the three point hitch 15; and the plough 60 adjustable in a manner described below by adjustment of one or more actuators.
Tractor/implement combination 10 includes a plurality of slave controllers for the sub-systems, in the form of microprocessors 41, 42, 43 and 48.
Certain parameters of the engine performance are controlled by means of an engine management system including microprocessor 41 that optimizes engine performance in dependence on the throttle or engine governor settings input either by the tractor operator using suitable control members, or from a programmable controller constituted as a further microprocessor 21 (described in greater detail in GB 9622087.6) located in the cab of the FIG. 1 vehicle. The engine management system operates by adjusting various parameters, such as the metering volume of a fuel injection system, the timing of the fuel injection system, the boost pressure of a turbocharger (if present), the opening of engine valves and the opening of portions of the vehicle exhaust system, via suitable powered actuators such as solenoids.
Tractor 10 includes a semi-automatic transmission system in which the transmission ratio selected is determined by a slave controller in the form of microprocessor 42 acting on one or more solenoids to engage and disengage gear sets of the gear box and/or gears of the transfer box, in dependence on the settings of a plurality of gear levers in the operator's cab or in dependence on signals from microprocessor 21.
The FIG. 1 embodiment includes hitch microprocessor 43 and plough control microprocessor 48.
Microprocessor (slave controller) 43 controls the positions of the elements of the implement (three point) hitch 15. Again, the microprocessor 43 controls a number of actuators such as solenoids in dependence on the settings of control levers in the operator's cab 13, on signals received from microprocessor 21, or in dependence on its own programming.
Microprocessor 48 is operatively connected to actuators, eg. hydraulic actuators, for adjusting the width of the plough and for reversing the plough at the end of each furrow and operates in dependence on signals received from microprocessor 21; from lever settings in cab 13; or according to its own programming.
Plough 60 is a fully-mounted, reversible plough 60. By "fully mounted" is meant an implement the depth of which is adjusted by the tractor implement hitch, and not by actuators on the implement itself. (The latter class of implement is generally referred to as a "semi-mounted" implement.) Thus the FIG. 2 implement is fully mounted notwithstanding the presence of a stabilizer wheel 49. However the ploughing depth may in alternative embodiments also be adjusted by virtue eg. of support wheels and/or remote actuators.
A further embodiment of the invention, not shown in the drawings, may be similar to the FIG. 1 embodiment except that the implement hitch has attached thereto a semi-mounted plough. Numerous other implements may equally well be secured to either the front or the rear of the tractor.
Microprocessor 21 in the embodiment shown lies within the cab 13 and is operatively connected to an operator interface/control unit 22. Preferably, although not essentially, microprocessor 21 includes in its NVM or a removable memory module a steady-state reference model of the operation of the tractor/implement combination when carrying out a variety of tasks under a variety of different field conditions. The reference model can be updated through use of the tractor/implement combination, in order to take account of contemporaneously prevailing field conditions such as soil strength and tractive efficiency. Thus the reference model may include some data that varies each time the vehicle is used; and some data, such as the mass of the vehicle hardware (i.e. those components whose masses do not alter during use of the tractor), the transmission ratios, the engine output at given engine speeds and torque loads, and so on, that are fixed.
A communication bus 23 interconnects the microprocessor 21 and the microprocessors 41, 42, 43 and 48 associated with the adjustable sub-systems.
Thus in the embodiment shown the controller 21 is able to control each of the microprocessors controlling the adjustable sub-systems. Microprocessor 21 may be regarded as hierarchically the primary microprocessor of the vehicle shown. However it is theoretically possible for the reference model and the control algorithms present in microprocessor 21 to be distributed among a number of microprocessors. In such an arrangement a specific, primary processor 21 may be dispensed with. The invention is considered to include such embodiments.
The mode of control may be adjusted, as desired. For example, the microprocessor 21 may include stored therein a control algorithm that seeks to optimize the workrate of the tractor 10 when carrying out a chosen task.
Another algorithm representing another control mode may seek to minimize the specific or actual fuel consumption of the tractor.
A further algorithm may be selected to return control of at least some of the tractor sub-systems to the operator, who may then use the conventional cab-mounted levers and controls of the vehicle. Such a mode is necessary e.g. when the tractor 10 is driven on roads between field operations; and when turning in the headland at the end of a field, where it is thought that automatic control of the entire tractor/plough combination would offer no benefits. When such a mode is selected, the microprocessor 21 ceases to influence the microprocessors 41, 42, 43 and 48 until an automatic control mode is again engaged, but the microprocessors 41, 42, 43 and 48 may remain active throughout this period in order to provide independently controllable sub-systems. The control of the microprocessor 48 during turning in the headland is described hereinbelow.
The various modes of operation need not be stored in any of the microprocessors. Indeed, there may be some benefit in providing the software for the various control modes in removable memory devices such as diskettes, so that a tractor user can purchase only the software that is of use to him. Similarly, modified versions of the reference model may be supplied in removable memory devices so that the control apparatus may be tailored to a farmer's individual requirements.
Referring now to FIG. 2, there is shown a flow diagram representative of the headland mode subroutine that is operated by microprocessors 43 and 48 when microprocessor 21 relinquishes control of them to permit turning of the tractor 10 in the headland.
In the FIG. 2 method during tilling operations the control software constantly calculates the implement draft in kN, by the formula:
D=(C1+C2·gs.sup.2)·d·w·n) (1)
in which:
D=draft (kN)
C1=static draught coefficient (kN/m 2 ) or soil strength
C2=dynamic draught coefficient ([kN/m 2 ]/[km/h] 2 )
gs=ground speed (km/h)
d=working depth (m)
w=furrow width (m)
n=no. of furrows
C2 is derivable from C1, that in turn is available from sensor measurements. In preferred embodiments of the invention, the transmission ratio, engine speed and (optionally) the implement settings are adjustable to take account of variations in the draft value D in order eg. to optimize workrate, minimize fuel consumption or otherwise control the performance of the vehicle/implement combination.
In the presently most preferred embodiment, in which the implement is a plough, the control software will maintain the plough depth constant throughout the ploughing operation. Thus adjustment of the implement is limited to width adjustments only--although (as is explained in more detail below) the software is such as not to permit width adjustments to occur while the plough tills the soil. This feature ensures that the resulting furrows do not vary in width from one end to the other.
As is apparent from block 140, the headland mode subroutine is called from a "disengaging mode" subroutine programmed into microprocessor 21, that controls the vehicle/implement combination while the plough rises from the soil at the end of a pass along the field. The disengaging mode subroutine returns control of the engine governor to the vehicle operator while turning occurs.
At block 141, the headland mode subroutine searches a soil strength histogram acquired during the previous pass in the direction about to be ploughed, and identifies the most frequently occurring soil strength range. This is achieved through analysis of the recorded soil strength values. The soil strength values are in the preferred embodiment stored as a histogram in microprocessor 21. If two soil strength values occur with equal frequency, the software identifies the higher of the two as the "most frequently occurring" value, to ensure that the draft of the plough remains within acceptable limits.
Alternatively, microprocessor 21 may at block 141 simply generate an average soil strength value from the recorded values, instead of identifying the most frequently occurring value. Nonetheless, for economy the latter term is used herein to cover either method of identifying a soil strength value characteristic of the previous pass along the field.
Subsequently (block 142) the software runs a prediction algorithm in respect of the most frequently encountered soil strength over the potential transmission gear range and over the available implement working width range. This results in a set of performance curves (workrate versus implement width in each gear) that is stored in the memory of the CPU.
At block 143, these performance curves are searched for the absolute best implement working width (ie. over the entire range of adjustment of implement working widths); and the best implement working width within (optional) operator-set limits (if they differ from the broad range referred to hereinabove).
A determination is then made (block 144) whether the absolute best working width lies within the operator-set limits. If the result of this determination is affirmative, or if the tractor operator has not specified his preferred plough width, at block 146 the software simply waits for the plough to turn over, tests whether this has occurred (block 147), sets the plough working width to "absolute best" value (block 148) (through operation of one or more adjustment actuators mounted on plough 60) and (block 149) reverts to an idle mode preparatory to running of subroutines (described in GB 9622087.6) for engaging the plough with the soil for tilling; and for controlling the operation of the tractor/plough combination during ploughing.
If the determination, of whether the absolute best working width is within the operator-set limits, is negative, the software then calculates whether the loss of workrate, resulting from failure to use the "absolute best" working width, is greater than a predetermined percentage (step 150). If the result of this determination is negative, the software waits for the plough to turn over, checks for plough turn over, sets the plough width to the best within operator-set limits value and reverts to the idle mode (blocks 146, 147, 151 and 149).
If on the other hand the loss of work rate determined at step 150 is excessive, a warning indication is made (eg. via the operator display 22 in the preferred embodiment) to the operator (block 152) that the potential performance loss is great. The operator is then given the option of overriding the operator-set working width limits in order to optimize workrates. The override may take the form of re-specifying the operator-set working width, or of allowing the software to calculate and implement an "absolute best" optimal width.
If (block 153) the operator overrides the previous operator-set width, steps 146, 147, 148 and 149 are repeated. If this results in an acceptable absolute best working width calculation, the subroutine reverts to idle mode preparatory to running of the engaging and operational subroutines mentioned above.
If the operator chooses not to override the previous operator-set limits at block 153, the software waits for the plough to turn over (block 146), checks for plough turnover (block 147); sets the plough working width to the best available working width within the range of operator-set limits (block 151) and reverts to idle mode preparatory to engagement of engaging and then engaged modes.
The steps of FIG. 2 are repeated each time the tractor/plough combination completes a pass along the field. The characteristic soil strength value obtained each time is derived from the histogram of soil strength values recorded during the last pass in the same direction as that about to be ploughed.
The bits of data corresponding to the respective directions of travel of the tractor/plough combination would of course be encoded in dependence on the orientation of the plough, since the plough is inverted by the control software each time the tractor changes direction. The plough may include a sensor 90 (FIG. 3) generating encoding signals indicative of its orientation.
During passes along the field, the software acquires data on the soil strength by measuring the draft experienced between the tractor and the plough, preferably at a sampling rate of equal to or greater than 4 Hz. This sampling rate has been found to provide adequate reaction times for the apparatus of the invention when eg. sudden changes in soil strength are encountered.
In addition to their function of providing a steady state model for setting of the implement width, a plurality of histograms of soil strength may also be stored in memory in, for example, microprocessor 48 or microprocessor 21, or in a removable memory device in order to provide a map of soil strength values in a field. The stored map may be appropriately electronically labelled to identify it to a particular field, and may be used by a farmer in subsequent operations on the field such as harrowing, furrow pressing and even the application of specialized chemicals in order to take account of variations in the soil strength in order to produce a more consistent crop.
Referring now to FIG. 3, the relationship between microprocessor 48 and the remainder of the components of FIG. 1 is shown in more detail.
Microprocessor 48 comprises a central processor or microcomputer 48a, having a digital input interface 48b and an analogue input interface 48c. Microprocessor 48a receives power via a voltage regulator 48d from the 12 volt power supply of the tractor. Microprocessor 48a can output signals via a solenoid driver 48e. There is also an input/output interface 48f with the controller area network (CAN) of the tractor/plough combination. The primary component of the CAN is microprocessor 21.
The digital interface 48b receives signals, including signals indicative of the orientation of plough 60 from a signal generator in the form of a pair of microswitches, indicated by reference numeral 90, that generate signals uniquely identifying the orientation of plough 60. The microswitches are physically secured to an ultrasonic depth sensor 91 that generates analogue signals (input via the analogue interface 48c to microprocessor 48a) indicative of the depth of ploughing. Thus the depth sensor provides feedback data on the ploughing depth for comparison against the set point ploughing depth calculated by microprocessor 21 during ploughing operations.
During ploughing, the draught values (that are proportional to the soil strength) are recorded in microprocessor 21, and encoded by microprocessor 48a using data from the microswitches 90 indicative of the orientation of plough 60.
Further feedback of the operation of plough 60 during ploughing operations is accomplished by a furrow width transducer 92 that provides feedback data on the actual width ploughed, for comparison against the set point plough width determined by microprocessor 21.
FIG. 3 includes an optional, manual control box 93 that may be used eg. for adjusting the width setting of plough 60 in the absence of signals from the CAN.
Finally, the solenoid driver 48e of controller 48 is operatively connected to a solenoid valve indicated schematically by reference number 94 for adjusting the width setting of the plough 60.
Solenoid valve 94 is shown schematically, since in practice the actual width adjustment arrangement may take a variety of different forms, and may be constituted as a plurality of actuators.
The sensor that provides data on the draft experienced during ploughing may be located on the three point hitch 15, or on a member of the plough 60 secured to three point hitch 15. Other locations for this sensor are also possible.
In use of the apparatus and method of the invention, the plough width and ploughing depth are maintained constant by microprocessor 21 (in accordance with the principles described in GB 9622087.6), and parameters of the tractor are varied eg. in order to maximize work rate or to minimize fuel consumption. If during ploughing the soil strength should increase, the microprocessor 21 responds by temporarily boosting the engine power output (if possible) and/or selecting a lower transmission ratio. Conversely, a reduction in soil strength would cause the microprocessor 21 to shift the transmission to a higher gear. At the headland turn after completion of a pass along the field, the furrow width is adjusted in accordance with the FIG. 2 method by microprocessors 21 and 48 after reversing (inversion) of the plough. The plough is adjusted to a furrow width that according to the determination made in microprocessor 21 at step 143 is most likely to provide an optimal work rate during the return pass down the field. This particular value is, as explained above, preferably determined by logging soil strength values during the previous pass along the field in the same direction, analyzing their distribution, and selecting the most frequently occurring value.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | In the field of agricultural tillage, there is a need for accurate, automated control of the widths of tilling implements, such as ploughs. The invention concerns methods of controlling a plough operatively combined with a vehicle such as a tractor, the methods including logging a series of values of the strength of soil encountered during a pass along a field; selecting the most frequently occurring soil strength value; and, for a subsequent pass of the tractor/plough combination along the field in the same direction, setting the width of the plough in dependence on the most frequently logged soil strength value. A microprocessor is provided to carry out the methods of the invention. | 0 |
[0001] This application is a Continuation-In-Part application of co-pending patent application Ser. No. 11/604,015 filed on Nov. 22, 2006 which was based on provisional patent application Ser. No. 60/739,989 filed on Nov. 22, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method of inoculating the vestibular region of the nares with virus to ascertain whether acquisition and/or prevention of transmission of infection may occur.
[0004] 2. Discussion of the Related Art
[0005] The nose is believed to be the primary incubator of various pathogenic organisms including bacteria, virus, and mold. However, it is the accepted belief in the medical community that inoculation of virus exclusively to the vestibular region of the nose will not play a major role in whether or not, and the degree to which acquisition of infection may occur.
[0006] Because viruses are acellular and do not use ATP (Adenosine Triposphate), they must utilize the machinery and metabolism of a host cell to reproduce. For this very reason, viruses are called obligate intracellular parasites. Before a virus has entered a host cell, it is called a virion (i.e., a package of viral genetic material). Virions (i.e., infectious viral particles) can be passed from host to host either through direct contact or through a vector, or carrier. After entering the cell, the virus's genetic material begins the destructive process of taking over the cell and forcing it to produce new viruses.
[0007] When the virus has taken over the cell, it immediately directs the host to begin manufacturing the proteins necessary for virus reproduction. The host produces three kinds of proteins: early proteins, which are enzymes used in nucleic acid replication; late proteins, which are proteins used to construct the virus coat; and lytic proteins, which are enzymes used to break open the cell for viral exit. The final viral product is assembled spontaneously, that is, the parts are made separately by the host and are joined together by chance. This self-assembly is often aided by molecular chaperones, or proteins made by the host that help the capsid parts come together.
[0008] The new viruses then leave the cell either by exocytosis or by lysis. Envelope-bound animal viruses instruct the host's endoplasmic reticulum to make certain proteins, called glycoproteins, which then collect in clumps along the cell membrane. The virus is then discharged from the cell at these exit sites, referred to as exocytosis. On the other hand, bacteriophages must break open, or lyse, the cell to exit. To do this, the phages have a gene that codes for an enzyme called lysozyme. This enzyme breaks down the cell wall, causing the cell to swell and burst. The new viruses are released into the environment, killing the host cell in the process. Viruses, very different from bacteria, require targeted host cells to effectively replicate.
[0009] The interior of the nasal passages, starting at the entrance into the nose at the nares, can be divided into distinct regions based on the type of nasal epithelial cells that line those regions. The nasal vestibule resides at the foremost position, just inside the nares. Keratinized stratified squamous epithelium lines the anterior two-thirds of the vestibule. In the underlying dermis, sebaceous and sweat glands, and hair follicles are present. These cells do not secrete, contain cilia nor express on their surfaces the cell-surface receptor, ICAM-1, to which all of the major group human rhinoviruses (including types 9 and 39) exclusively bind in order to initiate infection. This is the region focused on by the present invention. The posterior third of the nasal vestibule is lined by non-keratinized stratified squamous epithelium, which is similar to keratinized squamous epithelium except that the upper cell layers do not keratinize. At its posterior annular ring, which is lined by a small band of transitional cells, the vestibule opens into the main body of the nasal cavity, including the nasal turbinates, paranasal sinuses, and parts of the anterior, posterior, and lateral walls of the nasopharanx. This region, which constitutes the vast majority of the nasal interior, is lined by the nasal mucosa comprised of pseudostratified columnar ciliated epithelium with goblet cells scattered among ciliated cells. This region is responsible for the majority of secretions in the nose and its cells abundantly express the rhinovirus binding molecule, ICAM-1, on their surfaces:
[0010] Methods of inoculation with virus for the purpose of initiating infection employed by researchers skilled in the art is consistent with the accepted belief that viral infection requires deposition of virus inoculum on the mucosal region of the nasal cavities that are lined by pseudostratified ciliated and secretory columnar epithelial cells. This region represents the focus of viral spread and the symptoms of the common cold that include excess mucus production, swelling and inflammation. Access to these regions of the inner nasal surfaces is typically gained by the use of nasal dropper or pipette administration which maximizes the ability of the liquid inoculum to distribute itself in these areas. Nasal drop administration with the head held back largely bypasses the anterior portion of the nasal vestibule, with the exception of some run-out that may occur when the head regains its normal position.
[0011] Embedded within the currently held beliefs of the larger scientific community, and those intimately involved in respiratory epithelial cell research, lies the presumption that upper respiratory virus infection requires inoculation of the interior nasal mucosal epithelium. Consistent with the beliefs of the medical and research communities, and absent of the findings outlined in this disclosure of my invention, I too would have joined the greater scientific community in rejecting the notion that exclusive inoculation of the anterior nasal vestibule would be adequate to initiate viral infection.
[0012] Although the methods employed by others may have passively included inoculation of the vestibular region, those methods were and are consistent with the currently-accepted techniques of delivering inocula to the inner nasal cavity in order to achieve upper respiratory infection in test subjects. (see Al-Nakib et al (1989) Antimicrobial Agents and Chemotherapy, April 1989, Vol. 33, No. 4, p. 552-525, and Farr et al (1987) Antimicrobial Agents and Chemotherapy, August 1987, Vol. 31, No. 8, p. 1183-1187) The prior art teachings are in direct contradiction to the unique invention herein which involves selective viral inoculation of the anterior vestibule to the exclusion of all other nasal regions. Furthermore, given what is known about the nature of the cells lining the anterior vestibule, it appears to be neither obvious nor predictable based on current common practice or belief that exclusive viral inoculation of the anterior vestibule would result in infection.
[0013] Recent efforts to prevent infection have revolved around attempts to interrupt direct contact transmission by inactivating the pathogen before it reaches the pseudocolumnar epithelium. These attempts have included inactivation of the virus on the hands, or prevention of attachment of virus to the respiratory epithelium. The normal ciliary clearance of foreign material from the nose poses a formidable barrier to the use of the intranasal strategies. Inactivation of bacteria, virus, and mold in the vestibule, where ciliary clearance is not an issue, provides a strategy to overcome this barrier.
[0014] The potential utility of this strategy requires an assessment of whether a virus inoculated onto the vestibular epithelium actually contributes to the transmission of viral infection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Healthy volunteers who were found to have serum neutralizing antibody titers of <1:4 to rhinovirus type 39 were enrolled to validate the viability of the method described herein.
[0016] The description of the method of viral inoculation of the vestibular region of the nares is set forth below.
[0017] The challenge virus used in this study was a safety tested pool of rhinovirus type 39. This pool has a starting titer of approximately 103.8 TCID50/mL.
[0018] Virus challenge: On the day of the virus challenge, each volunteer had a symptom score evaluated in an interactive interview with the study coordinator to assure that all were asymptomatic and had a blood specimen collected for serologic testing. Each volunteer then had approximately 160 TCID50 of RV39, contained in a volume of 10 μl, placed into the “cup” formed by the thumb and first two fingers of the right hand. The volunteers were instructed to spread the virus over the fingertips with the thumb of the right hand. When the virus challenge had dried (˜10 min), each volunteer intentionally inoculated the anterior nares with the first and second fingers of the right hand. This procedure was carefully monitored to ensure that the finger was inserted only approximately 1 cm into the nose to limit inoculation to the vestibule region of the nares.
[0019] Subjects returned to the study site daily for 5 days after the virus challenge for collection of a nasal lavage specimen for viral culture. Nasal lavage was mixed 1:4 with 4× (four times) concentrated viral collecting broth and then stored frozen until cultured. Each specimen was cultured in two tube cultures of human embryonic lung fibroblast cells (one tube of MRC-5 and one tube of WI-38). These cultures were incubated on roller drums at 33C and observed for 10 days for development of viral cytopathic effect typical of rhinovirus. Rhinovirus isolates from subjects who did not have a serum neutralizing antibody response were neutralized with antibody to RV39 to confirm that the infection was due to the challenge serotype. Serum collected prior to challenge and again approximately 18 days later was assayed for antibody to RV39 by a microtiter neutralization assay. Volunteers with rhinovirus detected in any post-challenge culture or with at least a four-fold rise in serum neutralizing antibody titer between the acute and convalescent specimens were considered infected.
[0020] Fifty percent (50%) of the volunteers challenged with RV39 in this study became infected with the challenge virus (95% CI: 0.24-0.76). Three volunteers had both virus isolation seroconversion, two volunteers had infection documented by virus isolation alone.
[0000] Conclusions: Inoculation of the vestibule of the nares resulted in infection of 50% of challenged subjects in this study. These results document the feasibility of this route of infection and suggest that inactivation of virus by virucidal treatment of the nasal vestibule will potentially have an impact on rhinovirus infections transmitted by direct contact. | A method of inoculation of the vestibular region of the nares with a virus, provides the steps of: applying the virus exclusively to the anterior vestibular region of the nares; and avoiding penetration of the virus beyond the vestibular region during application. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application derives and claims priority from U.S. provisional application 61/579,416 filed 22 Dec. 2011, which application is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates principally to a novel device that produces tactile sensations discernible to human touch, and more particularly produces patterned tactile sensations in a fabric, or other pliable material, that are discernible by a user donning the fabric, and even more particularly to a novel device that converts electronically stored music into patterned tactile outputs in a matrix across a fabric. The discernible tactile sensations may, for example, be alternately created by retractable protrusions, contractible matrix cells, electric or temperature stimuli, and/or combinations of these.
[0004] For many years, there have existed for the purposes of entertainment countless devices that allow an individual or a multitude of individuals to listen to audio renditions of music stored in a variety of electronic formats. By way of example, such devices include speakers of all kinds in association with radios, record players, cassette players, CD players, and MP3 players. However, such devices provide limited tactile sensations for the listener, and then only indirectly or by way of a side-effect. From time to time, there have been forays into the presentation, at least in part, of creating a tactile sensation from music through vibration. However, aside from devices that directly or indirectly create musical vibrations or various braille generators, there currently exist no devices that are designed to convert electronically stored music or other audio or electronic files into tactile outputs that can be sensed or felt for entertainment.
[0005] It is therefore desirable to create a device that is capable of converting electronic files, including but not limited to music files, into patterned tactile outputs that can be sensed or felt through tactile sensations. Such a device may include for example, tactile outputs across a fabric that can be donned by an individual such that the individual is able to sense or feel the tactile outputs when the fabric is in contact with that individual's body. BRIEF SUMMARY OF THE INVENTION
[0006] Briefly stated, the present invention sets forth a tactile pattern player comprising a matrix of tactile actuators, with each actuator configured to produce a tactile event in response to an electric impulse applied to the actuator. An electronic data storage unit and a data converter operatively associate with the actuators in the matrix. The data converter is configured to convert electronic data into electrical impulses selectively directed to the actuators in a timed sequential pattern defined by the data converter. With the tactile pattern player disposed or incorporated into the clothing of a user, the actuation of the actuators in response to the electrical impulses produces tactile sensations that are perceived by the user when the clothing is donned by the user.
[0007] In one embodiment, the electronic data is representative of audio data, and the data converter is configured to control the actuators 26 to produce a tactile representation of the audio data that is perceptible to a user via contact with the user's body.
[0008] The foregoing features, and advantages set forth in the present disclosure as well as presently preferred embodiments will become more apparent from the reading of the following description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] In the accompanying drawings which form part of the specification:
[0010] FIG. 1 is a block diagram schematic of one embodiment of the novel tactile pattern player.
[0011] FIG. 2 is a block diagram schematic of another embodiment of the novel tactile pattern player.
[0012] FIG. 3 is a block diagram schematic of yet another embodiment of the novel tactile pattern player.
[0013] FIG. 4 is a perspective view of an embodiment of the novel tactile pattern player configured with the actuation matrix in a fabric headband worn about the head of a user.
[0014] FIG. 5 is a perspective view of a flexible course matrix of an embodiment of the novel tactile pattern player connected to a computer or microprocessor that controls the patterned actuation of the matrix.
[0015] FIG. 6 is a perspective view of a contraction-type tactile actuation cell or unit of a matrix of an embodiment of the novel tactile pattern player in a relaxed state and in an actuated state following application of an electric current to the actuator.
[0016] FIG. 7 is a perspective view of a protrusion-type tactile actuation cell or unit of a matrix of an embodiment of the novel tactile pattern player in a relaxed state and in an actuated state following application of an electric current to the actuator.
[0017] FIG. 8 is a perspective view of a heat emitting type tactile actuation cell or unit of a matrix of an embodiment of the novel tactile pattern player in a non-actuated state and in an actuated state following application of an electric current to the actuator.
[0018] FIG. 9 is a perspective view of an electric discharge type tactile actuation cell or unit of a matrix of an embodiment of the novel tactile pattern player in a non-actuated state and in an actuated state following application of an electric current to the actuator.
[0019] FIG. 10 is a perspective view of a flexible course matrix of an embodiment of the novel tactile pattern player connected to a computer or microprocessor that controls the patterned actuation of the matrix, and where the computer or microprocessor is operatively connected to an external electronic audio file storage device such as, for example, an MP3 player.
[0020] FIG. 11 is a block diagram schematic of another embodiment of the novel tactile pattern player.
[0021] FIG. 12 is a block diagram schematic of another embodiment of the novel tactile pattern player.
[0022] FIG. 13 is a block diagram schematic of another embodiment of the novel tactile pattern player.
[0023] FIG. 14 is a block diagram schematic of another embodiment of the novel tactile pattern player.
[0024] Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings. It is to be understood that the drawings are for illustrating the concepts set forth in the present disclosure and are not to scale.
[0025] 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 drawings.
DETAILED DESCRIPTION
[0026] The following detailed description illustrates the invention by way of example and not by way of limitation. The description enables one skilled in the art to make and use the present disclosure, and describes several embodiments, adaptations, variations, alternatives, and uses of the present disclosure, including what is presently believed to be the best mode of carrying out the present disclosure.
[0027] Referring to the drawings in general, several embodiments of the novel tactile pattern player 10 of the present disclosure are shown by way of example. As can be seen, the player 10 comprises a computer or microprocessor 12 having an integrated data converter 12 a and an integrated memory unit 12 b, that is operatively connected to an electronic data storage unit 14 , a battery or other power source 16 , and a pliant and elastic tactile fabric 18 having an inner surface 20 and an outer surface 22 . The fabric 18 comprises a matrix 24 of small and light-weight electronic tactile actuators 26 carried by the fabric 18 . ( FIGS. 5 , 10 ), where each of the actuators 26 is configured to produce a tactile event in response to an electric impulse applied to the actuator. Each actuator 26 is controlled by the computer 12 to selectively actuate in response to signals supplied from the computer 12 . Of course, the quantity, size and densities of actuators 26 comprising each matrix 24 may vary substantially from fabrics 18 having very course matrices, as depicted by way of example in FIGS. 5 and 10 , to fabrics 18 having very small actuators 26 in a very dense matrix 24 . Further, the matrix 24 is not limited to rectangular or square cells, but may be comprised of any variety of shaped cells and cellular alignments, such as for example, a matrix having hexagonal, octagonal or even haphazardly-shaped cells.
[0028] The computer 12 and electronic data storage unit 14 may each be further configured with one or more external connectors for receiving data from external sources. In addition, the player 10 may be configured to receive audio input ( FIG. 10 ) that can be immediately converted to tactile stimuli in the matrix 24 or that can be stored in the memory unit 12 b of the player 10 for recordation and future use of the input.
[0029] In at least one embodiment, such as for example as shown in FIG. 4 , the player 10 is configured to be fully portable with an associated portable power source 16 , such as for example a portable battery, set of batteries or solar cell. However, in other configurations the player 10 may be configured to attach to or plug into an external power source 16 such as a power outlet, a power jack in an electronic component or other such external power source.
[0030] It can be seen that each of the actuators 26 is electrically connected through the computer 12 or the data converter 12 a to the power source 16 . In one embodiment, the actuators 26 are each configured to produce or generate a retractable bump or protrusion 30 ( FIG. 7 ) in a direction opposite the outer surface 22 of the fabric 18 when stimulated by an electric impulse from the battery 16 as controlled by the computer 12 . In this embodiment, the actuator 26 maintains the protrusion 30 so long as the computer applies the electric impulse to the actuator 26 . The protrusion 30 retracts or relaxes when the electrical impulse ceases. Preferably, the protrusions 30 , and by correlation the absence of the protrusions 30 , are sized and shaped such that the actuation and emergence of the protrusion 30 is discernible by human epidermis. Likewise, the retraction and absence of the protrusion 30 , such as when the protrusion 30 relaxes or retracts, is also discernible by human epidermis.
[0031] In this embodiment, the computer 12 comprises an integrated programmable data converter 12 a and an integrated memory unit 12 b (see FIGS. 1-3 , 11 - 13 ), the data converter 12 a being operatively associated with each of the actuators 26 in the matrix 24 . Alternatively, the data converter 12 a can be a separate component operatively associated with the computer 12 and the actuators 26 . Similarly, the memory unit 12 b can be a separate component operatively associated with the computer 12 . The integrated data converter 12 a is configured to convert electronic data stored in the memory unit 12 b into electrical impulses that are then selectively directed to the actuators 26 in the matrix 24 over a period of time and in a pattern defined by the data converter 12 a. The electrical impulses, as dictated by the data converter 12 a, control the amplitude and the duration of each actuation of each of the actuators 26 . As can be appreciated, the controlled actuation of the actuators 26 can be patterned to represent specific musical notes, tones and/or volume levels, as well as for vocals. Hence, the player 10 can, for example, replicate a musical song that has been stored in the memory unit 12 b as an electronic data file by using a preprogrammed data conversion pattern stored in the data converter 12 b, where the conversion pattern defines which actuators 26 in the matrix 24 to actuate, including the timing and duration of each such actuation so as to provide a patterned tactile sensation across the matrix 24 that mimics or corresponds to each of the notes and vocals in the song being played as a tactile pattern by the player 10 .
[0032] The electric current or impulses that actuate the actuators 26 may be applied in a variety of manners as may be desired. For example, the electric current or impulses may be applied in a serial fashion, in a raster-scan fashion, or via independent isolated cell actuation. The ability to utilize a specific actuation manner will be dictated in part by the configuration of the interconnections between the actuators 26 and the computer 12 or the data converter 12 a. That is, in order to enable the computer 12 or the data converter 12 a to actuate specific actuators 26 in a matrix 24 independent of the order of actuating other actuators 26 in the same matrix 24 , each actuator 26 requires its own independent set of wires or other electric current carrying mechanism connected to the computer 12 or the data converter 12 a so as to allow the actuation of that particular actuator 26 without impacting the actuation of any of the other actuators 26 in the matrix 24 . In contrast, for a raster-scan actuation, the actuators 26 may be connected to the computer 12 or the data converter 12 a in groups—typically in rows and columns of the matrix 24 —such that a rapid timed actuation of the actuators 26 can be achieved sequentially across each row or column of the matrix 24 , which does not require individualized or isolated electrical connection between the computer 12 or the data converter 12 a and each actuator 26 .
[0033] The actuators 26 may be connected to the computer 12 or the data converter 12 a by wires, conductive fibers, conductive polymers, or any other electric current carrying mechanism or device that provides the flexibility and durability as may be desired or required for construction of the various configurations of the player 10 .
[0034] Preferably, the data converter 12 a comprises an integrated circuit device executing a set of software instructions or a program to convert electronic data retrieved from the storage unit 12 b into electrical impulses selectively directed to the actuators 26 over a period of time in a pattern defined by the program. In yet another embodiment, the data converter 12 b can be user-programmable or modifiable such that a user can selectively input variable correlations between the electronic data supplied to the data converter 12 b and the electric impulses directed to the actuators 26 so as to create or otherwise manipulate the conversion pattern or patterns stored in the data converter 12 b that convert the electronic data to patterned actuations of the actuators 26 across the matrix 24 .
[0035] Optionally, the data converter 12 a may be configured with an audio-signal input port, enabling the player 10 to be operatively connected to an external source of audio signals, such as for example a personal music or data storage device, a CD player, an MP3 player, a cell phone, a cassette or other tape player, or a radio. (See, e.g., FIGS. 10 , 12 ). Signals received via the input port may be converted by the data converter 12 a into electrical impulses directed to the actuators 26 , enabling the user to sense in a tactile fashion (i.e., “feel”) the signals. For example, the data converter 12 a may be configured to send one or more electric impulses associated with a particular musical note or vocal to an actuator or group of actuators 26 oriented in the matrix 24 such that the actuation of that actuator or group of actuators 26 corresponds to and replicates in a desired tactile sense the pitch, timbre, tone, duration, intensity, amplitude and/or resonance of the musical note or vocal.
[0036] The tactile events produced by the actuators 26 in response to the electrical impulses from the data converter 12 a or computer 12 may comprise, for example, any one or more of the following: a retractable protrusion ( FIG. 7 ); a retractable contraction ( FIG. 6 ); an electric discharge ( FIG. 8 ); a twisting or turning protrusion (not shown); a suction or pinching (not shown); or a discharge of heat ( FIG. 9 ), depending upon the specific type of tactile actuator 26 utilized in the matrix 24 . For example, the tactile actuators 26 may consist of individual micro-sized units of electro-active polymers (i.e., dielectric electro-active polymers or ionic polymers), which are essentially layered capacitors that change their capacitance when subjected to an electric current by allowing the polymer to compress in thickness and expand in area due to the electrical field. See for example, U.S. Patent Application Publication Nos. 2010/0205803 A1, 2010/0197184 A1, 2009/0293663 A1, 2010/0109486 A1, and 2008/08284277 A1, each of which are herein incorporated by reference. Alternately, by way of example, each tactile actuator 26 may define a cell consisting of a positive electric pole; a negative electric pole; and a coiled or circular dielectric positioned between and operatively associated with the positive and negative poles.
[0037] In order to facilitate improved use of the player 10 as a user-wearable article of clothing, it is preferable that the matrix 24 is pliable, and even more preferable stretchable or elastic, and housed in a fabric 18 with a means to snugly hold the matrix 24 operatively against the body of a user. (See FIGS. 4-5 ). In one embodiment, the player 10 is configured in the general shape of a headband 100 ( FIG. 4 ) that can be worn about the head. In other embodiments, the player 10 can form or be incorporated into any of a variety of articles of clothing that can be worn about a portion of the user's body, such as for example, an arm, leg, or torso. Such articles of clothing can comprise for example a jacket, a hat, a glove, a scarf, a wristband, an armband, pants, shorts, socks, a leg bands, or a shirt. Referring to the headband 100 of FIG. 4 by way of example, the matrix 24 of the headband 100 may be of sufficient elasticity so as to stretch to hold the headband 100 snugly to a person's head as shown. Alternately, the fabric 18 of the headband 100 may be of sufficient elasticity so as to stretch to hold the headband 100 snugly to a person's head with the matrix 24 pressed against the user's skin. Yet, alternatively again, the headband 100 may comprise an adjustment mechanism, such as for example, a set of cords to tie the headband 100 snugly to a person's head; a set of snaps, or hooks and loops, or buttons and button holes, or other such well-known attachment devices to allow the user to snugly secure the headband 100 to the user's head. In this way, a substantial portion, if not all, of the matrix 24 is in pressed against the user's skin to provide the optimum tactile sensation for the user when the actuators 26 are activated by the player 10 .
[0038] The present disclosure can be embodied in-part in the form of computer-implemented processes and apparatuses for practicing those processes. The present disclosure can also be embodied in-part in the form of computer program code containing instructions embodied in tangible media, or another computer readable storage medium, wherein, when the computer program code is loaded into, and executed by, an electronic device such as a computer, micro-processor or logic circuit, the device becomes an apparatus for practicing the present disclosure.
[0039] The present disclosure can also be embodied in-part in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the present disclosure. When implemented in a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
[0040] As various changes could be made in the above constructions without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A device that produces patterned tactile sensations discernible to human touch from micro-actuators housed in a fabric, or other pliable material, where such actuated sensations are discernible by a user donning the fabric. The device is configured to convert electronically stored music or audio data into a sequence of patterned tactile outputs in a matrix across the fabric, providing a tactile representation of the music or audio data to the user. The discernible tactile sensations may alternately comprise retractable physical features, electric stimuli, and/or combinations of these. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a device and method for impregnating elongate elements with a thermostabilizable substance.
More particularly, the present invention provides an improvement to the device and method for impregnating elongate elements, such as threads or resistant fabrics, reinforced by means of a thermosetting substance, such as a thermosetting liquid resin.
By thermostabilizable substance is meant all substances whose characteristics are durably and permanently modifed under the action of heat and/or temperature.
This thermal action may the sole action responsable for the process of modification of the characteristics of the substance, as may occur during cross linking or vulcanization of the material. This thermal action may also be not the only action to produce durable or permanent modifications of the material, but may act concurrently with other actions, such as oxidation or evaporation of the material, or of a part thereof.
The thermostabilizable substances which may be used by the invention are preferably, but not necessarily, fluid at the different temperatures imposed on the substance in the device, or following the method, of the invention. These substances may for example be thermosetting materials, elastomers, thermoplastics or metals.
The elongate element may be elongate reinforcement elements, such as reinforcing threads made from metal, polyamide, KEVLAR which is a polyaramide whose trademark is registered by the firm Dupont de Nemours, glass, carbon, disposed in layers of parallel threads, braids or fabrics.
In the prior art, when it is desired to impregnate elongate elements, a tank is used having heat regulation means, for example heating means, in which the impregnation substance is disposed and into which penetrates a drum transferring the substance to the zone for impregnation of the elongate elements. A radiating panel generally provides complementary heating of the substance at the impregnation zone level.
Relatively to the prior art, the present invention makes it possible to improve the impregnation quality of the elongate elements, particularly in so far as the deeper penetration of the substance and reduction of air bubble inclusions are concerned, to increase the production rate and finally to considerably restrict material waste, in particular of the thermostabilizable substance.
Moreover, the device and method of the present invention make it possible in numerous cases to reduce and even to omit the addition of solvent to the thermostabilizable substances.
So the present invention, by omitting the addition of solvent, makes it possible to get out solvent elimination means which are generally used upstream the impregnation device according to the prior art.
The flexibility of implementation of the present invention makes it possible to insert the proposed device in a continuous or discontinuous production line, particularly when stoppages thereof are possible.
SUMMARY OF THE INVENTION
Simply stated, the device and method of the invention consist more particularly, at the time of impregnation, in improving the characteristics of the impregnation substance, in particular in reducing its viscosity by a temperature rise, using circumscribed heating, while maintaining the substance waiting to be used at a lower temperature.
Depending on the substances which may be used in the impregnation device of the invention, the temperatures of the substance at the time of impregnation, or waiting to be used, may be either greater or less than the ambient temperature, or one greater and the other lower. For that, the means such as heating or cooling means used for maintaining a temperature difference will generally be defined as thermoregulation means.
The invention overcomes the drawbacks of the prior art which uses a much lower and often very insufficient impregnation temperature, and results in clogging of the transfer means and of the supply station, a rapid evolution of the substance waiting to be used and considerable waste of substance.
The invention provides a device for impregnating an elongate element by transferring a thermostabilizable substance from a station supplying the substance as far as the element by means of a transfer member, the element being moved longitudinally in front of the transfer means said transfer means including a mobile surface passing through the station then in front of the element, the substance being deposited on the surface at the level of the station while being transferred at least partially onto the element, in a zone adjacent said element. In the device of the invention, the transfer means comprise more particularly thermoregulation means such as heating means, adapted so that the temperature at the surface at the level of the impregnation zone is substantially higher than that of the substance in the station.
The supply station may comprise thermoregulation means adapted so that the temperature of the substance in the station is substantially lower than the temperature at the surface at the level of the impregnation zone.
The device may comprise a squeegee means adapted for removing from the surface the substance not transferred by the element, this squeegee means being situated upstream of said supply station.
The device may comprise a dosing element placed downstream of the supply station, this dosing element being adapted so as to produce, on the surface, a layer of substance which is uniform and adjusted in thickness.
The device may comprise at least one system, such as a roller, for preparing the element to be impregnated, upstream of the zone where the element is impregnated.
The device may include means for separating the elongate element from the transfer means and the transfer means may include safety drive means adapted for moving the transfer means once the separation means have been brought into action.
A part of said elongate element may be applied against a part of said transfer means, and the reinforcing element may drive said transfer means.
The thermostabilizable substance may be a thermosetting resin.
The transfer means may comprise at least one cylinder of revolution.
The supply station may comprise a tank in which said substance is situated and the transfer means may plunge into said tank.
The supply station may comprise a tank in which said substance is contained, and a circulating member adapted for picking up said substance situated in said tank, conveying it towards said transfer means and correctly coating this latter therewith.
The device may comprise spacing means adapted for moving the transfer means away from the supply station.
The invention also provides a method of impregnating a reinforcement element by transferring a thermostabilizable substance from a station supplying the substance as far as said element to be impregnated using a transfer means having a mobile surface on which said substance is deposited. In this method, in particular, the temperature of the surface is maintained substantially above that of the station.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood and its advantages will be clear from reading the following description relating, but not exclusively, to the impregnation of elongate reinforcing elements by means of a thermosetting substance and illustrated by the accompanying drawings illustrating two possible embodiments of the device of the invention wherein:
FIG. 1 is a schematic elevational view of one embodiment of the device of the invention wherein a transfer means in the form of a cylinder is employed to impregnate an elongate element; and
FIG. 2 is a schematic elevational view of another embodiment of the invention wherein a supply station includes a circulating member for conveying the impregnation substance to the transfer means contacting the elongated element to be impregnated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this FIG. 1, the elongate element 1 is for example formed of an assembly of one or more reinforcing filament rovings placed parallel along their longitudinal axis and substantially in the same plane. This elongate element 1 bears on two preparing or opening rollers 2, whose diameters, spacing and transverse arrangement are adapted to the nature and dimensions of the rovings so as to cause if required breakage of the binder which agglomerates the reinforcement threads and thus to allow opening of the rovings.
After passing through the zone of the preparing rollers, which may be limited to a single one, the elongate element 1 is first of all applied on the transfer means 3 so as to undergo impregnation with a given amount of thermosetting substance, then moves away from said transfer means 3 for spooling or to be used directly, for example, for the continuous manufacture of composite material weaves, particularly, the weaves forming part of the reinforced tube, or for manufacturing a tube or an object by filament winding.
In FIG. 1, the elongate element 1 is applied on the transfer means 3 but it could also not be applied thereon and pass close by, the transfer of material being provided by centrifugal, electrostatic or fluid projection, for example. However, the configuration described is simple and very efficient.
The transfer means 3 include a cylindrical drum of circular section which rotates about an axis 4 and is driven by means of the elongate element 1, whose drive is obligatory. The drum of the transfer means 3 could also be motorized, but experience shows that a reduced number of rovings in contact with a reduced portion of the drum does away with the need for a specific motor.
The transfer means 3 could also comprise a flexible transport belt mounted on rollers.
In the vicinity of its mobile external surface coming into contact with the elongate element, the inside of the transfer means 3 is provided with heating means 5, by electric resistance, hot air or heat carrying fluid, etc, adapted for maintaining a high temperature so that the substance, which behaves at this temperature like a fluid, has its lowest possible viscosity and impregnates the elongate element 1 in depth, without inclusion of air, sufficiently and without excess substance.
Tests made with a transfer means 3 of 50 cm wide and 30 cm in diameter and with a thermosetting resin as impregnation substance, show that depending on the production speed, the temperature at the surface of the transfer means at the level of the impregnation zone may for example be between 70° and 140° C. depending on the speed impregnation of the elongate element and the temperature of the supply station 7 between 7° and 25° C. depending on the temperature of the water used for cooling.
For these tests, the thermosetting resin was formed of a 100 parts of bisphenol A diglycidylether (base), 90 parts of acid internal anhydride 2.3, dicarboxylic, 1.5 norbonene, X methyl (hardener) and parts of benzyldimethylamine (accelerator).
Generally, the temperature of the supply station 7 is adapted so as to limit the chemical evolution of the substance contained in the supply station and to ensure the suitable supply of the transfer means 3.
Similarly, the temperature of the transfer means 3 is adapted so that the viscosity of the impregnation substance is the lowest necessary at the level of the impregnation zone so as to allow correct impregnation of the elongate elements 1 and so the chemical evolution of the substance on the transfer means is minimum.
For example, a thermosetting resin must remain fusible or molten in the device.
Whereas the zone 6 for impregnation of the elongate element 1 is situated in the upper part of the transfer means 3 station 7 supplying the thermosetting substance 8 is situated in the lower part of said means 3, so that the supply station may advantageously comprise a tank 9 containing the substance 8.
To avoid overheating of the substance 8 contained in tank 9 because of the heating of the transfer means 3, the tank 9 includes cooling means 10, such as a current water cooling coil, or an exchanger connected to a cooling unit or else cooling fins placed in a forced air flow.
Overheating of tank 9 is due to the heat coming from the transfer means 3, either directly by contact with substance 8, or by the substance which was deposited on the transfer means 3 at the level of the supply station 7, and which has not been removed during impregnation of the elongate element 1 which is removed from the surface of the transfer means 3, either after impregnation and upstream of the supply station 7, by means of a squeegee means 11 or downstream of the supply station by scrapers 14.
Upstream of a point considered is the zone which the material element passes through during the technical process before reaching the point considered, whereas on the contrary downstream is the zone which is reached after the point considered.
Cooling makes it possible to maintain the supply station 7 for example at a temperature of 20° C., so as to slow down gelling of the resin or generally the evolution of the impregnation substance.
The substance removed by the squeegee 11 is fed back into a cold zone of tank 9 by means of a separating wall 12, so as to stop the evolution of the substance removed as quickly as possible. However, the substance removed may also be fed back by distributing it in the vicinity of the transfer means 3, so that the substance is rapidly consumed by impregnation.
This process avoids stagnation of the substance on parts of the surface of the transfer means 3 which are not free of substance following impregnation of the elongate element 1.
Removal of the heated substance, mixing it with the fresh substance contained in tank 9, then distribution of the mixture over the heat surface of the transfer means leads more particularly to the saving of energy by preventing the heated substance from being cooled before being heated again a number of times. However, this rapid recycling is achieved to the detriment of a hardening effect which attenuates the evolution of the substance.
With this squeegee means 11, any stagnation is avoided of hot substance, such as resin, turning round and round between the rovings with the risk of gelling the surface of the transfer means.
Downstream of the supply station 7 is disposed a dosing element 13 for making the layer of substance uniform and adjusting it in thickness, whose transfer means 3 is covered when passing through the supply station 7. The excess substance then comes back to station 7.
The thickness of the layer is adjusted so that the rovings forming the elongate element 1 are correctly impregnated (neither too little nor too much).
Substantially at the same level as the dosing element, on each of the sides of the transfer means 3, two scrapers 14 are provided for removing the substance from the sides and then transferring this substance to a cooled zone of tank 9.
The supply tank 9 may conform to the geometry of the transfer means 3 so as to reduce the amount of substance contained in the tank and reheated by means 3. A thickness of substance between the bottom of tank 9 and means 3 from 5 to 30 mm is satisfactory. This arrangement however requires resupplying the tank with fresh resin more frequently than when the tank is larger.
By using adapted cooling means 10, or taking advantage of the poor heat conductivity of the substance, the volume of the tank may be increased.
During stoppage of the transfer member 3, in order to prevent the resin impregnating the elongate element 1, evolving under the action of the heat, the device includes separation means between the elongate element 1 and said means 3.
These means may be formed of a roller 16 actuated by a mobile arm 17 in the case of stoppage. With the roller initially situated between the rovings 1 and the transfer means 3, it then comes to occupy the position 18 shown with a broken line.
Similarly, when the production of impregnated rovings is stopped, the same means may be used for moving the rovings 1 away from the transfer means 3. In this case, a safety drive means 19 will maintain means 3 in rotation if it does not have its own motorization means.
With the device, very variable manufacturing rates may be obtained with a production of impregnated rovings of 0.2 m/min to 100 m/min and preferably from 2 m/min to 25 m/min, without any risk of gelling of the transfer means and of the supply station. In addition, the impregnation quality is improved by the good penetration of the resin into the elongate element.
The transfer means may also be motorized and cause the elongate element to travel in a direction opposite that of said means.
FIG. 2 illustrates the variant of the embodiment of the invention illustrated in FIG. 1. The similar elements in FIGS. 1 and 2 are designated by the same references.
The difference between the embodiments of FIGS. 1 and 2 resides in the fact that the supply station 7 includes a circulating member 21 of cylindrical shape rotating about a fixed shaft 22 and picking up on its periphery the impregnation substance by plunging this member 21 into tank 9 filled with substance.
The substance picked up by the circulating member 21 is conveyed by rotation of member 21 to the transfer means 3 which is then coated therewith. The space between the transfer means 3 and the circulating member 21 is adapted so as to allow correct coating thereof.
A gear train (not shown), protected from possible splashes of the substance, provides synchronization between the transfer means 3 and the circulating member 21, so that the transfer means are correctly coated and the impregnation be correct. The height of the teeth of these gears may be such that the circulating member 21 may be driven when, through spacing means 23, the transfer means 3 and the circulating member 21 are spaced apart, for example for a stoppage of the advance of the elongate elements 1, once the separation means 16, 17 and the safety drive means 19 of the transfer means 3 have been brought into action. The spacing apart produced makes it possible to completely squeegee the transfer means 3 and to prevent the substance there located to undergo chemical evolution.
To ensure the correct drive of the circulating member 21, recourse may also be had to an additional motor placed at the level of shaft 22 and driving member 21.
The supply station comprises two scrapers 24 removing the impregnation substance from the sides of the circulating member 21. These scrapers are advantageously disposed just upstream of where the substance is picked up by member 21, so as to provide the best possible cooling thereof and renewal of the substance situated on its sides.
A protector 25 placed at the end of scraper 24 situated close to shaft 22 prevents resin splashes from hindering the rotation of member 21.
The squeegee means 11 of the transfer means 3, which in the preceding embodiment discharged the substance beyond a separating wall 12, lets the substance fall directly into tank 9.
Since, in the second embodiment, the sides of the transfer means 3 are covered with substance over a more restricted zone than in the first embodiment (FIG. 1), the length of scrapers 14 may be reduced.
In the first embodiment of the invention, a spacing member may also be used between the transfer means and the impregnation station, so as to be able to completely squeegee the transfer means 3.
For some types of products and impregnation conditions it is possible to add a radiating panel to the device, in the impregnation zone, so as to locally increase the temperature of the substance in order to improve impregnation of the rovings.
The transfer means may also be coated by melting a block of substance placed at a temperature sufficient for it to be solid. The substance removed by the squeegee means may then for example be directly fed back to the contact point of the block and the transfer means.
The supply station will then include specific means for ensuring contact between the block and the transfer means. | The invention provides a method and device for impregnating at least one elongate element by transferring a thermostabilizable substance from a supply station by means of a supply means, the element being moved in front of the transfer means which includes a mobile surface passing in front of the station then in front of the element, the substance being deposited on the surface in said station and being transferred therefrom at least partially onto the element in a zone close thereto, wherein the transfer means includes thermoregulation means such as heating means, adapted so that the temperature at the surface in the impregnation zone is substantially higher than that of the substance in said supply station. | 3 |
This application is a divisional of application Ser. No. 07/651,370 filed on Feb. 28, 1991, now U.S. Pat. No. 5,443,747 which is the national phase of PCT/JP90/01372 filed Oct. 25, 1990.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cleaning compositions which will replace cleaning agents containing an organic solvent including flon and the like.
2. Description of the Related Art
In manufacturing various parts such as metal parts, plated and coated parts, and electronic and semiconductor parts, flon containing solvents such as flon 113, and organic solvents such as trichloroethane, trichlorethylene, tetrachloroethylene, and carbon tetrachloride are widely used as cleaning agents for eliminating oil stains and the like.
The above organic solvent containing cleaning agents are also used as dewatering cleaning agents after having washed various parts with water in order to avoid the following problems that are associated with direct drying of water present on an object to be cleaned:
(1) Heating (100° C. or more) which entails energy loss;
(2) Reducing in productivity due to time taken in drying;
(3) Likely deformation of the object to be cleaned due to heating (thermal expansion that exceeds the tolerance); and
(4) Increase in space for installing a cleaning system including a cooler and a heat shielding unit.
The term "dewatering cleaning agent" is used herein to denote a cleaning agent into which an object to be cleaned, which has been washed with water, is immersed or with which the object is rinsed by shower thereby to have water present on the object substituted by itself and then vaporized by air at room temperature or heated to 60° C. or less so that the object can be dried.
However, ever since it has been found that the destruction of the ozone layer by discharge of flon affects seriously the human body and the ecological system, the use of flons such as flon 12 and flon 113 whose ozone destruction coefficients are high is on the gradual decline on a global scale for an eventual total ban.
Stricter regulations are imposed also on chlorine containing organic solvents such as trichloroethylene and tetrachloroethylene which are presumed to induce soil and underwater contaminations and the like.
Flons whose ozone destruction coefficients are lower than the currently used flon containing solvents are being developed, some of which are under fabrication on a commercial basis. However, these new developments are not so welcome because they still are destroyers of the ozone layer.
What gradually attracts attention as a replacement for the above organic solvents is a surfactant-based water system cleaning agent which is free from environmental destruction and contamination. However, cleaning agents containing only surfactants are not satisfactory in penetrability, thereby not cleaning, e.g., stains penetrated into narrow portions and medium to high viscous, persistently sticky oil stains.
Japanese Patent Publication No. 50463/1988 discloses a method of cleaning woven materials by using silicone containing compounds. According to the disclosure, a liquid cleaning composition containing an effective amount of cyclic siloxane having 4 to 6 silicon atoms is used. However, the liquid cleaning compositions including the above silicone containing compound are not suitable for use not only in general industrial products due to their being specifically prepared for woven materials, but also in systems using water (hereinafter referred to as "water system") due to their being based on a single cyclic siloxane or the mixture of a cyclic siloxane and an organic solvent. Further, such compositions are not so dispersive in water that the addition of a surfactant thereto does not assist in blending them homogeneously, thereby causing phase separation immediately. Thus, they are not adapted for use as water system cleaning agents.
On the other hand, Japanese Patent Laid Open No. 56203/1978 recites an aerosol aqueous cleaning composition containing a chain polydimethylsiloxane having 2 to 3 silicon atoms in a single molucular. Since its content is limited to about 0.02 to 0.1 wt. %, no such advantage as improving the cleaning property of water system cleaning compositions is disclosed.
Under such circumstances, the development of high-performance water system cleaning agents free from environmental problems is strongly called for.
In the meantime, the use of lower alcohols such as isopropyl alcohol is under study for a new development that can replace the above-mentioned organic solvents for dewatering. However, isopropyl alcohol has a flash point of 11.7° C., which is lower than room temperature, and this involves some danger of fires under ordinary handling conditions. In addition, isopropyl alcohol is highly compatible with water, so that the initial dewatering property is ensured, but its repetitive use causes dissolved water to be present again. As a result its dewatering property will be impaired on a long-term basis. To refine isopropyl alcohol for reuse by removing water from the water containing isopropyl alcohol, a tremendous equipment investment is required. That isopropyl alcohol is toxin to the human body is another factor that tends to keep it from using.
The use of hydrocarbon and higher alcohols which have higher flash points than room temperature allows a comparatively easy removal of water, but their low volatility prevents drying themselves at low temperatures, e.g., 60° C. or less, thereby making them unsuitable for applications to dewatering cleaning agents.
Therefore, an object of the invention is to provide water system cleaning compositions which have cleaning capability equivalent to that of organic solvent containing cleaning agents including such as flon and which are stable as water system cleaning agents and free from environmental destruction and contamination.
Another object of the invention is to provide dewatering compositions which have the substituting and drying properties equivalent to those of organic solvent containing dewatering cleaning agents, which have few risks of fires and which are free from environmental destruction.
SUMMARY OF THE INVENTION
A cleaning agent composition of the invention comprises at least one low molecular weight polyorganosiloxane selected from the group consisting of straight chain polydiorganosiloxane represented by a general formula: ##STR3## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and l is an integer from 0 to 5), and cyclic polydiorganosiloxane represented by a general formula: ##STR4## (wherein R 1 is an organic group of single valence substituted by the same of different group of unsubstituted, and m is an integer from 3 to 7).
Each of such low molecular weight polyorganosiloxanes exhibits powerful penetrability to stains and satisfactory substituting property with water alone, making itself a feature component of the invention. Reference character R 1 in formulas (I) and (II) denotes a substituted or unsubstituted organic group of single valence including: a single-valence unsubstituted hydrocarbon group such as an alkyl group such as a methyl group, an ethyl group, a propyl group, and a butyl group and a phenyl group; and a single-valence substituted hydrocarbon group such as a trifluoromethyl group. As the R 1 which is placed at an end of formula (I), an amino group, an amide group, an acrylic acid ester group, and a mercaptan group are typical organic groups; however, the methyl group is most preferable from the viewpoint of stability, and maintainability of volatility, and the like.
The cleaning compositions of the invention may roughly be classified into two groups: a water system cleaning agent and a dewatering cleaning agent.
For use as a water system cleaning agent, suitable low molecular weight polyorganosiloxanes include: octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane and mixtures thereof, each having a cyclic structure; and octamethyltrisiloxane and decamethyltetrasiloxane, each having a straight chain structure, from the viewpoint of penetrability and cleaning capability. In regions where the water system cleaning composition has a strong alkaline property from the viewpoint of stability of polysiloxane, the low molecular weight polyorganosiloxane having a straight chain structure which is represented by formula (I) is preferable.
For use as a dewatering cleaning agent, low molecular weight polyorganosiloxanes having a cyclic structure are preferable from the viewpoint of substituting property with water and penetrability and the like, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, and mixtures thereof are more preferable.
A case in which the cleaning compositions of the invention are used as water system cleaning agents will now be described.
Although the low molecular weight polyorganosiloxanes represented by formulas (I) and (II) exhibit powerful penetrability to stains, each composition is not compatible with water singly nor is it soluble and stably dispersive in water so that it is likely to have phase separation in water. That is, it is proposed to use them in combination with polyoxyalkylene group containing polyorganosiloxane having in a single molecule at least one siloxy unit represented by a general formula: ##STR5## (wherein R 2 is an alkyl or phenyl group and A is a polyoxyalkylene group). As a result of such use in combination, the low molecular weight polyorganosiloxanes, providing stable dispersion in water, exhibit strong penetrability to stains. In addition, the use of a surfactant in combination with the compositions may improve their cleaning property.
Thus, preferable compositions for a water system cleaning agent of the invention contain the low molecular weight polyorganosiloxane represented by formula (I) or (II); the polyoxyalkylene group containing polyorganosiloxane having at least one siloxy unit represented by formula (III) in a single molecular; a surfactant; and water.
The polyoxyalkylene group containing polyorganosiloxane exhibits affinity for water owing to its polyoxyalkylene group bonded with the silicon atom, thus not only being a component for a stable water system dispersed solution or aqueous solution but also acting as an agent for eliminating stains by penetrating into the interface between the stains and a substrate which is made of, e.g, a metal and which has the stains deposited thereon, and as an antifoaming agent as well.
Such a polyoxyalkylene group containing polyorganosiloxane can be prepared by hydrosilyl group containing polyorganosiloxane and a polyoxyalkylene compound having an unsaturated group at the end to interact with each other for addition under the presence of a platinum containing catalyzer.
An example of the polyoxyalkylene group denoted by reference character A in formula (III) is, e.g., a single-valence group represented by the formula:
--R.sup.3 --(--O--R.sup.4 --).sub.n --OR.sup.5 (IV)
(wherein R 3 is a two-valance group selected from the group consisting of an alkylene group having from 1 to 8 carbon atoms, a β-hydroxypropyleneoxyalkylene group and a polymethylene oxyalkyelene group, both having from 4 to 11 carbon atoms; R 4 is an alkylene group having from 2 to 4 carbon atoms; R 5 is an end group selected from a hydrogen atom and a single-valence organic group; and n is a positive integer).
Siloxane that forms a main component of the polyoxyalkylene group containing polyorganosiloxane is not particularly limited. The organic group that is to be bonded with the silicon atom of the siloxane is basically a methyl group, but may also contain a single-valence hydrocarbon group such as an ethyl group, a propyl group, a butyl group, a phenyl group, or a single-valence substituted hydrocarbon group such as a trifluoromethyl group as long as the advantages of the invention can remain harmless therefrom.
Also, the molecular weight of the siloxane is not particularly limited nor is that of a single polyoxyalkylene group. Although they are large values, the addition of a surfactant thereto and the like allows the composition to be made sufficiently water soluble or stably water dispersive. However, it is practically preferable to limit the molecular weight of the single polyoxyalkylene group in the order of 100 to 5000. For a polyoxyalkylene chain, it is preferable to adjust its oxyethylene component to 40 mol % or more in the total polyoxyalkylene.
While the amount of the polyoxyalkylene group is not particularly limited, it is more preferable to limit it within 5 mol % or more of the total organic groups bonded with silicon atoms of the polyorganosiloxane from the standpoint of system stability.
Exemplary polyoxyalkylene group containing polyorganosiloxanes include:
a chain polysiloxane represented by the formula: ##STR6## (wherein p, q, r, and s are positive integers); and a cyclic polysiloxane represented by the formula: ##STR7## (wherein t, u, and v are positive integers).
The surfactant serves as a component for dissolving, emulsifying, and stabilizing the stains removed by the low molecular weight polyorganosiloxanes or polyoxyalkylene group containing polyorganosiloxanes.
Such surfactants can be classified by the activation chemical structure into the following types: cationic, anionic, nonionic, amphoteric, and combined types. The invention may be applied to all the above types of surfactants. However, to obtain the advantage from their combination with the polyoxyalkylene group containing polyorganosiloxane, it is preferable to use anionic, nonionic, or amphoteric surfactants. Particularly, the use of the polyoxyalkylene group containing polyorganosiloxane in combination with either anionic/nonionic surfactants or amphoteric/nonionic surfactants provides a remarkable synergetic effect in improving the cleaning property and penetrability of the low molecular weight polyorganosiloxanes or the polyoxyalkylene group containing polyorganosiloxanes.
Exemplary suitable surfactants to be applied to the invention include: anionic surfactants such as polyoxyalkylene alkylether sulfonates and phosphoric esters; nonionic surfactants such as polyalcohol fatty acid esters, polyoxyalkylene fatty acid esters, and polyoxyalkylene alkylethers; amphoteric surfactants such as imidazolin derivatives; and cationic surfactants such as alkylamine salts, alkyl quaternary ammonium salts. In addition thereto, terpene containing compounds which are rarely present in the form of a single substance and extracted from natural substances as well as higher fatty acid esters may also be applied. It is also possible to use synthetic compounds in which part of the chemical structure of each compound is substituted by a fluorine or silicon atom.
While the composition ratio of the above-mentioned quaternary water system cleaning agent is not particularly limited, it is preferable to blend 10 to 1000 parts by weight of a surfactant to 100 parts by weight of the polyoxyalkylene group containing polyorganosiloxane, and 1000 parts by weight or less of the low molecular weight polyorganosiloxane to 100 parts by weight of a total combination of the above surfactant(s) and the polyoxyalkylene containing polyorganosiloxane. Too small an amount of the surfactant reduces the cleaning capability, while too large an amount impairs the penetratbility. Too large an amount of the low molecular weight polyorganosiloxane not only makes the system difficult to disperse but also reduces stability as a water system composition. A preferable fraction of the surfactant is 30 to 700 parts by weight, or, more preferably, 50 to 300 parts by weight, to 100 parts by weight of the polyoxyalkylene group containing polyorganosiloxane. A more preferable fraction of the low molecular weight polyorganosiloxane is between 10 and 1000 part by weight. While the fraction of water in the quaternary water system cleaning agent is not particularly limited either, it is preferable to have water 40 wt. % or more or, more preferably, 70 to 99.5 wt. % to the total composition from a stability viewpoint.
By the way, the polyoxyalkylene group containing polyorganosiloxane having in a single molecule at least one siloxy unit represented by formula (III) penetrates, as described above, into the interface between the stains and the substrate made of, e.g., a metal to which the stains adhere to "peel off" the stains. Thus, even a tertiary composition consisting of the polyoxyalkylene group containing polyorganosiloxane, a surfactant, and water may serve as a viable water system cleaning agent. In this case, the fractions of the quaternary water system cleaning agent will apply to the tertiary composition.
The fractions of the tertiary or quaternary water system cleaning agents may be so designed that the value to be obtained by a canvas method at room temperature for evaluating penetrability will be 15 or less, 10 or less, or 5 or less. For the evaluation, the canvas method specified as a fiber/textile test method by Japanese Industrial Standards (JIS) is adopted.
Since the cleaning property of these water system cleaning agents depends on the pH value of the solution itself, it is desirable to adjust the pH value to the alkali region. The pH value is more preferably be between 8 to 14.
The tertiary or quaternary cleaning agents can be prepared easily by blending and stirring the above-mentioned polyoxyalkylene group containing polyorganosiloxane, a surfactant, water, or further the low molecular weight polyorganosiloxane represented by formula (I) or (II), where necessary. The use of a known dispersing device will help obtain a water system cleaning agent with ease.
The water system cleaning agents such as described above may have additives to be applied to ordinary water-soluble cleaning agents such as pH modifiers, adsorbents, solid particles, synthetic builders, rust preventives, and antistatic agents mixed as cleaning assistants or post-cleaning added-value improving agents and the like, depending on the property, amount, adhering state, cleaning condition, and the like of a stain. Such an addition may play an important part depending on their application.
The water system cleaning agents of the invention may be applied to metals, ceramics, plastics, and the like. More specifically, they may be applied to metallic parts, surface treated parts, electronic and semiconductor parts, electric and precision machinery parts, optical parts, glass and ceramic parts, and the like. An exemplary general-purpose cleaning process usually involves cleaning of any of the above-described parts by such a process as ultrasonic process, mechanical stirring and spraying, and thereafter, washing by water (preferably by pure water or ion-exchanged water), and is dewatered by drying the part with heated air or a like process. The cleaning composition in which the stain separated from the part is present is treated by, e.g., separating the stain through a filter or the like and thereafter by being subjected to a general waste water treatment process, thereby allowing the composition to be unhazardous and pollution-free easily.
According to the water system cleaning agent of the invention, the powerful penetrating property of the low molecular weight polyorganosiloxane represented by formula (I) or (II) for the interface between the stains and the substrate as well as the cleaning capability of the surfactant(s) to the stains provides a cleaning performance equivalent to that of the conventionally used flon containing cleaning agents. The use of the polyoxyalkylene group containing polyorganosiloxane in combination with the water system cleaning agents of the invention allows satisfactory dispersing property in water. In addition, when applied as a tertiary composition consisting of the polyoxyalkylene group containing polyorganosiloxane, the surfactant, and water, the cleaning agent of the invention exhibits excellent cleaning property by the penetrating capability of the polyoxyalkylene group containing polyorganosiloxane with respect to the stain. Being a water system agent, it will bring no risk of environmental destruction and pollution. Thus, it can be said from the above that the water system cleaning agent of the invention can be an attractive replacement for cleaning agents based on organic solvents containing flon and other substances which have considered hazardous.
A case in which a cleaning composition of the invention is used as a dewatering cleaning agent will now be described.
Here, the term "dewatering agent" is only so named after "water," which is a typical liquid capable of being substituted by the low molecular weight polyorganosiloxanes, and the cleaning compositions of the invention may also be used as "liquid removing" agents in substituting and cleaning liquids other than water. The applicable liquids may be those which are insoluble or difficult to be dissolved in the low molecular weight polyorganosiloxanes and whose surface tensions are larger than those of the low molecular weight polyorganosiloxanes. The "water" to be cleaned may include liquids using water as a dispersion medium such as mixtures of water and alcohols and liquids in which various substances are dissolved.
The low molecular weight polyorganosiloxane represented by formula (I) or (II) can be, as described previously, substituted by water alone, thus allowing itself to be easily vaporized and dried by hot air below 60° C.
Such a dewatering cleaning agent may consist substantially of the low molecular weight polyorganosiloxane and with it a satisfactory effect can be obtained. However, its cleaning and dewatering properties and the like will be further improved by forming it into a composition having the low molecular weight polyorganosiloxane mixed with a surfactant and/or a hydrophilic solvent.
The above-mentioned surfactants contribute to improving particularly the cleaning and dewatering property, and suitable surfactants to be applied to the invention include: anionic surfactants such as polyoxyalkylene alkylether sulfonates and phosphoric esters; nonionic surfactants such as polyalcohol fatty acid esters, polyoxyalkylene fatty acid esters, and polyoxyalkylene alkylethers; amphoteric surfactants such as imidazolin derivatives; and cationic surfactants such as alkylamine salts, alkyl quaternary ammonium salts. In addition thereto, terpene containing compounds which are rarely present in the form of a single substance and extracted from natural substances as well as higher fatty acid esters may also be applied. It is also possible to use synthetic compounds in which part of the chemical structure of each compound is substituted by a fluorine or silicon atom. However, it is more preferable to use nonionic surfactants if the effect as a dewatering cleaning agent used in combination with the low molecular weight polyorganosiloxane is to be further improved.
While the composition ratio of the surfactant is not particularly limited, it is desirable to have 20 parts by weight or less, or, more preferably, 3 parts by weight or less, of the surfactant to 100 parts by weight of low molecular weight polyorganosiloxane.
A suitable hydrophilic solvent may be one compatible with the low molecular weight polyorganosiloxanes, and more particularly, one whose flash point is 40° C. or more from the practical viewpoint. The hydrophilic solvent contributes to improving substituting property by water.
Suitable hydrophilic solvents include: polyalcohols and their derivatives such as ethylene glycol monomethyl ethers, ethylene glycol monoethyl ethers, ethylene glycol monopropyl ethers, ethylene glycol monobutyl ethers, ethylene glycol monobutyl ether acetates, diethylene glycol monobutyl ethers. Particularly preferable are diethylene glycol monobutyl ethers from the viewpoint of its compatibility with the low molecular weight polyorganosiloxanes and safety to the human body and the like. Since these compounds exhibit improved properties when coexisting with the low molecular weight polyorganosiloxanes, a composition only using this combination may allow substitution by water and drying.
While the composition ratio of the hydrophilic solvent is not particularly limited, it is preferable to have 100 parts by weight or less or, more preferably, 50 parts by weight or less of the hydrophilic solvent mixed with 100 parts by weight of the low molecular weight polyorganosiloxane.
The dewatering cleaning agents of the invention may be applied to metals, ceramics, plastics, and the like. More specifically, they may be applied to metallic parts, surface treated parts, electronic and semiconductor parts, electric and precision machinery parts, optical parts, glass and ceramic parts, and the like. An exemplary general-purpose cleaning process usually involves immersing of any of the above-described parts or spraying a dewatering cleaning agent of the invention onto the part to substitute it by water and drying by blowing hot air and the like. The immersing and spraying processes may be accompanied by an ultrasonic process and mechanical stirring.
The dewatering cleaning agents of the invention, exhibiting a powerful dewatering property, can not only provide cleaning and water-substituting effects equivalent to those of conventional cleaning agents containing flon and the like but also allow various materials to be stably cleaned with their low eroding action. In addition, containing no element halogen such as chlorine and bromine in general, the dewatering cleaning agents of the invention have few risk of destroying or polluting the environment. Thus, it can be said that the dewatering cleaning agents of the invention will be a viable replacement for the conventional organic solvent containing dewatering cleaning agents such as flon, which have been imposing the environmental problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an exemplary construction of a cleaning system using a dewatering cleaning agent of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described with reference to examples in which a cleaning composition of the invention is applied to water system cleaning agents.
EXAMPLE 1
Two kinds (A1 and A2) of polyoxyalkylene group containing polyorganosiloxane, each represented by formula (V) and (VI), were prepared. ##STR8##
Then, the polyoxyalkylene denatured silicone (A1) represented by formula (V), polyoxyalkylene denatured silicone (A2) represented by formula (VI), sodium laurate (B1) and polyoxyethylene octylphenyl ether (B2) (20 moles of polyoxyethylene), both serving as surfactants, and water were weighed so that their ratio by weight will be 5:5:4:4:82. Thereafter, these components were charged into a homogenizing mixer for blending to obtain a water system cleaning composition P1.
EXAMPLE 2
The polyoxyalkylene group containing polyorganosiloxane (A1), the sodium laurate (B1) and polyoxyethylene octylphenyl ether (B2), both serving as surfactants, and water were weighed so that they satisfy the composition ratio specified in Table 1. Then, a water system cleaning composition P2 was obtained as in Example 1.
EXAMPLES 3 to 5
The polyoxyalkylene group containing polyorganosiloxanes (A1) and (A2), dioctyl sodium sulfosuccinate (B3) that serves as a surfactant in addition to the surfactants (B1) and (B2), octamethyl tetrasiloxane (D1) and octamethyl trisiloxane (D2), both as low molecular weight polyorganosiloxanes, and water were selectively mixed to prepare water system cleaning compositions P3 to P5 having composition ratios specified in Table 1 in the same manner as that in Example 1.
Comparative examples 1 to 3
Three kinds of water system cleaning compositions were prepared in a manner similar to that of each of the above examples except that no polyoxyalkylene group containing polyorganosiloxane was mixed.
The properties as a cleaning agent were evaluated as to the water system cleaning compositions of Examples 1 to 5 and Comparative examples 1 to 3 by the following methods. The result is also shown in Table 1.
(1) Penetration Test
Measurements were made based on the JIS-specified canvas method. The smaller value means better penetrating property; i.e., the composition is more effective in cleaning smaller parts.
(2) Cleaning Property Test
A sample is prepared by applying a spindle oil over a steel strip and baking it at 135° C. for 48 hours. The property is evaluated by the time spent for cleaning the oil baked on the sample (by ultrasonic cleaning). The smaller the value is, the better the cleaning property becomes.
(3) Stability Test
Each composition was contained in a transparent bottle of 200 ml sealed thereafter and then heated at 50° C. for 6 hours. After being gradually cooled from 50 to 25° C., its appearance in bottle is observed.
TABLE 1__________________________________________________________________________ Examples Comparative examples 1 2 3 4 5 1 2 3__________________________________________________________________________Composition Polyoxyalkylene A1 5 0.5 1.0 -- 10 -- -- --ratio (wt. %) Denatured silicone A2 5 -- -- 1.0 -- -- -- -- Surfactant B1 4 0.8 0.3 0.3 4 1.2 0.8 0.8 B2 4 0.7 0.4 0.5 -- 0.8 0.7 0.7 B3 -- -- -- -- 0.5 -- 0.5 -- Water 82 98 98 98 82 98 98 98 Low molecular weight D1 -- -- -- 0.2 3.5 -- -- 0.5 polyorganosiloxane D2 -- -- 0.3 -- -- -- -- --Evaluation Penetrability (Canvas 7 8 4 3 2 25 22 18result method, in second) Cleaning property 14 14 12 11 7 22 23 17 (in minute) Stability ST ST ST ST ST ST ST SEP__________________________________________________________________________ Note: ST: stable SEP: separated
As is apparent from the result shown in Table 1, the water system cleaning agent of the invention exhibits excellent cleaning capability and penetrability, attesting to its availability as a replacement for the conventional solvent based cleaning agents containing flon and the like. With its stability, it is considered a highly practical product. In contradistinction thereto, the water system cleaning agents according to Comparative examples were satisfactory neither in cleaning capability nor in penetrability.
An exemplary process employed to clean a specific part using a water system cleaning agent of the invention will now be described.
EXAMPLE 6
In fabricating a liquid crystal device, a liquid crystal cell is evacuated to a high vacuum degree and a liquid crystal material is sealed in a device. In this case, the evacuation is carried out by a high performance diffusion vacuum pump. Since the diffused oil enters into the vacuum system in the form of mist, the pump must be cleaned often to remove the oil.
In this example, the water system cleaning agent of the invention was used in lieu of a conventional triethane cleaning agent.
A pump part made of a stainless steel SUS304 and a Ni-plated stainless steel SUS304 material having an adhesion of Silicon Oil F-4 (trademark of Shinetsu Chemical) as a diffusion oil was cleaned.
The composition ratio of the used water system cleaning agent is as shown below.
That is, in 80 wt. % of ion-exchanged water being sufficiently stirred at ambient temperature, 6 wt. % of the polyoxyalkylene group containing polyorganosiloxane having the following chemical structure was gradually added to obtain an achromatic translucent homogenous solution. ##STR9##
On the other hand, as a surfactant, a mixture of 8 wt. % of special nonionic Adecanol B-4001 (trademark of Asahi Electrochemical) and 6 wt. % of anionic TWA-2023 (trademark of Ipposha Oil and Grease) of sulfuric acid ester PURLONIC structure was added to the above water/siloxane solution.
After diluting the water system cleaning agent thus obtained was diluted by ion-exchanged water at an arbitrary ratio, Silicone Oil F-4 was cleaned using the diluted cleaning agents. As a result, the pump part was satisfactorily cleaned: through immersion by stirring for 1 minute in a 1/10 diluted cleaning agent at ambient temperature; through immersion by oscillating for 1 minute in a 1/30 diluted cleaning agent at 40° C. or through 1 minute ultrasonic cleaning at 20° C. in the same cleaning agent; and through 1 minute ultrasonic cleaning in a 1/50 diluted cleaning agent at 50° C., respectively.
For comparison, the pump part was similarly cleaned with compositions containing only surfactant(s) and no polyoxyalkylene group containing polyorganosiloxane. Silicone Oil was not removed sufficiently with 10 or more minute immersion ultrasonic cleaning in a 1/10 diluted composition at ambient temperature. To remove Silicone Oil with this composition, it took more than 5 minutes at 65° C. or more.
It is understood from this data that the cleaning agent that incorporates the polyoxyalkylene group containing polyorganosiloxane of the invention exhibits an outstanding cleaning property.
EXAMPLE 7
The polyoxyalkylene group containing polyorganosiloxanes and the low molecular weight polyorganosiloxanes of the invention contribute to significantly improve the cleaning capability of commercially available water-soluble cleaning agents.
An aqueous solution of Chemiclean MS-109 (trademark of Sanyo Kasei Kogyo), which is a surfactant containing, low foaming, rust preventive cleaning agent, is typically used to clean mechanical and metallic parts. Blending 3 wt. % of the polyoxyalkylene denatured silicon (A1) represented by formula (V) in Example 1, 5 wt. % of cyclic hexamethylcyclotrisiloxane, 17 wt. % of ion-exchanged water with 65 wt. % of the above aqueous solution, a new cleaning composition was prepared.
This new cleaning composition was 1/20 diluted by ion-exchanged water and its cleaning property was evaluated by the following method. The result is shown in Table 2. For comparison, the evaluation result of 1/20 diluted Chemiclean MS-109 was also shown.
TEST METHOD
(1) Cleaning Test--1
The following contaminants were applied to a degreased aluminum plate (AC-4A) by immersing, dried by blowing, and immersed while stirred (400 rpm) in respective cleaning agents (1/20 diluted) for 15 seconds to 1 minute. Then, after immersed in water, the aluminum plate was dried by blowing. Each contaminant was transferred on white paper through an adhesive tape for reflectance measurement by a calorimeter thereby to calculate the cleaning rate.
Contaminant:
______________________________________Spindle oil 78%Fatty acid ester 15%Chlorinated paraffin 5%Carbon black 2%______________________________________
Cleaning rate (%)=Rw-Rs/Ro-Rs
Ro: Reflectance of the original white paper
Rs: Reflectance of the standard contaminated plate
Rw: Reflectance of the contaminated plate after cleaned
(2) Cleaning Test--2
A contaminant was prepared by adding 2% of carbon black to a water-soluble machining oil (emulsive), and the test was performed in a manner similar to that of Cleaning test--1. Its cleaning rate was similarly calculated.
TABLE 2______________________________________ Immersion time Cleaning rate (%) (second) Invention MS-109______________________________________Cleaning test - 1 15 72.4 59.0 30 86.5 65.2Cleaning test - 2 60 100.0 67.8 15 81.7 58.0 30 93.8 71.0______________________________________
Similar tests were conducted on EP-680 (trademark of E.P. Japan) which is a commercially available supereffective cleaning solution and water system cleaning agent; Banrise D-20 (trademark of Joban Chemical Industries) which is an emulsive degreased cleaning agent; and Hikari Ace (trademark of Shoko Trade) which is a powerful special cleaning agent. As a result, these cleaning agents, when used in combination of the polyoxyalkylene group containing polyorganosiloxane and the low molecular weight polyorganosiloxane of the invention, exhibited a significantly improved cleaning property.
EXAMPLE 8
The water system cleaning agent of the invention exhibits remarkable effect on cleaning of fluxes used in mounting electronic parts on printed boards. The flux comes roughly in two types: rosin containing and water-soluble. A specific example of cleaning rosin containing fluxes, which is said to be a difficult task, will now be described.
As a step prior to soldering a part on a printed board, a WW rosin ester was put on a part and immersed in a solder bath at 230 to 250° C. and then the part was mounted. It was observed that the flux was completely removed when the printed board was shower-rinsed for 35° C. for 45 seconds using a water system cleaning agent described below.
The water system cleaning composition used here is prepared by blending 2 wt. % of the polyoxyalkylene group containing polyorganosiloxane represented by formula (VII), 3 wt. % of Senkanol FM (trademark of Nippon Senka), which is an amphoteric surfactant, 5 wt. % of Nikkol CMT-30 (trademark of Nippon Surfactant), which is a sodium-N-COCOIL methyl taurine containing nonionic surfactant, and adding ion-exchanged water to prepare 100 wt. % of the composition. ##STR10##
When acceleration aging tests which guarantees US MIL-F-14256C standard, surface insulation resistance tests, ion residual tests and the like were conducted on the above composition which was 1/10 diluted by ion-exchanged water, the results were satisfactory.
Examples in which cleaning compositions of the invention were applied to dewatering cleaning agents will now be described.
EXAMPLES 9 to 17
Octamethyltrisiloxane (E1), octamethylcytotetrasiloxane (E2), and decamethycyclopentasiloxane (E3) were prepared as low molecular weight polyorganosiloxanes; polyoxyethylene oleyl ether (F1) (P.O.E=6 moles), and polyoxyethylene octylphenyl ether (F2) (P.O.E=10 moles) as surfactants; and diethylene glycol monobutyl ether (G1) as a hydrophilic solvent were prepared.
These components were selected and blended so that the composition ratio shown in Table 3 were satisfied to obtain respective dewatering cleaning agents. Comparative examples 4 to 8
Flon 113, methylene chloride, isopropyl alcohol, and ethanol were prepared as conventional dewatering cleaning agents to obtain 5 types of dewatering cleaning agents whose composition ratios were as shown in Table 3.
The properties of Examples 9 to 17 and Comparative examples 4 to 8 were evaluated by the following methods. The result is also shown in Table 3.
(1) Dewatering Property
Various pieces (a stainless steel strip, a ceramic piece, a polycarbonate piece, a Ni-plated steel strip) were immersed in each dewatering cleaning agent after washed by water. In examples 13 to 15, each piece was then rinsed by the low molecular weight polyorganosiloxane blended to prepare each dewatering cleaning agent. Thereafter, each piece was dried in an oven at 50° C. The water marks (a stain by impurities dissolved in water) after drying each piece was observed visibly and by a scanning electron microscope and evaluated in accordance with the following criteria.
XX: Not evaluable due to erosion of the piece during dewatering.
X: Water marks were visibly observed.
∘: No water marks were visibly observed.
⊚: No water marks whose size is 50 μm or more were observed by the scanning electron microscope.
(2) Continuous Dewatering Property
A continuous dewatering test with a frequency of 50 times were conducted on a stainless steel strip and the appearance of the strip was evaluated in a manner similar to that of item (1).
(3) Drying Property
The stainless steel strip was immersed in each dewatering cleaning agent and dried in the oven at 50° C. During the drying process, the strip was touched by a finger to see the drying condition every 5 minutes and the time required for drying was recorded on a 5-minute basis.
TABLE 3__________________________________________________________________________ Examples Comparative examples 9 10 11 12 13 14 15 16 17 4 5 6 7 8__________________________________________________________________________Composition Low molecular weight E1 100 -- -- 50 100 -- -- -- -- -- -- -- -- --ratio (Parts polyorganosiloxane E2 -- 100 50 50 -- 100 100 100 -- 50 -- -- -- --by weight) E3 -- -- 50 -- -- -- -- -- 100 -- -- -- -- -- Surfactant F1 -- -- -- -- 0.3 0.3 -- -- -- -- -- -- -- -- F2 -- -- -- -- -- -- 0.2 -- -- -- -- -- -- -- Hydrophilic solvent C1 -- -- -- -- -- -- -- 10 20 -- -- -- -- -- Methylene chloride -- -- -- -- -- -- -- -- -- 50 100 -- -- -- Freon 113 -- -- -- -- -- -- -- -- -- -- -- 100 96 -- Ethanol -- -- -- -- -- -- -- -- -- -- -- -- 4 -- Isopropyl alcohol -- -- -- -- -- -- -- -- -- -- -- -- -- 100Dewatering Stainless steel ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ◯ ◯ ⊚ ⊚ ⊚property Ceramics ◯ ◯ ◯ ◯ ⊚ ⊚ ⊚ ⊚ ⊚ X X ⊚ ⊚ Polycarbonate ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ XX XX ⊚ ⊚ XX* Ni plated strip ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ XX XX ⊚ ⊚ ⊚Continuous dewatering property ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ⊚ ◯ ◯ ⊚ ⊚ ⊚Drying property (50° C. in oven 10 5 10 10 10 5 5 10 15 5 5 <5 <5 <5in minute)__________________________________________________________________________ Note: *Solvent cracks occurred.
As is apparent from the result shown in Table 3, the dewatering cleaning agents of the invention, exhibiting satisfactory dewatering property, can be a viable substitute for organic solvent containing flon and the like based cleaning agents.
Dewatering cleaning agents containing methylene chloride or isopropyl alcohol (Comparative examples 4 and 5) rust and erode metal films and plastics. In contradistinction thereto, the dewatering cleaning agents of the invention are stable to metal films and plastics and exhibit satisfactory dewatering property even to ceramics which have large surface roughness values, thereby ensuring their reliability when applied to parts including metal, plated, electronic, semiconductor, plastic, and ceramic parts. The dewatering cleaning agent containing isopropyl alcohol permitted water to be dissolved therein, thereby causing water to present on the part again.
Moreover, it is understood that mixing of surfactants and hydrophilic solvents with the dewatering cleaning agents of the invention improved the dewatering property, thereby attesting to their industrial applicability.
An exemplary cleaning system using a dewatering cleaning agent of the invention will now be described with reference to FIG. 1.
A cleaning system shown in FIG. 1 consists roughly of a cleaning/water-substituting process A and a rinsing/dewatering process B.
The cleaning/water-substituting process A, which is the first process involves a first cleaning vessel 1 and a second cleaning vessel 2, each serving both as a separator through sedimentation and a separator through overflow, and a dewatering vessel 3. The first and second cleaning vessels 1 and 2 communicate with each other through a drain line 2a and an overflow line 2b. The first and second cleaning vessels 1 and 2 are operated together with ultrasonic, oscillating, mechanical stirring, cleaning agent heating, and brushing processes and the like, if necessary.
The first and second cleaning vessels 1 and 2 respectively contain a cleaning agent D1 composed of a low molecular weight polyorganosiloxane and a surfactant, which is one of the dewatering cleaning agents of the invention. The surfactant containing cleaning agent D1 may be so prepared that its specific gravity is smaller than that of water and larger than that of an oily stain. Therefore, water Y introduced by an object to be cleaned X is separated by being sedimentated at the bottom of the surfactant containing cleaning agent D1 that has been charged in the first and second cleaning vessels 1 and 2. If an oily stain Z is present on the object X, the oily stain Z is separated by floating upward in the surfactant containing cleaning agent D1 in the first and second cleaning vessels 1 and 2.
The water Y separated by being sedimentated in the second cleaning vessel 2 is intermittently discharged to the first cleaning vessel 1 through a drain line 2a while the water Y separated by being sedimentated in the first cleaning vessel 1 is intermittently discharged to a cleaning agent recycling mechanism C (described later) through a drain line 4. A drain line 3a connected to the drainage vessel 3 is also connected to the cleaning agent recycling mechanism C.
The oily stain Z separated by floating in the first and second vessels 1 and 2 is discharged outside while continuously overflown through an overflow line 5 connected to the first cleaning vessel 1.
The surfactant containing cleaning agent D1 charged in the first and second cleaning vessels 1 and 2 is continuously circulated through a filter 6 that serves to remove solid particles, H 2 O particles, undissolved substances, and the like contained in the cleaning agent D1.
The rinsing/dewatering process B, which is the second process, involves a third cleaning vessel 7 and a shower rinse vessel 8. Below the shower rinse vessel 8 is a buffer tank 9 that communicates with the third cleaning vessel 7 through a drain line 9a and an overflow line 9b. The third cleaning vessel 7 is also operated together with ultrasonic, oscillating, mechanical stirring, cleaning agent heating, and brushing processes and the like, if necessary.
The third cleaning vessel 7 contains a cleaning agent D2 consisting only of a silicone composition identical to the low molecular weight polyorganosiloxane used in the first process A. The cleaning agent D2 may be so prepared that its specific gravity is smaller than that of water and larger than that of an oily stain. Therefore, as in the first process A, water Y is separated by being sedimentated at the bottom of the cleaning agent D2 and the oily stain Z is separated by floating upward in the cleaning agent D2.
The water Y separated by being sedimentated in the third cleaning vessel 7 is intermittently discharged to the cleaning agent recycling mechanism C through a drain line 10 while the oily stain Z separated by floating in the third cleaning vessel 7 is discharged outside through an overflow line 11.
The cleaning agent D2 charged in the third cleaning vessel 7 is continuously circulated through a filter 12 that serves to remove solid particles, H 2 O particles, undissolved substances, and the like contained in the cleaning agent D2.
The object to be cleaned X undergoes the first process A and then the second process B, cleaned and dewatered, and then dried by a fan forced drier (not shown) to complete the cleaning process.
The cleaning agent used in the cleaning system is subjected to the following recycling process.
As described above, the drain lines 4, 3a, 10 of the first, second, and third cleaning vessels 1, 2, and 7, and the dewatering vessel 3 are connected to the cleaning agent recycling mechanism C. The cleaning agent D1 or D2 contained in each cleaning vessel is constantly cleaned by the filters 6 and 12. However, when heavily contaminated, the cleaning agent is introduced to the cleaning agent recycling mechanism C through drain lines 4 and 10 by a conveyer pump 13 for fractional distillation. The cleaning agent D1 deposited in the dewatering vessel 3 is also supplied intermittently to the cleaning agent recycling mechanism C.
At the cleaning agent recycling mechanism C, the introduced cleaning agent is separated into liquid components and solid components by a filter 14, and only the liquid components are forwarded to a distiller 15 with the solid components being destroyed. The distiller 15 separates various components, water, oily stains in the cleaning agent utilizing the difference in their boiling points. Water and the like that remain in the distiller 15 are further separated by a decanter 16.
Since the cleaning agent D1 is an agent having a surfactant added to the cleaning agent D2 that contains only the low molecular weight polyorganosiloxane, the low molecular weight polyorganosiloxane, i.e., the cleaning agent D2, can be extracted from both cleaning agents D1 and D2, thereby allowing the cleaning agent D2 to be recycled. The components other than the recycled cleaning agent D2, i.e., the surfactant, water, and the like will be destroyed.
The recycled cleaning agent D2 is forwarded to a mixer 18 from which the cleaning agent D1 is supplied to the shower rinse vessel 8, the third cleaning vessel 7, or the second cleaning vessel 2 through a line 17.
In the shower rinse vessel 8, a shower rinsing process is conducted using only the recycled cleaning agent D2 or a cleaning agent D2 newly introduced through a cleaning agent supply line 19, both being free from impurities.
The mixer 18 mixes the recycled or new cleaning agent D2 with the surfactant newly supplied from a surfactant supply line 20 to prepare a new cleaning agent D1. The new cleaning agent D1 is supplied to the second cleaning vessel 2, if necessary.
With the cleaning system of such construction as described above, the dewatering cleaning agents of the invention can be used efficiently and effectively enjoying the advantage of excellent cleaning properties.
INDUSTRIAL APPLICABILITY
As described in the foregoing pages, the cleaning compositions of the invention, when used as water system cleaning agents, exhibit a cleaning effect equivalent to that of conventional flon containing cleaning agents and an excellent stability as a water system with no risk of enviromental destruction and pollution, thereby making a viable replacement for the organic solvent based cleaning agents including flon and the like which have environmental disadvantages. In addition, the cleaning compositions of the invention, when used as dewatering cleaning agents, provide a powerful dewatering property with no risk of environmental destruction and pollution, thereby serving a viable replacement for the organic solvent based dewatering cleaning agents including flon and the like which have environmental disadvantages. | A cleaning composition comprising at least one low molecular weight polyorganosiloxane selected from the group consisting of straight chain polydiorganosiloxane represented by a general formula: ##STR1## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and l is an integer from 0 to 5), and cyclic polydiorganosiloxane represented by a general formula: ##STR2## (wherein R 1 is an organic group of single valence substituted by the same or different group or unsubstituted, and m is an integer from 3 to 7). To use it as a water system cleaning agent, polyoxyalkylene group containing polyorganosiloxane, a surfactant, and water are additionally mixed. Accordingly, a cleaning effect free from environmental destruction and contamination, equivalent to flon containing cleaning agents, and satisfactorily stable in terms of dispersion as a water system cleaning agent can be obtained. In addition, to use as a dewatering cleaning agent, the low molecular weight polyorganosiloxane is additionally mixed alone or with a surfactant and/or a hydrophilic solvent. Accordingly, cleaning and water substituting properties equivalent to flon containing dewatering cleaning agents and environmental safety can be obtained. | 2 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
This invention relates to a foil composite material, to a method for manufacturing the foil composite material, as well as to a card body, in particular a card body for a portable data carrier, which contains the foil composite material, and to a method for manufacturing the card body.
B. Related Art
In the production of card bodies, in particular for portable data carriers, such as e.g. chip cards, several plastic foils lying one over the other are laminated to each other. As plastic foils there are usually employed thermoplastic foils because of their good laminatability, e.g. foils made of polyvinyl chloride, polycarbonate, polypropylene, polyethylene terephthalate or thermoplastic polyurethanes. A disadvantage of card bodies made of such thermoplastic foils is their deficient mechanical properties with regard to bending stress and the action of impact force. There result stresses in the card body, and finally cracks. The installation of electronic modules also usually leads to stresses, a weakening of the card body, and ultimately to an elevated susceptibility to cracks and breaks.
To improve the mechanical properties of such card bodies it is advantageous to employ foils made of thermoplastic elastomer, for example based on urethane, within the framework of the laminating process. These foils are exceptionally elastic and can considerably improve the bending strength and breaking strength of the card construction. In the print EP 0 430 282 A2 there is described a card body in the form of a multilayer identification card wherein a layer of thermoplastic elastomer is respectively provided between the card core and corresponding cover foils.
However, it is very difficult to process foils made of thermoplastic elastomer, so-called TPE foils, within the framework of a laminating process upon the manufacture of a card body. On account of their high elasticity the foils are very “limp”. The lack of stiffness leads to problems upon processing in the production machines, and the low dimensional stability can also cause register problems upon printing of the foils. In addition, the material tends to flow out upon laminating. Further, such foils possess a low glass transition range, which lies under 0° C., whereby it remains flexible and does not become brittle in this temperature range. Furthermore, the foils tend to block upon stacking, so that the foils in a stack are hard to single and transport. To obtain a sufficient connection stiffness upon lamination of such foils to other materials, it is moreover necessary to reach the glass point of the respective other material. Because this glass point regularly lies far above the glass transition range of thermoplastic elastomers, this frequently leads to the thermoplastic elastomer floating off, in connection with the dependence on the strength of the viscosity drop in the corresponding temperature range. This has the consequence that the employed laminating machines must often be cleaned. In some cases the foils adjacent to the thermoplastic elastomer can even likewise start to flow, and deform a printed image located thereon. Although it is possible to laminate at lower temperatures to thereby prevent the foils from floating off, an insufficiently good laminate bond is normally obtained upon laminating at low temperatures.
Hence, it is desirable to combine the positive properties of thermoplastic foils and of foils made of thermoplastic elastomer in a single foil material. A solution approach in this direction is disclosed in the document EP 0 384 252 B 1. The therein described foil composite material has a multiplicity of layers, whereby a middle layer is made of thermoplastic elastomer. This layer is adjoined by layers made of thermoplastic plastics. Upon the manufacture of the composite material there are applied to a foil forming the middle layer the further layers. One application method is simultaneous extrusion, whereby the layers are merged after leaving the extruder.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a foil material that is suitable for use as a layer in a card body. In particular, the foil material should be readily processable within the framework of producing a card body, and guarantee good mechanical properties of the card body. Desired properties of such a foil material are
high flexibility in order to guarantee the desired bending strength, in particular dynamic bending strength, of the card; the capability to avoid stresses, cracks and breaks in the card, in particular also upon installation of electronic modules into the card; good laminatability to common card materials, in particular thermoplastic foils, preferably without auxiliary layers; good printability, preferably without pretreatment for printing; good dimensional stability upon manufacture and processing; simple, and preferably inexpensive, manufacturability; good handling upon further processing, in particular avoidance of blocking, as well as higher chemical resistance to standard materials.
Another object of the present invention is to provide a card body, in particular a card body for a portable data carrier, that avoids the disadvantages of the prior art. In particular, the card body should readily tolerate the installation of electronic modules and have good resistance to stress cracks and breaks, for example upon bending stress and the action of impact force.
According to the invention there is provided a foil composite material that has at least three layers, whereby an inner layer made of a thermoplastic elastomer is covered on both its surfaces by outer layers made of thermoplastic polymer. Such a foil composite material combines the advantageous elasticity properties of the elastomer with the advantageous properties of the thermoplastic with regard to laminatability and handling. The manufacture of such a composite material raises technical problems, because the employed materials and process parameters must be carefully coordinated with each other to achieve the desired foil properties.
If thermoplastic polymer and elastomer are separately extruded and merged only immediately after leaving the respective extruder nozzle, the mutual adhesive strength of the partial layers may be deficient, so that upon stress in some cases there may occur a partial separation of the foil composite material into its individual layers. According to the invention, hence all employed materials still in a molten state are merged into the foil composite material prior to leaving the extruder nozzle. Only after leaving the extruder nozzle the foil composite material cools down and becomes solid, that is, the foil composite material as a whole cools down and becomes solid and thus forms a so-called coextrusion foil. This procedure requires that the thermoplastic plastic material and the thermoplastic elastomer must be processed at the same temperature or at least within a common temperature range. Thermoplastics typically have a slightly higher melting or processing temperature than thermoplastic elastomers. If thermoplastic elastomers are heated to the typical processing temperatures of thermoplastics, thermoplastic elastomers tend, more than thermoplastics, to thermal degradation, which in turn leads to decreasing viscosity and thus to worse foil bond between thermoplastic plastic and thermoplastic elastomer. Furthermore, thermoplastic plastic and thermoplastic elastomer of course must not repel each other, rather, they must be well compatible with each other and bond to each other, so that they do not delaminate when they are later present in a heavily-used card body. Comparable rheological properties, i.e. comparable melt viscosities, in thermoplastic and thermoplastic elastomer promote a homogeneous melt superimposition and improve the mutual adhesive strength of the layers.
Besides the careful coordination of thermoplastic plastic material and thermoplastic elastomer, one must of course also make sure that extruders are selected whose screw geometries allow the processing of the selected material and make possible the respective necessary throughput for the desired layer thicknesses. In particular, a continuous flow stream of the thermoplastic elastomer must be guaranteed, so as to avoid the danger of thermal degradation and thus the deterioration of the rheological properties of the thermoplastic elastomer.
According to the invention it was found that the requirements for a foil to be used as a layer in a card body are fulfilled in the optimal way when the inner plasticlayer of the foil composite material is manufactured of a thermoplastic copolyester elastomer, and the two outer plastic layers are manufactured of a polyethylene terephthalate glycol copolymer (PETG), the so-called glycol-modified polyethylene terephthalate. One has to bear in mind here that the thermoplastic copolyester elastomer as well as the PETG respectively only represent the plastic materials of the inner layer or of the outer layers. The materials for the inner layer or the outer layers may also contain, besides the plastic material, usual additives, for example color pigments, oxidation stabilizers, flame retardants, optical brighteners, fillers, UV stabilizers, release additives and other auxiliary agents. Color pigments can simultaneously act as fillers. The usual extenders can also be contained, but preferably the layers are free of extenders. In general, the admixture of auxiliary agents is preferably kept low so as to interfere with the coordination of the plastic materials as little as possible.
The two outer plastic layers can be identical or different. Although both outer plastic layers preferably consist of PETG, they can differ with regard to the PETG type used, with regard to their thickness, or with regard to their accessory agents. For example, one of the outer plastic layers could contain an antiblocking agent, while the other one of the outer plastic layers consists of 100% PETG. Preferably, both outer plastic layers are identical.
The foil composite material according to the invention may also consist of more than three layers. According to an embodiment of the foil composite material according to the invention, one or both outer plastic layers respectively consist of two partial layers, an interior outer layer which borders on the inner plastic layer, and an exterior outer layer. Preferably, the layer construction of the foil composite material is symmetrical with regard to the number of outer layers, i.e. either both outer layers respectively consist of only one layer, or both outer layers respectively consist of two partial layers. The two partial layers of an outer layer can also differ with regard to the PETG type used, with regard to their thickness, and with regard to their accessory agents. According to a preferred embodiment, the respectively exterior outer layer contains a small amount of an antiblocking agent, but the interior outer layer not.
According to a different embodiment, the inner plastic layer consists of more than one layer, for example of two or three layers. These layers can in turn be identical or different, i.e. differ with regard to the thermoplastic copolyester elastomer used, with regard to their thickness and/or with regard to their accessory agents. Preferably, however, the layer construction is symmetrical at least with regard to the number of inner layers. A construction with several partial layers can be very advantageous for example when the inner plastic layer is to have a high thickness, but the available extruders do not have the required flow rate. The extrusion process after all must be carried out quickly, so that at the necessary extrusion temperatures no thermal degradation of the thermoplastic copolyester elastomer takes place.
For the inner layer or for the partial layers of the inner layer there can be used a single thermoplastic copolyester elastomer or a mixture of thermoplastic copolyester elastomers. The elastomers must, of course, be readily intermiscible and compatible with each other, i.e. they must have comparable material properties and processing properties.
Thermoplastic copolyester elastomers are available with Shore D hardness from 25 to 70 and with different elongation at break (150 to over 300%). The processing temperatures lie between 200 and 240° C. The melting viscosities (MFI), for example at 2.16 kg and 230° C., can also vary between 3 and 50 cm 3 /10 min. For the purposes of the present invention, thermoplastic copolyester elastomers (TPC) are preferably used, whose Shore D hardness lies in the range of 33 to 55, whose elongation at break is greater than 300%, and whose melt viscosity lies in the range of 7 to 11 cm 3 /10 min. This melt viscosity is comparable to that of PETG.
Particularly preferred TPC materials are thermoplastic polyester elastomers of the polyether type. A particularly preferred TPC material is Arnitel VT 3104 (DSM Engineering Plastics).
The thickness of the foil composite material according to the invention varies, depending on the place in the layer sequence of a card body where the foil composite material is to be provided. When the foil material is used as an intermediate layer (inlay), total layer thicknesses in the range of about 50 to 350 μm, for example 240 μm, are preferred. When the foil composite material according to the invention is used as a cover layer (overlay foil), total layer thicknesses in the range of about 80 μm to 130 μm, for example 105 μm, are preferred. Referring to the total layer thickness as 100%, about 10 to 30% respectively falls on the first and the second outer plastic layer here, and accordingly about 80 to 40% on the inner plastic layer. It generally applies that the higher the proportion of the TPC material in the total layer thickness, the better the elasticity properties of the foil composite material. With given TPC content, the advantageous effects of the foil composite material according to the invention in general are the more pronounced, the further outward the foil composite material is located in the card body.
It is further pointed out that each of the above-mentioned layers can consist of a mixture of polymers, for example of a mixture of PETG and TPC, whereby the content of TPC should be the more, the further inward the layer is located, and the content of PETG should be the higher, the further outward the layer is located. The two outermost layers or the two outermost partial layers of the foil composite material should contain exclusively PETG as a plastic material. The particular advantage of the present invention, however, is that no polymer mixtures have to be manufactured for obtaining gradations in the properties of the individual layer materials and thus a good mutual connecting strength of the layers. Rather, upon using PETG and thermoplastic copolyester elastomers without compoundings, i.e. each with only TPC and only PETG, good bond values of the foil composite material (adhesion strength greater than 30 N/cm) can be achieved. Simultaneously, the elastomer proportion is high and the processing uncomplicated.
The manufacture of the foil composite material according to the invention is effected by coextrusion. In so doing, the materials provided for the individual layers of the foil composite material according to the invention are respectively melted in suitable extruders and supplied to a wide slot nozzle or a so-called feedblock. In the nozzle or the feedblock they are merged in the provided layer sequence and jointly extruded through the nozzle. It is of essential significance that the individual plastic melts are merged prior to their discharge from the wide slot nozzle. It is also of significance that the extrusion temperature and the extrusion speed are coordinated with the materials used. The temperatures of the extrusion nozzle can typically lie in the range between 210 and 260° C., whereby it must be taken into account that at higher temperatures the thermoplastic copolyester elastomer material can thermally decompose, so that then a correspondingly high extrusion speed must be ensured. Process data for two exemplary formulations are stated in connection with the FIGS. 1 and 2 . Prior to processing all materials must be predried, since they are hygroscopic and through the absorbed moisture in the processing operation they can be degraded through hydrolytic digestion in the extruder. The moisture content should not exceed 0.05%.
The foil composite material according to the invention is in particular suitable for being used as a layer in the layer construction of a card body in order to improve the mechanical properties of the card body.
Card bodies, in particular card bodies for chip cards and other data carriers, typically consist of a multiplicity of layers which are interconnected by laminating. The individual layers usually consist of thermoplastic polymeric materials, such as polyvinyl chloride, polycarbonate or polyethylene terephthalate. Between the layers or in recesses of the layers there can be located electronic components and imprinted antennas. As at least one of the layers of the card body here there is used a foil composite material according to the invention. In particular, the foil composite material according to the invention is used as one or as both cover layers (overlay foil) of the card body. Alternatively or additionally, the foil composite material according to the invention can be provided as an intermediate layer within the card construction (inlay foil).
For manufacturing the card body, the plastic foils that are to form the later card body are laminated to each other. Laminating can be effected in a single operation, i.e. all foil materials that are to form the card body are stacked and laminated in one operation. Alternatively, laminating can be carried out in two or more operations, that is, only a portion of the foils is respectively laminated jointly into a partial stack, and the partial stacks are then stacked and laminated into the card body in a further operation later. A good laminate bond is obtained here by laminating at a suitable pressure and at a temperature between 120° C. and 200° C., in particular between 130° C. and 180° C., preferably between 140° C. and 160° C.
Preferably, laminating is carried out in a heating station and a cooling station. The laminating time preferably lies respectively between 10 minutes and 25 minutes in the heating and/or cooling station.
The card bodies according to the invention typically have total thicknesses in the range of about 0.5 to 1.0 mm. The total thickness of the foil composite material according to the invention normally lies between 50 μm and 350 μm, depending on the place in the layered composite of the card body where the foil composite material is to be used. Inlay foils are usually thicker than overlay foils, whereby the total thickness for inlay foils typically lies in the range of 200 μm to 280 μm, and the total thickness for overlay foils typically lies in the range of 80 gm to 130 μm. The foil composite materials according to the invention, due to their outer layers made of PETG, fuse very well with neighboring layers of the card-body layer construction, so that a stable card-body laminate bond is obtained. Laminating adhesives can be used, but they are not necessary. Simultaneously, the PETG outer layers ensure, when the foil composite material according to the invention is used as an overlay foil, that the card bodies can be printed and handled without any problems, and do not tend to block.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will hereinafter be illustrated further on the basis of Figures. It is pointed out that the figures are not true to proportion and not true to scale. Moreover, it is pointed out that the Figures are only intended to explain the invention more closely and are by no means to be understood as restrictive. The same reference numbers designate the same elements.
There are shown:
FIG. 1 a section through a foil composite material according to the invention having an inner plastic layer, two first outer plastic layers and two second outer plastic layers,
FIG. 2 a section through a foil composite material according to the invention having an inner plastic layer which consists of an interior inner layer and two exterior inner layers, and having a first outer plastic layer and a second outer plastic layer,
FIG. 3 a section through a foil composite material according to the invention having an inner plastic layer, a first outer plastic layer and a second outer plastic layer,
FIG. 4 a section through a card body according to the invention having two foil composite materials according to the invention as cover layers,
FIG. 5 a section through a card body according to the invention having two foil composite materials according to the invention as intermediate layers, and
FIG. 6 a section through a card body according to the invention having two foil composite materials according to the invention as cover layers.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a first embodiment of a foil composite material 4 according to the invention. In the represented embodiment, the foil composite material has five layers, an inner plastic layer 3 , a first outer plastic layer 1 and a second outer plastic layer 2 , whereby the outer plastic layer 1 consists of an interior partial layer 11 and an exterior partial layer 12 , and the outer plastic layer 2 consists of an interior partial layer 21 and an exterior partial layer 22 . The inner layer 3 consists of 100% thermoplastic copolyester elastomer or a mixture of thermoplastic copolyester elastomers, and the first outer plastic layer 1 and the second outer plastic layer 2 consist of thermoplastic plastic material, whereby the two interior outer layers 11 , 21 consist of 100% PETG, while the two exterior outer layers 12 , 22 , contain, in addition to PETG, an antiblocking agent, for example about 4 wt. % antiblocking agent, with the balance being PETG. The contents are always stated in wt. %.
The manufacture of the foil composite material 4 can be effected for example by melting granules with three different compositions (granules A: 96% PETG+4% antiblocking agent; granules B: 100% PETG; granules C: 100% TPC) in three extruders A, B, C, and merging the corresponding molten streams (material A from extruder A, material B from extruder B, material C from extruder C) in a feedblock and jointly extruding them through a wide slot nozzle. In the represented embodiment, the foil composite material is symmetrical in construction, i.e. the interior outer layers 11 , 21 and the exterior outer layers 12 , 22 respectively have the same composition and the same thickness. This is not compulsory. Rather, the interior outer layers 11 , 21 or the exterior outer layers 12 , 22 can respectively differ from each other, for example contain different PETG, have a different thickness or have a different content of antiblocking agent. In such a case, correspondingly more extruders are necessary in a modified feedblock or wide slot nozzle arrangement. Preferably, however, the foil composite materials are symmetrically constructed, for reasons of an easier manufacturability, on the one hand, and since an unsymmetrical construction usually provides no advantages, on the other hand.
In the represented embodiment, the inner plastic layer 3 is the thickest layer. This usually will actually be so in practice, since a proportion of TPC material as high as possible is desired, in order to achieve a high elasticity of the foil composite material 4 . Exemplary layer thicknesses are respectively about 10% of the total thickness for the layers 12 , 22 , respectively 20% of the total layer thickness for the layers 11 , 21 , and about 40% of the total layer thickness for the layer 3 .
The following extruder settings achieved good results:
Temperature [° C.]
Feed zone [° C.]
Extruder A
220-260
40-60
Extruder B
225-250
40-60
Extruder C
215-245
40-70
Nozzle
210-260
The respective most favorable extruder settings can vary in dependence on the extruders employed (throughput, screw geometries or the employed materials and their residual moisture content). They provide information for orientation, which a person skilled in the art can optionally adapt to the given extruder configurations and given material facts by a few routine tests.
FIG. 2 shows a different embodiment of a foil composite material 4 according to the invention in cross section. In this embodiment, the inner plastic layer consists of an interior partial layer 31 and two exterior partial layers 32 , 33 . Located thereon are a first outer plastic layer 1 and a second outer plastic layer 2 . The inner layers 31 , 32 , 33 in turn consist of thermoplastic copolyester elastomer (TPC), whereby all inner layers can consist of the same TPC material or of different TPC materials. If desired, for one or several of the inner layers 31 , 32 , 33 there can also be employed a mixture of TPC materials, or a mixture of one or several TPC materials with a thermoplastic, for example PETG. In this way gradations can be produced, i.e. a gradual transition from, for example, a layer 31 made of 100% TPC material over a layer 32 or 33 made of TPC material with PETG admixture to a layer 1 or 2 made of 100% PETG. It is preferred, however, to use pure TPC material, in particular the same TPC material, for all inner layers 31 , 32 , 33 . The special advantage of the present invention lies in the fact that upon using thermoplastic copolyester elastomers for the inner layers in combination with PETG for the outer layers, no compoundings are necessary for producing compatible transitions between the layers.
The manufacture of the foil composite material 4 represented in FIG. 2 can be effected analogously to the foil composite material represented in FIG. 1 . That is, in an extruder A for example a plastic material made of 96% PETG with 4% antiblocking agent is melted for the outer layers 1 and 2 and fed to a wide slot nozzle, and in two extruders B and C a plastic material made of 100% TPC is respectively melted and fed to the wide slot nozzle, whereby the feeding is effected such that the layer construction represented in FIG. 2 is produced. Extruder C, which extrudes the material for the thickest inner layer 31 , must have the greatest flow rate. However, it is also possible that the extruder C does not have the greatest flow rate. The flow rate of the individual extruders can be generally adapted to the production conditions and to the specific requirements of the plastic material respectively used and the layer to be manufactured therewith.
In the following there are stated exemplary extruder settings for manufacturing the foil composite material 4 , which optionally are to be adapted to the extruder configurations and material moistures present in the respective individual case.
Temperature [° C.]
Feed zone [° C.]
Extruder A
220-250
40-60
Extruder B
215-240
40-60
Extruder C
215-240
40-60
Nozzle
210-250
For all embodiments and layer sequences of the foil composite material according to the invention it has proven to be particularly useful to use the following materials:
Arnitel VT 3104 as a thermoplastic copolyester elastomer, Eastman PETG 6763 as a thermoplastic polymer, Release Sukano S 462 as an antiblocking agent.
FIG. 3 shows a further embodiment of the foil composite material 4 according to the invention. This embodiment has the simplest layer construction with a single inner layer 3 made of TPC material and two outer layers 1 , 2 made of PETG. One or several of the layers can contain, as in all other embodiments, usual accessory agents, for example dyes, UV protection agents or (in the outer layers) antiblocking agents. Antiblocking agents, however, are not absolutely necessary.
Usually it is desired that the inner layer made of TPC material has an as great a proportion as possible in the total thickness of the foil composite material, so that the advantageous elasticity properties of the TPC material have a good effect. The outer layers 1 , 2 made of PETG are usually kept thin because they are to serve for equipping the inner TPC layer(s) with the surface properties of the thermoplastic polymer PETG. Further, the outer layers 1 , 2 are to provide the needed stiffness to the foil, so that this can be further processed in the common methods, such as e.g. for printing, handling etc. These properties are for example the good laminatability, handling without massive danger of blocking, good printability, etc. From this point of view, the layer thickness of the inner TPC layer should have a proportion of at least 40% in the total thickness of the foil composite material. Preferred are proportions of 60 to 80% TPC layer thickness in the foil material layer thickness. In order to be able to achieve these high layer thicknesses, the inner TPC layer is composed of several partial layers usually with the help of several extruders.
It is in principle possible that both the outer plastic layers 1 , 2 and the inner plastic layer 3 are respectively composed of several partial layers. Simultaneously, however, it is preferred that the foil composite material 4 produced has no more than seven partial layers, since the coextrusion is more difficult in terms of process engineering, the more partial layers have to be coextruded with each other. Therefore, preferably either the inner layer 3 or the outer layers 1 , 2 consist of partial layers, whereby the outer layers respectively should be constructed from no more than two partial layers, and the inner layer should be constructed from no more than five, preferably no more than three, partial layers.
FIGS. 4, 5 and 6 respectively show exemplary layer constructions for card bodies 5 according to the invention (exploded views). In general, card bodies according to the invention consist of a card core 9 which is typically constructed from one to seven layers. The layers consist of thermoplastic foils, typically made of PVC, ABS, polyester, polycarbonate, PEC (blend of PC and one or several other polyesters) and the like. Between the layers and/or in recesses of the layers there can be located electronic components such as electronic modules and antennas. Other features, such as for example security elements or imprints, can also be provided. The layer construction is respectively completed on the outer side by a cover layer. The foils forming the layer construction are preferably interconnected by laminating, which is why all materials used should be readily laminatable to each other.
FIG. 4 shows an embodiment of a card body 5 according to the invention having a card core 9 , consisting of a PET foil 60 (152 μm), onto which, optionally, a coil (not shown) can be imprinted, and two PVC foils 61 , 62 (240 μm each). The layer construction is completed by the two cover foils 80 , 81 (105 μm each), which consist of the foil composite material 4 according to the invention, as was described hereinabove.
FIG. 5 shows another embodiment of a card body 5 according to the invention. Here, the card core 9 consists of a single PET foil 60 (152 μm) having an imprinted antenna (not shown). The PET foil 60 is adjoined on both sides by the layers 70 , 71 (240 μm each). The layers 70 , 71 in this embodiment consist of the foil composite material 4 according to the invention. The layer construction is completed by the two cover layers 80 , 81 made of a PETG overlay foil (105 μm each).
A further alternative embodiment for a card body 5 according to the invention is represented in FIG. 6 . Here, the card core 9 consists of the PETG foils 60 , 61 (310 μm each), onto which the cover layers 80 , 81 (105 μm each) are laminated. The cover layers 80 , 81 consist of the foil composite material 4 according to the invention.
In FIGS. 4, 5 and 6 , the μm-values in brackets respectively denote the thicknesses. It goes without saying that the specified layer thicknesses as well as the specified materials are to be understood only by way of example, and that other materials which are laminatable to each other as well as deviating layer thicknesses and deviating numbers of layers can also be used. Further, the card constructions are represented symmetrically in the Figures, which, however, is by no means compulsory. Essential is, that the foil composite material 4 according to the invention can be both used as a cover layer, as shown in FIG. 4 and FIG. 6 , and as an intermediate layer, as shown in FIG. 5 . Embodiments are also possible wherein the foil composite material 4 according to the invention is used only as one of the cover layers and/or as an intermediate layer, and embodiments which have cover layers and intermediate layers which are both made of the foil composite material 4 according to the invention. Upon use as a cover layer (overlay foil), the layer thickness of the foil composite material 4 is typically no more than half as thick as upon a use as an intermediate layer (inlay foil). As a cover layer the foil composite material according to the invention is preferably transparent, while as an intermediate layer it is preferably opaque.
Through the employment of the foil composite material according to the invention as cover layer(s) and/or as intermediate layer(s) in a card body, the mechanical properties of card bodies can be decisively improved over card bodies of the prior art. The card bodies can be subjected to stronger and more frequent bending loads without there occurring stresses, cracks or breaks of the card body. Stresses arising from the installation of electronic modules, which always cause a weakening of the card body, can also be compensated and thus the mechanical properties of the card body improved. The foil composite material according to the invention can be employed in the card bodies instead of any standard foil. It is itself highly flexible and gives the card bodies flexibility.
In particular card constructions wherein the foil composite material according to the invention is employed as an intermediate layer, as represented by way of example in FIG. 5 , have excellent mechanical properties, such as excellent strength and stiffness. This becomes evident particularly in the case of actions of impact force, which otherwise as a rule lead to card breakage. This is presumably caused by the greater thickness of the foil composite material intermediate layers, and thus the higher proportion of the foil composite material according to the invention in the card body altogether.
The foil composite material according to the invention is also very stable in itself, i.e. there is a firm bond between the partial layers made of PETG and thermoplastic copolyester elastomer without any danger of the partial layers separating from each other upon load. This stability can be achieved without producing gradations between the partial layers by the use of material mixtures. Therefore there is no need for producing compoundings of granules upon the coextrusion.
The foil composite material according to the invention can be manufactured inexpensively, and there is a wide spectrum of thermoplastic copolyester elastomers with different properties available on the market. The foil composite material made of PETG and thermoplastic copolyester elastomers is easier to process by the coextrusion method than foils with other thermoplastic elastomers. It is also characterized by especially simple handling in further processing, i.e. it can for example be printed without any problems and laminated to all common card materials. It also does not tend to block. A special advantage that makes the foil composite material according to the invention excellently suitable in particular for use as a layer in a card body, is the act that the foil composite material can be manufactured with a very high proportion of thermoplastic elastomer, thereby improving the mechanical properties of the card body in an excellent manner. | A composite film material usable in a data carrier card body includes a first outer plastic layer, an inner plastic layer and a second outer plastic layer, all the layers together forming a coextruded composite. The plastic material of the first outer layer is a polyethylene terephthalate glycol copolymer (PETG) or contains a PETG, the plastic material of the inner layer is a thermoplastic elastomer (TPC) or contains a TPC, and the plastic material of the second outer layer is a PETG or contains a PETG. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/893,293, filed Jul. 19, 2004 now U.S. Pat. No. 7,385,167, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to multilayer light shields for semiconductor-based photoimaging devices and to methods of forming and using the light shields.
BACKGROUND
A semiconductor photoimaging device includes a focal plane array of pixel cells supported by a substrate. Each of the pixel cells includes a photoconversion device, for example, a photogate, a photoconductor, or a photodiode, for generating and accumulating photo-generated charge in a portion of the substrate. A readout circuit is connected to each pixel cell and typically includes at least an output transistor, which receives photogenerated charges from a doped diffusion region and produces an output signal that is periodically read-out through a pixel access transistor. The imager may optionally include a transistor for transferring charge from the photoconversion device to the diffusion region or the diffusion region may be directly connected to, or be part of, the photoconversion device. A transistor is also typically provided for resetting the diffusion region to a predetermined charge level before it receives the photo-converted charges. A CMOS imager circuit is often associated with a color filter, such as a Bayer filter, for discerning various wavelengths of light.
One typical CMOS imager pixel circuit, the three-transistor (3T) pixel, contains a photodiode for supplying photo-generated charge to a diffusion region; a reset transistor for resetting the diffusion region; a source follower transistor having a gate connected to the diffusion region, for producing an output signal; and a row select transistor for selectively connecting the source follower transistor to a column line of a pixel array. Another typical CMOS imager pixel employs a four-transistor (4T) configuration, which is similar to the 3T configuration, but utilizes a transfer transistor to gate charges from the photodiode to the diffusion region and the source follower transistor for output.
Exemplary CMOS imaging circuits, processing steps thereof, and detailed descriptions of the functions of various CMOS elements of an imaging circuit are described, for example, in U.S. Pat. No. 6,140,630, U.S. Pat. No. 6,376,868, U.S. Pat. No. 6,310,366, U.S. Pat. No. 6,326,652, U.S. Pat. No. 6,204,524, and U.S. Pat. No. 6,333,205, each of which is assigned to Micron Technology, Inc., the entire disclosures of which are incorporated herein by reference.
Typical imaging devices have a light shield providing apertures exposing at least a portion of the photoconversion devices to incoming light while shielding the remainder of the pixel circuit and neighboring pixels from the light. Light shields separate received light signals of adjacent pixels, known as crosstalk, and prevent photocurrent from being generated in undesirable locations in the pixel. As a result, the imaging device can achieve higher spatial resolution and color affinity with less blooming, blurring, and other detrimental effects. Light shields can also serve to protect the circuitry associated with the pixels from radiation damage, for example.
In the prior art, light shields have typically been formed in the metal interconnect layering (e.g., the Metal 1 (M1), Metal 2 (M2), or, if utilized, Metal 3 (M3) layers) of the integrated circuit. Metallization layer light shield structures have some drawbacks, such as limiting use of the metal layer to the light shield rather than for its normal conductive interconnect purpose. Additionally, having the light shield in upper metallization (conductive interconnect) layers, spaced some 18,000 Å from the photo-sensitive area, can increase crosstalk, light piping, and light shadowing in the pixels, which can cause errors.
To satisfy optical performance specifications, light masks need to exhibit good light absorption, low reflectivity (higher reflectivity might induce light back scattering) and be as close as possible to the pixel surface to minimize light scattering to vicinal pixels. Metal layers in CMOS imaging devices normally provide this function. Metal layers also serve as conductors. An example of a metal light shield formed on an insulator above the pixel surface is provided in U.S. Pat. No. 6,611,013, assigned to Micron Technology, Inc., and U.S. application Ser. No. 10/410,191 filed Apr. 10, 2003 in the name of Rhodes, the entire disclosures of which are incorporated herein by reference.
Performance objectives become more difficult to satisfy as device sizes become smaller. Widths of metal lines used as light masks also become smaller, down to equal to or less than the wavelength of the light being detected. Additionally, objects at sub-wavelength sizes exhibit a great deal of scattering. Consequently, the need to locate the light shield closer to the pixel surface increases with advancing miniaturization. As light shields are located closer to the pixel surface, however, the light shield layers are exposed to more manufacturing steps and hence are subjected to greater temperatures.
Light shields that can be located close to the pixel surface are needed. The light shields must have good thermal stability, be able to withstand the rigors of “front end” CMOS processing, and be compatible with adjacent structures in the pixel.
SUMMARY
The present invention provides a multilayer stack of light shielding materials and dielectrics. An exemplary light shielding material is a refractory metal that can withstand the high temperatures of front end CMOS processing. Refractory metals have high compressive stress, and putting high stress refractory metal layers close to silicon introduces additional stress on adjacent silicon, for example, and can increase leakage, cause contamination of the photodiode layer, and increase dark current. According to the present invention, transparent layers of materials having high tensile stress are interleaved with the refractory metal layers. The high tensile strength layers offset the high compressive stress of the refractory metal layers to prevent damage to silicon, for example, by adjacent refractory metal layers.
The invention also relates to methods for forming the multilayer light shield and an imaging device incorporating the shield. The light shield and method of forming of the invention are particularly well suited for CMOS imaging devices.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-described features and advantages of the invention will be more clearly understood from the following detailed description, which is provided with reference to the accompanying drawings in which:
FIG. 1 is an exploded view of an exemplary pixel according to the invention;
FIG. 2 is a partial cross-sectional view of the pixel of FIG. 1 taken along the line II-II;
FIG. 3 is a partial cross-sectional view of an alternative embodiment of a pixel constructed in accordance with the invention;
FIG. 4 is a cross-section of a single-layer tungsten light shield stack provided for comparative purposes;
FIG. 5 is a cross-section of an exemplary two-layer tungsten-dielectric light shield stack according to the invention;
FIG. 6 is a cross-section of an exemplary multilayer tungsten-dielectric light shield stack according to the invention;
FIG. 7 is a cross-section of an exemplary multilayer tungsten-dielectric light shield stack according to the invention;
FIG. 8 is a graph illustrating the total stress in the stacks of FIGS. 4-7 ;
FIG. 9 is a graph of transmission data for the stacks of FIGS. 5-7 ;
FIG. 10 shows a stage of fabrication of a circuit like that shown in FIGS. 1 and 2 in accordance with the invention;
FIG. 11 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 10 ;
FIG. 12 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 11 ;
FIG. 13 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 12 ;
FIG. 14 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 13 ;
FIG. 15 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 14 ;
FIG. 16 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 15 ;
FIG. 17 shows a stage of fabrication of a circuit subsequent to that shown in FIG. 16 ;
FIG. 18 shows a partial cross-sectional view of a 3T pixel similar to the 4T pixel shown in FIGS. 1 and 2 through the same cross-section portion of the pixel along line II-II of FIG. 1 ;
FIG. 19 shows a pixel array integrated into a CMOS imager system in accordance with the invention;
FIG. 20 shows circuit diagram of a 4T pixel like that shown in FIG. 1 ; and
FIG. 21 shows a processor system incorporating at least one CMOS imaging device, constructed in accordance with the invention.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings, which are a part of the specification, and in which is shown by way of illustration various embodiments whereby the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to make and use the invention. It is to be understood that other embodiments may be utilized, and that structural, logical, and electrical changes, as well as changes in the materials used, may be made without departing from the spirit and scope of the present invention. Additionally, certain processing steps are described and a particular order of processing steps is disclosed; however, the sequence of steps is not limited to that set forth herein and may be changed as is known in the art, with the exception of steps or acts necessarily occurring in a certain order.
The terms “wafer” and “substrate” are to be understood as interchangeable and as including silicon, silicon-on-insulator (SOI) or silicon-on-sapphire (SOS), doped and undoped semiconductors, epitaxial layers of silicon supported by a base semiconductor foundation, and other semiconductor structures. Furthermore, when reference is made to a “wafer” or “substrate” in the following description, previous process steps may have been utilized to form regions, junctions, or material layers in or on the base semiconductor structure or foundation. In addition, the semiconductor need not be silicon-based, but could be based on silicon-germanium, germanium, gallium arsenide, or other known semiconductor materials.
The term “pixel” refers to a photo-element unit containing a photoconversion device and transistors for converting electromagnetic radiation to an electrical signal. The pixels discussed herein are illustrated and described as 4T pixel circuits for the sake of example only. It should be understood that the invention is not limited to a four transistor (4T) pixel, but may be used with other pixel arrangements having fewer (e.g., 3T) or more (e.g., 5T) than four transistors. Although the invention is described herein with reference to the architecture and fabrication of one pixel, it should be understood that this is representative of a plurality of pixels in an array of an imaging device. In addition, although the invention is described below with reference to a CMOS imager, the invention has applicability to any solid state imaging device having pixels. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
Referring to the drawings, where like reference numbers designate like elements, FIGS. 1 and 2 show an exemplary embodiment of the invention used in connection with a four transistor (4T) CMOS pixel 12 having a photodiode 14 as a photoconversion device. The photodiode 14 is formed in a p-type substrate 10 , and includes an n-type conductivity region 18 and an uppermost thin p-type conductivity layer 20 over the n-type region 18 . It should be understood that while FIGS. 1 and 2 show the circuitry for a single pixel 12 , in practical use there will be an M×N array of pixels 12 arranged in rows and columns with the pixels 12 of the array being accessed using row and column select circuitry, as is known in the art. The pixel 12 shown can be laterally isolated from other pixels of the array by shallow trench isolation regions 42 . Although the isolation region 42 is shown only along two sides of the pixel 12 for simplicity, in practice trench isolation regions may extend around the entire perimeter of the pixel 12 .
The 4T CMOS pixel 12 shown in FIGS. 1 and 2 is formed partially in and over a doped p-type region 16 in the substrate 10 , and includes a transfer gate 22 , a reset gate 28 , a source follower gate 32 , and a row select gate 36 . The transfer gate 22 forms part of a transfer transistor for electrically gating the charges accumulated by the photodiode 14 to a floating diffusion region 24 . A first conductor 26 at the floating diffusion region 24 is in electrical communication with the gate 32 of the source follower transistor through a second conductor 34 . The two conductors 26 , 34 are electrically connected via a conductive path 50 in a conductive interconnect layer, e.g., the M1 metal layer. Sharing the floating diffusion region 24 with the transfer transistor is reset transistor having the reset gate 28 . The reset transistor is connected to a voltage source (V dd ) through a source/drain region having a conductor 30 for providing a resetting voltage to the floating diffusion region 24 .
An electrical equivalent circuit for the FIG. 1 pixel is illustrated in FIG. 20 with pixel 12 being operated as known in the art by RESET, TRANSFER, and ROW SELECT control signals. As shown in FIG. 20 , the 4T pixel circuit can be converted to a 3T pixel circuit by removing the portion contained within the dotted box 22 ′, i.e., the transfer transistor, and electrically coupling the photodiode 14 output to the floating diffusion region 24 , the floating diffusion region 24 being connected to the gate 32 of the source follower transistor.
Over the pixel 12 circuitry is a light shield 44 , as shown in FIG. 1 , which is an opaque multilayer configured to prevent light energy from irradiating the underlying circuitry and vicinal pixels. The multilayer light shield 44 includes at least one layer of a light-shielding material, such as tungsten (W), molybdenum (Mo), cobalt (Co), tantalum (Ta), chromium (Cr), titanium (Ti), carbon (C), tungsten silicide (WSi x ), titanium nitride (TiN), or other materials with the desired light-blocking, electrical, and physical characteristics. Of these, the refractory metals, particularly W, Ta, and Mo, are preferred. The light shield 44 can be very thin, and in particular must be able to withstand the temperatures (approximately 1,000° C.) experienced during front end CMOS processing. The light shield of the present invention can be located at least within 3,000 Å-4,000 Å of the pixel surface.
Referring to FIGS. 4-7 , light shield structures 2 , 4 , 6 , 8 are respectively illustrated schematically in cross-section. FIG. 8 is an associated graph depicting the total stack stress in each of the structures 2 , 4 , 6 , 8 . FIG. 4 illustrates a single layer light shield structure 2 shown for comparative purposes. Light shield structure 2 is a single layer 3 of tungsten (W) about 1680 Å in thickness. As shown in FIG. 8 , the compressive stress of tungsten is about 1.4E10 dyne/cm 2 . Referring to FIG. 5 , the light shield stack 4 includes the 1680 Å layer of tungsten 3 and a layer of silicon nitride 5 . Alternatively, silicon oxide can be used, but silicon nitride is preferred. Silicon nitride layer 5 has a thickness of about 600 Å. Silicon nitride exhibits tensile stress of about 4E9 dyne/cm 2 . The combination of tungsten layer 5 and silicon nitride layer 6 reduces the total stress in the stack structure 4 , as illustrated in FIG. 8 . Referring to FIG. 6 , stack 6 includes two 840 Å layers 7 of tungsten and two 600 Å layers 5 of silicon nitride, and in FIG. 7 stack structure 8 includes three 560 Å layers 9 of tungsten and three 600 Å layers 5 of silicon nitride. As is evident from FIG. 8 , the total stack stress varies inversely with the number of metal/dielectric layers in the multilayer light shield stack structure.
Referring to FIG. 9 , in addition to reduced stress, stack structures 4 , 6 , 8 exhibit improved light shielding. FIG. 9 is a graph illustrating transmission of red light (649 nm wavelength) through each of the stacks 4 , 6 , 8 . As can be seen from the plots in FIG. 9 , stacks 4 , 6 , 8 exhibit increasing ability to block red light in direct relation to the number of layers in the stack, even though the combined thickness of the tungsten layers is the same in each stack. As a result, the combined thickness of the tungsten layers, and the overall thickness of light shield can be reduced as compared to a single-layer light shield, while obtaining the same or better light-shielding properties.
Further improvements in light-handling properties of the multilayer light shield are obtained by forming the dielectric layers with a thickness equal to one-quarter wavelength of the light to be blocked. Where multiple colors are involved, an average of their wavelengths, for example, can be used. By separating the light-shielding layers by one-quarter wavelength of the light to be blocked, light waves reflected at the interface between the light shielding layers and the transparent dielectric will be off-set by one-half wavelength with respect to incoming light waves traveling through the light shield. The reflected light having a one-half wavelength offset will tend to cancel the incoming light waves, further adding to the light absorbing capabilities of the multilayer light shield. Consequently, further reductions in thickness of the light-shielding layer are possible. For visible light, the dielectric layer will have a thickness between about 100 Å and about 1,000 Å. Thicknesses of about 600 Å or 700 Å are appropriate for red and green light.
It is preferred that less than 0.01% of light impacting the light shield 44 penetrates to the underlying wafer. As shown in FIG. 2 and described in relation thereto, a transparent borophosphosilicate glass (BPSG) layer 52 can be positioned between the light shield 44 and the underlying pixel 12 . As shown in FIG. 3 , the light shield 44 can be a conformal layer formed directly on the photodiode 14 layer.
Again referring to FIG. 1 , an M1 layer containing conductive interconnect pattern 54 is formed above the light shield 44 , which is between the pixel transistors and the M1 layer 50 . Optionally, the first conductive interconnect M1 layer 50 can be formed directly over the light shield 44 if the light shield 44 is not conductive.
The light shield 44 defines an aperture 46 over the photodiode 14 to allow light to pass. The light shield 44 , if conductive, can also optionally be electrically grounded by a grounding circuit 47 , by which it can provide electrical shielding to the underlying pixel circuitry. In another embodiment, the light shield 44 can be used for electrical strapping in the periphery. Additional openings 48 are provided in the light shield 44 to allow the various circuitry contacts 26 , 30 , 34 , 38 , 40 to be in electrical communication between overlying conductive interconnect layers 50 , 60 , such as M1, M2, etc., and underlying pixel circuitry, e.g., gates 22 , 28 , 32 , 36 .
FIGS. 2 and 3 show alternative cross sections of a portion of the FIG. 1 pixel 12 taken along the line II-II and with some additional detail. As is shown, a light transparent first dielectric layer 52 can be provided over the pixel 12 having an upper surface above the level of the transistor gates, e.g., gate 22 , of the pixel 12 . Light shield layer 44 is formed over the first dielectric layer 52 above the pixel 12 . As shown by FIG. 3 , this light shield 44 , as well as the other layers of the pixel cell, can be conformally deposited. A second dielectric layer 54 having similar light transmitting and insulating properties as the first dielectric layer 52 can be formed over the light shield layer 44 (and within the aperture 46 ). Over this layer can be formed the first conductive interconnect layer 50 , i.e., M1 layer, which may be connected by contacts (e.g., conductor 26 ) to the underlying circuitry provided in openings 48 through the various layers 44 , 52 , 54 . Additional layering over the first conductive interconnect layer 50 is also shown in FIGS. 2 and 3 , such as a third dielectric layer 56 having light transmitting and insulating properties similar to the other two dielectric layers 52 and 54 . Over this second dielectric layer 56 can be formed a second conductive interconnect layer 60 (M2), which can be in electrical contact with the first conductive interconnect layer 50 (or other parts of the pixel 12 circuitry or imaging device) by conductors 58 . Additional dielectric, conductive interconnect, or passivation layers can be formed over the second conductive interconnect layer 60 , but are not shown for the sake of clarity. Pixel 12 devices as shown in FIGS. 1-3 can be formed as described below.
FIG. 10 shows a preliminary stage of processing. As mentioned above in discussing FIG. 1 , each pixel 12 is isolated within the substrate 10 by isolation regions 42 , which are preferably STI (shallow trench isolation) regions, but may also be formed by LOCOS processing. FIG. 10 shows the formed STI isolation regions 42 . The STI isolation regions 42 can be formed by using a photoresist mask, patterning, and etching to leave trenches where the isolation regions 42 are desired. The photoresist mask is removed, and a layer of dielectric material (e.g., silicon dioxide, silicon nitride, oxide-nitride, nitride-oxide, or oxide-nitride-oxide, etc.) is formed within the trenches by chemical vapor deposition (CVD), low pressure chemical vapor deposition (LPCVD), high density plasma (HDP) deposition, or other suitable means. After filling the trenches with the dielectric material, the wafer is planarized, for example by chemical mechanical polishing (CMP) or reactive ion etch (RIE) dry etching processes, and the isolation regions are complete as shown in FIG. 10 and surround the pixel 12 area.
Next, as shown in FIG. 11 , transistor gates are formed, including the transfer gate 22 shown in FIGS. 1 and 2 . Standard MOS gates are formed by forming a gate oxide layer 100 (e.g., silicon oxide) over the substrate 10 , then forming a doped polysilicon layer 102 over the gate oxide layer 100 (the polysilicon layer can be doped in situ or subsequently implanted with a dopant), then forming an insulative cap layer 106 (e.g., oxide or nitride). These layers 100 , 102 , 106 are then masked, with patterned photoresist for example, and etched to leave stacks (which will become the transistor gates, including the transfer gate 22 ). In an alternative embodiment, a silicide layer 104 (shown in FIG. 2 , but not in FIG. 11 ) can be formed over the polysilicon layer 102 . However, omission of the silicide layer 104 is preferred. Additionally, a V t implant can be performed during processing as is known in the art.
After forming the gate stacks (e.g., transfer gate 22 ) a dopant implant 108 is performed in the substrate 10 to form a p-type region 16 . A photoresist mask 160 prevents the implant 108 from doping the area of the pixel where the photodiode 14 will later be formed (see FIG. 2 ). As an alternative, the p-type region 16 may be formed by a blanket implant. Note, however, the dopant conductivity types utilized throughout processing can easily be reversed to form a PMOS type pixel structure, as opposed to an NMOS pixel.
After forming the p-type region 16 , another implant 118 is used to form a floating diffusion region 24 adjacent the gate stack 22 , as is known in the art (source/drain regions 23 for other transistors can be formed simultaneously at this time). The floating diffusion region 24 acts as a source/drain region of the transfer transistor. The floating diffusion region 24 implant 118 can be performed in the implant dose range of about 1×10 12 to about 2×10 16 ions/cm 2 . In a preferred embodiment the implant dose range for this implant 118 is about 4×10 12 to about 2×10 15 ions/cm 2 and the floating diffusion region 24 is completed by diffusion.
The photodiode 14 (see FIG. 2 ) is a p-n-p structure including the underlying p-type substrate 10 , an n-type region 18 within the p-type well 16 , and a p-type layer 20 above the n-type region 18 . The layers of the photodiode 14 (i.e., layers 10 , 18 , and 20 ) can be formed as shown in FIGS. 12 and 13 . FIG. 12 shows the substrate 10 masked with a patterned photoresist 110 and another ion implantation 112 of a second conductivity type, here n-type, is performed. This forms an n-type region 18 in the active area of pixel 12 and below the transfer gate 22 . An angled implant 112 can be utilized to form region 18 to achieve certain spatial characteristics of the photodiode 14 .
As shown in FIG. 13 , after removing the photoresist 110 , an insulating layer 120 (TEOS) is formed over the transistor gate 22 (this same layer 120 can also form sidewall spacers for other transistor gates). The conformal multilayer light shield 44 of FIG. 3 can now be formed on the TEOS layer 120 by depositing alternating layers of tungsten and silicon nitride using processes know in the art. The opening 46 can be etched in the light shield layer 44 , with TEOS layer 120 acting as an etch stop. Otherwise, or subsequent thereto, another mask of photoresist 111 is formed partially over the transistor gate 22 and a dopant implant 114 is performed to form a top p-type layer 20 of the photodiode 14 . Optionally, an angled implant for implant 114 may be used as well.
As shown in FIG. 14 , a dielectric layer 52 is deposited over the pixel 12 circuitry, including the transfer gate 22 . (Dielectric layer 52 would be deposited over the alternative conformal light shield multilayer 44 shown in FIG. 13 .) This dielectric layer 52 should be optically transparent so as not to impede light from reaching the photodiode 14 . The dielectric layer 52 can comprise, e.g., silicon oxides or nitrides, glasses, or polymeric materials, and can be deposited by evaporative techniques, CVD, plasma enhanced chemical vapor deposition (PECVD), sputtering, or other techniques known in the art. The dielectric layer 52 may be planarized by various techniques, such as CMP or RIE etching. Alternatively, if a conformal dielectric layer is desired (see FIG. 3 ), the planarization step can be excluded.
The multilayer light shield 44 is formed over the dielectric layer 52 by depositing alternating layers of opaque or nearly opaque material, such as tungsten, and a transparent material, such as silicon nitride, as thin films. Such materials can be deposited on the dielectric layer 52 by conventional methods, such as by evaporation techniques, physical deposition, sputtering, CVD, etc. The light shield 44 can be a conformal layer (see FIG. 3 ) or a planar layer. The light shield 44 layers can be electrically conductive or electrically insulative. If formed of conductive material layers, the light shield 44 layer can be connected to a ground potential, thereby offering an electrical shield to protect the underlying circuitry from the overlying conductive interconnect, e.g., metallization, layers, which will be formed in subsequent steps. The light shield 44 is positioned relatively close to the underlying photodiode, as compared to those of the prior art formed in the M1 and/or M2 layers. Thus, the detrimental effects of crosstalk, light piping, and shadowing are mitigated.
Next, as shown in FIG. 15 , a patterned photoresist mask 122 is formed over the light shield 44 layer. Subsequently, the multilayer light shield 44 is etched to form an aperture 46 over the photodiode 14 . The dielectric layer 52 can serve as an etch stop. Then, as shown in FIG. 16 , a second dielectric layer 54 is deposited over the light shield 44 and within the aperture 46 over the first dielectric layer 52 . This dielectric layer 54 can be the same or similar in composition and light transmission and dielectric properties as the first dielectric layer 52 and can be deposited in a similar fashion. This second dielectric layer 54 can be planarized by CMP or RIE etching techniques, or alternatively, can be a conformal layer. A patterned photoresist 124 is formed over the second dielectric layer and the wafer is subsequently etched to form openings 48 through the two dielectric layers 52 , 54 and the light shield 44 to expose the active areas in the substrate, including the floating diffusion region 24 .
Conductors are formed within the openings 48 as shown in FIG. 17 . Optionally, a thin insulating layer (not shown) can be deposited within the openings 48 to electrically isolate the light shield 44 , if conductive, from the conductors. One such conductor 26 is formed to connect the floating diffusion region 24 . Over the second dielectric layer 54 and in electrical communication with conductor 26 a conductive interconnect layer 50 , preferably of metal, is deposited to form an M1 layer. Preferably, the conductive interconnect layer 50 should not extend over the aperture 46 and photodiode 14 if composed of an opaque or translucent material. However, transparent or semi-transparent materials such as, e.g., polysilicon, can be used for the conductive interconnect layer 50 , and if so they can overly the photodiode 14 , if desired.
The floating diffusion region 24 is electrically connected with the source follower gate 32 through standard metallization steps, e.g., forming a conductor 26 to the floating diffusion region 24 and a conductor 34 (see FIG. 1 ) to the source follower gate, and forming a conductive interconnect 50 therebetween. Conductor 26 is in electrical communication with the M1 conductive interconnect layer 50 and there through with the source follower gate 32 and the rest of the integrated circuit, of which the pixel 12 is a part. Additional processing can follow, such as formation of an overlying dielectric layer 56 and a second conductive interconnect layer 60 (M2), as known in the art.
As indicated above, the light shield 44 of the invention is suitable for use with the circuitry of any CMOS pixel, no matter how many transistors are used in the pixel circuit. FIG. 18 shows a cross-section of a 3T pixel 12 , which is similar in most ways to the 4T circuit discussed above, but differs in that the transfer gate 22 is removed. The photodiode 14 is electrically linked directly with the source follower gate 32 through the floating diffusion region 24 and conductor 26 , the M1 conductive interconnect layer 50 , and conductor 34 . No transfer transistor is needed to gate charges generated at the photodiode 14 since the floating diffusion region 24 is in direct electrical contact with the photodiode 14 . However, the reset gate 28 is still provided and is electrically connected to a voltage source (V dd ) via contact 30 and part of the conductive path 50 .
FIG. 19 illustrates an exemplary imaging device 700 that may utilize pixels 12 including light shielding constructed in accordance with the invention. The imaging device 700 has an imager pixel array 705 comprising pixels with light shields constructed as described above with reference to FIGS. 1-18 . Row lines are selectively activated by a row driver 710 in response to row address decoder 720 . A column driver 760 and column address decoder 770 are also included in the imaging device 700 . The imaging device 700 is operated by the timing and control circuit 750 , which controls the address decoders 720 , 770 . The control circuit 750 also controls the row and column driver circuitry 710 , 760 .
A sample and hold circuit 761 associated with the column driver 760 reads a pixel reset signal Vrst and a pixel image signal Vsig for selected pixels. A differential signal (Vrst−Vsig) is produced by differential amplifier 762 for each pixel and is digitized by analog-to-digital converter 775 (ADC). The analog-to-digital converter 775 supplies the digitized pixel signals to an image processor 780 which forms and outputs a digital image.
FIG. 21 shows system 800 , a typical processor system modified to include the imaging device 700 ( FIG. 19 ) of the invention. The processor-based system 800 is exemplary of a system having digital circuits that could include image sensor devices. Without being limiting, such a system could include a computer system, still or video camera system, scanner, machine vision, vehicle navigation, video phone, surveillance system, auto focus system, star tracker system, motion detection system, image stabilization system, and data compression system.
System 800 , for example a camera system, generally comprises a central processing unit (CPU) 802 , such as a microprocessor, that communicates with an input/output (I/O) device 806 over a bus 820 . Imaging device 700 also communicates with the CPU 802 over the bus 820 . The processor-based system 800 also includes random access memory (RAM) 804 , and can include removable memory 814 , such as flash memory, which also communicate with the CPU 802 over the bus 820 . The imaging device 700 may be combined with a processor, such as a CPU, digital signal processor, or microprocessor, with or without memory storage on a single integrated circuit or on a different chip than the processor.
The processes and devices described above illustrate preferred methods and typical devices of many that could be used and produced. The above description and drawings illustrate embodiments which achieve the objects, features, and advantages of the present invention. However, it is not intended that the present invention be strictly limited to the above-described and illustrated embodiments. Any modification, though presently unforeseeable, of the present invention that comes within the spirit and scope of the following claims should be considered part of the present invention. Although certain advantages and embodiments have been described above, those skilled in the art will recognize that substitutions, additions, deletions, modifications and/or other changes may be made without departing from the spirit or scope of the invention. Accordingly, the invention is not limited by the foregoing description but is only limited by the scope of the appended claims. | An improved imaging device having a pixel arrangement featuring a multilayer light shield. The multilayer light shield includes stacked layers of light-shielding and light-transparent material. The light-transparent material, such as a dielectric, is selected to have a stress, such as a tensile stress, that offsets the stress, such as a compressive stress, of the light shielding material. Without the stress offset, the high compressive stress of the refractory metal could damage the integrity of the nearby silicon. The refractory metal is capable of withstanding the high temperatures associated with front end CMOS processing. The laminate structure allows the light shield to be placed close to the pixel surface. The light-transparent material has a thickness equal to about one-quarter wavelength of the light to be blocked, to act as an anti-reflective coating. An aperture in the light shield exposes the active region of the pixel's photoconversion device. | 7 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for automatically supplying and removing pallets of a pallet magazine, which can each carry a workpiece, into and out of the working space of a machine tool and, more particularly, to such a method and apparatus in which the pallets rest loosely and at any desired distance from each other on rotating chains which effect transport of the pallets, the pallets being moved from a loading station, where they are each loaded with a workpiece to be machined, through a separating mechanism to the working space, where each workpiece to be machined is received by a clamping mechanism, is machined with a tool and is then released, and then being moved to an unloading station, where the machined workpieces are removed, the pallets thereafter returning along the underside of the magazine to the loading station.
BACKGROUND OF THE INVENTION
Such pallet magazines for supplying machine tools with workpieces which must be machined and for removing the machined workpieces therefrom are known. For some cases of use, however, for example gear shaving machines, they are not entirely suitable. More specifically, the workpieces move at the rotational speed of the chain, which typically is approximately 80 to 100 mm/sec, from the separating mechanism to the working space of the machine and then removed from the working space. As a result, the workpiece exchange times are too long in relationship to the actual machining time.
Therefore, a basic purpose of the invention is to provide a method and an apparatus suitable for carrying out such method, with which a quick workpiece exchange independent of the rotational speed of the chain can be carried out.
SUMMARY OF THE INVENTION
This purpose is attained according to the invention by providing a method in which each pallet carrying a workpiece to be machined is, after passing the separating mechanism, moved by the chains to a waiting station where it is lifted from the chains, is picked up by a slide mechanism, is moved on a guide to a working station and is there set down on a support. The slide mechanism, at the same time, moves a pallet which carries a machined workpiece and is already at the working station from the support back onto the chains, which then effect further transport of that pallet to the unloading station, the slide mechanism thereafter returning to its initial position. Thus, the respective front-most pallet with a workpiece which must be machined is lifted from the rotating chains by means of a hydraulically or pneumatically operated slide mechanism and is moved to the working station of the machine tool. At the same time, a pallet which is already at the working station is moved with its workpiece which has already been machined back onto the chains. A slide mechanism adapted for carrying out this method includes two parallel guides which extend next to the pallet magazine in the region of the waiting station and the working station, are spaced from one another by a distance corresponding to the spacing between rollers provided laterally on the pallets, and are supported on a frame which is pivotal about a horizontal axis extending transversely of the magazine and disposed between the working station and unloading station, such pivotal movement occurring between a position in which the frame is inclined toward the waiting station and a horizontal position. A slide member is slidably supported on the frame and can be moved in the conveying direction in the horizontal position of the guides and can be moved opposite the conveying direction in the inclined position of the guides. A mechanism is provided for driving the slide member, and the guides thereon have cams which are operatively, simultaneously coupled to the pallet which is to be transported from the waiting station to the working station and also the pallet which is to be transported away from the working station. The swivelling movement of the frame is preferably effected by a hydraulic or pneumatic cylinder-piston unit which is arranged within the pallet magazine on the side of the frame opposite its swivel axis and extends approximately parallel to the conveying direction, the piston rod of such unit effecting movement of the frame through a toggle lever which has a pivot axis extending parallel to the frame swivel axis. The movement of the slide member is preferably effected by a hydraulic or pneumatic cylinder-piston unit which is arranged within the pallet magazine on the side of the frame which faces the swivel axis of the frame and is supported for pivotal movement with the frame, the piston rod of such unit being connected to the slide member. Such a slide mechanism requires almost no additional space outside of the actual pallet magazine, since the important parts are disposed within the magazine.
Also advantageous is a development in which the guides are directly or indirectly urged to their horizontal position by springs, movement thereof being limited by a stop. With this, the cylinder-piston unit which causes the swivelling movement need not constantly be supplied with pressurized fluid.
When the pallet magazine is supposed to supply preworked gears to a gearlike tool which meshes with the gears, a mechanism is advisable which can influence the movement of the slide member and, when the tool and workpiece engage tooth-tip to tooth-tip and swing the frame downwardly against the force of the springs, causes first a reverse movement of the pallet which carries the workpiece to be machined, during which movement the frame is pulled back to its horizontal position by the springs, and then causes resumption of movement of the pallet in the direction of the tool. With this, a tooth-tip to tooth-tip engagement which interferes with the sequence of operation can be remedied and a satisfactory tooth mesh can take place.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter in connection with an exemplary embodiment which is illustrated in FIGS. 1 to 8 and an operating sequence which is illustrated in FIGS. 9 to 12.
In the drawings:
FIG. 1 is a longitudinal sectional side view of a mechanism embodying the present invention;
FIG. 2 is a sectional top view of the apparatus of FIG. 1;
FIG. 3 is a fragmentary sectional view taken along the line III--III of FIG. 1;
FIG. 4 is a fragmentary sectional view taken along the line IV--IV of FIG. 2;
FIG. 5 is a sectional view taken along the line V--V of FIG. 2;
FIG. 6 is a side view taken in the direction of arrow VI in FIG. 5;
FIG. 7 is a side view taken in the direction of arrow VII in FIG. 5 and illustrating an operational position in which the guides and cams are lowered;
FIG. 8 is a fragmentary sectional view taken along the line VIII--VIII of FIG. 2; and
FIGS. 9 to 12 respectively and diagrammatically illustrate sequential steps of operation of the apparatus of FIG. 1 during a workpiece exchange.
DETAILED DESCRIPTION
Referring to FIGS. 5 and 8, a pallet magazine 101 (FIG. 1) of a conveying mechanism includes upper chain guides 3 and 4 and lower chain guides 5 and 6 supported below the upper guides 3 and 4 by plates 7, which are arranged on two longitudinal supports 1 and 2 (FIGS. 5 and 8). Endless chains 8 and 9 rest on the chain guides 3, 4, 5 and 6, and are each deflected 180° at each of two spaced sprocket wheels (not illustrated) so that upper chain strands 8' and 9' and lower chain strands 8" and 9" extend between such sprocket wheels. The chains 8 and 9 are driven by a drive mechanism which is also not illustrated, the upper chain strands 8' and 9' moving in a conveying direction 10. A plurality of pallets 11 rest freely on the upper chain strands 8' and 9' and are carried along by the continuously rotating chains due only to friction with the chains generated by their own weight. The pallets 11 each include a base plate 12 (FIG. 5), a cradle 15 for receiving a respective workpiece 20, and laterally spaced, downwardly pointing, inwardly bent angle plates 13 and 14. Furthermore, lateral rollers 16 are rotatably supported on the pallets 11 and serve as guide rollers which run on appropriately constructed surfaces described hereinafter. (FIGS. 1 and 2, for clarity do not show the pallets 11, and FIG. 2 also does not show the lower chain strands and guides).
The pallets 11 are loaded by a conventional loading mechanism 106 (FIG. 9) at a loading station with respective workpieces 20 which must be machined and carry such workpieces to a tool 25 of a machine tool 107 (FIG. 9). A separating mechanism 21 (FIG. 9) which is operated by a not illustrated control unit of the machine tool ensures that, at any given time, only one pallet reaches a waiting or pick up position 22, from which it is moved to a working station 24 in the working space of the machine tool by a slide or feed mechanism 23 which will yet be described in greater detail. The workpiece 20 is clamped at the working position 24 by a conventional mechanism 108 (FIG. 9) of the machine tool, is machined, and is then released. The associated pallet 11 remains stationary during this period of time. In the meantime, the next pallet 11 moves to the waiting position 22. It is then moved with the slide mechanism 23 to the working station 24 of the machine, and at the same time the pallet 11 with the machined workpiece 20, which pallet is already at the working station 24, is moved from the working station 24 to an unloading station where the workpiece 20 is removed by a conventional unloading mechanism 109. After passing the unloading station, the pallets 11 come to one set of the sprocket wheels supporting the chains 8 and 9. They are then rotated 180° and hang from the moving lower chain strands 8" and 9" by means of angle plates 13 and 14 until they come to the other set of sprocket wheels, where they are again rotated 180° and then move again to the loading station.
The slide mechanism 23 is illustrated in FIGS. 1 to 7. A frame 33 (FIG. 2) is supported for pivotal movement about a horizontal axis 34 located between the working station 24 and the unloading station on a pin 35, either within recesses 31 and 32 (FIG. 1) provided in the longitudinal supports 1 and 2 or next to the longitudinal supports 1 and 2 in the region of the waiting station 22 and the working station 24. The pin 35 is received in a clevis 36 which is secured on a connecting piece 37 extending between and secured to the two longitudinal supports 1 and 2. The frame 33 includes two parallel guide rods 38 and 39 of cylindrical cross section which are connected by three spaced webs 40, 41 and 42. The web 40 is pivotally supported on pin 35 by a bearing sleeve 43. The guide rods 38 and 39 are attached by screws to the outer webs 40 and 42, and the center web 41 is positionally secured with snap rings 44 or the like on the guide rods 38 and 39. Two guides 45 and 46 are mounted on opposite lateral sides of the middle web 41 and extend longitudinally toward the web 42 or toward the loading station. The spacing 17 between the guides 45 and 46 is chosen so that the pallets 11 can be supported by means of their rollers 16 on the guides 45 and 46. A fluid actuated cylinder-piston unit 47 disposed between the longitudinal supports 1 and 2 is also secured to the center web 41, and the piston rod 48 thereof is connected by a threaded coupling 49 to a slide member 50 which is slidably supported on the guide rods 38 and 39.
The slide member 50 includes a crossbeam 51 and two spaced cams 52 and 53, each of which has two spaced noses 54 and 55. The cam 52 extends beyond the middle web 41. It is slidably supported between the webs 40 and 41 on the guide rod 38 by a bearing sleeve 56. Similar bearing sleeves 56' are provided for slidably supporting the crossbeam 51. A cam support bar 57 is secured to the cam 52, on which bar cams 58, 58' and 58" are adjustably supported and cooperate with a switch 60 which is supported on web 40 by a support 59.
The parts mounted on the frame 33 are pivotal therewith about the axis 34. To carry out this pivotal movement, a fluid actuated cylinder-piston unit 63 is arranged on the side of the frame 33 opposite the axis 34 and is located between the longitudinal supports 1 and 2. The cylinder-piston unit 63 is supported for pivotal movement about a horizontal axis 67 by a pin 66 supported in a clevis 68 secured on a connecting piece 69 supported between the longitudinal supports 1 and 2. The end of its piston rod 70 supports a plate 71 having a slot 72 therein. A pin 73 extends through the slot 72 and is received on both sides of the plate 71 in openings in a slotted arm 74 of a toggle lever 75. The toggle lever 75 is supported by a bearing sleeve 76 (FIG. 3) for pivotal movement about an axis 77 on a pin 78 which is secured on the longitudinal support 2. The other arm 79 of the lever 75 has a slot 80 therein through which the web 42, which in this region has a cylindrical cross section, extends.
Supports 81 and 82 (FIGS. 6 and 7) are mounted on the longitudinal supports 1 and 2. Respective helical expansion springs 83 and 84 are supported on these supports and also on the web 42 and pull the frame 33 upwardly. The web 42 comes to rest, in the horizontal position of the frame 33, on a stop screw 85 (FIG. 4) which is screwed into a plate 86 secured on the longitudinal support 2. Unintended rotation of the screw 85 is prevented by a lock nut 87.
Supports 90 and 91 (FIGS. 1, 5 and 7) are arranged in the region of the working station on the inner sides of the upper chain guides 3 and 4, the upper sides of the supports 90 and 91 projecting above the chains 8 and 9 and having noses 92 which form a stop. Holders 93 and 94 (FIGS. 1 and 6 to 8) are provided on the longitudinal supports 1 and 2, which holders have bars 95 and 96 screwed thereon which extend above the slides 45 and 46 and the cams 52 and 53 in the region of the waiting and working stations. These bars 95 and 96 prevent the pallets from moving off the slides 45 and 46 when being moved upwardly by the web 42. This upward move will be discussed in detail below.
For controlling the pallet transport and the orderly sequence of pallet movement, a two-arm lever 98 (FIG. 6) and a switch 99 are also mounted on the support 1. One lever arm 98' projects next to and slightly beyond the guide 45 in the horizontal rest position of frame 33, and the other lever arm 98" engages a stop 100. When a pallet reaches the waiting station 22, one of the rollers 16 thereon presses down the lever arm 98' and the lever arm 98" is thus moved and operates the switch 99.
The slide mechanism operates as follows. According to FIG. 9, two pallets 11.1 and 11.2 which are loaded with workpieces 20 are at the separating mechanism 21. It is possible for a queue of further pallets supplied from the loading station to be on the left of the pallet 11.1. The pallet 11.2 is held by a catch 26 of the separating mechanism 21, whereby movement of the pallet 11.1 and possibly further pallets is stopped, the chains 8 and 9 sliding under the pallets. A pallet 11.3 is at the waiting station 22, and is also loaded with a workpiece 20 which must be machined. A further pallet 11.4, which carries a workpiece 19 which has already been machined, is at the working station 24 in the working space of the machine tool. The tool is only indicated and is identified with reference numeral 25. The slide mechanism 23 is, in FIG. 9, in a horizontal position which corresponds to FIGS. 5 and 6. The two pallets 11.3 and 11.4 rest with their rollers 16 on the guides 45 and 46, the noses 54 of the cams 52 and 53 being disposed between the rollers 16 of the pallet 11.3 which is at the waiting station 22 and the noses 55 thereof being disposed behind the rear rollers 16 of the pallet 11.4 which is at the working station 24.
Pressurized fluid is now supplied by a not illustrated control unit to the cylinder-piston unit 47 (FIG. 2) at the fluid connection indicated at 61, causing the piston rod 48 and the slide member 50, as seen in FIGS. 1 and 9, to move to the right and thus move the cams 52 and 53 to the right too. The pallet 11.4 is thereby moved down the ramps 97 of the guides 45 and 46 and is again placed onto the chains 8 and 9, and the pallet 11.3 is at the same time moved to the working station 24. This movement of the pallets is illustrated in FIG. 10 and occurs considerably faster than the transport of the pallets on the chains. The end of the movement of the slide member 50 is controlled by the cams 58 (FIG. 2), which operate the switch 60.
The cylinder-piston unit 63 (FIG. 2) is then supplied with fluid at the fluid connection indicated at 64, causing the piston rod 70 to move out and rotate the toggle lever 75, to the right, namely, clockwise. Thus, the web 42 is moved downwardly against the force of the springs 83 and 84 and, with this, the entire frame 33, including the parts connected to it, becomes inclined (FIG. 11). The pallet 11.3 will then rest on the supports 90 and 91 (FIG. 7). The workpiece 20 on the pallet 11.3 is, in the meantime, clamped by the clamping mechanism of the machine tool and is machined. The catch 26 of the separating mechanism 21 in the meantime releases the pallet 11.2, and it is moved to the waiting station 22 by the chains 8 and 9, where it comes to rest against the noses 92 on the supports 90 and 91. The pallet 11.1 is held by a catch 27.
As the next step (FIG. 12), the cams 52 and 53 are moved to a pick-up position below the waiting station 22. For this purpose, the cylinder-piston unit 46 is supplied with fluid at the fluid connection designated at 62, causing the piston rod 48 and the slide member 50 to move, as seen in FIGS. 1 and 12, to the left until the noses 54 are below the space between the rollers 16 of the pallet 11.2. Termination of this movement is controlled by the cams 58' and the switch 60. The catch 27 then releases the pallet 11.1, which is moved forward by the chains to the catch 26. The pallets, if any, provided behind it also move forward. The machining of the workpiece at the working station 24 is completed in the meantime.
As the last step, the frame 33, including the parts connected to it, is pivoted back to the horizontal position. For this, the cylinder-piston unit 63 (FIG. 2) is supplied with fluid at the fluid connection designated at 65. The piston rod 70 moves in and rotates the toggle lever 75, as seen in FIG. 1, to the left, namely, counterclockwise. Thus, the web 42, assisted by the springs 83 and 84, is moved upwardly into engagement with the stop 85. The pallet 11.2 is thereby lifted off the chains 8 and 9 and the pallet 11.3 is lifted off the supports 90 and 91 by engagement of their rollers 16 with the guides 45 and 46. The noses 54 of the cams 52 and 53 are between the rollers of the pallet 11.2 which is at the waiting station 22, and the noses 55 are behind the rear rollers 16 of the pallet 11.3 which is at the working station 24. The clamping mechanism 108 of the machine tool 107 then releases the workpiece and it again rests on the pallet 11.3. With this, the situation illustrated in FIG. 9 is again achieved, but with the positions of each of the pallets being offset one position in conveying direction.
When the workpieces 20 which are to be worked are preworked gears and the tool 25 is a gearlike tool, for example a shaving gear or the like for precision machining of the tooth flanks of the preworked gears, then it may occur that a workpiece 20 does not engage the tool 25 with their teeth meshed, but prior to reaching the working station 24 comes into a tip-to-tip tooth engagement in which the tool obstructs further movement of the workpiece or the pallet which carries it. In such a case, the frame 33 is swung away downwardly against the force of the springs 83 and 84, due to the vertical force which results from the tip-to-tip engagement and a continued supply of fluid to the cylinder-piston unit 47. The slot 72 in the plate 71 on the end of piston rod 70 of cylinder-piston unit 65 permits the necessary pivotal movement of lever 75 as the frame 33 swings downwardly. A switch 88 (FIG. 7) is thereby operated by an extension 59' (FIGS. 2 and 7) on the support 59, which switch first stops the further movement of the workpiece and then effects movement of the chains in the reverse direction until the workpiece 20 and tool 25 are separated from one another, and then switches the workpiece back into the original direction of movement 10. The contact between the tooth tips of the workpiece and the tool typically results in a small rotation of the two parts relative to one another so that, during a second approach to the working station 24, an orderly tooth mesh is, as a rule, achieved. If necessary, the reversal movement is repeated. The switch 88 is also operated when the frame 33, during the course of the workpiece exchange, swings downwardly or upwardly, but through a suitable connection with the switch 60, which is operated by the cams 58 and 58' to indicate the end position, the switch 88 is rendered temporarily ineffective. Stated differently, actuation of the switch 88 is effective only when the frame 33 is swung downwardly and the pallet which is to be moved to the working station 24 has not yet reached the working station.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A pallet magazine for automatically supplying and removing pallets, each carrying a workpiece, to and from the working space of a machine tool. The pallets, which rest freely and with any desired spacing from one another on moving chains which effect the transport thereof, are lifted off the chains at a waiting station and are then moved to the working station where the workpiece is machined. At the same time a pallet at the working station with a workpiece which has already been machined is placed back on the moving chains. For lifting, sliding and moving out or lowering the pallets, there is provided a hydraulically operated slide mechanism, which effects the sliding and moving of the pallets to and away from the working station more quickly than the pallets are transported on the chains. | 1 |
BRIEF DESCRIPTION OF THE INVENTION
The invention relates to a control mechanism, particularly for a sewing machine to exactly operate the stitch forming instrumentalities of the sewing machine by precluding minor mechanical operation errors thereof, thereby to produce correct stitches.
For attaining this object, one spring of a predetermined moment is employed to bias a drive transmission element toward a drive source, and another spring is employed to bias the drive source toward the drive transmission element. The latter spring is of a moment equal to that of the former spring to counter-balance the same with respect to the drive source.
In the conventional sewing machines, there are errors more or less in the movement transmission, due to clearances at the mechanical connections, from a drive source, for example, a control motor to the needle bar mechanism or to the fabric feeding mechanism. These mechanical clearances are generally compensated by a spring applied to the transmission elements. Such a spring, however, results in encouraging the drive of the drive source to the needle bar mechanism (or the feeding mechanism) in one direction, and in lowering the drive of the drive source to the driven mechanism in the opposite direction, and vice versa. Such an unbalance of drive adversely influences the control of the driven mechanism, and necessitates the employment of a big sized drive source of a strong power.
The present invention has been provide to eliminate the defects and disadvantages of the conventional sewing machines.
It is a primary object of the invention to effectively provide first and second springs, one applied to a transmission element connected to a drive mechanism, and the other applied to a drive source, said first and second springs counterbalancing each other with respect to the drive source.
It is another object of the invention to provide a sewing machine control mechanism of simple structure and of effective operation.
The other features and advantages of the invention will be apparent from the following description of the preferred embodiments in reference to the attached drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a sewing machine control mechanism of the invention,
FIG. 2 is a detailed view of a cam of the control mechanism, and
FIG. 3 is a perspect view of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In reference to FIG. 1 the reference numeral 1 is a support body secured to the housing of a sewing machine (not shown). A stopper plate 2 is secured to a shaft 3 of a pulse motor which is to control the lateral needle swinging movement. As shown, the stopper plate 2 has two spaced projections 2a, 2b for limiting the rotation range of the pulse motor shaft 3 in cooperation with a stopper 4 secured to the support body 1. The refence numeral 5 is a photo-interrupting plate secured to the stopper plate 2 for rotation therewith in order to interrupt a light from a light emitting part 6 provided on the support body 1 as shown, thereby to produce the rotational position indicating signals of the pulse motor. A double cam 7 is secured to the stopper plate 2 for rotation therewith. As shown in FIG. 2, the double cam 7 is, on the front side thereof, formed with a control cam face 8 of a control range A for controlling the lateral needle swinging movement. The double cam 7 is also, on the rear side thereof beyond a peripheral flange 9, formed with a balancing range B. The control cam face 8 is engaged by a follower pin 12 which is secured to one end of a transmisstion lever 11 as shown in FIG. 1. The transmission lever 11 is, at the intermediate part thereof, turnably mounted on the support body 1 by means of a stepped screw 13. The other end of the transmission lever 11 is connected to one end of a transmission rod 14 by means of a pin 16. The transmission rod 14 has the other end operatively connected to the needle bar (not shown). As shown, a first tension spring 15 is, at one end thereof, connected to the transmission rod 14, and is, at the other end thereof, anchored to the support body 1, so as to normally bias the transmission rod in the rightward direction, thereby to press the follower pin 12 against the cam face 8. At the same time, the tension spring 15 presses the level 11 against a part of the pivot 13, and also the connecting pin 16 against a part at the end of the lever 11. The pressure of the pin 12 against the cam face 8 pushes the double cam 7 in the counter-clockwise direction due to the component force of the cam face 8. The cam face 10 is engaged by a follower pin 18 which is secured to the free end of a balancing lever 17 which is turnably mounted on the support body 1 by means of a stepped screw 19. A tension spring 20, is at one end thereof, connected to the balancing lever 17, and is, at the other end thereof, connected to the support body 1, thereby to press the follower pin 18 against the balancing cam face 10. The pressure of the follower pin 18 against the cam face 10 pushes the double cam 7 in the clockwise direction due to the component force of the cam face 10. Provided that there is not frictional force at the points P 1 , P 2 of the cam faces 8, 10 engaged by the follower pins 12, 18 respectively, the balancing condition, that the compound moment due to the engaging pressures at the points P 1 , P 2 becomes zero with respect to the pulse motor shaft 3, is that the moment of the point P 1 and the moment of P 2 each around the motor shaft 3 are of the same amount in the opposite rotational directions. In other words, the moment produced at the point P 1 around the center pivot 13 by the lever 11 due to the tension spring 15 is a moment produced by the tangential component force of the pressure normal to the cam face point P 1 around the central axis 3. Similarly, the moment produced at the point P 2 around the center pivot 19 by the lever 17 due to the tension spring 20 is a moment produced by the tangential component force of the pressure normal to the cam face point P 2 around the central axis 3. Since the two moments are equal and directed in the opposite rotational directions, it is possible to determine the tensional force of the springs 15, 20, the distances between the pivot positions 13, 19 of the levers 11, 17 and the engaging points P 1 , P 2 of the double cam 7, and the configuration of the double cam 7, so that such a condition of the two moments may be applied to all the rotational phases of the double cam 7. Since there is actually a frictional force at the cam points P 1 , P 2 in the tangential directions of the cam faces 8, 10, this is taken into account to seek for the configuration of the cam 7 by a graphical calculation. According to the invention, the cam faces 8, 10 are made symmetrical so as to approximately meet the various requirements.
FIG. 3 shows another embodiment of the invention, in which a pulse motor 21 has a shaft 22 fixedly connected to a link 23 which is connected to one end of a transmission rod 24 by means of a pin 34. The transmission rod 24 has the other end connected to another link 25 by means of a pin 35 as shown. The link 25 is secured to a fabric feed adjusting shaft 26 of a sewing machine. A fabric feed adjuster 27 with a vertical groove 28 as well known is secured to the free end of the feed adjusting shaft 26. As well known, the feed adjuster 27 is angularly adjusted to vary the horizontal movement of a feed dog, thereby to control the feeding amount of a fabric to be sewn. A coil spring 29 is, at one end thereof connected to one of the holes 30 of the link 25, and is, at the other end thereof, anchored to a machine housing (not shown), thereby to bias the feed adjusting shaft 26 in the clockwise direction and therefore to bias the motor shaft 22 in the clockwise direction. A coil spring 31 is, at one end thereof, connected to a hole 32 of a disk secured to the pulse motor shaft 22, and is, at the other end thereof, anchored to the machine housing, thereby to bias the motor shaft 22 in the counterclockwise direction. The coil springs 29, 31 are so set as to give a zero compound rotational force of the motor shaft 22 by way of the transmission rod 24. Namely the moments of the springs 29, 31 are of the same amount in the opposite direction. | The stitch-forming instrumentalities of a sewing machine are subject to small mechanical operational errors due to play in the motion-transmitting connections. The invention overcomes this problem by providing two springs which are respectively connected to a transmission element coupled to a driven mechanism of the machine, and to a drive. The two springs counterbalance one another with respect to the drive. | 3 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to vibration attenuation in vehicle drivelines and, more particularly, to an improved noise attenuating propshaft and a method for its construction.
BACKGROUND OF THE INVENTION
[0002] Propshafts are commonly employed for transmitting power from a rotational power source, such as the output shaft of a vehicle transmission, to a rotatably driven mechanism, such as a differential assembly. As is well known in the art, propshafts tend to transmit vibration while transferring rotary power. When the propshaft is excited at a harmonic frequency, vibration and noise may be amplified, creating disturbances that are undesirable to passengers riding in the vehicle. Thus, it is desirable and advantageous to attenuate vibrations within the propshaft in order to reduce noise within the vehicle passenger compartment.
[0003] Various devices have been employed to attenuate the propagation of noise from propshafts including inserts that are made from cardboard, foam, or resilient materials, such as rubber. The inserts that are typically used for a given propshaft are generally of a construction, size, mass and density to attenuate bending mode vibrations within the propshaft. While such inserts offer various advantages, several drawbacks remain.
[0004] One such drawback is the susceptibility of current propshaft assemblies to experience shell mode vibrations in the environment in which they are installed. Long aluminum propshafts have been found to produce significant noise resulting from the propshaft being excited at a shell mode natural frequency. Previously known inserts operable to attenuate propshaft tube vibrations are typically heavy and inefficient in attenuating both bending and shell mode vibrations. For long aluminum propshafts that are generally obliged to have damping treatments, these known inserts many times create concerns regarding to their mass loading effect on critical speed as well as their effectiveness on tube shell mode vibrations. It is therefore desirable to provide an improved propshaft with a lightweight however highly efficient damping treatment that is operable to attenuate propshaft tube vibrations to reduce noise transmitted to the vehicle occupants.
[0005] Furthermore, because different propshaft structures may exhibit different shell mode natural frequencies, it may be desirable to provide a propshaft assembly having an insert operable to be tuned to attenuate specific shell mode natural frequencies.
SUMMARY OF THE INVENTION
[0006] A propshaft assembly includes a shaft structure having a hollow cavity and an insert member being positioned within the hollow cavity and engaging the shaft structure. The shaft structure vibrates in response to receipt of an input of a predetermined frequency such that a shell mode anti-node is generated. The insert member is located at a position that approximately corresponds to the anti-node and has a compressive strength that is tailored to an anticipated displacement of the anti-node to thereby attenuate vibration of the shaft structure.
[0007] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Additional advantages and features of the present invention will become apparent from the subsequent description and the appended Claims, taken in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a schematic illustration of an exemplary vehicle constructed in accordance with the teachings of the present invention;
[0010] FIG. 2 is a top partially cut-away perspective view of a portion of the vehicle of FIG. 1 illustrating the rear axle and the propshaft in greater detail;
[0011] FIG. 3 is a sectional view of a portion of the rear axle and the propshaft;
[0012] FIG. 4 is a top, partially cut away view of the propshaft;
[0013] FIG. 5 is a partially cut-away perspective view of the propshaft and an insert member of the present invention;
[0014] FIG. 6 is a perspective view of the propshaft of FIG. 5 showing a first shell mode deformed condition;
[0015] FIG. 7 is a sectional view of the propshaft of FIG. 6 taken along line 7 - 7 shown in FIG. 6 ;
[0016] FIG. 8 is a sectional view of the propshaft of FIG. 6 taken along line 8 - 8 of FIG. 6 ;
[0017] FIG. 9 is a perspective view of the propshaft of FIG. 5 showing a second shell mode deformed condition;
[0018] FIG. 10 is a sectional view of the propshaft of FIG. 9 taken along line 10 - 10 shown in FIG. 9 ; and
[0019] FIG. 11 is a sectional view of the propshaft of FIG. 9 taken along line 11 - 11 shown in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] With reference to FIG. 1 of the drawings, a vehicle having a propshaft assembly that is constructed in accordance with the teachings of the present invention is generally indicated by reference numeral 10 . The vehicle 10 includes a driveline 12 , which is drivable via a connection to a power train 14 . The power train 14 includes an engine 16 and a transmission 18 . The driveline 12 includes a propshaft assembly 20 , a rear axle 22 and a plurality of wheels 24 . The engine 16 is mounted in an in-line or longitudinal orientation along the axis of the vehicle 10 and its output is selectively coupled via a conventional clutch to the input of the transmission 18 to transmit rotary power (i.e., drive torque) therebetween. The input of the transmission 18 is commonly aligned with the output of the engine 16 for rotation about a rotary axis. The transmission 18 also includes an output 18 a and a gear reduction unit. The gear reduction unit is operable for coupling the transmission input to the transmission output at a predetermined gear speed ratio. The propshaft assembly 20 is coupled for rotation with the output 18 a of the transmission 18 . Drive torque is transmitted through the propshaft assembly 20 to the rear axle 22 where it is selectively apportioned in a predetermined manner to the left and right rear wheels 24 a and 24 b , respectively.
[0021] With additional reference to FIGS. 2 and 3 , the rear axle 22 is shown to include a differential assembly 30 , a left axle shaft assembly 32 , and a right axle shaft assembly 34 . The differential assembly 30 includes a housing 40 , a differential unit 42 and an input shaft assembly 44 . The housing 40 supports the differential unit 42 for rotation about a first axis 46 and further supports the input shaft assembly 44 for rotation about a second axis 48 that is perpendicular to the first axis 46 .
[0022] The housing 40 is initially formed in a suitable casting or stamping process and thereafter machined as required. The housing includes a wall member 50 that defines a central cavity 52 having a left axle aperture 54 , a right axle aperture 56 , and an input shaft aperture 58 . The differential unit 42 is disposed within the central cavity 52 of the housing 40 and includes a case 70 , a ring gear 72 that is fixed for rotation with the case 70 , and a gearset 74 that is disposed within the case 70 . The gearset 74 includes first and second side gears 82 and 86 and a plurality of differential pinions 88 , which are rotatably supported on pinion shafts 90 that are mounted to the case 70 . The case 70 includes a pair of trunnions 92 and 96 and a gear cavity 98 . A pair of bearing assemblies 102 and 106 are shown to support the trunnions 92 and 96 , respectively, for rotation about the first axis 46 . The left and right axle assemblies 32 and 34 extend through the left and right axle apertures 54 and 56 , respectively, where they are coupled for rotation about the first axis 46 with the first and second side gears 82 and 86 , respectively. The case 70 is operable for supporting the plurality of differential pinions 88 for rotation within the gear cavity 98 about one or more axes that are perpendicular to the first axis 46 . The first and second side gears 82 and 86 each include a plurality of teeth 108 which meshingly engage teeth 110 that are formed on the differential pinions 88 .
[0023] The input shaft assembly 44 extends through the input shaft aperture 58 where it is supported in the housing 40 for rotation about the second axis 48 . The input shaft assembly 44 includes an input shaft 120 , a pinion gear 122 having a plurality of pinion teeth 124 that meshingly engage the teeth 126 that are formed on the ring gear 72 , and a pair of bearing assemblies 128 and 130 which cooperate with the housing 40 to rotatably support the input shaft 120 . The input shaft assembly 44 is coupled for rotation with the propshaft assembly 20 and is operable for transmitting drive torque to the differential unit 42 .
[0024] The left and right axle shaft assemblies 32 and 34 include an axle tube 150 that is fixed to the associated axle aperture 54 and 56 , respectively, and an axle half-shaft 152 that is supported for rotation in the axle tube 150 about the first axis 46 . Each of the axle half-shafts 152 includes an externally splined portion 154 that meshingly engages a mating internally splined portion (not specifically shown) that is formed into the first and second side gears 82 and 86 , respectively.
[0025] FIG. 4 depicts the propshaft assembly 20 to include a shaft structure 200 , first and second trunnion caps 202 a and 202 b , first and second spiders 206 a and 206 b , a yoke assembly 208 and a yoke flange 210 . The first and second trunnion caps 202 a and 202 b , the first and second spider 206 a and 206 b , the yoke assembly 208 and the yoke flange 210 are conventional in their construction and operation and as such, need not be discussed in detail. Briefly, the first and second trunnion caps 202 a and 202 b are fixedly coupled to the opposite ends of the shaft structure 200 , typically via a weld. Each of the first and second spiders 206 a and 206 b is coupled to an associated one of the first and second trunnion caps 202 a and 202 b and to an associated one of the yoke assembly 208 and the yoke flange 210 . The yoke assembly 208 , first spider 206 a , and first trunnion cap 202 a collectively form a first universal joint 212 , while the yoke flange 210 , second spider 206 b and second trunnion cap 202 b collectively form a second universal joint 214 .
[0026] The shaft structure 200 is illustrated to be generally cylindrical, having a hollow central cavity 220 and a longitudinal axis 222 . The shaft structure 200 is preferably formed from a welded seamless material, such as aluminum (e.g., 6061-T6 conforming to ASTM B-210) or steel.
[0027] FIG. 5 shows an insert member 250 may be inserted into the shaft structure 200 to attenuate shell mode vibration that is produced during transmission of rotary power by the propshaft assembly 20 . In the particular example provided, a single insert member 250 is employed. The insert member 250 is a substantially cylindrical structure having a shape that is generally complimentary to the inside surface of the shaft structure 200 . In the embodiment illustrated, the insert member 250 is configured as an elongated cylinder with a generally circular cross-section. The insert member 250 is further defined by a plurality of closed cells 252 interconnected to one another.
[0028] In the exemplary insert member 250 , closed cells 252 are arranged in a honeycomb pattern where each cell 252 includes a substantially hexagonal cross-section. Each cell may be shaped as a right hexagonal prism having a predetermined length. A cell length “L” ranging from about 1 mm to 2 mm is contemplated to provide desirable stiffness and energy absorption characteristics for at least one shaft structure having a known length, diameter, wall thickness and material. Because the frequencies at which the shell modes are excited vary from component to component, the length and width of the cells may be varied to tune the insert to isolate certain frequencies. In similar fashion, the insert material may be changed to target certain frequencies for attenuation. One embodiment of the invention utilizes an insert member constructed from polypropylene. Other materials such as aluminum may also be used. Insert 250 is constructed from a material having a compressive strength in the range of 140-250 psi. This compressive strength is sufficient to resist the radially inward deflection of portions of the shaft structure. As such, the insert 250 increases structural stiffness of the tube to provide energy absorption during the shell vibration modes.
[0029] The insert 250 includes an outer surface 254 defining a first outer diameter when insert 250 is in a “free” or unloaded condition. The first outer diameter is greater than an inner diameter defined by an inner surface 256 of shaft structure 200 . To assemble propshaft assembly 20 , an adhesive 258 is applied to outer surface 254 . A force is applied to insert 250 to reduce the first outer diameter to a second outer diameter less than the inner diameter of inner surface 256 . Insert 250 is positioned within cavity 220 where the external force is released. Insert 250 is constructed from a substantially elastomeric material such that insert 250 tends to spring back to its original un-deformed stated. Shaft structure 200 resists this tendency and an equilibrium is reached where insert 250 biasedly engages shaft structure 200 . The biased engagement as well as the adhesive bond between the insert 250 and inner surface 256 assures that insert 250 maintains a proper load-transfer-type engagement with shaft structure 300 .
[0030] FIGS. 6-8 depict a first shell mode of vibration of shaft structure 200 . FIGS. 9-11 depict shaft structure 200 in a deformed state while in a second shell mode. In the first shell mode depicted in FIGS. 6-8 , portions 260 of shaft structure 200 move radially inwardly towards longitudinal axis 222 while portions 262 move radially outwardly from longitudinal axis 222 . The maximum amplitude of deflection during a first shell mode occurs at approximately the midpoint along the length of shaft structure 200 . The maximum deflection location is termed an anti-node.
[0031] FIGS. 9-11 depict the second shell mode of vibration for shaft structure 200 . The second shell mode includes a first anti-node 270 and a second anti-node 272 spaced apart from one another along the length of shaft structure 200 . Portions 274 located at first anti-node 270 deflect radially inwardly while portions 278 deflect radially outwardly. The radially inwardly deflecting portions are substantially diametrically opposed from one another as are the radially outwardly deflecting portions. The radially inwardly extending portions 274 are aligned along an axis Y while the radially outwardly extending portions 278 are aligned along an axis X orthogonal to axis Y.
[0032] Radially inwardly extending portions 280 are substantially diametrically opposed from one another and axially located along shaft structure 200 at second anti-node 272 . The radially inwardly extending portions 280 are positioned along axis X. Radially outwardly extending portions 282 are substantially diametrically opposed to one another and aligned along axis Y. The magnitude of deflections both radially inwardly and radially outwardly at second anti-node 272 are substantially similar to the magnitude of deflections located at first anti-node 270 . However, the shell mode shape of second anti-node 272 has been rotated substantially 90 degrees about longitudinal axis 222 in relation to the shape of shaft structure 200 at first anti-node 270 .
[0033] While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the Claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. It is, therefore, intended that the invention not be limited to the particular embodiments illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended Claims. | A propshaft assembly includes a shaft structure having a hollow cavity and an insert member being positioned within the hollow cavity and engaging the shaft structure. The shaft structure vibrates in response to receipt of an input of a predetermined frequency such that a shell mode anti-node is generated. The insert member is located at a position that approximately corresponds to the anti-node and has a compressive strength that is tailored to an anticipated displacement of the anti-node to thereby attenuate vibration of the shaft structure. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 440,334, filed Feb. 7, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method and device for the removal of ridges or fins from workpieces of rubber or similar materials, which become brittle by coldness.
A known device of this kind (German Pat. No. 1,207,616), consists of two vertical disks opposing each other, between which, along a part of the circumference of the disk, an endless caterpillar strap is arranged. The workpiece, from which the ridges shall be removed, and which become brittle by a refrigerating agent, are moved upwards by the caterpillar strap, and drop back on the strap by their own weight. By these movements the edges and borders of the workpieces are freed from ridges. For the improvement of the effect of the removal of ridges, in addition, a jet is directed toward the workpiece by a fan blower (centrifugal wheel).
Therefore, in the case of the known device, it is in principle a matter of a horizontally located drum trough, inside of whose interior space there are workpieces, which are freed from the ridges by their proper motion as a consequence of the rotation of the drum.
The invention starts from the above state of the art and has as its object a method and device for removing the fins or ridges from workpieces, considerably simpler in its construction than the known device, which guarantees an optimum removal with respect to quality and amount of workpieces. It is a further object to provide such a method and device which does not contain any expensive parts, which are exposed to wear and tear, such as e.g. the caterpillar belt of the known device.
SUMMARY OF THE INVENTION
The device for freeing workpieces of rubber or the like, from fins or ridges, by the material becoming brittle when cold, consists of a drum rotatable around its horizontally arranged axis, having a fill opening capable of being closed, in which, according to the invention, free hanging chains are fastened at one end to the inside wall of the drum. The length of each chain is the same or shorter than the inside diameter of the drum.
In an advantageous form of this invention the chains are detachably mounted to the drum by being secured to strips which in turn are removably mounted to the drum wall. The strips serve the additional function of agitating or conveying the workpieces during a portion of the drum revolution and additionally permit the ready selection of chains having the proper link dimensions so as to be able to remove flashing from the exposed interior of the workpieces.
THE DRAWINGS
The single FIGURE schematically illustrates in cross-section a device in accordance with this invention.
DETAILED DESCRIPTION
The inventive device includes a rotatable drum having a filling opening and having fastened to its inner surface chains of a length no longer than the inside drum diameter. The drum can have a cylindrical or polygonal column form.
In the device for the removal of ridges according to the invention, molded parts of elastomers can be treated, which are compressed or extruded in multiple tools, are connected with each other by flash and flow channels and form sheets. Also molded parts can be treated, in whose case the flash is relative strong and occurs inside of the molded articles.
The effect of the removal of the ridges originates at relative motional overlappings between the cooled, embrittled molded parts and the enforced direction of motion of the chains. In this manner the mass of the total charge prevents the molded parts from turning aside and pressing away. As another effect, the chains form with their multibranches or links a granulate, which works off the flashes, located at the inside of the parts.
In an advantageous further development of the invention, the chains are fastened in an easily interchangeable way. The interchangeability of the chains has the advantage that an adaptation to the form of the workpieces to be freed from ridges is possible by using chains with differently shaped chain links in each case. As later described the interchangeable or detachable mounting of the chains is accomplished by securing each chain at one end thereof to a strip which in turn is detachably mounted to the inner wall of the drum. As later described the removable strips serve the dual function of not only permitting chains to be easily replaced but also of assisting in the deflashing operation.
In an advantageous further development of the invention, the chains are fastened to strips, which are arranged parallel to the axis on the inside wall of the drum. The device can then be so arranged, that the chains are tightly or permanently fastened to the strips and are exchanged, by exchanging the strips with the chains fastened to them.
The chains are suitably distributed uniformly over the inside wall of the drum; however, this is not a prerequisite for the effectiveness of the device according to the invention.
The drawing illustrates a drum 1 with drum insulation 2. Through a fill opening 3 the drum can be filled with workpieces to be freed from fins or ridges. On the inside wall of the drum strips 4 are arranged parallel to the axis, on which chains 5 are easily detachably fastened. As shown in the drawing, each chain 5 is fastened at only one end to its strip 4. Thus, the chains hang down in part from above, and in part they always lie on the lower part of the inside wall of the drum or between the molded parts. In other words as shown in the drawing when a particular strip 4 is disposed along the top of the drum wall at a particular time during the drum rotation its chain 5 hangs vertically downward from above. When, however, the drum rotates as indicated by arrow 6, that strip will eventually be disposed in the lower portion of the drum whereupon its chain will no longer hang vertically downwardly but will lie along the lower part of the inside wall of the drum or between the molded parts should there be parts in that location. The direction of drum rotation is indicated by arrow 6 and the path of the motions of the workpieces is indicated by arrows 7. The workpieces themselves are not shown for the sake of clarity. The strips 4 have a favorable effect on the motion of the workpieces, since they take along the workpieces in the direction of the motion. In this respect since the strips 4 extend along the inner wall of drum 1 and project inwardly thereof the strips have a tendency to carry the workpieces upwardly during the rotation around the lower portion of the drum until the workpieces are elevated to such an extent that they then fall downwardly. Accordingly, the strips act to further agitate the workpieces and facilitate the removal of the flashing therefrom.
Upon discharging, the fill opening is swung toward its lowest level. The workpieces then drop out, while the chains remain in the drum. Therefore, a separation, e.g. of a jet device or of a granulate, is not required.
The cooling agent is introduced into the drum through a hollow shaft in the form of liquid nitrogen or liquid carbon dioxide its temperature being regulated during the operation via a temperature regulator. However, the workpieces can become brittle also already prior to their introduction into the drum.
In summary the invention is practiced by first subjecting the workpieces to a conventional coolant such as nitrogen which causes the flashing to be embrittled. This embrittling may be accomplished prior to insertion into the drum or may be accomplished after the workpieces are inserted therein by a suitable nozzle. In the meantime detachable mounting strips are selected for securement in any suitable manner to the drum interior. The mounting strips have attached thereto chains with the links being of a sufficiently small size so as to be able to react against the flashing in exposed interior portions of the workpieces. Rotation of the drum is then begun as indicated by the arrow 6. Since the chains have a length no greater than the drum diameter some of the chains would hang freely down from the drum wall while others would have their lower portions disposed against the drum wall. Continued rotation of the drum causes the chains to react against the workpieces including the flashing in the interior thereof to remove the flashing. During rotation this deflashing step is enhanced by strips 4 serving to carry or agitate the workpieces. Rotation is continued until the flashing has been sufficiently removed. | Fins or ridges are removed from molded workpieces by insertion into a rotating drum where they are subjected to the action of free hanging chains each mounted at one of its ends to the inner wall of the drum. Each chain has a length no greater than the inside diameter of the drum. | 1 |
The Government has rights in this invention pursuant to Contract No. DAAK10-80-C-0066 awarded by the Department of the Army.
This application is a continuation of application Ser. No. 07/599,932, filed Oct. 19, 1990.
BACKGROUND OF THE INVENTION
This invention relates generally to bearing systems and more particularly to ball bearing systems.
Ball bearings are widely used where one part must rotate relative to another part. Ball bearing assemblies are commercially available.
These assemblies contain an outer ring and an inner ring. The inside of the outer ring and the outside of the inner ring are grooved. The grooves are aligned to form a raceway to contain metal balls. The two rings "roll" on the balls and are free to rotate relative to each other. In use, the inner ring is often mounted to a shaft. The outer ring is mounted to some base. The shaft is thus free to rotate relative to the base.
Commercially available ball bearing assemblies will withstand a specified range of axial and radial forces on the shaft. If forces in excess of the specified range are applied to the shaft, the bearing assembly may fail. For example, the balls or the races might become permanently deformed such that the balls no longer roll smoothly in the races. Alternatively, the balls or races might fracture.
One method of lessening failures associated with forces along the shaft is to use several bearings. For example, using four ball bearings on a shaft instead of two allows twice as much force to be applied to the shaft before the ball bearings fail.
The ability of the ball bearings to withstand forces without failing can also be increased by increasing the size of the bearings or the number of balls in each ball bearing.
While these known techniques can increase resistance to forces on the shaft, they also add manufacturing complexity, cost, size, and weight. The known techniques for making bearing assemblies which can withstand high forces also have more friction than a simple assembly. Since higher friction requires more power to turn the shaft, the known techniques may not be adequate for some applications. In a class of modern military projectiles, called "smart munitions", these limitations can be very significant. For example, when the projectile is fired, very large forces are applied to the shaft. Thereafter, a seeker head mounted on the shaft must spin very smoothly in order to guide the projectile. Since the projectile explodes at the end of its flight, the cost of the projectile must be minimized. Also, size and weight impact the performance of the projectile.
SUMMARY OF THE INVENTION
With the foregoing background of the invention in mind, it is an object of this invention to provide a ball bearing assembly which can withstand high forces on its shaft.
It is a further object to provide a spacer assembly for use with ball bearings which withstand specified radial and axial forces which allow the ball bearings to operate after higher radial and axial forces have been applied.
The foregoing and other objects are achieved in a ball bearing assembly comprising two conventional ball bearings separated by a spacer assembly. The spacer assembly comprises two rings. One ring is fixedly attached to the inner rings of the ball bearings. The second ring of the spacer assembly is fixedly attached to the outer rings of the ball bearings. The two rings of the spacer interlock with a tongue and groove arrangement. The tongue and groove are fabricated with tight tolerance such that very little motion of the rings of the spacer assembly is possible in either a radial or axial direction and hence limit movement of the inner rings of the bearing assembly relative to the outer rings when large forces are applied. The limited movement of the inner and outer rings ensures the contact stresses between the balls and the races remain below their elastic limit, thereby preventing bearing failure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood by reference to the following more detailed description and accompanying drawings in which:
FIG. 1 shows an exploded isometric view of a bearing assembly fabricated according to the invention; and
FIG. 2 shows a cross section of the bearing assembly of FIG. 1 taken along the line marked 2--2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a bearing assembly 10. Bearing assembly 10 comprises ring assemblies 12A and 12B. These ring assemblies are separated by spacer assembly 14. Here, the bearing assembly 10 is a preloaded bearing assembly in the back to back configuration Preloaded bearings are known in the art and used where precision is required. However, preloaded bearings do not have to be used.
Ring assemblies 12A and 12B are conventional ball bearings. Taking ring assembly 12A as representative, the ring assembly comprises an outer ring 16A and an inner ring 18A. Inner ring 18A has a groove 19A and outer ring 16A has a groove 17A. As seen in FIG. 1, inner ring 18A and outer ring 16A are aligned such that grooves 17A and 19A are aligned Grooves 17A and 19A form a raceway which contains balls 20 1A . . . 20 NA .
Balls 20 1A . . . 20 NA roll in the grooves 17A and 19A, allowing inner ring 18A to rotate relative to outer ring 16A. In use, a shaft 30 is mounted to inner rings 18A and 18B. Outer rings 16A and 16B are mounted in a base 32 allowing the shaft 30 to rotate relative to the base.
Spacer assembly 14 is constructed from three separate pieces: T-spacer 22, L-spacer 24, and rectangular spacer 26 (FIG. 2). These spacers are made from materials conventionally used to make the ring assemblies and balls in a ball bearing assembly. For example, stainless steel made by the hot isostatic press process known as HIP WD65 (1% C, 14.75% Cr, 4% Mo, 1.2% V) could be used for its hardness, corrosion resistance, ability to withstand large loads, and ability to withstand high temperatures. Other materials, preferably with a hardness in excess of Rockwell C58, could be used instead. These spacers will be better understood by reference to FIG. 2.
FIG. 2 shows the ball bearing assembly 10 in cross section. Here, the inner rings 18A and 18B are shown mounted to a shaft 30. Outer rings 16A and 16B are in contact with a base 32. Here, base 32 is any component with respect to which shaft 30 will rotate.
Spacer assembly 14 is comprised of T-spacer 22 which forms an outer spacer ring (more clearly shown in FIG. 2), L-spacer 24, and rectangular spacer 26 form an inner spacer ring 28 with a groove 36. Here, the inner spacer ring 28 is made up of two pieces to enable assembly while the outer spacer ring is made up of one piece for ease of fabrication. One of skill in the art will appreciate that both the inner and outer spacer rings might be made from any number of separate pieces.
Tongue 34 of T-spacer 22 fits into groove 36 in inner spacer ring 28. Tongue 34 fits into groove 36 with a close clearance. The amount which the inner spacer ring 28 may move axially relative to outer spacer ring 25 is denoted by clearance 38A and 38B. The amount which inner spacer ring 28 may more radially relative to outer spacer ring 25 is denoted by clearance 38C.
The bearing assembly 10 is held together by a combination of locking rings and shoulders. These features can be more clearly seen in FIG. 2. Shaft 30 has a shoulder 40 contacting inner ring 18A and restraining it. Base 32 has a shoulder 42 contacting outer ring 16A and restraining it. Outer locking ring 25 screws into threads on base 32 to secure outer ring 16B. Inner locking ring 27 screws into threads on shaft 30 to secure inner ring 8B. In this way, the individual pieces of bearing assembly 10 are held tightly together.
One of skill in the art will appreciate that, where precision bearings are required, special tools and assembly techniques may be required. Such techniques are known in the art. To assemble bearing assembly 10, ring assembly 12A is installed to bank against shoulders 40 and 42. Next, spacer assembly 14 is installed in the following order: first rectangular spacer ring 26, T-spacer ring 22 and L-spacer 24. Ring assembly 12B is then installed. Outer locking ring 25 is then installed to clamp outer rings 16A, 16B, and outer spacer ring 22 together. Locking ring 27 is then installed. Locking ring 27 is torqued until tongue 34 is centered in groove 36. This configuration provides minimum friction and removes radial and end play in the assembly.
The way in which spacer assembly 14 prevents bearing failures may be understood as follows:
A force on shaft 30 tends to displace inner rings 18A and 18B relative to outer rings 16A and 16B. The force also tends to displace inner spacer ring 28 relative to T-spacer 22. If the force is along shaft 30, inner spacer ring 28 will move an amount equal to clearance 38A or 38B. If the force is applied radially in relation to shaft 30, inner spacer ring 28 will move an amount equal to clearance 38C. Then the walls of groove 36 in inner spacer ring 28 will contact tongue 34 of T-spacer 22. Thereafter, no further motion of inner spacer ring 28 relative to T-spacer 22 will be possible. Accordingly, no further motion of inner rings 18A or 18B relative to outer rings 16A and 16B is possible.
As described above, a ball bearing assembly will not fail if motion of the inner ring relative to the outer ring is limited to keep contact stresses below the elastic limit of the components of the assembly. Ball bearing failures only occur if inner rings 18A and 18B move more than a predetermined amount, causing the contact stresses to exceed the elastic limit. That predetermined amount depends on many factors such as the size of the balls 20 1A , 20 2A . . . 20 NA , 20 1B , 20 2B . . . 20 NB , the depth of grooves 17A, 17B, 19A, and 19B and the tolerance with which balls 20 1A , 20 2A . . . 20 NA , 20 1B , 20 2B . . . 20 NA fit into grooves 17A, 17B, 19A, and 19B. Regardless of the exact dimensions of the predetermined amount inner rings 18A and 18B can move relative to outer rings 16A and 16B, clearances 38A, 38B, and 38C must be less than this amount. For precision ball bearing assemblies where the predetermined amount is very small, precision manufacturing techniques will also have to be employed to fabricate T-spacer 22, L-spacer 24, and rectangular spacer 26.
With the invention, when a large radial or axial forces are applied to shaft 30, spacer assembly 14 prevents damage to ring assemblies 12A and 12B. While these large forces are applied, bearing assembly 10 does not spin freely. However, once the large forces are removed, bearing assembly 10 operates normally.
Having described one embodiment of the invention, it will be apparent to one of skill in the art that numerous alternative embodiments could be constructed. Here, inner spacer ring 28 is shown made of two separate pieces to facilitate assembly. Inner spacer ring 28 could be constructed from a different number of pieces. The outer spacer ring could also be constructed from several pieces having, in the aggregate, the shape of T-spacer 22.
Also, two ring assemblies 12A and 12B are shown here. It will be appreciated that if inner spacer ring 28 is firmly secured to shaft 30 and the outer spacer ring made up of T-spacer 22 is firmly secured to base 32, the benefits of the invention can be obtained with only one ring assembly adjacent spacer assembly 14. Of course, other ring assemblies might be required on shaft 30 to balance shaft 30.
Here, inner and outer spacer rings are secured by retaining rings. Other methods of securing a spacer 14 could be used.
Also, the inner spacer ring is shown with a groove and the outer spacer ring is shown with a tongue. The outer ring could be formed with the groove and the inner ring could be formed with the tongue. Moreover, while a tongue and groove arrangement is shown here, other shapes could be used. In essence, any arrangement which allows a portion of the outer spacer ring to interlock with a portion of the inner spacer ring could be used.
This invention is shown with preloaded ball bearings of the type known in the art. However, non-preloaded ball bearings could be used if the application does not require the precision of preloaded bearings.
It is felt, therefore, that this invention should be limited only by the spirit and scope of the appended claims. | A ball bearing assembly with a spacer to prevent ball bearing failures. The spacer has a ring with a tongue that fits into a groove in a second spacer ring. One spacer ring is coupled to the outer ring of the ball bearing assembly and the other spacer ring is coupled to the inner ring of the ball bearing assembly. The spacer therefore allows relative rotation of the rings of the ball bearing assembly but prevents relative translation of the rings beyond a point which will damage the ball bearing assembly. | 5 |
FIELD OF THE INVENTION
This invention relates to knitted fabric covers and in particular to knitted covers used in automobile trim.
BACKGROUND OF THE INVENTION
The invention is useful in machine knitting on weft knitting machines having independently operable needles arranged in two needle beds, for example, a flat "V" bed machine producing mainly double jersey structure fabric.
It has recently been found possible to knit one-piece upholstery covers for covering three-dimensional objects which removes the need for sewing portions of the covers together. In U.S. Pat. Nos. 5,308,141and 5,326,150, a method is disclosed for knitting one-piece covers for the base and/or back cushions of a motor vehicle seat.
Motor vehicles, in particular motor cars, are now commonly provided with air bag restraint to prevent vehicle passengers or drivers from injury during a collision. Some vehicles are now being provided with side collision air bags, which in their stand-by condition may be housed within a vehicle seat back or base.
On conventional seats when the air bag is activated and inflates, it escapes through the seat covers by bursting through the sewn seams where the portions of the cover are sewn together.
With 3D knitted seat covers, the covers are completely homogeneous, and there may be a slight time delay before the air bag bursts through the cover. Furthermore, since the material is homogeneous, the location of the burst is not fully predictable.
An object of the invention is to provide a knitted cover which can split or burst in a predicted manner,
SUMMARY OF THE INVENTION
According to the present invention, there is provided a knitted fabric cover for an object, the cover having a line of weakness knitted into the knitted fabric, preferably in a coursewise direction.
Preferably the cover fabric is a weft knitted double jersey fabric having a back layer with a technical back face and a front layer with a technical front face. Preferably the line of weakness comprises at least one portion of at least one course of knitting which is of a single jersey construction.
For a seat cover, it is preferable to form the line of weakness so that it is not visible on the from face of the cover, and therefore the single jersey course or courses is/are formed in the front layer of the fabric.
Alternatively, the cover has a knitted course which at least in part is formed from a yarn which is weaker than the ground yarn from which that layer of the cover fabric is formed.
Preferably the line of weakness comprises at least a portion of at least one course in the back layer which is formed at least in part of a yarn which is weaker than the ground yarn(s) from which both the back layer and front layer are formed.
Alternatively, the front layer of the double jersey fabric is knitted from a weakened yarn, and the front and back layers of the fabric are interconnected by an interlock structure of weakened yarn formed on alternate stitches in the front and back layers.
Such a cover can be made by three-dimensional knitting and is suitable for use in motor vehicle trim and in particular for the use as motor vehicle seat covers.
The invention also provides for a method of forming a weakened line in a knitted fabric cover wherein the knitted fabric is knitted so that at least a portion, preferably a portion of at least one course, of the fabric is made weaker than the surrounding knitted fabric.
Preferably the fabric is a weft knitted double jersey fabric knitted on a weft knitting machine having needles arranged in two independently operable needle beds. The fabric has a front layer knitted on one needle bed and a back layer knitted on a second needle bed. The fabric is knitted on both needle beds in a mainly double jersey construction, and at a predetermined course said portion is made weaker by several different methods.
Said portion is made weaker by removing stitches from at least some of the needles of the second needle bed while said one needle bed continues to knit for a further two to six courses and thereafter recommencing knitting on both needle beds to continue the double jersey construction.
The stitches can be transferred to needles in said one needle bed. Alternatively, the stitches on some or all of the needles on the second needle bed may be pressed off and preferably the edge is sealed by a fusible thread.
Alternatively, said portion is made weaker by holding up the needles on said one needle bed while some or all of the needles of the second needle bed continue to knit using a weaker yarn than the ground yarn for between one to four courses, and thereafter knitting of the double jersey construction continues on both needle beds.
In another alternative, the ground yarn is knitted only on selected needles in both needle beds, and a yarn weaker than the ground yarn is knitted onto the other needles for at least one further course, and preferably no more than a further four courses, and thereafter the ground yarn is knitted on all needles in both needle beds.
In yet another method where the front layer of the double jersey fabric is made from at least one ground yarn and the back layer of the fabric is made from a lower strength ground yarn which is weaker than the first ground yarn, said portion is made weaker by knitting the lower strength ground yarn on selected needles on said one needle bed and on the second needle bed for at least one course, and preferably on alternate needles on two courses.
In a further method, a low strength yarn is knitted on the needles of the second needle bed for at least one course while said one needle bed continues to knit the front layer. The weaker yarn is then pressed off, and preferably sealed with a fusible thread, and the double jersey construction knitting continues on both needle beds thereafter.
Preferably the knitted double jersey fabric has its front layer formed from a chenille yarn and its back layer formed from a polyester yarn. The chenille yarn may be of the type disclosed in the applicant's Published Application EP-A627,516. The chenille yarn may have a decitex in the range 1500 to 3000. Conveniently, the fabric has 8 to 16 wales per inch (2.54 cm) in a course-wise direction, and in the range 8 to 30 courses per inch in the wale-wise direction. The chenille yarn is knitted into the fabric as knitted looped stitches.
The polyester yarn is preferably an air-textured polyester yarn having a decitex in the region of 550 to 900, or 600 to 800, or 600 to 750, or 650 to 700 decitex. The chenille yarn may be formed of a pair of twisted nylon and/or polyester strands, for example by the use of a low-melting point nylon strand, or the pile may be moveable relative to the strands.
The chenille yarn may have a count in the range 1500 to 3000 decitex. The chenille yarn is preferably one having moveable pile and/or an extensible core.
Preferably, the air textured polyester yarns are continuous filaments yarns having a count, in the unrelaxed state, of 680 to 750 decitex.
Preferably, the method of knitting is such that, in the relaxed state, the fabric has from 4 to 6 wales per cm.
The fabric may be knitted on a flat bed knitting machine having a pair of opposed needle beds. The machine may have a gauge in the range 10 to 16, preferably 10 to 14, further preferably 12.
The machine may be a double system machine or a triple system or four system machine.
The present invention preferably provides a method of knitting a cover, preferably an upholstery fabric, in which the knitting is carried out on a machine having a pair of opposed independently operable needle-beds, and in which the needles in each bed can be moved independently of one another in that bed into the path of an operating cam box reciprocating along the needle beds.
An upholstery fabric for a vehicle seat preferably has a weight in the relaxed state ready for use in excess of 500 g/m 2 , preferably 500 to 900 g/m 2 . This compares to traditional knitted products which have a weight of 300 to 350 g/m 2 .
Preferably, the upholstery fabric is a weft knitted upholstery fabric formed of yarn having a decitex in the range 625 to 850 and having been knitted on a machine having a machine gauge in the range 10 to 18, the fabric being of generally double jersey construction having interengaging loops between the two layers of the double jersey structure.
The knitted fabric may be a three-dimensional cover for use on a three-dimensional structure to form an upholstered structure. The fabric may be formed of two or more different colored ground yarns.
Also according to the present invention, there is provided a method of allowing with minimal hindrance the inflation of an air bag housed within a vehicle trim component having a cover, typically a vehicle seat cushion, wherein the component is covered with a knitted fabric cover having a coursewise line of weakness knitted into the knitted cover allowing inflation of the air bag with minimal hindrance from the cover. Preferably, the weakness is made substantially invisible externally of the cover.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a knitting diagram of a first embodiment of the invention,
FIG. 2 is a second knitting diagram of a second embodiment of the invention,
FIG. 3 is a third diagram of a third embodiment of the invention,
FIG. 4 is a fourth knitted diagram of a fourth embodiment of the invention,
FIG. 5 is a fifth pattern of a fifth embodiment of the invention,
FIG. 6 is a sixth knitting diagram of a sixth embodiment of the invention, and
FIG. 7 is an isometric view of a vehicle seat cushion.
DESCRIPTION OF PREFERRED EMBODIMENTS
In order that the invention can be fully understood, reference will be made to a flat V-bed knitting machine. More details on such knitting machines are to be found in the publication "Dubied Knitting Manual", published by Edouard Dubied et Cie SA, Neu Chatel, Switzerland in 1967. Flat V-bed knitting machine are very well known and many such machines are now computer controlled. It has been proposed recently to manufacture upholstery fabric on such flat V-bed knitting machines and proposals have been made (see, for example, U.S. Pat. No. 5,308,141 and U.S. Pat. No. 5,326,150) to knit upholstery fabric suitable for use in vehicles.
The knitting of a fabric cover by the method according to the invention uses a Stohl CMS machine with 12 gauge needles. This machine is a flat V-bed machine of the type provided with presser foot means to assist take-down of the knitted fabric. The machine can operate with a plurality of yarn supplied, each of which is associated with a respective cam box.
The cam box traverses across the needle beds supplying yarn to the needles as desired in each direction of travel.
Referring to FIG. 7, there is shown an upholstered seat cushion or squab generally indicated by 1. The seat cushion is formed by the covering of a core 2 normally in the form of semi-rigid foam supported on a frame, with a fabric cover generally indicated by 3. The core is shaped so as to provide wings 4 or any other desired shape in the seat.
Such seats have particular application in vehicles but may be used in numerous other applications. When used in motor cars, the seat frame may support an air bag inflation mechanism which is operated by side collisions.
Stretched over the core 2 is a fabric cover 5, which is provided with a main body portion covering the seat with integral wing portions 6,7 and side portions such as portion 8. There is also a from portion 9. The fabric cover is folded over the base of the seat squab and may be secured in a manner known. The seat may have indentations 10 formed therein in order to create aesthetic effects.
Such seat structures are described in U.S. Pat. Nos. 5,308,141 and 5,326,150. In those patents, there is described a three-dimensional knitted fabric upholstery cover which is knitted in a single operation. In the present invention, the fabric cover 5 is stretched over the core 2. In order to aid or control the bursting of the air bag through the otherwise homogeneous knitted cover 5, the cover is provided with a line of weakness 11 extending in a course-wise direction relative to the direction of knitting. A course-wise direction is the direction in the fabric extending at right angles to the selvage.
Referring to FIG. 1, there is shown a stitch diagram in which each row labeled 101-117 represents a row of knitting, each using a different yarn on one pass of the yarn carrier for a three system machine. A three system machine has a cam box which can carry up to three yarn carriers on a pass across the needle beds. In each row, such as row 101, the upper line of small dots represents individual needles on the rear bed of the knitting machine, and the lower row of dots represents the from bed of the knitting machine. In the terminology used herein, the front face of the fabric is knitted on the from bed of needles and the rear face is knitted on the rear needle bed. The yarn is represented by loops and interconnecting cross-links.
The zones X and Z outside of the lines A and B represent a double jersey structure knitted from a chenille yarn according to European Patent Application EP-A- 0627,516. Zone Y between the lines A and B is where the course-wise line of weakness 11 is formed.
On the first pass of the yarn carriers on the knitting machine from right to left, a chenille yarn 21 is knitted on all needles on the front bed. There is no difference between the zones. A first contrast yarn 22 is knitted on alternate needles on the front bed and all the needles of the rear bed (row 102) with interconnecting loops between the yarn knitted on the front and rear beds. A second contrast yarn 23 is knitted on the other respective alternate needles in the front bed and all the needles on the rear bed with interconnecting loops between the yarn knitted on the two beds (see row 103). The three rows 101-103 make up a repeat unit (R 1 ). The relationship between the contrast yarns 22, 23 in the from needle bed is determined by the required pattern on the front face of the fabric. On the next pass of the yarn carriers from left to right, the needles in zone Z are put out of action and the yarns 21-23 knit as before, forming the second repeat unit R 2 .
On the next pass of cam box, the yarn carrier for the first contrast yarn 22 only knitting from right to left, zones X and Z are put out of action, with the first contrast yarn 22 being knitted only in zone Y on the rear needle bed (row 107). This is repeated in the next pass of that yarn carrier, from left to right (row 108). These two courses may be termed "reparation courses". The loops are then transferred to the front needle bed (row 109). The chenille yarn 21 is then knitted on alternate needles in zone Y as its yarn carrier passes from right to left (row 110) and then from left to right (row 111 ), knitting on alternate needles in each pass.
On the next pass, all three yarn carriers move from right to left to repeat the repeat unit R 2 with rows 112-114. Finally on the next pass, all the yarn carriers pass from left to right, forming the repeat unit R 1 with rows 115-117, which forms part of the main jacquard material.
Thus, a weakness is created in zone Y adjacent to the transfer of the stitches from the rear bed to the front bed when the subsequent two rows 110,111 form a course of single jersey fabric.
In FIG. 2, there is illustrated a second embodiment of the invention, and the same reference numbers will be used in this figure and subsequent figures as was used with respect to FIG. 1.
The first four passes of the cam box right to left and left to right are identical to those described with reference to FIG. 1, forming the repeat units R 1 and R 2 and the two preparation courses 107, 108.
The loops are then transferred from the rear needle bed to the front needle bed at row 109. Alternatively, these stitches could be pressed off, especially if the first contrast yarn 22 was replaced by a fusible thread.
A weaker yarn 24 is then carried across the zone X by float stitches and tuck stitches and knitted on alternate needles on the front needle bed in zone Y in two passes of its respective yarn carrier (rows 110, 111) from left to right and then right to left.
The two repeat units R 2 and R 1 are then knitted as previously described with reference to FIG. 1.
The weaker yarn 24 on the front bed provides for a weakened line extending in a coursewise direction in a single course of fabric.
The chenille yarn 21 will have a yarn count of about 2000 decitex. The contrast yarns 22 and 23 are preferably polyester yarns with a count of about 900 decitex, whereas the weakened yarn 24 will have a count of about 200 decitex. The weakened yarn could be a bicomponent fusible yarn called Grillon Yarn or a three component yarn comprising nylon 11, acrylic and polyester fibers.
Referring to FIG. 3, there is shown yet another method of forming a weakened course. The first two passes of the yarn carrier right to left and left to right form the repeat units R 1 and R 2 .
A weaker yarn 24 is then carried across zone X by float stitches and tuck stitches until it is knitted in zone Y on the rear needle bed on all needles in zone Y, on both passes of the yarn carrier, from left to right and right to left (rows 107 and 108). The repeat units R 2 and R 1 are then produced as previously described.
Thus in this embodiment, the weaker yarn 24 forms two weakened courses in the back layer of the double jersey material.
Referring to FIG. 4, the embodiment shown therein is very similar to that shown in FIG. 3 except that in rows 107 and 108, the weaker yarn 24 is knitted on alternate needles on the rear needle bed on the two passes of its respective yarn carrier, thus forming only a single course of weakened yarn knitted on the rear bed.
Referring to FIG. 5, again the repeat units R 1 and R 2 are knitted as before. At row 107 the weakened yarn 24, in this case a fusible yarn, is floated and tucked across zone X to be knitted on the rear needle bed in zone Y. Several courses of fusible yarn are knitted in zone Y. This is represented by row 108 only. At least two, and preferably four or six, rows of fusible yarn are knitted. Then the yarn carrier takes the fusible yarn back across zone X by float stitches and tuck stitches as shown in row 109. The fusible yarn 24 in zone Y is then pressed off the rear bead needles (row 110). The repeat units R 2 and R 1 are then knitted as before.
The courses of weakened fusible yarn on the rear needle bed again form a weakened single jersey construction area in the fabric formed the rear needle bed.
Referring to FIG. 6, a weakened line in zone Y is created by bringing in the weakened yarn 24 after repeat unit R 1 and then knitting a course of standard interlock construction using the weakened yarn in two passes of the yarn carrier to form rows 104, 105. The interlock course of weakened yarn provides a weakened coursewise extending line of stitches. | A knitted fabric cover, especially for a vehicle seat having a vehicle air bag housed therein, in which the cover is adapted to provide minimal hindrance to inflation of the air bag by having at least one line of weakness knitted into the cover, in particular in a coursewise direction. | 3 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to the field of flow control. More specifically, the invention relates to a device and method for controlling flow using an inflatable element.
2. Related Art
Oil companies are continually improving their recovery systems to produce oil and gas more efficiently and economically from sources that are continually more difficult to exploit, without significantly increasing the cost to the consumer. One area in which the industry has strived for improvement is in the area of flow control. Other industries have significant needs for improved flow control as well.
SUMMARY
In general, according to one embodiment, the present invention provides an inflatable flow control device. Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
FIG. 1 illustrates a well having two devices of the present invention therein.
FIGS. 2 and 3 illustrate a side and end view of an embodiment of the present invention.
FIG. 4 illustrates another embodiment of the present invention.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
FIG. 1 shows a well 10 with a casing 12 and a production tubing 14 therein. The well also contains two valves 20 of the present invention that control flow within the well 10 . A control line 30 extends from the surface to the valves 20 . The control line 30 communicates with the valves 20 allowing remote control of the valves 20 .
FIG. 2 discloses one embodiment of the present invention in the form of a fluid pressure actuated bladder valve. The bladder 44 of the invention is positionable in a section of pipe such that an outer diameter thereof is attached to the inner diameter of the pipe 40 and the inner orifice of the bladder 44 is open or closed depending upon the amount of pressure inside the bladder relative to ambient pressure in the vicinity of the bladder. A toroidal shaped bladder 44 is positioned in the inside of a pipe 40 . The bladder 44 may be bonded to the inside of the pipe 40 (the inside surface) using an adhesive or any other suitable attachment arrangement which includes but is not limited to a mechanical attachment magnetic element inside the bladder 44 which then pinches the wall of the bladder 44 between the magnetic element and the pipe 40 in which the bladder is positioned. Alternatively, the bladder 44 may be simply positioned in the pipe 40 and maintained in the desired position by friction caused by pressure internal to the bladder 44 . The bladder 44 may also be attached by other mechanical methods. The bladder 44 has an orifice 42 that allows fluid flow through pipe 40 when the bladder 44 is not inflated. The bladder 44 is preferably made of an elastic material that can be inflated and deflated repeatedly without structural degradation. Pressurization and depressurization of the bladder of the invention 44 is effected through a control line 45 that communicates with the interior of bladder 44 . The control line 45 is in sealed communication with bladder 44 . The control line 45 controls the pressure within the bladder 44 and can inflate or deflate the bladder 44 through hydraulic, pneumatic or other pressure sources.
Positioned within the pipe 40 and the bladder 44 is an inner pipe 46 . The inner pipe 46 may be attached to the pipe 40 at one or both ends. Any attachment mechanism may be used. The inner pipe 46 in one embodiment has a plug 48 that prevents flow through the inner pipe 46 . Although shown as a permanently attached plug in FIG. 2, the plug 48 may be a removeable plug, a flapper valve, or some other type of valve or plug that prevents flow through the inner pipe. Using a flapper valve or removeable plug facilitates access through the inner pipe 46 if needed, such as for re-entry, as well as opening of a flowpath through the valve 20 should the valve 20 fail.
In an alternative embodiment, the inner pipe 46 does not have a plug 48 therein. Instead, the inner pipe extends to a packer or other sealing device that prevents flow between the interior of the inner pipe 46 and the annulus between the inner pipe 46 and the outer pipe 40 in the area or zone of interest.
When inflated, the bladder 44 expands. Because expansion radially outwardly is inhibited by the pipe 40 in which the bladder 44 is located, the expansion is limited to radially inward and longitudinal. As the bladder undergoes radial inward expansion, the flow area between the pipe 40 and the inner pipe 46 decreases, restricting the flow therethrough. When fully inflated, the bladder 44 tends to close off orifice 42 (the annular flowpath between the pipe 40 and the inner pipe 46 ) by sealing against the outer surface of the inner pipe 46 , thus sealing flow through the pipe 40 . Desired flow through the pipe 40 can be achieved through applying a determined amount of fluid pressure to the bladder 44 to vary the flow area between opened and closed and provide for a variable orifice valve. Accordingly, the inflatable bladder 44 , controls the flow between a first surface and a second surface of a tool or tools. Although described as creating a seal when closed, it should be noted that some flow through the valve 20 (e.g. five percent of full fully open flow) may be permissible and the term “closed” includes substantially closed in which there is some flow through the valve 20 .
FIG. 3 is an end view of the pipe 40 shown in FIG. 2 including the pressure controlled valve 20 positioned inside of the pipe 40 . As noted above, the centrally located orifice 42 may be opened or closed by deflating or inflating the bladder 44 to control flow through the pipe 40 .
Due to the simplicity of design, the pressure controlled valve can withstand numerous cycles of opening and closing without failure. This reliability makes the pressure controlled valve ideal for applications such as downhole flow control and other applications, where ambient conditions are adverse and valve maintenance or replacement is difficult.
The pressure controlled valve may be controlled from the surface of the well or through downhole intelligence located within the well. A representative downhole intelligent control is schematically illustrated in FIG. 2 but it will be appreciated that the invention is also capable without the intelligent systems illustrated. Downhole intelligence, intelligent sensor arrangements, (e.g., position sensors, pressure sensors, temperature sensors, etc.) and communications for communicating to a downhole or surface microprocessor via any conventional communication device or media such as telemetry devices, wireline, TEC wire, cable, etc., are beneficial to the operation of the above-described valve. By monitoring conditions downhole, metered adjustments of the pressure controlled valve can be made to boost efficiency and production of any given well. This type of downhole intelligence is employable and desirable in connection with all of the embodiments disclosed herein and while only some of the embodiments contain direct reference to intelligent systems and controls it will be understood that these can be for all of the embodiments.
FIG. 4 shows an alternative embodiment of the present invention. In the figure, the well 10 contains two valves 20 , each controlling flow from a separate formation, 50 and 52 . A packer 60 seals between an inner pipe 44 46 and a casing 12 in the well 10 . The bladder 44 (or elements) for the valve 20 are connected to the inner pipe 46 . An outer pipe 40 extends from the packer to a position radially surrounding the bladder 44 . Ports 62 through the inner pipe 46 are positioned between the packer 60 and the bladder 44 . Thus, the valve 20 defines a flowpath from the free end of the outer pipe 40 through the annulus between the outer pipe 40 and the inner pipe 46 , past the bladder 44 , through the ports 62 , and into the inner pipe 46 for continued, controlled flow through the packer 60 . Flow through the control line 45 controls inflation and deflation of the bladder and, thus, the variable flow through the valve 20 . It should be noted that, although the figure shows two valves 20 sharing a common inner pipe 46 , each of the valves 20 may have a separate inner pipe 46 . Also, the figure discloses a separate control line for each valve 20 , multiple valves may share one control line. In one example, multiple redundant valves may be used to control the flow from one formation (or multiple formations) and may share a common control line.
The above-described system refers to a control line provided from the surface. However, other actuating systems may be used. For example, the electro-hydraulic actuator of U.S. Pat. No. 6,012,518, which is hereby incorporated herein by reference, may be used to inflate and deflate the bladder 44 of the present invention. Other downhole actuators may be used.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | A valve has a pair of surfaces, such as those of pipes, with an inflatable bladder disposed therebetween. Controlled inflation and deflation of the bladder provides for control of flow through the valve. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to and incorporates by reference the entire contents of Japanese priority document 2008-003469 filed in Japan on Jan. 10, 2008.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The disclosures herein generally relate to device drivers and methods of customizing the layout of a user interface. The disclosures herein particularly relate to a device driver for which the layout of a user interface can be customized, and also relate to a layout customizing method of customizing a device-driver user interface.
2. Description of the Related Art
Embedding a device driver into an operating system (hereinafter referred to as an OS) makes it possible for a personal computer (hereinafter referred to as a PC) or the like to drive a peripheral device such as a printer or a multifunctional machine. The device driver is software for driving a peripheral device, and serves to assist an OS in controlling the peripheral device.
In general, a device driver is provided with a user interface (hereinafter referred to as a UI) for allowing a user to make and change settings. It is known, however, that user preference for the layout (display layout) of a device driver UI tends to widely vary from user to user depending on user taste.
To satisfy a variety of user needs for the display layout of a device driver UI, software vendors have been designing display layouts according to priorities determined at the vendor's end. As a result, the display layouts of device driver UIs are imposed on users by software vendors, failing to satisfy a variety of user needs.
Japanese Patent Application Publication No. 2000-75977 discloses a technology for allowing a user to freely customize the display layout of a UI.
However, the mere fact that a user can freely customize the display layout of a device driver UI does not necessarily mean that the customized display layout is user-friendly. The display layout of a device driver UI may be freely customized even with respect to the fine details of each setting item, for example. In such a case, a user with expert knowledge knows what customization is necessary to make the device driver UI easy to use, and can thus properly design a display layout of the device driver UI that is easy for the user to use.
When the display layout of a device driver UI can be freely customized with respect to the fine details of each setting item, a general user often has no idea about what customization is necessary to make the device driver UI easy to use, and cannot properly design a display layout of the device driver UI that is easy for the user to use.
SUMMARY OF THE INVENTION
The present inventors recognized a general user typically does not wish to freely customize the details of a display layout of a device driver UI. A general user rather wishes to be able to design, in a flexible, easy, and swift manner, a display layout of a device driver UI that is easy to use.
In view of the above, the present inventors recognized a need for a device driver and a method of customizing the layout of a user interface that can accommodate user needs for the layout of a device driver user interface in a flexible, easy, and swift manner.
It is accordingly an object of the present invention to address the problems in the background technology.
According to an aspect of the present invention, a device driver that operates a periphery device comprises a display mode storage unit that stores setting items, which are operable by a user using a user interface interfacing the device driver, into functionally mutually-related groups, as plates, the plates indicating display modes of the user interface for each group of the setting items; an alignment sequence setting unit that sets an alignment sequence for the plates by allowing the user to set the alignment sequence; and an arrangement unit that arranges the plates in a plate display area on the user interface depending on the alignment sequence set by the alignment sequence setting, wherein each of the plates has a width that equals either a whole length or a half length of a width of the plate display area, and the arrangement unit arranges the plates in the plate display area depending on the alignment sequence set by the alignment sequence setting unit.
According to another aspect of the present invention, a method of customizing layout of a user interface used for a device driver that operates a periphery device comprises storing setting items, which are operable by a user using a user interface interfacing the device driver, into functionally mutually-related groups, as plates, the plates indicating display modes of the user interface for each group of the setting items; setting an alignment sequence for the plates by allowing the user to set the alignment sequence; and arranging the plates in a plate display area given to the user interface depending on the alignment sequence, wherein each of the plates has a width that equals either a whole length or a half length of a width of the plate display area, and the arranging arranges the plates in the plate display area depending on the alignment sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIGS. 1A and 1B are drawings showing system configurations according to an embodiment of the present invention;
FIG. 2 is a drawing showing an example of the hardware configuration of a PC;
FIG. 3 is a drawing showing an example of the software configuration of a PC;
FIG. 4 is an illustrative drawing showing an example of the appearance of a printer driver UI;
FIG. 5 is an illustrative drawing showing an example of plates;
FIG. 6 is a drawing showing an example of the configuration of a plate-status management table;
FIGS. 7A through 7G are illustrative drawings showing various patterns in which plates are arranged from top to bottom in an area;
FIGS. 8A through 8C are illustrative drawings showing examples of the appearance of an area in which plates are arranged;
FIG. 9 is an illustrative drawing showing an example of updates being made to the plate-status management table in response to a history of user operations;
FIG. 10 is an illustrative drawing showing an example of updates being made to the plate-status management table in response to changes made from the initial settings provided at the time of shipment from a factory;
FIGS. 11A through 11D are illustrative drawings showing examples of plate-status management tables that can be switched from one to another at the time of use; and
FIG. 12 is an illustrative drawing showing examples of plate-status management tables that can be switched from one to another by selecting a user customized mode, a history mode, or a change-from-initial-setting mode.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following, embodiments for carrying out the present invention will be described by referring to the accompanying drawings. The embodiments are directed to an example in which a printer driver is used as an example of a device driver. This is not a limiting example, and a device driver can be any type of device driver for which a user can edit setting items on its user interface. Further, the embodiments are directed to an example in which a multi-function peripheral (hereinafter referred to as a MFP) is used as an example of a peripheral device that is driven through an embedded device driver. This is not a limiting example, and the peripheral device can be any type of peripheral device.
FIGS. 1A and 1B are drawings showing system configurations according to a first embodiment of the present invention. A system 1 may have a configuration as shown in FIG. 1A , in which a PC 2 and an MFP 3 operated by users are connected to each other via a network 4 such as a LAN to perform data transmission. Alternatively, the system 1 may have a configuration as shown in FIG. 1B , in which the PC 2 and the MFP 3 are connected to each other via a data transmission line 5 such as a USB to perform data transmission.
The PC 2 may have a configuration as shown in FIG. 2 , for example. FIG. 2 is a drawing showing an example of the hardware configuration of a PC. The PC 2 shown in FIG. 2 includes an input unit 1 , an output unit 12 , a driver unit 13 , an auxiliary memory unit 14 , a main memory unit 15 , a computing unit 16 , and an interface unit 17 , all of which are connected together via a bus B.
The input unit 11 includes a keyboard and mouse, for example, and serves to receive various input signals. The output unit 12 includes a display apparatus and the like, and serves to display various types of windows, data, and the like. The interface unit 17 includes a modem, a LAN card, a USB interface (I/F), and the like, and serves to establish a connection with the MFP 3 via the network 4 or the data transmission line 5 .
A printer driver according to the present embodiment is software for use by the PC 2 to operate the MFP 3 . The printer driver serves to assist an OS of the PC 2 to control the MFP 3 . The printer driver is provided through the delivery of a recording medium 18 or through downloading via the network 4 . The recording medium 18 having a printer driver recorded therein can be any type of recording medium. That is, it may be a recording medium for recording information by use of an optical, electrical, or magnetic device such as a CD-ROM, a flexible disk, or a magneto-optical disk, or may be a semiconductor memory for recording information by use of an electrical device such as a ROM or a flash memory.
Upon setting the recording medium 18 containing a printer driver to the driver unit 13 , the printer driver is installed from the recording medium 18 to the auxiliary memory unit 14 through the driver unit 13 . A printer driver that is downloaded through the network 4 is installed to the auxiliary memory unit 14 through the interface unit 17 .
The auxiliary memory unit 14 stores an installed printer driver, and also stores various files and data. Upon power-on, the printer driver is read from the auxiliary memory unit 14 to be loaded to the main memory unit 15 . The computing unit 16 performs various types of processing by use of the printer driver stored in the main memory unit 15 as described later.
FIG. 3 is a drawing showing an example of the software configuration of a PC. The PC 2 shown in FIG. 3 includes an application 21 , an OS 22 , and a printer driver 23 . Upon receiving a request regarding the MFP 3 from the application 21 , the OS 22 controls the MFP 3 by use of the printer driver 23 .
The printer driver 23 includes a sequence position setting unit 31 , a display on-off setting unit 32 , a plate arranging unit 33 , a UI generating and displaying unit 34 , a table switchover unit 35 , a mode switchover unit 36 , a plate storage unit 37 , and a plate-status management table 38 .
The configuration of the printer driver 23 shown in FIG. 3 includes only the portions relevant to the disclosures of the present embodiment. Further, the configuration of the printer driver 23 shown in FIG. 3 is only an example, and may be divided and provided as separate files.
The sequence position setting unit 31 , the display on-off setting unit 32 , the plate arranging unit 33 , the UI generating and displaying unit 34 , the table switchover unit 35 , the mode switchover unit 36 , the plate storage unit 37 , and the plate-status management table 38 , which constitute the printer driver 23 , are described later in detail.
As shown in FIG. 4 , the printer driver 23 provides a printer driver UI 40 which is used by a user to make settings regarding the MFP 3 ; FIG. 4 is an illustrative drawing showing an example of the appearance of a printer driver UI. In the printer driver UI 40 shown in FIG. 4 , a custom settings window (display screen) 41 and a detail settings window (display screen) 42 can be switched from one to the other by selecting respective tabs.
The detail settings window 42 includes all the setting items usable by the user, and receives user inputs regarding those setting items. It should be noted that the display layout of the detail settings window 42 cannot be customized.
The custom settings window 41 includes at least one or more of the setting items used by the user, and receives user inputs regarding such one or more of the setting items. It should be noted that the display layout of the custom settings window 41 can be customized. Specifically, the choice and arrangement of the setting items displayed in an area 43 indicated by a dotted-line frame can be customized in the custom settings window 41 .
However, the custom settings window 41 does not allow a user to freely customize the choice and arrangement of the setting items displayed in the area 43 in detail. Instead, setting items are grouped into units (hereinafter referred to as plates) according to their functions to allow plates 44 a through 44 c to be customized. FIG. 5 is an illustrative drawing showing an example of plates. Plates in general will hereinafter be referred to by using reference numeral “ 44 ”.
As shown in FIG. 5 , each plate 44 is uniquely identified by its plate ID. Each plate 44 is already fixed at the time of delivery to customers. Each plate 44 is configured in such a manner that setting items belonging to a corresponding group as having related functions are displayed.
When plates 44 are used to customize the display layout of the custom settings window 41 , each plate 44 has its plate ID and associated UI controls. Here, in the case of the plate 44 having the plate ID=16 as an example, the UI controls refer to the character string “Staple:”, a combobox for providing choices, and a balloon icon placed on the left-hand side of the combobox. The information regarding each plate 44 is stored in the plate storage unit 37 .
To use plates 44 to customize the display layout of the custom setting window 41 , the printer driver 23 manages and controls the sequence position and display on-off status of each plate 44 by use of a plate-status management table 38 shown in FIG. 6 .
FIG. 6 is a drawing showing an example of the configuration of a plate-status management table 38 . The plate-status management table 38 stores a display on-off status (as shown in the “display” column) and a sequence position (as shown in the “order” column) separately for each plate ID. In the plate-status management table 38 , the display on-off status “Yes” indicates a display-enabled status, and the display on-off status “No” indicates a display-disabled status. The sequence position in the “order” column in the plate-status management table 38 indicates a sequence number in the display sequence arranged in an ascending order.
The display on-off status in the plate-status management table 38 is set by the display on-off setting unit 32 as described later. The sequence position in the plate-status management table 38 is set by the sequence position setting unit 31 as described later. The display on-off setting unit 32 and the sequence position setting unit 31 update display on-off statuses and sequence numbers, respectively, in the plate-status management table 38 in response to instructions from a user.
The plate arranging unit 33 arranges plates 44 from top to bottom in the area 43 in an ascending order of the sequence numbers such that only the plates 44 for which the display on-off status indicates a display-enabled status (“Yes”) in the plate-status management table 38 are displayed. If the display on-off status indicates a display-disabled status (“No”) for a given plate 44 in the plate-status management table 38 , this plate 44 is not displayed regardless of its sequence position. When sequence positions are changed in the plate-status management table 38 , the sequence of the displayed plates 44 will be customized.
FIGS. 7A through 7G are illustrative drawings showing various patterns in which plates are arranged from top to bottom in an area. FIGS. 7A through 7G illustrate patterns P 1 through P 7 . In FIGS. 7A through 7G , hatched areas represent the background of the area 43 , and encircled numbers indicate the sequence numbers of the displayed plates 44 . As shown in FIGS. 7A through 7G , each plate 44 has either a width equal to the width of the area 43 or a width equal to half the width of the area 43 . Further, the height of each plate 44 is not restricted to any particular length. As previously described, the display format within each plate 44 is already fixed at the time of delivery to customers.
The plate arranging unit 33 uniquely determines the display sequence of the plates 44 based on a user's settings of the plate-status management table 38 . The plate arranging unit 33 further determines the coordinates of each plate 44 in response to the width and height of each plate by taking into account the patterns shown in FIGS. 7A through 7G .
Three plates 44 having respective sequence numbers 1 , 2 , and 3 may have respective widths that are half the width of the area 43 , half the width of the area 43 , and equal to the width of the area 43 , respectively. In such a case, the plate arranging unit 33 determines the coordinates of the plates 44 by fitting these plates into one of the patterns (P 1 ) through (P 3 ) by taking into account the heights of the plates 44 . In another example, three plates 44 having respective sequence numbers 1 , 2 , and 3 may have respective widths that are equal to the width of the area 43 , half the width of the area 43 , and equal to the width of the area 43 , respectively. In such a case, the plate arranging unit 33 determines the coordinates of the plates 44 by fitting these plates into the pattern (P 4 ). Patterns (P 5 )-(P 7 ) show other examples.
When the plates 44 shown in FIG. 5 are arranged according to one of the patterns (P 1 ) through (P 3 ) shown in FIGS. 7A through 7C , the plates 44 will appear in the area 43 as shown in FIGS. 8A through 8C , respectively. FIGS. 8A through 8C are illustrative drawings showing examples of the appearance of an area in which the plates 44 are arranged, corresponding to patterns (P 1 )-(P 3 ). Upon the coordinates of the plates 44 being fixed, the UI generating and displaying unit 34 generates the custom setting window 41 including the area 43 for display on the output unit 12 of the PC 2 .
In this manner, the printer driver 23 of the present embodiment allows a user to freely customize the arrangements of the plates 44 by specifying the display on-off status and sequence number of each plate according to his/her preference. The printer driver 23 can thus satisfy user needs regarding the layout of the printer driver UI 40 in a flexible, easy, and swift manner.
In the printer driver 23 of the first embodiment, the display on-off setting unit 32 and the sequence position setting unit 31 update display on-off statuses and sequence numbers, respectively, in the plate-status management table 38 in response to instructions from a user. In a second embodiment of the present invention, the printer driver 23 automatically customizes, without the user needing to directly set up the plate-status management table 38 , the plates 44 arranged in the area 43 of the custom setting window 41 in view of an operation history, as now explained.
FIG. 9 is an illustrative drawing showing an example of updates being made to the plate-status management table in response to a history of user operations. In FIG. 9 , a plate-status management table 38 - 1 demonstrates the state of the table prior to the user operations for editing settings. In the plate-status management table 38 - 1 , the display on-off status of each plate 44 is set to the display-disabled state (“No”). In the plate-status management table 38 - 1 , further, no sequence position (“N/A”) is set to the plates 44 . Since the display on-off status of each plate 44 is set to the display-disabled state (“No”) in the plate-status management table 38 - 1 , the plate arranging unit 33 arranges and displays no plates 44 in the area 43 .
In response to an example user operation regarding a setting item made through the detail settings window 42 , the sequence position setting unit 31 and the display on-off setting unit 32 update the plate-status management table 38 - 1 to a plate-status management table 38 - 2 . The plate-status management table 38 - 2 shows an example in which the setting item corresponding to the above-noted user operation belongs to the plate 44 that is uniquely identified by the plate ID=3.
Specifically, when the user identifies plate ID=3 to be displayed, the plate-status management table 32 automatically changes the display on-off status of the plate ID=3 to the display-enabled state (“Yes”), and the sequence position setting unit 31 automatically changes the sequence position of the plate ID=3 to “1” when the user selects displaying the plate with ID=3. The plate arranging unit 33 then automatically arranges a plate 44 from top to bottom in the area 43 according to one of the previously-described patterns wherein the display on-off status of this plate 44 indicates the display-enabled state (“Yes”) in the plate-status management table 38 - 2 .
After this, in response to another user operation regarding a setting item made through the detail settings window 42 , the sequence position setting unit 31 and the display on-off setting unit 32 automatically update the plate-status management table 38 - 2 to a plate-status management table 38 - 3 . The plate-status management table 38 - 3 shows an example in which the setting item corresponding to the above-noted user operation belongs to the plate 44 that is uniquely identified by the plate ID=15.
Specifically, when the user next requests display of the plate with ID=15 in the detail settings window 42 , the plate-status management table 32 automatically changes the display on-off status of the plate ID=15 to the display-enabled state (“Yes”). Further, the sequence position setting unit 31 automatically changes the sequence position of the plate ID=15 to “1”, and changes the sequence position of the plate ID=3 to “2”. The plate arranging unit 33 thereby arranges the plates 44 of ID=3 and ID=15 from a top of the area 43 in an ascending order of the sequence numbers, i.e., arranges the plate 44 of ID=15 first and the plate 44 of ID=3 second according to one of the previously-described patterns, wherein the display on-off status indicates the display-enabled status (“Yes”) for each of these plates in the plate-status management table 38 - 3 .
After this, in response to another user operation regarding a setting item made through the detail settings window 42 , the sequence position setting unit 31 and the display on-off setting unit 32 automatically update the plate-status management table 38 - 3 to a plate-status management table 38 - 4 . The plate-status management table 38 - 4 shows an example in which the setting item corresponding to the above-noted user operation belongs to the plate 44 that is uniquely identified by the plate ID=2.
Specifically, when the user next requests display of the plate with ID=2 in the detail settings window 42 , the plate-status management table 32 automatically changes the display on-off status of the plate ID=2 to the display-enabled state (“Yes”). Further, the sequence position setting unit 31 automatically changes the sequence positions of the plates ID=2, ID=15, and ID=3 to “1”, “2”, and “3”, respectively.
The plate arranging unit 33 thereby arranges the plates 44 of ID=2, ID=3, and ID=15 from top of the area 43 in an ascending order of the sequence numbers, i.e., arranges the plate 44 of ID=2 first, the plate 44 of ID=15 second, and the plate 44 of ID=3 third by using one of the previously-described patterns, wherein the display on-off status indicates the display-enabled status for each of the plates ID=2, ID=3, and ID=15 in the plate-status management table 38 - 4 .
In the printer driver 23 of the second embodiment, the contents of the plate-status management table 38 are automatically updated as shown in FIG. 9 in response to user operations regarding setting items. Namely, the plate-status management table 38 is automatically updated such that the display on-off status of the plate corresponding to an edited setting item is changed to the display-enabled state (“Yes”), and also the sequence positions are updated by changing each existing sequence number to a next-higher sequence number and by setting the sequence position of the last-edited plate to “1”.
As described above, the printer driver 23 of this second embodiment automatically customizes, without direct user setting of the plate-status management table 38 , the plates 44 arranged in the area 43 of the custom setting window 41 in view of an operation history of the user. In the description of the second embodiment, a redundant explanation overlapping that of the first embodiment has been omitted as appropriate.
In the printer driver 23 of a third embodiment of the present invention, the initial settings of the printer driver 23 provided at the time of delivery to customers may differ from the current settings. In such a case, the printer driver 23 automatically customizes, without direct user setting of the plate-status management table 38 , the plates 44 arranged in the area 43 of the custom setting window 41 , such that these different setting items are displayed in the area 43 .
FIG. 10 is an illustrative drawing showing an example of updates being made to the plate-status management table in response to changes made from the initial settings provided at the time of delivery. In FIG. 10 , a plate-status management table 38 - 5 demonstrates the state of the table prior to changes made to settings from the initial settings provided at the time of delivery to customers (or at the time of shipment from the factory). In the plate-status management table 38 - 5 , the display on-off status of each plate 44 is set to the display-disabled state (“No”). In the plate-status management table 38 - 5 , further, the plates 44 are provided with their initial sequence positions. Since the display on-off status of each plate 44 is set to the display-disabled state (“No”) in the plate-status management table 38 - 5 , the plate arranging unit 33 does not arrange or display any of the plates 44 in the area 43 .
When a setting item is changed through the detail settings window 42 from its initial setting provided at the time of shipment, the display on-off setting unit 32 updates the plate-status management table 38 - 5 , e.g., to a plate-status management table 38 - 6 . The plate-status management table 38 - 6 shows an example in which the setting item changed from its initial setting provided at the time of shipment belongs to the plate 44 that is uniquely identified by the plate ID=3.
Specifically, when the user request display of the plate with ID=3 in the detail settings window 42 , the plate-status management table 32 changes the display on-off status of the plate ID=3 to the display-enabled state (“Yes”). The plate arranging unit 33 arranges a plate 44 from top of the area 43 according to one of the previously-described patterns wherein the display on-off status of this plate 44 indicates the display-enabled state (“Yes”) in the plate-status management table 38 - 6 .
When a setting item is further changed through the detail settings window 42 from its initial setting provided at the time of shipment, the display on-off setting unit 32 updates the plate-status management table 38 - 6 to a plate-status management table 38 - 7 . The plate-status management table 38 - 7 shows an example in which the setting item changed from its initial setting provided at the time of shipment belongs to the plate 44 that is uniquely identified by the plate ID=15.
Specifically when the user request display of the plate with ID=15 in the detail settings window 42 , the plate-status management table 32 changes the display on-off status of the plate ID=15 to the display-enabled state (“Yes”). The plate arranging unit 33 arranges the plates 44 of ID=3 and ID=15 from top of the area 43 in an ascending order of the sequence numbers, i.e., arranges the plate 44 of ID=3 first and the plate 44 of ID=15 second according to one of the previously-described patterns, wherein the display on-off status indicates the display-enabled status (“Yes”) for each of these plates in the plate-status management table 38 - 7 .
When a setting item is further changed through the detail settings window 42 from its initial setting provided at the time of shipment, the display on-off setting unit 32 updates the plate-status management table 38 - 7 to a plate-status management table 38 - 8 . The plate-status management table 38 - 8 shows an example in which the setting item changed from its initial setting provided at the time of shipment belongs to the plate 44 that is uniquely identified by the plate ID=2.
Specifically when the user request display of the plate with ID=2 in the detail settings window 42 , the plate-status management table 32 changes the display on-off status of the plate ID=2 to the display-enabled state (“Yes”). The plate arranging unit 33 arranges the plates 44 of ID=2, ID=3, and ID=15 from the top of the area 43 in an ascending order of the sequence numbers, i.e., arranges the plate 44 of ID=2 first, the plate 44 of ID=3 second, and the plate 44 of ID=15 third by using one of the previously-described patterns, wherein the display on-off status indicates the display-enabled status (“Yes”) for each of the plates ID=2, ID=3, and ID=15 in the plate-status management table 38 - 8 . In the third embodiment, the printer driver 23 does not update the sequence positions in the plate-status management table 38 , and uses the sequence positions as set forth in the initial plate-status management table 38 - 5 .
In the printer driver 23 of the third embodiment, the contents of the plate-status management table 38 are updated as shown in FIG. 10 in response to changes that are made to setting items through the detail settings window 42 from the initial settings provided at the time of shipment from the factory. Namely, the plate-status management table 38 is updated such that the display on-off statuses of plates are changed to the display-enabled state (“Yes”) with respect to the setting items changed from their initial settings provided at the time of shipment from the factory.
When the initial settings of the printer driver 23 provided at the time of shipment from the factory differ from the current settings, the printer driver 23 of the third embodiment automatically customizes, without direct user setting of the plate-status management table 38 , the plates 44 arranged in the area 43 of the custom setting window 41 , such that those setting items different from the initial settings provided at the time of shipment from the factory are displayed in the area 43 . In the description of the third embodiment, a redundant explanation overlapping that of the first or second embodiments has been omitted as appropriate.
The printer driver 23 of a fourth embodiment of the present invention stores a plurality of plate-status management tables 38 each serving as a single setting, and switches between the plate-status management tables 38 . FIGS. 11A through 11D are illustrative drawings showing examples of plate-status management tables 38 A- 38 D that can be switched from one to another at the time of use.
FIGS. 11A through 11D show four plate-status management tables 38 A through 38 D. Switching between the four plate-status management tables 38 A through 38 D is performed by use of the table switchover unit 35 .
When the plate-status management table 38 A is used, no plate 44 is arranged in the area 43 of the custom setting window 41 . When the plate-status management table 38 B is used, only the plate 44 corresponding to the plate ID=3 is arranged in the area 43 of the custom setting window 41 . When the plate-status management table 38 C is used, all the plates 44 are arranged in the area 43 of the custom setting window 41 . When the plate-status management table 38 D is used, all the plates 44 are arranged in the area 43 of the custom setting window 41 in an order reverse to the order of arrangement that appears at the time of use of the plate-status management table 38 C.
In response to a user request, further, the table switchover unit 35 can additionally store the contents of the plate-status management table 38 as existing at a certain point in time as another plate-status management table ( 38 E or 38 F, not shown), for example. In response to a user request, moreover, the table switchover unit 35 can allow an additionally stored plate-status management table ( 38 E or 38 F, not shown) to be used by switching over to such a table.
As described above, the printer driver 23 of the fourth embodiment can store the contents of a plate-status management table 38 as existing at a certain point in time, and allows a user to use one of the stored plate-status management tables 38 by switching over to this table according to user preference. In the description of the fourth embodiment, a redundant explanation overlapping that of the first through third embodiments has been omitted as appropriate.
In a fifth embodiment of the present invention, the printer driver 23 can switch between a user customized mode, a history mode, and a change-from-initial-setting mode to use a desired customized mode regarding the plates 44 arranged in the area 43 of the custom setting window 41 in view of the first through third embodiments.
FIG. 12 is an illustrative drawing showing examples of plate-status management tables 38 - 9 to 38 - 12 that can be switched from one to another by selecting a user customized mode, a history mode, or a change-from-initial-setting mode. A plate-status management table 38 - 10 is provided for use in the user customized mode. A plate-status management table 38 - 11 is provided for use in the history mode. A plate-status management table 38 - 12 is provided for use in the change-from-initial-setting mode. A plate-status management table 38 - 9 is a default table provided at the time of shipment from the factory.
Switching between the plate-status management tables 38 - 10 through 38 - 12 is performed by use of the mode switchover unit 36 . The user customized mode starts by using a copy of the plate-status management table 38 - 9 . The history mode starts by using a copy of the plate-status management table 38 - 9 in which the display on-off status of all the plates 44 is set to the display-disabled state and the sequence position of all the plates 44 is set to “N/A”. The change-from-initial-setting mode starts by using a copy of the plate-status management table 38 - 9 in which the display on-off status of all the plates 44 is set to the display-disabled state (“No”).
Each time a user switches between the user customized mode, the history mode, and the change-from-initial-setting mode by use of the mode switchover unit 36 , the plate-status management table 38 is reset, so that the plates 44 arranged in the area 43 of the custom setting window 41 are updated to reflect the contents of one of the plate-status management tables 38 - 10 through 38 - 12 corresponding to the selected one of the user customized mode, the history mode, and the change-from-initial-setting mode.
The descriptions of the imaging apparatus of exemplary embodiments have been provided heretofore. The present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention. As one example only, the printer driver 23 of the embodiments may be configured such that two or more plate-status management tables 38 are provided for different models of the MFP 3 . Such plate-status management tables 38 may be switched from one to another in the printer driver 23 , so that the printer driver 23 can serve as a universal printer driver.
Obviously, numerous other or additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A device driver or method that operate a periphery device. A display mode storage unit stores setting items, which are operable by a user using a user interface interfacing the device driver, into functionally mutually-related groups, as plates, the plates indicating display modes of the user interface for each group of the setting items. An alignment sequence setting unit sets an alignment sequence for the plates by allowing the user to set the alignment sequence. An arrangement unit arranges the plates in a plate display area on the user interface depending on the alignment sequence set by the alignment sequence setting. Each of the plates has a width that equals either a whole length or a half length of a width of the plate display area, and the arrangement unit arranges the plates in the plate display area depending on the alignment sequence set by the alignment sequence setting unit. | 6 |
This is a continuation, of application Ser. No. 089,626, filed Oct. 29, 1979, now abandoned, which in turn is a division of application Ser. No. 888,757 filed Mar. 21, 1978, U.S. Pat. No. 4,211,573.
BACKGROUND OF THE INVENTION
The invention relates to a method for the production of cement clinkers low in alkali from alkali-containing raw material, whereby the latter is thermally treated in a multiple, step calcination process, preferably consisting of a pre-heating step, a deacidification step, a sintering step and a cooling step, and whereby fuel of any type is introduced both in the deacidification step as well as also in the sintering step, and hot air of the cooling step is supplied both to the calcination step as well as also to the sintering step as combustion air. The invention relates also to an apparatus for carrying out the method.
It is known that alkali-compounds in cement may appreciably shorten the solidification time and carry out the so-called change-over of the cement. Furthermore, it is known that too high an alkali-content in the cement may lead to blistering of alkali-sulfates in the concrete. Also, with the so-called additive substances capable of reaction, through a high alkali-content in the cement, a reaction of the alkalies with these additive substances may cause an alkali-expansion of the cement and thereupon endanger the constancy of volume of the concrete. Upon burning of cement clinkers, out of alkali-containing raw material, the alkalies, particularly the alkali-chlorides are volatilized quantitatively in the combustion furnace and reach with the exhaust gas of the combustion furnace into the preheater whereby they deposit themselves on the raw material and are conveyed back again in circulation with the pre-heated raw material into the combustion furnace. In this way, result the alkali-circulations in the stream of material and stream of gas, known to every expert, which lead to high increases in alkali and to cakings or deposits of alkali-compounds in the system of the calcination installation.
For the prevention of these disadvantages, it is known to burn the cement clinkers in two steps. According to earlier suggestions, the alkali-containing exhaust gases of the combustion furnace--sintering step--are conveyed off from the total calcination process, so that no alkalies may condense on the colder raw material. In this manner, no highly increasing circulation of harmful material can build up in the system. This method has, however, the extraordinarily great disadvantage that the sintering step in each case is lost without utilization of the combustion process, whereby the production costs of the cement are increased up to complete lack of economy.
In more recent times, for the production of cement clinkers low in alkali, from alkali-containing raw material, a method has become known (German Laid-Out Specification No. 22 62 213) in which a part of the exhaust gases of the sintering step is continuously removed through a bypass from the combustion process and the other part of the furnace exhaust gases is used for the raw material drying. For the pre-heating and calcination of the raw material, hot cooler-exhaust-air is used, in which additional fuel is burned, whereby the exhaust gases of the calcination step are used for the preheating of the raw material in the preheating step. The higher the alkali-content in the furnace exhaust gases, the higher is also the portion of the furnace gases which are discarded directly out of the system. In the case of less alkali-containing furnace exhaust gases, indeed a greater part of the exhaust gases are used for the raw material drying, however, in this connection, thermally high-valent furnace exhaust gases must indeed be directly discarded. This method can accordingly in no manner satisfy in respect of an economical heat-use of the combustion process. Besides, this method is unsuitable upon the treatment of raw material with greatly fluctuating and timewise very high alkali-content.
SUMMARY OF THE INVENTION
It is the object of the invention to overcome the disadvantages portrayed and to improve a method for the thermal treatment of particularly alkali-chloride-containing raw material to be used in the manufacture of cement, to the extent that also a raw material to be used in the manufacture of cement with a greatly fluctuating and timewise very high alkali-content may be treated with the lowest possible heat losses and without the danger of alkali-circulations, with low investment costs. Furthermore, the object lies therein, namely without disadvantageous interventions in the calcination process, to adjust exactly the alkali-content in the cement clinkers to predetermined values permissible in each case, and in this manner even with the most cumbersome conditions on the raw-material side produce a so-called--"low-alkali"--cement.
This object is solved according to the invention thereby, that at least a part of the alkali-containing exhaust gases directly from the sintering step is mixed with the combustion gases from the deacidification step, in the pre-heating step, and the mixing gas hereupon serves for the precalcination and/or pre-heating of the raw material, and that the other part of the alkali-containing exhaust gases of the sintering step is removed in a manner known per se from the calcination process. In this manner, it is possible that in spite of changeably high alkali-contents in the raw material to be used in the manufacture of cement, the heat content of a part of the alkali-containing furnace exhaust gases may be made use of for the preheating of the raw material, and in spite of this, a cement clinker with low alkali-content may be calcined. The heat losses previously taken into consideration upon the calcining of cement clinker loss in alkali-content, from particularly high-alkali-containing raw material to be used in the manufacture of cement, are in this manner now quite appreciably limited. Thus, a best-possible utilization of fuel is insured. It is suitable in this connection to intermix the exhaust gases from the sintering step and the combustion gases from the deacidification step at the same temperature level, preferably at 800°-1000° C.
In development of the invention, it is provided that the partial quantity of exhaust gas of the sintering step is conveyed to the preheating step, and before entry into the preheating step is cooled by mixing with a partial quantity of the raw material which has been preheated to the temperature level of the combustion gases from the deacidification step. In this manner, a partial quantity of the raw material in the hot stream of exhaust gas, on account of the high temperature-difference between gas and particles of comminuted raw material, intensively deacified is, because the CO 2 is driven to a fargoing extent rapidly and almost without resistance out of the particles of comminuted raw material to be used in the manufacture of cement. During the deacidification, on account of the endothermic process, heat is used, so that through a predetermined partial quantity of comminuted raw material, the hot partial quantity of exhaust gas obtained may be adjusted to the temperature-level of the combustion gases from the deacidification. It is, however, also possible instead of the preheated raw material, to use a partial quantity of raw material from the deacidification step, already calcined to a fargoing extent, for the cooling of the gas. This may particularly take place then when only a small partial quantity of exhaust gas may be utilized for the thermal treatment, and the other partial quantity on account of the high alkali-content in the exhaust gases must be discarded. The low quantity of heat required for the complete deacidification of the particles of raw material already deacidified to a fargoing extent is then withdrawn from these hot exhaust gases of the sintering step.
In a further development of the invention, it is provided that to the partial quantity of exhaust gas conveyed for use in the preheating step preferably is conveyed hot exhaust air of the cooling step as carrier medium. This measure is of advantage particularly then when only a very small partial quantity of the alkali-containing gases from the sintering step can be utilized for the thermal treatment of the raw material, and in such case, the danger exists that the raw materials used for the cooling of the exhaust gases are not dragged along by the stream of gas, but under certain circumstances, drop directly into the sintering step. In order to prevent this, air and preferably the hot exhaust air of the cooling step is used as carrier medium, so that the raw materials used for the cooling of the hot exhaust gases of the sintering step are reliably taken along by the gases. There may be taken internally with the same result, hot air, hot gases from the preheating step or purified bypass-gases.
In preferred development of the invention, it is provided that the alkali-containing partial quantity of exhaust air of the sintering step is conveyed in several preheating steps arranged preferably parallel to one another, so that the method permits also of introduction with advantage in an installation with very high output yield. It is suitable in this connection, that in the case where about 50% of the alkali-containing exhaust gases of the sintering step are removed from the combustion process, the remaining partial quantity of exhaust gas is conveyed exclusively in one of the two preheating steps present, and is there mixed with the combustion gases from the combustion step. In this manner, even with two preheating steps arranged parallel with one another, the one line is acted on fully with the hot exhaust gases of the sintering step, while the other preheating step, referred to the sintering step, is completely cut off on the gas-side. This has the advantage of the better thermal utilization of the hot exhaust gases of the sintering step.
The invention relates also to an apparatus for carrying out the method, and is characterized by at least one cyclone-preheater operating according to the suspension-gas-principle with calcination device which is connected in series with a rotary kiln, with which on its part is connected in series a material cooler, whereby the rotary kiln and the calcination device are in connection on the hot gas side with the material cooler, whereby furthermore, the rotary kiln is connected through at least one bypass conduit with the atmosphere and through at least one exhaust gas conduit during bypassing of the calcination device, with the cyclone-preheater. In this manner, with constructively simple means, a cement-production-installation is set up, with which it is possible also to treat a raw material to be used in the manufacture of cement with greatly fluctuating or high-alkali-containing starting material, respectively, and at the same time to lower quite appreciably the heat losses per kilogram of burnt cement clinker.
With a production installation developed constructively in such a manner, it is possible for the first time to treat cumbersome starting materials in economical manner and with optimal utilization of the fuel-heat. It is suitable in this connection that the exhaust gas conduit from the rotary kiln together with the gas conduit from the calcination device is connected directly with the lowermost cyclone of the cyclone-heater. Particularly then when the gas conduit from the calcination device discharges above the exhaust gas conduit in the cylindrical part of the lowermost cyclone, the raw material separated off in this cyclone from the gas stream of the calcination device subsequently comes into contact with the hot exhaust gases of the sintering step, so that there a certain post-calcination is attained. It is, however, principally also possible to guide the exhaust gas conduit from the sintering step into the conical part of the lowermost cyclone or into its discharge tip.
In development of the invention, it is provided that in the exhaust gas conduit from the sintering step, a branch conduit is conveyed for preheated and/or calcinated raw material, so that in this manner a cooling of the hot exhaust gases from the sintering step may take place through the raw material itself.
In further development of the invention, it is provided that in the exhaust gas conduit preferably in the area of the discharge from the rotary kiln, an air conduit is conveyed, suitably an air conduit which connects the material cooler and the exhaust gas conduit with one another or discharges from the connecting conduit, respectively, between calcination device and material cooler, and is guided in the exhaust gas conduit from the otary kiln. In this way, hot carrier-air may reach into the exhaust gas conduit, in case with a high bypass-guidance of the alkali-containing exhaust gases, for example, above 85%, the remaining alkali-containing exhaust gases, on account of the determined cross-sectional conditions of the exhaust-gas conduit are not in position to drag along the raw material introduced into this exhaust-gas conduit for the separation in the lowermost cyclone of the preheater.
For the accurate adjustability of the partial quantity of raw material introduced into the exhaust gas conduit, in dependence on the partial quantity of furnace-exhaust-gas, there is arranged in the material-offtake of the lowermost cyclone of the preheater, a divided conduit with an adjustable distributor member, so that it is also possible to exactly adjust the quantity of material both with the calcination device as well as to the exhaust gas conduit from the rotary kiln. Thus, care is taken that the temperature of the combustion gas from the calcination device and the temperature of the exhaust gases from the rotary kiln at the entry into the lowermost cyclone of the preheater have approximately the same temperatures, so that the entire quantity of the hot exhaust gases at uniformly high temperature level may serve for the preheating of the raw materials.
Countless further features of the invention will be explained in greater detail in the following on the basis of the description of an embodiment by way of example for an installation for the thermal treatment of alkali-containing raw material to be used in the manufacture of cement.
THE DRAWING
The drawing shows a diagrammatic disclosure of a cement production installation with two suspension gas preheaters arranged in parallel each consisting of several cyclones.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The partial view shown in the drawing illustrates an installation with a rotary kiln 1, furnace-inlet-head 2 and two parallel suspension gas preheaters 4, 5 arranged parallel with one another, each consisting of several cyclones 3 disposed in series. A bypass 6 is connected with a furnace-inlet-head 2 and is provided with a chamber 7 for the cooling of the alkali-containing exhaust gases with cold air or water or both, and is connected to an electro-dust-removal installation for discharge to the atmosphere.
On both sides of the bypass conduit 6 are arranged the cyclone-preheaters 4 and 5. The furnace-inlet-head 2 is in connection through the exhaust gas conduit 8 with the lowermost cyclone 3/IV of the preheater. In this cyclone is besides guided the gas conduit 9 of the calcination device 10, which on its part is in connection through the hot air conduit 11 with a sinter-material cooler 28 for the raw material for cement burnt to completion in the rotary kiln, is constructed as reaction-line or-section, and has a calcination device 24. The exhaust gas conduit 8 and the gas conduit 9 are guided in common in the cylindrical part of the lowermost cyclone 3/IV, whereby the gas conduit 9 is arranged above the exhaust gas conduit 8. The exhaust gas conduit 8 is also in connection with the hot air conduit 11 through a branch-air-conduit 12. The cyclones 3 of one of each cyclone-preheaters 4, 5 are connected with one another by means of gas conduits 13, 14, 15 in such a manner that the hot mixing-gases from the lowermost cyclone 3/IV are guided by means of a blower 31 consecutively through the individual cyclones of the preheater.
On the material side, the cyclones 3 of the cyclone-preheaters 4,5 are so connected with one another that the raw material to be used in the manufacture of cement delivered to the preheaters in each case in the upper area at 16, 17, in counter current to the rising hot gases, passes through the cyclones 3 from above downwardly in known manner. After the third cyclone 3/III in each case, viewed in direction of the material passage, its material discharge 18 is divided at 19 with a distributor member 20 and a branch conduit 29 connected to the exhaust gas conduit 8. In the material discharge 21 which leads from the lowermost cyclone 3/IV to the furnace inlet head 2 of the rotary kiln 1, a division 22 is also arranged, in which similarly an adjustable distributor member 23 is inserted, whereby the division 22 is in connection with the lower area of the exhaust gas conduit 8 through the branch conduit 30.
The modus operandi of the installation shown is the following.
The cold raw material to be used in the manufacture of cement supplied to the cyclone preheaters 4, 5 in the upper area at 16, 17 passes through the cyclones from above downwardly in counter-current to the hot gases from the rotary kiln 1 and the calcination device 10 which are intermixed with one another in the lowermost cyclone 3/IV of the particular cyclone-preheater. A part, preferably the larger part of the heated raw material withdrawn from the cyclone 3/III and already preheated to a fargoing extent is delivered to the calcination device 10 and there almost completely deacidified in the hot combustion gases which are produced by means of combustion or burning of the fuels introduced through the combustion device 24 into the hot cooler-exhaust air. The other part of the preheated raw material is conveyed through the bifurcation 19 and the branch conduit 29 into the lower area of the exhaust gas conduit 8 and there into the hot alkali-containing stream of exhaust gas of the rotary kiln, occurring at approximately 1,200° to 1,400° C. Both partial streams of raw material absorb heat during the endothermic progress of the deacidification, so that the temperature of the hot gases from the calcination device or from the rotary kiln, respectively, lie upon entry into the lowermost cyclone at approximately 800° to 1,000° C., and both streams of hot gas upon entry into the lowermost cyclone of the particular cyclone-preheater, have equally high temperature level. The mixing gases serve then for the preheating of the raw material in the upper cyclone-steps of the heat exchanger.
The raw material calcined to a fargoing extent is separated off in the lowermost cyclone from the mixing gas and introduced through the material discharge 21 for the subsequent sintering in the rotary kiln 1. Through the distributor member 23 arranged in the bifurcation 22, an exactly determined partial quantity of this calcined material is delivered through the branch conduit 30 into the lower area of the exhaust gas conduit 8 so that also hereby, the furnace exhaust gases are so cooled, that at the entry into the lowermost cyclone 3/IV, a gas temperature between 800°-1,000° C. is adjusted.
If only a small partial quantity of the alkali-containing furnace exhaust gases is introduced into the exhaust gas conduit, which no longer is in position to distribute into the gas stream the partial quantity of raw material delivered to the exhaust gas conduit for the gas-cooling and take it along to the lowermost cyclone, then through the branch-air-conduit 12, hot exhaust air is supplied from the material cooler, so that the gas-velocity lies so high that reliably the raw material from the gas conduit is taken along in the lowermost cyclone 3/IV of the preheater. The quantity of gas of the alkali-containing exhaust gases from the rotary kiln to be discarded in each case is shortly after the exit from the furnace-inlet-head in the lower area of the bypass 6, chilled by means of a cold stream of air 32 introduced in torsion into the cooling device 7, and if need be, chilled additionally through a spray-device 25a with water, so that reliably all alkalies in the gas stream sublimate and may be separated as dust-fine particles in the electro-separator 33, not shown in greater detail. The locking members 25, 26, 27, of known type of construction arranged separately in each case in the exhaust gas conduit 8, the bypass conduit 6 and the branch air conduit 12, make possible, each according to selected and mutually interlocked adjustment, a 0-100 percent bypass. Some characteristic operational conditions are described in the following.
With a 100% bypass for the alkali-containing furnace exhaust gases, the exhaust-gas-conduit 8 on the furnace-inlet-head 2 is closed by means of the locking member 25. With a 0% bypass, all of the furnace exhaust gases are conveyed through the exhaust gas conduit 8 into the lowermost heat-exchanger-cyclone 3/IV, whereby by means of the distributor members 20 and 23 the quantity of material guided into the exhaust gas-conduit 8 is so adjusted that the furnace-gas-temperature at the cyclone-inlet amounts to between 800° C. and 1,000° C.
With an operational condition lying between 0 and 100% bypass, only a corresponding portion of the furnace-exhaust-gases is conveyed through the exhaust-gas-conduit 8 in the lowermost heat-exchanges-cyclone 3/IV, whereby then apart from this quantity of exhaust gas, the partial quantity of raw material introduced or sent back respectively, into the exhaust-gas-conduit 8 is so adjusted that the exhaust gas temperature at the inlet into the lowermost cyclone again amounts to between 800° and 1,000° C. Particularly with a bypass of the alkali-containing furnace exhaust gases above 85%, the locking member 27 in the branch air conduit 12 is opened, so that hot cooler-exhaust-air can enter into the exhaust gas conduit as carrier medium.
With a 50% furnace bypass, the other half of the alkali-containing furnace-exhaust-gases is conveyed exclusively through an exhaust gas conduit 8 into the lowermost heat, exchanges-cyclone 3/IV in each case, of a preheater. In the case of the two-line-heat-exchanger shown, only the one heat exchanger or the one exhaust-gas-conduit, respectively, is acted on with half of the furnace-exhaust-gases, and thereupon run as 0% bypass, while the other heat exchanger is completely shifted off through the locking members 25 of the furnace-exhaust-gas and this line is driven or operated as at 100% bypass.
The invention is not limited solely to the embodiment shown by way of example, but permits with the lowest investment costs and the lowest heat losses of the heat-content of the alkali-containing furnace-exhaust-gases, of also being utilized in an installation which is laid out for lower output-yields, and contains for example only one heat, exchanger-line. Even so, the cyclone-heat-exchanger may be guided otherwise than shown. It lies also within the scope of the invention to guide the exhaust-gas-conduit out of the rotary kiln to a desired point in the lowermost cyclone of the preheater. Even so, it is with the same success possible to guide the exhaust gas conduit while bypassing the lowermost cyclone directly into the exhaust-gas-conduit of this cyclone. | A method for the production of low alkali-cement clinker from alkali-containing raw material comprising a preheating step, a deacidification step and a sintering step utilizes a portion of the alkali-containing exhaust gases from the sintering step which are mixed with deacidified combustion gases from the deacidification step and reintroduced into the system in contact with the raw material to preheat and precalcity the raw material in a plurality of cyclones. | 2 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/475,515, filed Jun. 3, 2003, which application is incorporated herein by reference for purposes of the US filing and all other jurisdictions permitting such incorporation.
[0002] The invention was supported with funds from NSF Grant No. IBN-9118977. The United States government may have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] This application relates to oligonucleotide primers and nucleic acid probes that are useful for amplification and/or detection of human inhibitor of DNA-binding (Id) genetic sequences, and in particular for selective amplification and/or detection of human Id1, Id2 and Id3.
[0004] Inhibitor of DNA-binding (Id) proteins are transcription factors and are members of a subfamily of Helix -Loop- Helix (HLH) proteins. These proteins contain a motif that consists of two segments capable of forming amphipathic alpha helices connected by a nonconserved loop. Other members of the HLH family (basic HLH, or bHLH proteins) also contain a basic region just to the amino terminal side of this motif that consists of two to three clusters of basic amino acid residues. Various proteins containing the bHLH motif can form homodimeric and heterodimeric complexes with other bHLH proteins and it is through the basic region that these complexes bind to the target DNA (Murre et al., Cell, 1989, 56, 777-783; Murre et al., Cell, 1989, 58, 537-544). The Id proteins containing the helix -loop- helix domain, but are lacking the basic region. These Id proteins are still able to form heterodimers with other bHLH transcription factors affecting transcription, but they lack DNA-binding ability and are therefore negative regulators of the bHLH transcription factors.
[0005] Four members of the Id family have been identified in mammals and the first, Inhibitor of DNA binding-1 (Id-1), originally isolated in the mouse, has been shown to exist in two forms in the human as a result of alternative splicing (Benezra et al., Cell, 1990, 61, 49-59; Deed et al., Biochim. Biophys. Acta., 1994, 1219, 160-162; Hara et al., J. Biol. Chem., 1994, 269, 2139-2145; Nehlin et al., Biochem. Biophys. Res. Commun., 1997, 231, 628-634; Zhu et al., Brain Res. Mol. Brain Res., 1995, 30, 312-326).
SUMMARY OF THE INVENTION
[0006] The present invention provides oligonucleotide primers and polynucleotide probes that provide selective amplification and detection of Id genetic sequences. Forward and reverse primer pairs for amplification of Id1, Id2 and Id3 are given in Seq. ID Nos 1 and 2, 3 and 4 and 5 and 6 respectively. These primer pairs were selected both (1) to provide the desired specificity so that they amplify only the specific Id type to which they are targeted; and (2) to introduce terminal restriction endonuclease cleavage sites into the amplicon that facilitate the incorporation of the amplicon into plasmid-based vectors. Detection of Id genetic sequences can be carried out using the labeled-amplicon by reamplifying the amplicon with the primers in the presence of labeled, for example radiolabeled, deoxynucleotide triphosphates. The probes of the invention correspond in sequence to the amplicon produced using the primers of the invention, after cleavage at the restriction endonuclease sites. The sequences of sense probes that correspond to wild-type human Id1, Id2, and Id3 are set forth in Seq ID Nos. 7, 8 and 9 respectively. Antisense strands of the same sequence may also be employed.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The present invention relates to two types of nucleic acid polymers which are useful in the detection of human Id1, Id2 or Id3 genetic sequences. For convenience, these two types of nucleic acid polymers are referred to herein as “primers” and “probes” although it will be appreciated from the description below that the shorter “primers” can also be used in detection procedures, and that the longer “probes” can also serve as a primer for extension reactions. Thus, the names are used as labels for clarity, and there is no implication in the name that the utility of the nucleic acid polymer is in any way limited to the single function of the name.
[0008] As used in the specification and claims of this application, the term “genetic sequences” refers to either DNA or RNA sequences encoding some or all of human Id1, Id2 or Id3 protein, both in vivo and in vitro. The “genetic sequences” may be amplification products or they may be unamplified materials. The “genetic sequence” may be detected in situ to obtain maps of Id protein expression, it may be detected in a milieu of other human nucleic acids and cellular components, or it may be detected in an artificial environment, such as in host cells (prokaryotic or eukaryotic) expressing a plasmid-based vector harboring nucleic acids encoding a human Id protein.
[0009] The primers of the present invention were developed to meet several specific goals. First, each set of forward and reverse primers was designed to have little or no cross-reactivity with other Id proteins and members of the HLH family in hybridization experiments with human tissue samples. Second, the primers each include a restriction endonuclease cleavage site, such that the ends can be trimmed from amplicons produced using the primers in a PCR amplification to produce a sequence that can be readily inserted into a plasmid-based vector for cloning to produce multiple copies of the amplicon for use as a probe. Construction of oligonucleotides of defined sequence is routine and companies exist to provide requested materials. Primers of the invention can be constructed using such known techniques for synthesis of oligonucleotides.
[0010] For Id1, the primers of the invention have the sequence:
Forward: ataggatcc c accctcaacg gcgagat Seq ID No. 1 Reverse: gtggaattc c ccacagagca cgtaattcct Seq ID No. 2
In each sequence, the underlined portions corresponds to the sequence of Id1, while the remainder is an introduced segment to provide the restriction endonuclease cleavage site.
[0011] For Id2, the primers of the invention have the sequence:
Forward: ataggatcc c cgcatcccac tattgtca Seq ID No. 3 Reverse: gtggaattc a acaccgtcta ttcagccaca Seq ID No. 4
In each sequence, the underlined portions corresponds to the sequence of Id2, while the remainder is an introduced segment to provide the restriction endonuclease cleavage site.
[0012] For Id3, the primers of the invention have the sequence:
Forward: ataggatcc a ccttcccatc cagacagcc Seq ID No. 5 Reverse: gtggaattc c ctgagcacca ggttcagtct Seq ID No. 6
In each sequence, the underlined portions corresponds to the sequence of Id3, while the remainder is an introduced segment to provide the restriction endonuclease cleavage site.
[0013] These primers pairs can be used for selective amplification of Id1, Id2 or Id3 sequences using polymerase chain reaction procedures. In this case, the amplification products are suitably separated by size on a matrix such as a polyacrylamide gel and incorporated label detected. Suitable labels include without limitation radio-labels, fluorescent labels, colored labels, and fluorogenic or chromogenic labels.
[0014] The amplicons of sizes characteristic of the Id1, Id2 and Id3 genes are also used in accordance with the invention for construction of vectors which can be used in the production of the probes of the invention. The amplicons are purified (for example by purification-scale electrophoresis), digested with restriction endonucleases BamH1 and EcoR1 and cloned into a BamH1/EcoR1 site of a vector, such as a pBluescript vector (pBS-KS-). The modified vector is introduced into a suitable host, for example E. coli in the case of pBluescript, to make multiple copies of the vector. These copies are recovered, and the probe of the invention obtained by direct reamplification of the plasmid.
[0015] The probes of the invention have lengths of 147 bp, 171 bp and 241 bp for Id1, Id2 and Id3, respectively, and the sequences as set forth in Seq. ID. Nos. 7, 8 and 9. The probes of the invention are suitably used in Northern hybridization analysis of RNA extracted from human cells that are to be assessed for the expression of one or more Id proteins. In a general sense, the probes of the invention can be used for qualitative or semi-quantitative assessment of Id mRNA levels in human tumor specimens. The specificity exhibited by these probes makes them of great utility in distinguishing between different Id family members, as well as between Id and other members of the helix-loop-helix family. Such measurements have diagnostic and prognostic value in the management of human disease.
[0016] For diagnostics, it has been observed that there are characteristic patterns of Id expression which distinguish some tumor types from corresponding normal tissues. For example, Northern analysis using the probes of the invention can be used to distinguish human rhabdomyosarcoma cells from normal primary human muscle cells. (See International Patent Publication WO97/05283 (designating the US), which is incorporated herein by reference in all jurisdictions permitting such incorporation.). Another, non-limiting example of the use to which the probes of the invention may be put is the evaluation of human brain tissue samples for the presence of astrocytomas. Deregulated Id expression has also been observed in disseminated medullablastoma, stage II/IV neuroblastoma and melanoma.
[0017] For prognostic purposes it has been observed that the presence of Id2 in neuroblastoma of children is an indicator of poor prognosis. Thus, detection of Id2 using the probes of the invention can be used as a basis for selecting a more aggressive course of therapy and for enhanced monitoring of the individual for disease recurrence. Similarly, Id1 positivity in astrocytomas and early stage lesions of the skin have been shown to signal more aggressive disease, and changes in disease treatment and management may therefore be indicated.
[0018] The probes of the invention may also be used in detection of low levels of Id in circulating tumor cells as a measure of metastatic risk in certain patient populations. High Id levels have also been observed in circulating endothelial cell precursors which are required for vascularization of certain tumors and which may be the targets of anti-angiogenic drug regimens. Monitoring of Id levels in these cells may be used for determining if a tumor is recruiting new blood vessels and therefore likely to begin metastasizing and whether angiogenic intervention is having the desired effect.
EXAMPLE 1
[0019] A PCR reaction was performed using human Id1 or human genomic DNA template and an Id1-specific primer pair (Seq. ID Nos. 1 and 2). Each reaction contained 5 ng of template, 500 ng of each of the 5′ and 3′ primers, 5 μl of 10× PCR mix (500 mM KCl, 100 mM Tris HCl pH 8.4, 15 mM MgCl 2 , 1 mg/ml gelatin), 20 μM of each deoxynucleotide triphosphate and 3 units of Taq polymerase in a 50 μl reaction volume. PCR was performed for 25 cycles to produce amplicons using a standard Perkin-Elmer automated PCR machine (60° C. hybridization temperature, 72° C. extension temperature). The amplification mixtures were loaded on a polyacrylamide gel and separated by electrophoresis. The product band was excised, and the resulting gel slices were rotated at room temperature for 2 days in elution buffer (0.3 M sodium acetate, pH 8.0, 5 mM EDTA). Supernatant was removed from the rotated slices, and the slices were rinsed again in 100 μl elution buffer. The removed supernatant and the elution buffer from the rinse were pooled in to an Eppendorff tube to yield a total volume of about 400 μl. 40 μl 5M NaCl, 4 μl 1M MgCl 2 and 600 μl isopropyl alcohol were added to the tube which was centrifuged for 30 minutes. The resulting pellet was washed in 80% ethanol and dried under vacuum for 5 minutes. The pellet was then resuspended in 15 μl PCR sterile TE to form an amplicon solution.
[0020] The probe can now be used directly used directly to make a probe for in situ hybridization by reamplification as described above using 32 P-labeled deoxynucleotide triphosphates. The reamplified, labeled probe is separated from unincorporated dNTPs using a G-50 Sephadex spin column and applied to tissue samples as described in Jen et al.
[0021] The unlabeled probe was also cloned into the BamHI+EcoRI sites of pBluescript (KS − ) (Stratagene) to ensure a limitless supply of template without reamplification of cDNA. 10 μl of the unlabeled amplicon solution was combined with 3 μl of 10× KGB buffer, 8 units of of BamH1, 8 units of EcoR1, and 15.5 μl of water and incubated at 37° C. for about 4 hours to cleave the BamH1 and EcoR1 restriction sites. 40 μl TE (10 mM Tris pH 7.4, 1 mM EDTA) and 40 μl phenol (pH 8.0) was added to the mix, centrifuged to recover the aqueous phase which was then applied to a G-50 Sepharose column to remove residual phenol. The material was precipitated by adding 1/10 volume of 3 M NaOAc, EtOH and centrifuged for 30 minutes.
[0022] The recovered pellet was resuspended in 10 μl PCR-sterile TE. 3 μl of this suspension was combined with BamH1/EcoR1 cut pBluescript vector (pBS-KS − ), ATP and ligase in buffered and incubated overnight at 15° C. The ligated vector was transferred into E. coli strain JM109 using standard protocols. After growth, colonies harboring the ampicillin resistance marker of the Bluescript vector were selected by plating on ampicillin containing agar. Plasmids were isolated and tested for the presence of the amplicon insert. The resulting probe has the sequence given in Seq. ID No. 7.
EXAMPLE 2
[0023] A probe was created for human Id2 using an Id2-specific primer pair (Seq. ID Nos. 3 and 4) in the procedures of Example 1. The resulting probe has the sequence given in Seq. ID No. 8.
EXAMPLE 3
[0024] A probe was created for human Id3 using an Id3-specific primer pair (Seq. ID Nos. 5 and 6) in the procedures of Example 1. The resulting probe has the sequence given in Seq. ID No. 9.
EXAMPLE 4
[0025] RNA was extracted from human rhabdosarcoma cancer cell lines and primary human muscle cells (as a control). Northern analysis was performed using the procedures previously described in Benezra et al. (1990) Cell 61: 49-59, which is incorporated herein by reference, and the Id1, Id2 and Id3 probes (Seq. ID Nos 7-9). The observed hybridization patterns demonstrated the specificity of the probes, since the Id1 probe hybridized to a differently and correctly sized messenger, as compared to Id2 and Id3. In addition, in case of Id2, the specificity of the probe was confirmed by hybridization to an Id2 containing plasmid.
EXAMPLE 5
[0026] ID1 specific probe (Seq. ID No. 7) is used for in situ hybridization in the evaluation of sample suspected of being early stage melanoma. 6-7 micron sections are processed with [α- 33 P]-labeled probes using the general procedure previously described in Lyden et al., Nature ( Lond ) 401: 670-677 (1999), which is incorporated herein by reference, and observed for binding of the label. Binding is indicative that the sample is early stage melanoma. | Oligonucleotide primers and polynucleotide probes provide selective amplification and detection of Id genetic sequences and are selected both (1) to provide the desired specificity so that they amplify only the specific Id type to which they are targeted; and (2) to introduce terminal restriction endonuclease cleavage sites into the amplicon that facilitate the incorporation of the amplicon into plasmid-based vectors. Detection of Id genetic sequences can be carried out using the labeled-amplicon by reamplifying the amplicon with the primers in the presence of labeled, for example radiolabeled, deoxynucleotide triphosphates. The probes of the invention correspond in sequence to the amplicons produced using the primers of the invention, after cleavage at the restriction endonuclease sites. | 2 |
TECHNICAL FIELD
The field of this invention relates to a high voltage connector assembly and more particularly for a high voltage connector assembly that incorporates a high voltage interlock loop connector assembly for automotive applications.
BACKGROUND OF THE INVENTION
Vehicles that are propelled by internal combustion engines have low voltage circuits that are used to operate numerous devices for example, turn signals, headlights, brake lights, radios, and electronic instrument panels. Electric or hybrid vehicles on the other hand need to have a high voltage circuitry to provide the needed wattage to run the main electric motors and other devices that have typically been belt driven. It is foreseen that many more electric type vehicles will enter the commercial market that use high voltage (typically 300V or higher) to power these devices and will need high voltage connectors for the circuits.
In order to allow easy installation and disconnection of various electrical components for repair and replacement, the high voltage circuit for these electric and hybrid vehicles may have several conveniently placed high voltage connectors that may be connected together or disconnected from each other.
Furthermore, due to the high voltage and large amperage involved, it is a prerequisite to shut down the high voltage circuit in question before an automotive technician or other individual disconnects any high voltage connector. To prevent premature physical contact with the high voltage circuit, interlock loop circuitry, often referred to as high voltage interlock loops (HVIL), have been devised which when triggered will activate a shut-off program to shut down the high voltage circuit. One such trigger is an interlock loop connector in the HVIL circuit that often is piggybacked onto the high voltage connectors to allow the high voltage electrical circuit to shut down and adequately discharge after the HVIL circuit becomes disconnected but before the connector housing of the high voltage connector assembly can become disconnected.
Present HVIL connectors system are costly, bulky and contain extra parts which are subject to grease and grime buildup that may eventually interfere in its operation.
What is needed is a smaller and more reliable connector for an HVIL system. What is also needed is an HVIL connector that uses as part of its structure a connection position assurance device on the high voltage connector housing.
SUMMARY OF THE DISCLOSURE
In accordance with one aspect of the invention, a high voltage and interlock loop connector assembly has first and second high voltage connector housings as part of a high voltage circuit running therethrough. The first and second high voltage connector housings are complementarily constructed for releasable engagement with each other. First and second connectors for an interlock loop circuit are also complementarily constructed for releasable engagement with each other. The first and second interlock loop connectors preferably are movable to disconnect and break an interlock loop circuit running therethrough. One of the first or second interlock loop connectors is mounted on one of the high voltage connector housings. The first and second interlock loop connectors each have complementarily abutment shoulders with one abutment shoulder being on a flexible tab. The abutment shoulders abut each other and prevent full engagement of the connectors when the first and second high voltage connector housings are not fully engaged with each other. The flexible tab is movable by one of the high voltage connector housings to misalign its abutment shoulder from the other abutment shoulder when the high voltage connector housings are properly engaged together to allow full engagement of the first and second interlock loop connectors.
Preferably, the first and second high voltage connector housings have a latching handle mechanism constructed to be non-releasable when the first and second interlock connectors are engaged to each other. It is also preferred that the high voltage connector housings require engagement with a tool to complete disconnection of the high voltage circuit within the high voltage connector housings after disconnection of the interlock loop circuit within the interlock loop interlock loop connectors.
In one embodiment, one of the high voltage connector housings has a connector positioned assurance device. Preferably, the connector position assurance device has a slide member with a locking protrusion that extends into an opening in the first high voltage connector housing when in the engaged position. The locking protrusion is recessable out of the opening by a tool sized to enter the opening to allow the connector position assurance slide member to move to its disengaged position and to allow the latching handle mechanism to be releasable and to allow disconnection of the first and second high voltage connector housings. Furthermore, the locking protrusion may be positioned at a distal end of a resiliently flexible tongue section of the slide member. The tongue section is flexible to allow the locking protrusion to flex and descend out of the opening under a stop shoulder. It is desired that the opening and the locking protrusion are covered by the interlock loop connectors when the interlock connectors are engaged.
In one embodiment, the flexible tab is deflectable upward by a surface of the connector position assurance slide member when the high voltage connector housings are in the fully engaged position and the connector position assurance slide member is in the locked position. One of the interlock loop connectors and the high voltage connector housings have a groove to receive the flexible tab to let it resiliently bias back downward to a rest position when the interlock loop connectors are fully engaged.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference now is made to the accompanying drawings in which:
FIG. 1 is a perspective assembled view of a high voltage and HVIL connector assembly showing the first and second HVIL connectors assembled on top of the first and second high voltage connector housings;
FIG. 2 is a perspective view of the second HVIL connector shown in FIG. 1 ;
FIG. 3 is a perspective view of the first high voltage connector housing shown in FIG. 1 ;
FIG. 3A is a top plan partially broken view of the first high voltage connector housing illustrating the connection position assurance slide member;
FIG. 4 is a perspective view of the first HVIL connector shown in FIG. 1 ;
FIG. 5 is a cross-sectional view of the assembly shown in FIG. 1 with the high voltage connector housing fully engaged and the HVIL connectors in position to be engaged;
FIG. 6 is a cross-sectional view similar to FIG. 5 with the HVIL connectors fully engaged;
FIG. 7 is a cross-sectional view similar to FIG. 5 with the HVIL first connector disengaged and the high voltage connector housing ready to be disengaged;
FIG. 8 is a cross-sectional view similar to FIG. 5 with the connector position assurance mechanism slid back to allow the main latching device to be operated to unlock the high voltage connector housings;
FIG. 9 is a cross-sectional view similar to FIG. 5 illustrating another improper installation attempt with the high voltage housing connected but the connection position assurance device not positioned in the installed position; and
FIG. 10 is a cross-sectional view similar to FIG. 5 illustrating an improper sequence of installation of the HVIL connectors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a high voltage and HVIL connector assembly 10 is shown with a male high voltage housing 12 connected to a female high voltage housing 14 . A latching device 16 and connection position assurance device 18 are housed on the female connector housing 14 . High voltage wires 20 extend from each housing 12 and 14 and connect together when the two housings 12 and 14 are connected as part of a high voltage circuit 21 .
A male HVIL connector 22 is piggy backed on top of the male housing 12 . The connector 22 may be integrally formed with the male housing 12 . A female HVIL connector 24 is removably mounted on top of the female housing 14 . 14 . Low voltage HVIL wires 26 are operably connected to the HVIL connectors 22 and 24 that contact each other to form part of an HVIL circuit 27 . When the connectors 22 and 24 become disconnected the HVIL circuit 27 becomes open and is programmed to open the high voltage circuit 21 by disconnecting from a high voltage source (not shown). A period of time, for example 5 seconds, is required to insure an adequate discharge of the voltage to less than 60 volts after the high voltage circuit 21 is disconnected from the high voltage source.
In order to assure that the appropriate period of time occurs between the opening of the HVIL circuit 27 and the access to the high voltage circuit 21 , the high voltage connector housings 12 and 14 and the HVIL connectors 22 and 24 are constructed to take time to disconnect. In particular, the period of time needs to be long enough from first disengagement of the HVIL circuit 27 and when the HVIL connector housings are disengaged to the time the high voltage connector housing 12 and 14 become accessible and are first pulled apart to open the high voltage circuit 21 .
It is desired that the latching device 16 is inoperable and/or inaccessible when the HVIL connectors 22 , 24 are engaged. Furthermore, once the HVIL low voltage circuit 27 is open by pulling apart the two connectors 22 and 24 , the needed use of a tool provides time when a person picks up the tool and uses it to access a mechanism before the full disconnection of the two high voltage housings 12 and 14 is possible.
A male low voltage connector 22 is housed or mounted on the male high voltage housing 12 as more clearly shown in FIG. 2 . The low voltage connector 22 may be integrally formed with the high voltage housing 12 . The low voltage connector 22 has a stop shoulder 30 formed near the male entry end 32 for the low voltage electric terminal connectors (not shown). A slot 34 is formed between the stop tab 30 and the end 32 that axially extends rearwardly.
As shown in FIGS. 3 and 5 , the female high voltage connector housing 14 has a first end 36 for receiving an end 38 of the male connector housing 12 and has high voltage terminals 40 that engage complementary high voltage terminals. (not shown) in male connector housing 12 . At a top surface, the latch device 16 has a latch handle 44 that operates locking latches 46 that releasably engage complementary recesses 48 in the male housing 12 to latch and lock the two high voltage housings 12 and 14 together.
The connector position assurance device 18 includes a slide member 50 that slides along a groove 54 in the female connector 14 under the latch handle 44 . The male connector 12 as more clearly shown in FIGS. 5 and 6 has an abutment section 56 which receives and deflects the slide 50 upwardly within the groove 54 when pushed to the assured position. When the movable slide member 50 is fully engaged, its thicker handle end 55 prevents the latch handle 44 from being operably depressed to pivot the latches 46 upward. Therefore, the latches 46 cannot lift and disengage from the male connector housing 12 .
As shown in FIG. 4 , the connector 24 has a female end 58 with low voltage terminals 59 for the HVIL circuit 27 . A flexible tab 60 is formed with one abutment shoulder 61 at end 58 that can be radially flexed inwardly (upwardly as shown in the Figures) but resiliently biased to its rest position as shown in FIG. 4 .
As shown in FIG. 5 , when the two low voltage connectors 22 and 24 are engaged after the high voltage connector housings 12 and 14 are engaged, the flex tab 60 is flexed upwardly as it rides on top of the slide 50 . Slide 50 misaligns its abutment shoulder 61 to pass over the stop shoulder 30 and enter slot 34 to the engaged position as shown in FIG. 6 . In the engaged position as shown in FIG. 6 , terminals 58 engage terminals 63 in housing 24 . The latch handle 44 even though exposed is not operational because of the lock out function of the CPA device 18 , particularly by the interposition of thicker section 55 . Once the low voltage connectors 22 and 24 are fully engaged the flex tab 60 is allowed to resiliently flex back to a rest position as shown in FIG. 6 by engaging a recess 65 within the slot 34 . This alleviates long term stress on the flex tab 60 during the installed position and increases it durability.
Referring now to FIGS. 6 and 7 , the flex tab 60 has a canted surface 72 to allow the female connector 24 to be axially pulled and disengaged from the male connector housing 22 . Once the female connector housing 24 is disengaged from the assembly 10 , the slide 50 member has a lock protrusion 64 extending into an opening 66 in the latch handle 44 . The opening 66 may be continuous with groove 54 . A lock shoulder 67 is at one end of opening 66 . The lock protrusion 64 is at a distal end of resilient tongue section 52 . A tool, for example a small screw example a small screw driver or a pick, needs to push the protrusion 64 downwardly as shown by arrow 75 to disengage it from the opening 66 to bypass shoulder 67 in order to allow the slide member 50 to slide back to the set position as shown in FIG. 8 . Aperture 70 with stop shoulder 71 prevents the slide member 50 from undesirably disengaging from housing 14 . After the slide member 50 is moved back to the set position as shown in FIG. 8 , the latch handle 44 becomes free to be depressed and release the latches 46 to unlock high voltage housings 12 and 14 from each other. The time it takes for an operator to pick up a tool, press it into opening 66 and slide the slide 50 seems to generally well exceed the preferred 5 second period of time to adequately lower the voltage below the 60 volt level.
Furthermore, with reference to FIGS. 9 and 10 , the HVIL connectors 22 and 24 cannot be engaged without the high voltage connector housings 12 and 14 previously being engaged. If the slide member 50 is not in the engaged position as shown in FIGS. 5 and 6 , the flex tab 60 is in a lower position by flexing into groove 54 and its shoulder 61 abuts against the stop shoulder 30 and prevents full engagement. For example in FIG. 10 when the female high voltage connector 14 is not there, it can be seen that the tab 60 abuts the stop shoulder 30 . Even if the female connector housing 14 as shown in FIG. 9 is there and partially engages but the slide member is not properly engaged, the slide 50 does not fill groove 54 and the flex tab 60 is allowed to drop into the same groove 54 and abut the stop shoulder 30 .
In this fashion, an HVIL connector system for a high voltage connector provides several advantages of a system that prevent unwanted and undesirable premature connection of the low voltage HVIL circuit while also preventing unwanted and undesirable premature disconnection of a high voltage circuit of an electrically driven motor vehicle before the low voltage circuit is disconnected.
It will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those described above, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description, without departing from the substance or scope of the present present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the following claims and the equivalents thereof. | A high voltage and interlock loop assembly has first and second high voltage connector housings complementarily constructed for releasable engagement with each other and for having a high voltage circuit running therethrough. First and second connectors for an interlock loop circuit are complementarily constructed for releasable engagement with each other with one of the interlock loop connectors being mounted on one of the high voltage connector housings. The first and second interlock loop connectors have complementarily abutment shoulders with one abutment shoulder being on a flexible tab. The flexible tab is movable to misalign its abutment shoulder from the other abutment shoulder when the high voltage connector housings are properly engaged together to allow full engagement of the first and second interlock loop connectors. | 1 |
CROSS-REFERENCE TO RELATED PATENTS
[0001] Provisional Application Ser. No. 60/984,705, filed Nov. 1, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of Invention
[0004] The present application relates to the field of leashes for use with surfboards. This application claims the benefit of priority from the provisional patent application filed on Nov. 1, 2007, Ser. No. 60/984,705.
[0005] 2. Background of the Invention
[0006] A surfboard leash is a cord that is used to attach a surfboard to the surfer. It is useful for preventing waves from taking a runaway surfboard to the beach, or from hitting other surfers. Leashes were introduced to surfing on or about the early 1970's, and they have evolved significantly since then, but the basic purposes for the leash are the same. Most modern leashes are comprised of a plastic cord, which is usually urethane, where one end has a band with a Velcro® styled strap (clinging pile and corresponding loop fastener mechanism) that is attached to a surfer's back foot, and where the other end has a Velcro® strap attached to the tail of a user's surfboard.
[0007] Despite the advances in surf leash technology, one major problem that persists with surf leashes is the tendency of the leash to tangle around the surfer's board and legs. The most common material for a surfboard leash is urethane. While the urethane is well suited for strength and balanced elasticity, the properties of this material, and other plastic cords, cause the leash to coil and tangle the user, often at undesirable times. On a day when waves are small, the problem may be just an annoyance. However, when the waves are large, or where the surf break has reef or sharp rocks, the condition of a tangled surfer can be extremely dangerous, or even deadly. A leash tangled around an ankle or a surfboard can delay take offs, limit needed mobility, or prevent a surfer from freedom to swim. A tangle in the leash can compromise a surfer's ability to gain distance from the surfboard, from other surfers, from large wave sets, and it increases the likelihood that a surfboard will strike and harm the surfer.
[0008] There have been some notable improvements that have tried to address the problem of leash tangling, however, they have not taken the approach of the embodiments of the present application or are inadequate for a variety of reasons. For example, U.S. Pat. No. 4,610,634 (1986) to Kimura taught swivel mechanisms at opposite ends of a leash cord, near the ankle cuff and near the cushion strip. This improvement is very helpful, but the cords still have a considerable length between the swivels that is susceptible to tangling. U.S. Pat. No. 5,194,026 (1993) to Corwin teaches a leash that attaches to a surfers hip, however, this does not eradicate the tangle factor adequately and many surfers, who are contraption resistant, do not want to deal with such an obstruction to movement, or to feel the presence of the equipment. U.S. Pat. No. 7,204,734 (2007) to Kawasaki, and related pending applications, teach a circular weight disposed at a mid-point of the leash cord, however, many surfers do not want to drag a weight, and there is some concern that a weighted object on a slinging leash could potentially be dangerous to surfers, other boards, or swimmers. U.S. Pat. No. 6,500,039 (2002) to Underwood teaches an apparatus where a modification to the surf cuff is used to address leash tangling. While each of the improvements are noteworthy, Applicants believe that they fail to adequately control the tangling factor of surf leashes. Moreover, Applicants believe that many of the prior art technologies are unlikely to be embraced and desired by surfers by reason of awkwardness of use, for reasons of inadequate safety, or simply because they distract the surfer's ability to experience the waves unencumbered by contraptions.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is an object of the present application to provide a surfing leash that resists tangling.
[0010] It is yet another objective of the present application to provide a surf leash adaptation that may be constructed originally, or be used to retrofit existing surf leashes so they will resist tangling.
[0011] It is yet another objective of the present application to provide a surf leash that enhances the safety of the surfer.
[0012] It is yet another objective of the present application to provide a surf leash that does not obstruct existing equipment and that is not overly cumbersome or awkward to a surfer.
[0013] Other objectives of the invention will become apparent to those skilled in the art once the invention has been shown and described. These objectives are not to be construed as limitations of applicant's invention, but are merely aimed to suggest some of the many benefits that may be realized by the apparatus of the present application and with its many embodiments.
BRIEF DESCRIPTION OF THE DRAWING
[0014] The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0015] FIG. 1 is a perspective drawing of a surfer, a surfboard, and a prior art leash as such leashes tend to tangle around the leg of the surfer.
[0016] FIG. 2 is a perspective drawing of a standard prior art surf leash and typical components.
[0017] FIG. 3 is a perspective drawing of a preferable embodiment of this application where the tangle factor of a typical surf leash has been augmented by the use of a sheath with physical characteristics that cause a bias of the surf leash away from its natural coiling tendencies.
[0018] FIG. 4 is a perspective drawing of a preferable attachment of a sheath described in this application to a typical surf leash.
[0019] FIG. 5 is a cross sectional and perspective view of the sheath embodiment of the present application as it typically relates to components of a typical surf leash.
[0020] FIG. 6 is a closer cross sectional view of the sheath embodiment of the present application as it may be fastened around the cord of a typical surf leash, and also demonstrating a resilient member used to augment the natural tendencies of leashes to coil.
[0021] FIGS. 7 , 7 A, and 7 B are cross sectional views of alternate embodiments and shapes of sheaths that may be used to accomplish the inventive purposes of this application.
[0022] FIG. 8 is a depiction of a sheath embodiment of this application, with strategically placed supports to maintain sheath shape and positioning on a surf leash.
[0023] FIGS. 9 , 10 , 10 A, and 11 relate to alternate cord shapes for a surf leash that are operationally configured to resist tangling.
[0024] FIG. 12 is a cross section of a surf cords to illustrate the various dimension of a typical surf leash cord that may be modified, as seen in FIGS. 9 , 10 , 10 A, and 11 .
[0025] FIG. 13 is an alternate embodiment of this application featuring an adaptation for a surf leash featuring a plurality of ties that are used to envelop and modify the properties of a surf leash prone to tangling.
[0026] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments that will be appreciated by those reasonably skilled in the relevant arts. Also, drawings are not necessarily made to scale but are representative.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 is a perspective drawing of a surfer, a surfboard, and a prior art leash as such leashes tend to tangle around the leg of the surfer. This is a primary problem addressed by the inventive embodiments of this application.
[0028] FIG. 2 is a perspective drawing of a standard prior art surf leash and typical components thereof, which include but are not necessarily limited to, a cord 5 ; the cord 5 being adapted to connect ultimately on one end to a surfboard, and on a second end to a surfer. Such a cord 5 is usually made of urethane because this material has been found to have adequate strength and elastomeric properties, including a minimal tendency to cause a board to snap back at the user (such as is typical of surgical tubing). Various chemical compositions may be used to make up a surf leash cord 5 , but the most common plastic is urethane. At one end of the cord (surfboard end), the cord 5 usually is connected to the board through a first connector 9 , which usually meets a cushion strip 3 , fastened to a string 1 , which string 1 is usually adapted to fasten the leash to a surfboard through an anchor attachment in a surfboard. The first connector 1 is usually a hard (usually high density) plastic component that fastens securely to the cord 5 , which first connector 1 may or may not feature a swivel mechanism (which is also aimed at reducing leash tangle). The first connector 1 of a typical leash will usually merge with a cushion strip 3 , which serves a dual role of connecting a cord 5 to the surfboard string 1 and protecting the surfboard surface from abrasion by the cord 5 . Many modern cushion strips 3 have a sandwiching Velcro® fastening mechanism that permits secure, but rapid separation of the surf leash from a surfboard. At the opposite end of a surf leash (the surfer end), the cord 5 has a second connector 11 which may or may not have a swivel mechanism, but that merges into a cuff 7 configured to wrap around the leg of a surfer. Cuffs 7 are commonly known and have a variety of quick release features, such as a Velcro® styled loop and fastener mechanism that allows a surfer to separate him or herself from the leash and surfboard, for instance, when transporting the surfboard, or when the surfboard or leash is caught on an underwater structure such as a reef and threatens to drown the surfer.
[0029] FIG. 3 is a perspective drawing of a preferable embodiment of this application where the tangle factor of a typical surf leash has been augmented and diminished by the use of a sheath 13 with physical characteristics that cause a bias of the cord 5 of the surf leash away from its natural coiling tendencies. The sheath 13 envelops a portion the cord 5 and does not allow the natural coiling tendencies.
[0030] FIG. 4 is a closer view of an embodiment of the sheath 13 of the present application, including a view of resilient member 12 housed in the sheath 13 . The resilient member 12 typically extends over a substantial portion of the length of the sheath 13 and is integrally housed in, on, or to the sheath 13 . The resilient member 12 serves to stabilize and augment the natural tendency of urethane cord 5 to coil. The cord 5 cannot curl because it is physically restricted from doing so by the resilient member 12 of the sheath 13 , which only bends in a restricted plane. The shape and flexibility of the resilient member 12 may be modified to accomplish a flexibility that will neither obstruct the normal trailing of the surf leash behind the surfer, nor remain so stiff to prevent bending of the leash. Also, as further discussed herein, a sheath 13 that envelops the cord 5 may feature a resilient member 12 with polygonal or rectangular shapes that restrict motion along the length of the sheath 13 in a plane so that tangling is prevented.
[0031] FIG. 5 is a cross sectional and perspective view of the sheath 13 embodiment of the present application as it typically relates to components of a typical surf leash. The sheath 13 is adapted to envelop the cord 5 along a substantial portion of the length of the cord 5 . The sheath 13 may be secured around the leash cord 5 by use of a fastening means 10 , such as may be appreciated by those skilled in the arts, and may include, but are not limited to adhesives, zippers, or Velcro® styled fasteners. The sheath 13 is adapted for aftermarket use on existing surf leashes as they are purchased off of the shelf in a typical surf store, so ease of attachment is of concern. FIG. 5 also shows the resilient member 12 , in a rectangular shape and fixedly disposed along the sheath 13 of the embodiment. While the sheath 13 is adapted to envelop the cord 5 , a distance “a” is used to show that some space is contemplated between the cord and the interior of the sheath 13 , and the sheath may or may not move up and down along the length of the cord 5 . This distance “a” between the cord 5 and sheath 13 interior may range and vary from about 0.1 to 30 millimeters, although it is possible that greater distances could operate.
[0032] FIG. 6 is a closer cross sectional view of the sheath 13 embodiment of the present application as it may be fastened around the cord 5 of a typical surf leash, and also demonstrating a resilient member 12 used to augment the leash's natural tendencies to coil. While there is some play inside of the sheath 13 with the cord 5 that moves within the sheath 13 , the resilient member 12 restricts coiling motion of cord 5 . The resilient member 12 is of such a construction that its tendency to bend is restricted to a particular plane of motion, but without coil. The resilient member 12 lends its flexibility, yet limited range of motion to the sheath 13 , which surrounds the cord 5 . However, the cord 5 still benefits from the elastomeric and strength of a typical urethane cord 5 . Thus, the leash of this embodiment enjoys all the benefits of a typical surf leash, without the likelihood of tangling. While most leashes are made of urethane, it is contemplated that the embodiment of this invention will work with a cord 5 of any chemical construction. The resilient member 12 is typically constructed of a semi-flexible plastic material, including but not limited to materials such as high density polyethylene, high density polypropylene, polyvinyl chloride, or other hard plastic, composite, metal, or any other partially flexible, but resilient material 12 .
[0033] FIGS. 7 , 7 A, and 7 B are cross sectional views of alternate embodiments and shapes of sheaths that may be used to accomplish the inventive purposes of this application. FIG. 7 is an embodiment of the sheath 13 where the sheath 13 is made to substantially define a circle around the cord 5 , and where a resilient member 12 is fixedly and integrally connected to such sheath 13 along its interior. The sheath 13 material may be of a variety of constructions, but is typically formed from a durable cloth, preferably capable of withstanding the rigors of repeated exposures to salt and sea. Examples of such cloth may include but are not limited to ripstop nylon, polyester or other materials having such qualities. These materials will be appreciated by those skilled in the arts. It is generally the case that the sheath 13 material will have greater flexibility than the resilient member 12 , although it is possible that the sheath 13 itself could also be used to impart a limited range of motion to the cord 5 of a surf leash. FIG. 7A represent another embodiment of the sheath 13 wherein a resilient member 12 may be fixedly connected along the exterior of the sheath 13 , and where the sheath 13 may also define a principally ovular configuration around the cord 5 with a greater distance “a” occurring between the cord 5 and the interior of the sheath at the “sides.” FIG. 7B represents an embodiment of the sheath 13 where the resilient member 12 comprises a broad portion of sheath 13 and is integrally connected to the sheath 13 , including on the exterior, although the resilient member 12 may be woven or sandwiched inside the material of the sheath 13 . A resilient member 12 is suitably of a range of width from about 2 millimeters to 40 millimeters in width, although other ranges are possible. A resilient member 12 typically extends over the entire length of sheath 13 , although the resilient member may also be sectioned in the fashion of vertebrae of a spine, so long as the range of motion remains slightly restricted in a plane that prevents tangling.
[0034] FIG. 8 depicts the sheath 13 embodiment of the present application, wherein the sheath 13 is further modified by supports 15 along the length of the sheath, which supports may be used to keep the sheath 13 from collapsing along its length, or also to secure the sheath to a desired place along the length of the cord 5 . It is contemplated that the sheath 13 of the present application may extend along the entire length of the cord 5 , or merely along a portion of the leash cord 5 adequate to prevent tangling. Most commercially available surf leashes range from 4 to 12 foot in length. The sheath 13 of the present application may be the same length of the cord 5 of the surf leash, but more typically is shorter that the cord 5 portion of the leash on which it is used. For example, on a 6 foot surf leash, which is a common short board size, the sheath 13 would typically be in the range of about 1.5 to 4 foot in length, and depending on the relative flexibility of the resilient member 12 employed.
[0035] FIGS. 9 , 10 , 10 A, and 11 depict alternate embodiments of the present application wherein the surf leash accomplishes tangling avoidance by virtue of a cord 5 with a shape fabricated to avoid tangling. FIG. 9 features a cord 5 that is rectangular in shape along the length. The rectangular shape is less prone to coiling because the rectangular shape causes motion and bending along a more restricted plane. In all other respects, the leash of FIG. 9 is similar to those known in the art. By the same token, FIG. 10 represents yet another embodiment of the invention where the cord 5 is of an ovular definition, and where the substantially “flatter” shape of the cord 5 resists tangling. FIG. 11 represents a hybrid version of the leash cord of the present application wherein the cord 5 varies in shape along its length. In FIG. 11 , the flat section of the cord 5 is centrally located, but the cord 5 is principally circular near each end where it meets the first 9 and second 11 connectors.
[0036] FIG. 12 is a cross section of a surf cord 5 designed to illustrate the various dimension of a typical surf leash cord that may be modified, as seen in FIGS. 9 , 10 , 10 A, and 11 , and where “x” and “y” represent cross sectional dimensions of a cord 5 and where “z” represents the longitudinal length of a cord 5 . In FIGS. 9 , 10 , and 10 A for example, the “x” distance would exceed the “y” distance to accomplish a more rectangular shape along the entire length “z” of the cord 5 . In one non-limiting example, a typical “x” distance could be 2 centimeters, whereas a “y” would be 1.5 centimeters or less. Such as ratio of height to width avoids tangling, although various other ratios may also accomplish the non-tangling characteristics.
[0037] FIG. 13 is an alternate embodiment of this application featuring an adaptation for a surf leash featuring a plurality of ties 16 that are used to envelop and modify the properties of a surf leash cord 5 prone to tangling. In this embodiment, the sheath 13 is avoided and the tendency of the cord 5 to tangle is augmented instead by directly tying a resilient member 12 to the surf leash cord 5 . Alternatively, this embodiment may be covered by a sheathing material in order to provide a uniform appearance and feel. Said sheathing material may consist of any type of ripstop nylon, polyester, urethane or other material with appropriately flexible characteristics.
[0038] Therefore, minimally disclosed are an apparatus for avoiding tangling of a surf leash comprising a sheath operationally configured to envelop the cord of a surf leash; said sheath securable around said cord by a fastening means; said sheath having at least one resilient member disposed along at least a portion of the length of said sheath. Further minimally disclosed is a tangle resistant surf leash comprising a cord; said cord having a first connector at one end with said first connector being fixed to a cushion strip for attachment to the string of a surfboard; a second connector at opposite end of said cord, said second connector secured to a cuff; wherein said cord is defined by the distance of an “x” component that is greater than a “y” component, or wherein said cord 5 defines a rectangular shape, or a substantially flattened shape, or an ovular shape.
[0039] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention, are not to scale, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments which are appreciated by those skilled in the arts. | An improved surf leash with a tangle resistant cord, fabrication methods thereof, and an apparatus operationally configured to resist tangling of existing surf leashes. | 1 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a process for liquefaction of nitrogen produced by separating air by cryogenic distillation using an improved refrigeration source, particularly, vaporizing LNG, to yield the liquefied nitrogen.
BACKGROUND OF THE INVENTION
The separation of air to produce oxygen, nitrogen, argon, and other materials is done by distillation under low pressure to achieve power conservation. It is known that the refrigeration available from liquefied natural gas (LNG) can be utilized for cooling feed air and/or compressing component gases.
When pipelines are not feasible, natural gas is typically liquefied and shipped as a bulk liquid. At the receiving port, this liquefied natural gas (LNG) must be vaporized and heated to ambient temperatures. An efficient use of this refrigeration at the time of vaporization is highly desirable. It is becoming more common to build air separation plants with liquefiers which utilize the refrigeration available from the vaporizing LNG. An efficient scheme, which more effectively utilizes the refrigeration available from LNG to produce liquid products from air, can lead to substantial savings in energy and capital investment.
Liquefier processes are needed, especially for the case where the demand for liquid product is so high that the available amount of refrigerant LNG is unable to fully meet the total refrigeration demands. Generally, this situation occurs where the equivalent tons of liquid nitrogen produced per ton of LNG is greater than 0.45. In such instances, supplemental refrigeration from existing energy sources is needed to meet the extra refrigeration demand. While some solutions have been proposed, they do not involve any precooling of the gaseous component for liquefaction, prior to each cold compression stage, nor do they suggest using an expander means to produce liquid product, suited to provide supplemental refrigeration. The technical problem is to integrate the added refrigeration requirements with the primary one available from LNG and to do it at variable temperature levels.
Several publications disclose the production of liquid nitrogen by indirect heat exchange against vaporizing LNG. Since the coldest temperature of LNG is typically above -260° F., the nitrogen must be at a pressure greater than ambient pressure in order to be condensed because the normal boiling point of nitrogen is -320° F. Typically, to condense at temperatures of about -260° F., the nitrogen must be compressed to above 225 psia. Compression of the nitrogen prior to its condensation by heat exchange with LNG is one of the major sources of energy consumption in producing a liquid nitrogen product.
U.S. Pat. No. 3,886,758 discloses a method wherein a nitrogen stream is compressed to a pressure of about 15 atm (221 psia) and then condensed by heat exchange against vaporizing LNG. Since all the gaseous nitrogen is not precooled against the warming natural gas prior to compression, the amount of energy required for the nitrogen compressor is quite high.
U.K. patent application 1,520,581 discloses a process of using the excess refrigeration capacity associated with a natural gas liquefaction plant to produce additional LNG, specifically for the purpose of providing refrigeration for the liquefaction of nitrogen. In the process, the nitrogen gas from the air separation plant to be liquefied is compressed without any precooling with LNG.
Yamanouchi and Nagasawa (Chemical Engineering Progress, pp 78, Jul. 1979) describe another method of using LNG refrigeration for air separation. Once again, nitrogen at about 5.2 atm is compressed to about 31 atm without any precooling. Moreover, in this paper, LNG is vaporized in the LNG heat exchanger at close to ambient pressure (15 psia).
U.K. patent 1,376,678 teaches that evaporation of LNG at close to atmospheric pressure is inefficient because the vaporized natural gas must be admitted into a distribution pipeline at a pressure at which it can reach its destination, i.e., a transport pressure. This transport pressure is much higher than atmospheric pressure usually not exceeding 70 atm (1029 psi). Therefore, if LNG is vaporized at atmospheric pressure, then a considerable amount of energy is required to recompress the vaporized gas to its transport pressure. As a result, in U.K. patent 1,376,678, the LNG is first pumped to the desired pressure and then vaporized. Unfortunately, the process of refrigeration energy recovery taught in this patent is inefficient because not all of the refrigeration available from the LNG is recovered and the vaporized natural gas leaving the LNG heat exchanger is still quite cold (-165° F.). This incomplete recovery of refrigeration implies that, for this process, large quantities of LNG will be required to produce the desired quantity of liquid nitrogen.
Japanese patent publication 52-37596 (1977) teaches vaporizing low pressure LNG against an elevated pressure nitrogen stream, which is obtained directly from a distillation column which operates at an elevated pressure. In the process, only part of the LNG is vaporized against the condensing nitrogen and the remainder of the LNG is vaporized in the other heat exchangers; this is an inefficient use of the refrigeration energy of LNG. The vaporized natural gas is then compressed.
U.S. Pat. No. 3,857,251 discloses a process for producing liquid nitrogen by extraction of nitrogen from the vapors resulting from the evaporation of LNG in storage tanks. The gaseous nitrogen is compressed in a multistage compressor with interstage cooling provided by water, air, propane, ammonia, or fluorocarbons.
Japanese patent publication 46-20123 (1971) teaches cold compression of a nitrogen stream which has been cooled by vaporizing LNG. Only a single stage of nitrogen compression is used. As a result, an effective use of LNG cold energy, which vaporizes over a wide range of temperature, is not obtained.
Japanese patent publication 53-15993 (1978) teaches the use of LNG refrigeration for the high pressure nitrogen drawn off the high pressure column of a double column air distillation system. The nitrogen is cold compressed in a multistage compressor, but without any interstage cooling with LNG.
German patent 2,307,004 describes a method for recovering LNG refrigeration to produce liquid nitrogen. Nitrogen gas from the warm end of a cryogenic air separation plant is close to ambient pressure and ambient temperature. This feed nitrogen is compressed, without any LNG cooling, in a multistage compressor. A portion of this compressed gas is partially cooled against LNG and expanded in an expander to create low level refrigeration. The other portion of compressed nitrogen is cold compressed and condensed by heat exchange against the expanded nitrogen stream. The expanded gas is warmed and recompressed to an intermediate pressure and then fed to the nitrogen feed compressor operating with an inlet temperature close to ambient. It is clear that most of the nitrogen compression duty is provided in compressors with inlet temperature close to ambient temperature and that no interstage cooling with LNG is provided in these compressors.
U.S. Pat. Nos. 4,054,433 and 4,192,662 teach methods whereby a closed loop, recirculating fluid is used to transfer refrigeration from the vaporizing LNG to a condensing nitrogen stream. In U.S. Pat. No. 4,054,433, a mixture of methane, nitrogen, ethane or ethylene and C 3 + is used to balance the cooling curves in the heat exchangers. The gaseous nitrogen from the high pressure column (pressure≃6.2 atm) is liquefied without any further compression. However, a large fraction of nitrogen is produced at close to ambient pressure from a conventional double column air distillation apparatus. Its efficient liquefaction would require a method to practically compress this nitrogen stream, which is not suggested in this U.S. patent.
In U.S. Pat. No. 4,192,662, fluorocarbons are used as recirculating fluid wherein it is cooled against a portion of the vaporizing LNG and then used to cool low to medium pressure nitrogen streams. This scheme presents some problems and/or inefficiencies. Energy losses due to fluorocarbon recirculation are large; requiring additional heat exchangers and a pump. Furthermore, the use of fluorocarbons has negative environmental implications and use of alternate fluids are expensive.
Japanese patent publication 58-150786 (1983) and European patent application 0304355-A1, (1989) teach the use of an inert gas recycle such as nitrogen or argon to transfer refrigeration from the LNG to an air separation unit. In this scheme, the high pressure inert stream is liquefied with natural gas, and then revaporized in a recycle heat exchanger to cool a lower pressure inert recycle stream from the air separation unit. This cooled lower temperature inert recycle stream is cold compressed and a portion of it is mixed with the warm vaporized high pressure nitrogen stream. The mixed stream is liquefied against LNG and fed to the air separation unit to provide the needed refrigeration and then returned from air separation unit as warm lower pressure recycle stream. Another portion of the cold compressed stream is liquefied with heat exchange against LNG and forms the stream to be vaporized in the recycle heat exchanger. These schemes are inefficient. For example, all of the recirculating fluids are cold compressed in a compressor with no interstage cooling with LNG.
Consequently, the previous process is considerably limited to the instances where each ton of liquid nitrogen produced per ton of LNG used is below 0.5, and preferably below 0.45. So there are still situations where the amount of nitrogen to be liquefied well exceeds the refrigeration available from LNG at the aforelisted cold temperature range (-180° F. to -260° F.). The present invention addresses this practical constraint by the teaching of a thermodynamically more effective process for nitrogen liquefaction.
As just noted, there is a growing need for a liquefaction system which more efficiently utilizes the cold energy of vaporizing LNG to produce liquid products from air with substantial economies. Also, there is a demand to be able to produce liquid nitrogen per ton of LNG refrigerant beyond the prior art constraints of the ratio 0.45.
BRIEF SUMMARY OF THE INVENTION
The present invention is to a cryogenic process for the production of liquefied air components starting with the intermediate product streams generated in a double column distillation system being fed air, and usually comprising a high pressure column and a low pressure column. In the present process, both the low pressure and the high pressure (if an inlet stream) gaseous feed components to be cold compressed are each cooled to differing temperatures in a comparatively warm, heat exchange step. The precooled inlet streams to the multi-stage compressor means for each feed stream are at markedly different temperatures. One of the produced high pressure, nitrogen streams is passed (as a side stream) through an expander zone to provide added refrigeration (supplemental to that provided by LNG) at the cold end of the liquefaction system. The energy drawn from the first expander zone is employed to cold compress another high pressure nitrogen stream in the final-stage, cold compressor to the highest pressure to provide the highest pressure condensed air component. Lastly, a second dense fluid expander is used on the condensed, cold highest pressure liquid stream, which then provides a major part of the liquid nitrogen product take-off stream.
Precooling of the feed nitrogen streams in the warm end, cooling zone to different temperatures, for intermediate cold compression, facilitates the fuller use of the refrigeration available in the LNG stream, while reducing the energy then needed in the multi-stage compressors. This process serves to make the cooling curves for the initial heat exchangers less irreversible.
According to the invention, a process for the liquefaction of a nitrogen stream produced by a cryogenic air separation unit having at least one distillation column comprises: (a) compressing the nitrogen stream to a pressure of at least 300 psi in a multi-stage compressor wherein interstage cooling is provided by heat exchange against vaporizing liquefied natural gas; (b) dividing the compressed nitrogen stream into first and second compressed nitrogen substreams; (c) cooling the first compressed nitrogen substream by heat exchange against vaporizing liquefied natural gas and then expanding the cooled first compressed nitrogen substream to produce an expanded nitrogen substream; (d) condensing the second compressed nitrogen substream by heat exchange against vaporizing liquefied natural gas and the expanded nitrogen substream of step (c); (e) reducing the pressure of the condensed, second compressed nitrogen stream, thereby producing a two-phase nitrogen stream; (f) phase separating the two phase nitrogen stream into a liquid nitrogen stream and a nitrogen vapor stream; and (g) warming the nitrogen vapor stream to recover refrigeration.
A variation of the above described process comprises subcooling the condensed, second compressed nitrogen substream of step (d), prior to reducing the pressure in step (e), by heat exchange against the warming nitrogen vapor stream of step (g) and the expanded nitrogen substream of step (c). Concurrently, the process also comprises recycling the warmed nitrogen vapor stream of step (g) to an intermediate stage of the multi-stage compressor of step (a).
In another major process embodiment, the reduction in pressure of step (e) is accomplished by work expanding the condensed, compressed nitrogen stream in a dense fluid expander.
In still another process embodiment, this involves recycling at least a portion of the warmed, expanded nitrogen substream of step (d) to an appropriate intermediate stage of the multi-stage compressor of step (a).
In a preferred variation of the first described embodiment, the temperature of the cooled, first compressed nitrogen substream of step (c) is between -100° F. and -250° F. prior to expansion.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a flow diagram of a process that is state-of-the-art for liquefaction of fractionated air components like nitrogen employing recirculating freon as the medium for using the cold energy of refrigerated LNG.
FIG. 2 is a flow diagram of a first embodiment of the present invention for liquefying air components and omitting a common recirculating liquid making use of an LNG refrigerant and also of multi-staged cold compression and reflecting the stream inlet and outlet temperatures about the plural cold compressors and expander.
FIG. 3 shows a second embodiment of the invention for liquefying an air component.
FIG. 4 shows a third embodiment of the present invention for liquefying an air component including precooling of the warm feed streams in an exchanger with a portion of the highest pressure air component product of the process.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing and to FIG. 1, in particular, a state-of-the-art (prior art) nitrogen liquefaction system using recirculating freon as the energy transfer medium between the refrigerant LNG liquid and the gaseous air separation products, like nitrogen, to be liquefied is shown. The inlet feeds, from an air separation unit (not shown), are warm high pressure gaseous nitrogen stream 10, warm low pressure gaseous nitrogen stream 12 and cold low pressure gaseous nitrogen stream 14. The sole product stream from the process is liquid nitrogen stream 16. The system is intended to recover substantially all of the refrigeration available from vaporizing LNG feed stream 18, which exits the process as pressurized natural gas stream 20, now suited to pipeline transport. The only other refrigeration input is from cooling water stream 22, which is heat exchanged in ancillary space heat exchanger 24 which is disposed in closed system 26 for the recirculating freon. The amount of LNG available is deemed enough refrigeration to cool the inlet gaseous nitrogen stream to the cold range of about -180° F. to -260° F. (normal B.P. of nitrogen is -320.5° F.) and produces the required quantity of liquid nitrogen product as stream 16.
Nitrogen feed streams 10, 12 and 14 to be compressed in cold compressors 32, 29 and 54 are typically cooled to the same temperature range in the warm end, heat exchangers located downstream of the first and second stage feed gas compressor.
Nitrogen stream 10 passes through primary heat exchanger 28 for precooling before entering primary cold compressor 29. Compressed gas recycle stream 30 passes through primary exchanger 28 before entering second-stage cold compressor 32. Cooled compressed stream 34 then is further cooled in exchangers 36 and 38, thus forming the primary source of liquid nitrogen product. Cooled stream 40 passes through phase separator 42 with its liquid underflow stream 44 passing through heat exchanger 46, partially warming inlet stream 14 therein, then through another phase separator 48, and exiting as liquid nitrogen product stream 16.
The overhead nitrogen vapors from separators 42 and 48 are recycled through heat exchangers 50 and 46, respectively, before recycling to cold compressors 32 and 29, respectively, wherein they undergo cold compression and then condensation in the heat exchangers.
Inlet stream 12 also is precooled in exchanger 28 before being cold compressed in first stage compressor 54, then being recycled to join other inlet stream 10, with combined streams 56, being again cooled in exchanger 28 before their cold compression in primary cold compressor 29, and the subsequent cooling treatment described earlier for major inlet nitrogen stream 10. Inlet stream 14 is partially warmed in exchangers 46 and 50 and combined with inlet stream 12.
Closed-loop fluorocarbon refrigeration circuit 26 provides refrigeration to main heat exchanger 28 and side heat exchanger 24, located in cooling water loop 22. Primary refrigerant LNG stream 18 is vaporized in downstream exchangers 38 and 36 against cooling, condensing nitrogen and in exchanger 58 against the fluorocarbon in refrigeration circuit 26 and exits the process as product, via stream 20.
Fluorocarbons have long been used as a recirculating fluid to avoid bringing low pressure gaseous nitrogen streams next to LNG in heat exchangers. Otherwise, if a leak were to occur, hydrocarbons would contaminate liquid nitrogen leaving the downstream separators. Utilization of fluorocarbons, however, involves additional energy losses due heat exchangers and pump power requirements; note exchanger 58 and booster pump 60. Use of fluorocarbons also has burgeoning environmental implications, while the use of alternate circulating fluids means an added operating cost.
The process of the present invention will now be described in detail with respect to liquefaction of nitrogen obtained from an air separation unit. The air separation unit used for this purpose is a conventional double column air distillation process. The details of such a process can be found in a paper by R. E. Latimer, "Distillation of Air", Chemical Engineering Progress, pp 35-39, February, 1967. However, the process to be described is applicable to any distillation column configuration.
FIG. 2 depicts the process of the present invention in its simplest embodiment. In this embodiment, nitrogen to be liquefied is supplied from the air separation unit (not shown) as high pressure and low pressure streams. The high pressure nitrogen stream comes from the high pressure column at a pressure greater than 75 psia, and the low pressure nitrogen is obtained from the lower pressure column at a pressure greater than or close to ambient pressure. These streams are supplied as warm (close to ambient temperature) and cold streams to the liquefier system. This mixed supply balances the cooling curves in the heat exchangers (not shown) used in the air separation unit to cool the feed air stream thereto.
Low pressure nitrogen stream 80 is supplied at close to ambient temperature. Stream 82 brings in low pressure nitrogen at a temperature between -150° F. to 300° F. Optionally, boil-off vapor from a liquid nitrogen storage tank (not shown) is fed for liquefaction as stream 84. High pressure nitrogen is supplied from the high pressure distillation column (not shown) as stream 86 at a temperature close to the high pressure distillation column temperature. LNG to be vaporized is provided through line 88. Although LNG is suitable for use as a refrigerant at any pressure, typically, the pressure will be between 100 psi to 1200 psi, such that the vaporized LNG can be sent as stream 90 to the pipeline distribution system without any further compression.
Low pressure nitrogen stream 80 is first cooled with LNG in heat exchanger 92 and then fed to compressor 94. Cold, low pressure nitrogen inlet streams 82 and 84 are combined as stream 96 and used to condense and subcool highest pressure nitrogen split stream 98 in heat exchangers 100 and 102. Resulting slightly warmed, combined feed stream 104 is mixed with cooled low pressure nitrogen stream 106 into combined stream 108. Combined stream 108 is compressed in cold compressor 94 to a pressure such that temperature of boosted nitrogen stream 110 is colder than the ambient temperature. Typically, this temperature is in the range of -100° F. to ambient temperature.
Boosted nitrogen stream 110 is slightly warmed in heat exchanger 112 against chilled water (line 114), and then cooled by heat exchange against vaporizing LNG in heat exchanger 92 to produce cold stream 116 which is fed to second-stage compressor 118. The exhaust of this compressor is high pressure nitrogen stream 120, which is at a pressure similar to that of the high pressure distillation column pressure of the air separation unit; typically, this pressure is in the range of 75 psia to 200 psia. High pressure nitrogen stream 120 is admixed with a cold high pressure nitrogen 122 to produce combined high pressure nitrogen stream 124.
Combined high pressure nitrogen stream 124 is then cold compressed in third-stage compressor 126 to obtain nitrogen stream 128, which is partially cooled in the main heat exchanger 92, and fed as stream 129 to the fourth-stage compressor 130 thereby producing elevated pressure nitrogen stream 132. Nitrogen stream 132 is then compressed in fifth-stage compressor 134 to provide highest pressure nitrogen stream 136. The pressure of stream 136 is in the range of 350 to 1500 psi, and, typically, in the range of 600 to 1220 psi.
Due to LNG precooling being effectuated in exchanger 92, the inlet stream temperature to all the four compressors (with the possible exception of last-stage compressor 134) will be below ambient temperature. Typically, the temperature will be in the range of -50° F. to -260° F., and more likely from -90° F. to -220° F. It is worthwhile to note that the inlet streams to cold compressors 94, 118, and 130 are taken out of heat exchanger 92 at different locations. Cooling of the nitrogen streams to different temperatures in warm heat exchanger 92 for cold compression aids in the proper utilization of refrigeration available in the LNG stream while minimizing the energy used in these compressors.
Highest pressure nitrogen stream 136 is cooled with cooling water in exchanger 137, and divided into two highest pressure nitrogen substreams 138 and 140. First highest pressure nitrogen substream 140 is cooled in heat exchanger 92, and then expanded isentropically in expander 142 thereby producing stream 144. The pressure of stream 144 is now similar to the inlet pressure of high pressure nitrogen stream inlet 86. Augmented inlet stream 146 is combined with stream 144 and the combined stream, line 147, is used in heat exchangers 100 and 102 to cool the other highest pressure nitrogen stream 98. Expander 142 for stream 168 can be loaded with an electric power generator. In the preferred mode, expander 142 is coupled to final-stage compressor 134, and the energy derived from this expander 142 is used to compress elevated pressure nitrogen stream 132 in compressor 134.
Highest pressure nitrogen substream 138 is cooled in heat exchangers 92, 102 and 100 against vaporizing LNG and returning cold gaseous nitrogen streams, i.e., streams 147 and 96 from heat exchanger 100, thereby producing stream 148, which is further subcooled in the heat exchanger 100 to obtain cold, highest pressure nitrogen stream 150. The pressure of stream 150 is reduced to a pressure of about 75 psi to 200 psi by feeding it to a dense fluid expander 152. This isentropic expansion of stream 150 makes the process more efficient. Exhaust stream 153 can be further reduced in pressure and fed to separator 154. Alternately, cold highest pressure nitrogen stream 150 can bypass the dense fluid expander, via stream 156, and reduced in pressure across isenthalpic valve 158. Either way, the reduced pressure cold stream is fed to phase separator 154. The operating pressure of separator 154 is similar to the pressure of high pressure inlet gaseous nitrogen stream 86 (i.e., 75 psi to 200 psi). Vapor stream 160 from separator 154 is mixed with the rest of cold pressure nitrogen stream 86 and sent to heat exchanger 100 as stream 146 for further processing. Liquid nitrogen underflow stream 162 from separator 154 is reduced in pressure and fed to phase separator 164. Liquid nitrogen underflow stream 166 from separator 164 is sent to the air separation unit (not shown) for further handling and production of liquid products. In the air separation unit, other liquid products, such as liquid oxygen and liquid argon can be easily produced by using the refrigeration from the liquid nitrogen supplied, via line 166 of the liquefier.
EXAMPLE
Computer simulations of the process were carried out to determine the functional relationship between the amount of liquid nitrogen produced and the amount of LNG available. The calculated results are summarized in Table I below for the case when the ratio of liquid nitrogen produced to liquid oxygen produced from the air separation unit is three.
TABLE I______________________________________Tons-Liquid Nitrogenper ton-LNG KWH/Ton-Liquid Nitrogen______________________________________0.48 2070.56 2480.67 264No LNG 470______________________________________
The last entry in Table I is for an all electric powered liquefaction plant, i.e., no LNG is used for refrigeration. The power consumptions listed include the power consumed by the air separation unit to produce the gaseous nitrogen and oxygen feed streams.
Table II shows the inlet/outlet temperatures to the various compressors from one of the computer simulations if the process depicted in FIG. 2.
TABLE II______________________________________ °F.______________________________________First Stage, Inlet Stream 108 -190First Stage, Outlet Stream 110 -75Second Stage, Inlet Stream 116 -146Second Stage, Outlet Stream 120 -23Third Stage, Inlet Stream 124 -111Third Stage, Outlet Stream 128 51Fourth Stage, Inlet Stream 129 -95Fourth Stage, Outlet Stream 132 47Fifth Stage, Outlet Stream 136 84Internal Cold Nitrogen Stream 168 -174to Expander 142:Expander 142, Outlet Stream 144 -284______________________________________
It is readily observed that the inlet temperatures of each of the five compressors are different from each other. These temperature differences aid in the proper utilization of the refrigeration available in the LNG stream, while minimizing the electric energy used in operating these compressors. Also, the cooling curves in the heat exchanger 92 are less irreversible. Note in Table II, that the main inlet to final-stage cold compressor 134 has not been cooled against LNG but is direct flow from compressor 130. Also, the inlet temperature of intermediate compressed stream 168 to cold expander 142 is chosen at an appropriate level.
Although FIG. 2 depicts the preferred embodiment of the present invention, there are some inefficiencies. One such is the mixture of exhaust stream 120 of cold compressor 118, which is at -23° F., with cold stream 122, which is at -195° F., to provide inlet stream 124 to cold compressor 126, which is at -111° F. This inefficiency can be easily remedied by further heating the recycle stream 122 in heat exchanger 92 to an appropriate temperature level (not shown), prior to mixing with compressed stream 120. At the same time, stream 120 would have to be cooled in heat exchanger 92 to the same appropriate temperature level. The two streams will then have to be mixed to provide inlet stream 124 for third-stage cold compressor 126. These steps will make the inlet streams to some of the cold compressors even colder and, thus, reduce energy consumption.
FIG. 3 shows another embodiment of the process of FIG. 2. In this embodiment, intermediate-stage compressor 126A uses interstage cooling of stream 128A in exchanger 92A, before passing stream 129A back to cold compressor 126B, and inlet stream 132B which is fed to final-stage compressor 134A is cooled to an appropriate temperature.
Recycle stream 132A undergoes two-stage cold compression and is precooled in exchanger 92A, before introduction as stream 132B into final stage cold compressor 134A. Somewhat similarly, compressed stream 128A from compressor 126A is recooled in exchanger 92A and forms stream 129A which is compressed in compressor 126B.
FIG. 4 depicts still another process embodiment of FIG. 2. In this embodiment, warm end gaseous nitrogen inlet streams 80B and 140 are precooled in exchanger 112B, against portion 138B of highest pressure nitrogen stream 138A drawn from final stage cold compressor 134B. Small portion 138C of highest pressure nitrogen 138A, along with a portion of medium pressure nitrogen feed stream 142, are used to warm and vaporize oxygen stream 144, which has been increased in pressure by pump 144A to pipeline pressure. The warmed oxygen exits as stream 146. Otherwise, the process configuration is functionally equivalent to the specific embodiment process of FIG. 3, regarding multi-stage stream compression linked with interstage cooling. The embodiment of FIG. 4 allows the integration of nitrogen compression with a pumped liquid oxygen system, such that a portion of compressed nitrogen stream recovers refrigeration from a pumped liquid oxygen stream to deliver gaseous oxygen product at an elevated pressure. This embodiment saves the cost associated with an oxygen compressor.
For the processes of both FIGS. 2 and 3, the lowest pressure nitrogen stream is cooled to the lowest temperature for the first cold compression (i.e., inlet stream 108 to compressor 94). As the stream pressure and its flowrate are increased, the temperatures of the cold compression steps are increased successively. However, it is important to note that this may not always be true. Depending on the quantity of LNG refrigeration available, the cold compressors, such as 126 and 130, could have colder inlet temperatures than compressions 94 and 118, which is contrary to Table II. The primary objective is to match the cooling curves in warm-end heat exchanger 92, as well as possible. To achieve this, various combinations of the inlet temperatures to the cold compressors must be attempted, which models are within the skill of the art, so to result in the most optimum inlet temperature balancing; namely, one giving the lowest energy consumption or to provide maximum utilization of the refrigeration available from the LNG.
LNG is typically composed of more than one component and they each vaporize at different temperatures. This leads to fairly high heat capacities of the vaporizing natural gas over a wide range of temperatures. On the other hand, the heat capacity of the cooling nitrogen streams is a strong function of temperature and pressure. For temperatures in the range of ambient down to -200° F., heat capacity of a nitrogen stream at pressures below 100 psia is about 7 BTU/lb mole °F. Whereas, a nitrogen stream at 800 psia has a heat capacity of about 7.6 BTU/lb mole °F. at 75° F., 9.0 BTU/lb mole °F. at -100° F., 11 BTU/lb mole °F. at -150° F., and about 24.0 BTU/lb mole °F. at -200° F.
The LNG stream (91.4% CH 4 , 5.2% C 2 H 6 and 3.4% C 2 + ) at 725 psia has approximate heat capacities of 14 BTU/lb mole °F., in the temperature range of -160° F. to -240° F.; 19.6 BTU/lb mole °F. at -120° F., 25.6 BTU/lb mole at -100° F., 21.5 BTU/lb mole °F. at -50° F., and 11.5 BTU/lb mole above 0° F. Thus, the amount of LNG used to cool the highest pressure, (say 750 psia), nitrogen stream 98 in the cold heat exchanger 102 to (-180° F. to -250° F. temperature range) will have more refrigeration to cool streams other than this highest pressure nitrogen stream 98 at warmer temperatures in heat exchanger 92.
Because at temperatures lower than -180° F., highest pressure nitrogen stream 98 has a heat capacity either comparable to or higher than LNG. At temperatures higher than -150° F., its capacity is much less than LNG. Between ambient to -150° F., the heat capacity of the highest pressure nitrogen is less than half of the vaporizing LNG. It implies that for efficient recovery of all the refrigeration energy between ambient and -180° F., stored in LNG, some other streams besides the highest pressure nitrogen stream 98 must be cooled.
The present process effectively utilizes the refrigeration available at above -180° F., by cooling lower pressure nitrogen streams, along with the highest pressure nitrogen stream, in heat exchanger 92. Lower pressure inlet nitrogen streams 80, 110 and 128 are cooled and compressed. The compression energy heats the internal nitrogen stream 110, which is again cooled by LNG in heat exchanger 92. Because of recooling of compressed nitrogen after each compression, the enthalpy of LNG from warm heat exchanger 92 is considerably higher. This more fully utilizes the cold energy stored in LNG.
In the disclosed process, after efficient utilization of the LNG refrigeration in warm heat exchanger 92 (ambient down to -190° F. temperature range), the refrigeration in downstream cold heat exchanger 102 is supplemented by expansion of cooled high pressure nitrogen stream 168 in expander 142. This most effectively transfers some of the refrigeration of LNG in the temperature range of ambient to -190° F. to lower temperatures. This also aids in the condensation of larger quantities of nitrogen.
As stated earlier, in order to condense nitrogen at temperatures in the range of -200° F. to 260° F., it must be compressed to a considerably higher pressure. In the present process, nitrogen is precooled prior to each compression stage. This substantially reduces the energy consumption of the liquefaction process. Thus, the process of the current invention effectively utilizes cold energy stored in LNG and produces liquid nitrogen product with low energy consumption.
The present invention has been described with reference to some specific embodiments thereof. These embodiments should not be considered a limitation of the scope of the present invention. The scope of the following invention is ascertained by the following claims. | The present invention relates to a process for the liquefaction of a nitrogen stream produced by separating air components, by using the combination of cryogenic distillation with improved refrigeration. Very cold liquefied natural gas (LNG) is employed as refrigerant, with the LNG currently being revaporized for transportation.
Multi-stage component compression is used, with the component feed to each compression stage being precooled using sequential refrigeration from the LNG. Expander means for the coldest air component product stream provides supplemental refrigeration at the cold end beyond that which is available from the refrigerant LNG.
In a preferred embodiment, the feed nitrogen stream(s) are compressed to at least 300 psi in a multi-stage compressor with interstage cooling provided by heat exchange against vaporizing LNG; the resulting compressed stream is directed into first and second nitrogen substreams, followed by further cooling of the first substream by heat exchange against vaporizing LNG and then expanding the cooled first substream to produce an expanded nitrogen substream. Condensing of the second compressed substream against both vaporizing LNG and the expanded nitrogen substream is carried out. Reducing the pressure of the condensed second nitrogen substream produces a two phase nitrogen stream. Phase separation yields a recyclable nitrogen vapor stream and a liquid nitrogen stream as product. | 5 |
CLAIM OF PRIORITY
[0001] This application claims priority to U.S. Provisional Application No. 61/453,403 filed on Mar. 16, 2011 and by reference is hereby incorporated in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to the field of jewelry and more particularly to a modular system for creating a custom military service ring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 illustrates a perspective view of an exemplary embodiment of an unadorned ring of a modular system for creating a custom military service ring.
[0004] FIG. 2 illustrates a top view of an exemplary embodiment of an unadorned ring of a modular system for creating a custom military service ring.
[0005] FIG. 3 illustrates a left side view of an exemplary embodiment of an unadorned ring of a modular system for creating a custom military service ring; right side being a mirror thereof.
[0006] FIG. 4 illustrates a perspective view of an exemplary embodiment of an unadorned ring of a modular system for creating a custom military service ring with optional military insignia.
BACKGROUND
[0007] Personalized military rings are known in the art and typically have one or more customizable aspects with the level of customization varying for different manufacturers and for varying styles of rings. For example, some jewelers offer school-style U.S. Army, U.S. Air Force, U.S. Navy, U.S. Marines, and U.S. Coast Guard rings. After the individual selects the Military branch, he or she then selects a ring style (e.g., rectangle or oval). The individual then selects a side panel for each side of the ring. For example, if the individual selects the U.S. Army, side panel options include 1st Infantry, 82nd Airborne, 7th Cavalry Regiment, 18th MP Brigade. Other customizable aspects include stone color (e.g., birthstone), metal quality, wording around the stone, and inside engraving (e.g., name or initials). The school-style type military rings offered by these jewelers and many other manufactures are not desirable because they generally look gaudy and cheap.
[0008] Further, other ring designers offer U.S. Army, U.S. Navy, U.S. Air Force, U.S. Marine Corps, U.S. Coast Guard, and U.S. Merchant Marine Classic Military Rings. The Classic Military Rings are solid metal and are designed to look cleaner and higher-end than the school-style military ring. The customization of these rings, however, is limited and the individual can select only a single insignia to be displayed. For example, for U.S. Army, the individual may select an insignia from the following types: traditional insignia (e.g., Army, Army National Guard, Army Vietnam, Army Reserve), historic insignia (e.g., Army Air Force, Women's Army Corps, Army Security Agency), special forces insignia (e.g., Army Ranger, Special Forces), badges/medals insignia (e.g., Drill Sergeant, Combat Medic, Parachutist), branch and command insignia (e.g., Cavalry, Army JAG Corps, Army Engineer, Military Police Corps), rank insignia (e.g., Army Staff Sergeant, Army Colonel), division./brigade/regiment combat team insignia (e.g., 1st Cavalry Division, 25th Infantry Division), or POW/MIA insignia. The only other customizable aspects of the ring are the metal choice and a diamond option. These rings are not desirable because they are capable of displaying only a single insignia.
[0009] Therefore, it is desirable to have military service ring having a plurality of customizable aspects and interchangeable insignia.
[0010] Further, it is desirable to have a military service ring that is commemorative.
[0011] Moreover, it is desirable to have a high-end customizable military service ring capable of displaying more than one insignia and/or pieces of information.
TERMS OF ART
[0012] As used herein, the term “interchangeable circular insignia” means any symbol, picture, stamp, design, pin, or memorabilia which may be attached to a ring.
[0013] As used herein, the term “mounting hole” means any aperture, groove, slot or hole which a peg or knob may be inserted.
[0014] As used herein, the term “trough” means an indentation or recessed area below the surface.
[0015] As used herein, the term “word insignia” means any combination of letters and numbers which may be mounted on a ring.
SUMMARY OF THE INVENTION
[0016] The present invention is a modular ring apparatus and system for creating a custom military service ring. The modular apparatus and system is comprised of a ring having an inner wall and outer wall, wherein the outer wall has two troughs indented where military insignia may be mounted and interchanged. Further, the top of the modular ring has a circular mounting component comprised of three concentric circular mounting portions. An outside mounting porting may be used to mount word indicia indicating rank and theater, and the inner portion may be used to mount more military insignia. Both troughs and the center circular mounting portion have mounting holes, which allow military insignia to be connected and disconnected. Military insignia may be removed and interchanged to create a customizable military ring displaying an individual's service.
DETAILED DESCRIPTION OF INVENTION
[0017] For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a modular system for creating a custom military service ring, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent designs and placement may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
[0018] It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.
[0019] Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could perm permissibly vary without resulting in a change in the basic function to which it is related.
[0020] FIG. 1 illustrates a perspective view of an exemplary embodiment of unadorned modular ring 100 and system for creating a custom military service ring. Modular ring 100 is comprised of ring body 10 which is a solid closed loop ring having inner wall 11 outer wall 12 , front side surface 13 and back side surface 14 . In an exemplary embodiment, modular ring 100 is made of gold, platinum, titanium, silver, white gold, brass, tungsten carbide, stainless steel or any other metal known to those skilled in the art.
[0021] In the embodiment shown, modular ring 100 has left trough 20 , right trough 30 and an indicia receiving mounting portion comprised of outer circular mounting portion 40 , middle circular portion 50 and center circular mounting portion 60 . Mounting portions 40 , 50 and 60 are raised concentric rings which form a mounting portion for receiving military insignia. In an exemplary embodiment, the three concentric rings may be different colors and have different insignia mounted to them. In other embodiments, the three concentric rings may also be different heights.
[0022] In the embodiment shown, left trough 20 and right trough 30 are indentations in outer wall 12 which allow military insignia to be placed into the indention. Troughs 20 and 30 are flush with outer wall 12 at the bottom most end and indent into ring body 10 closer to outer circular mounting portion 40 . This allows for military insignia to be recessed into the sides of the ring. In the embodiment shown, troughs 20 and 30 are semi-square shaped.
[0023] Further, in the embodiment shown, modular ring 100 has left mounting hole 70 , right mounting hole 80 , and center mounting hole 90 . Mounting holes are small apertures where military insignia ay be attached. For example, a small military insignia will have a knob or peg on the back which inserts into the mounting holes. Military insignia may be removed and interchanged to make a modular customized ring.
[0024] FIG. 2 is a top view of an exemplary embodiment of an unadorned modular ring 100 and system for creating a custom military service ring. Ring body 10 has inner wall 11 (not shown), outer wall 12 , front side surface 13 and back side surface 14 . In the embodiment shown, outer wall 12 includes left trough 20 and right trough 30 are capable of receiving military insignia. Troughs 20 and 30 are flush with outer wall 12 at the bottom most end and indent into ring body 10 closer to outer circular mounting portion 40 . This allows for military insignia to be recessed into the sides of the ring and for the military insignia to be seen from an overhead view. In the embodiment shown, troughs 20 and 30 are semi-square shaped. In other embodiments, troughs 20 and 30 may be elliptical, circular or other shapes known in the art.
[0025] In the embodiment shown, the main mounting portion of unadorned modular ring 100 is comprised of outer circular mounting portion 40 , middle circular portion 50 and center circular mounting portion 60 . In the embodiment shown, outer circular mounting portion 40 and center circular mounting portion 60 may be the same color, and middle circular portion 50 may be of a different color to accent the outside and center sections. The entire main mounting portion is circular, but in other embodiments may be square, rectangular, triangular or any other geometric shape used in the art.
[0026] FIG. 3 illustrates a side view of an exemplary embodiment of unadorned modular ring 100 and system for creating a custom r Military service ring. In the embodiment shown, ring body 10 has outer wall 12 , front side surface 13 and back side surface 14 . Left trough 20 is an indentation near circular mounting portion. In the embodiment shown, left trough 20 is a semi-square indentation with three walls which allow an insignia to be sunken into the side of outer wall 12 . In other embodiments, left trough 20 and right trough 30 (shown in FIG. 1 ) may be comprised of four sided indented section.
[0027] In the embodiment shown, left trough 20 has left mounting hole 70 which is an aperture in ring body 10 that allows military insignia to be mounted and displayed. Outer circular mounting portion 40 is raised about ring body 10 . In the embodiment shown, ring body 10 is narrower at the bottom and wider at the top where the mounting portion is located. In other embodiment, ring body 10 may be one consistent width. In the embodiment shown, the walls of trough 20 are parallel to front side surface 13 and back side surface 14 . In other embodiments, trough 20 may be entirely square or oval shaped.
[0028] FIG. 4 illustrates a perspective view of an exemplary embodiment of an unadorned modular ring 100 and interchangeable military insignia for creating a custom military service ring with military insignia. Ring body 10 has left trough 20 with left mounting hole 70 and right trough 30 with right mounting hole 80 . Further, in the embodiment shown, unadorned modular ring 100 has circular mounting portion comprised of outer circular mounting portion 40 , middle circular portion 50 , and center circular mounting portion 60 . Center circular mounting portion 60 also includes center mounting hole 90 . Mounting holes 70 , 80 and 90 are circular holes or apertures which allow military insignia to be mounted and removed and interchanged.
[0029] In the exemplary embodiment shown, word insignia 120 is comprised of two concentric metal rings with words between them. Word insignia ring 120 may be mounted to outer circular mounting portion 40 . Word insignia 120 may contain any identifying words, for example, the theater of operation (e.g., Vietnam, Iraq, Afghanistan) and the dates of service appear in lettering on the top half of word insignia 120 . The unit name may appears in lettering on the bottom half of word insignia 120 . For example, the top half of word insignia 120 may read, from left to right; “2/67 VIETNAM 5/69” while the bottom half of word insignia 120 may read, from right to left, “716th COMBAT MP BN”. Word insignia 120 may be integrally mounted to outer circular mounting portion 40 by any means including but not limited to adhesives, soldering, welding and any other means known to those skilled in the art.
[0030] In the embodiment shown, unadorned modular ring 100 also includes interchangeable military insignia 130 a, 130 b, and 130 c which may be any insignia with a small peg or knob that can mount to mounting holes 70 , 80 or 90 . Interchangeable circular insignia 130 a - c may have pegs or knobs which may be soldered, glued, or connected using any other means known to one skilled in the art. In the embodiment shown, interchangeable circular insignia 130 a - c are removably connected but may be connected permanently.
[0031] In an exemplary embodiment of the modular system, interchangeable circular insignia 130 a - c depicting an image that represents a military specialty, unit, rank or rate, combat, service campaign, medal or award, or another image of significance would be available. Additionally, interchangeable circular insignia 130 a - c may be any plurality of military insignia, for example, traditional U.S. Army insignia, modern U.S. Army insignia, U.S. Navy insignia, U.S. Marine Corps insignia, traditional U.S. Air Force insignia, modern U.S. Air Force insignia, and U.S. Coast Guard insignia.
[0032] In the embodiment shown, unadorned modular ring 100 , interchangeable circular insignia 130 a - b, and word insignia 120 may be comprised of gold, platinum, titanium, silver, brass, white gold, tungsten carbide, stainless steel or any other metal known to those skilled in the art. Interchangeable circular insignia 130 a - b, and word insignia 120 may be minted, molded, or created using another process known in the art. Interchangeable circular insignia 130 a - b, and word insignia 120 may be secured permanently to the top and sides of the ring or may be removable, allowing the insignia to be interchanged as desired.
[0033] In the embodiment shown, enter circular mounting portion 60 may be recessed and adapted to receive interchangeable circular insignia 130 a. The dimensions of the circular insignia would correspond to the dimensions of center circular mounting portion 60 and when interchangeable circular insignia 130 a is positioned in the recessed area, the top of interchangeable circular insignia 130 a would be flush with the surface of middle circular portion 50 surrounding the recessed center circular mounting portion 60 . In an alternate embodiment, the top of the interchangeable circular insignia 130 a may be slightly raised over the middle circular portion 50 surrounding the recessed area. In other embodiments, both outer circular mounting portion 40 and center circular mounting portion 60 may be lower than middle circular portion 50 , so that when word insignia 120 and interchangeable circular insignia 130 a may be level across. In the embodiments shown, the upper portion of each of the side insignias is visible from the top of the ring when positioned. | A modular apparatus and system for creating a custom military service ring. The modular ring apparatus and system is comprised of a ring having a circular recessed area on the top portion of the ring and a beveled recessed area on each side of the ring and a plurality of insignia pieces illustrating a piece of information relevant to military service. Each of the recessed areas is adapted to receive one insignia chosen by an individual, resulting in a customized ring. | 0 |
U.S. Pat. No. 3,958,305 relates to a method for eliminating or equalizing the combing periods in combing machine slivers in which the phase position of the combing periods of the individual combing machine outputs (i.e., the combing machine slivers) is regulated and/or controlled in such a way that they at least approximately compensate one another. By "combing periods" is meant periodic fluctuations in sliver density which occur, for example, in cotton spinning processes and the like.
The corresponding apparatus for carrying out the method described in the above-referenced patent comprises means for determining the phase position of the combing periods of the individual combing machine outputs, and means for varying the phase position of the combing periods in dependence upon a control signal.
In the exemplary embodiment described in the above-referenced patent, the phase position of the combing periods of each individual combing machine output is determined by means of a sensor, the signals from these sensors being converted into control commands which modify the respective phase positions of the combing machine slivers until they cancel one another out. This arrangement requires a number of sensors corresponding to the number of combing machine outputs, which in some cases requires a very complicated, expensive arrangement.
The present invention improves this method for eliminating or equalizing combing periods in combing machine slivers, in which the phase position of the combing periods of the individual combing machine outputs is regulated and/or controlled in such a way that they at least approximately compensate one another, and is distinguished by the fact that the effect of compensating the combing periods is determined on the basis of the periodicity (i.e., the periodic variation in density) of the resulting complete sliver. In other words, the periodic fluctuations in density (or periodicity) of the completed sliver is used as the control parameter rather than the periodicity of the individual combing machine output slivers.
The invention also relates to an apparatus for carrying out this method comprising means for modifying the phase position of the combing periods in dependence upon a control signal, and is distinguished by the fact that the control signal for modifying the phase position of the combing periods is derived from the magnitude and phase position of the residual periodicity of the total output, i.e., the complete sliver. In other words, the control signal for modifying the phase position of the combining periods is derived from the periodic character of the density fluctuations in the completed sliver.
Thus, the present invention provides a process for compensating the combining periods of combing machine slivers which comprises combining a plurality of combing machine slivers together to form a complete sliver, measuring the density of the complete sliver, and adjusting in response to the periodicity of the complete sliver the relative phase positions of the respective combing machine slivers so that the combing periods of the respective combing slivers approximately compensate one another.
In addition, the present invention further provides an apparatus for compensating the combining periods in combing machine slivers comprising means for combining a plurality of combing machine slivers to form a complete sliver, measuring means for measuring the magnitude and phase position of the density variations in said complete sliver, and means responsive to said measuring means for varying the phase positions of the respective combing machine slivers so that the combing periods of the respective combing slivers approximately compensate one another.
The present invention is based on the recognition that, ultimately, it is only the quality of the total output in which several combing machine slivers are combined with one another that is important, the way in which this quality is obtained being of secondary importance. For this reason, it is sufficient to determine the residual periodicity of the sliver as a whole and to reduce this residual periodicity to a minimum by modifying the phase position of the individual outputs, i.e., the individual combing machine slivers.
The method as a whole is essentially an empirical method in that the phase positions of the individual outputs are modified until and in such a direction that the residual periodicity of the total output reaches a minimum. Basically, this empirical method is laborious. However, since the changes is phase take place slowly in the combing machine itself, a certain amount of time can be set aside in which to make these tests.
However, it is also possible for the variation in the phase position of each individual output to pass through controlled, predetermined programs, i.e., for the combing periods to wobble. The wobble frequencies of the individual outputs must differ from one another. Observation of the residual periodicity of the total output will show that a certain, related phase position of the individual outputs produces a minimum, while all other combinations of the individual phase positions produce greater residual periodicities.
The means for adjusting the phase position then have to be held in that position which produces a minimum of residual periodicity in the complete sliver.
Further monitoring of the residual periodicity then only has to confirm that the minimum value reached is being maintained. In the event of appreciable and permanent changes, the combing periods have to be wobbled again in order once again to find the minimum residual periodicity.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention is described by way of example in the following with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic diagram illustrating a combing machine producing four outputs, i.e., four combing machine slivers.
FIG. 2 is a schematic diagram illustrating an automatic wobble control system.
FIG. 3 shows a first vector diagram.
FIG. 4 shows another vector diagram explaining wobbling of the phase positions.
DETAILED DESCRIPTION
FIG. 1 diagrammatically illustrates a combing machine or comber with four comber heads 1, 2, 3 and 4. The slivers 5, 6, 7 and 8 issuing from the individual comber heads are deflected through approximately 90°, stretched together in a drawing system 9 following the comber and, finally, deposited into a can 10. The periodicity of the complete sliver is determined by means of a sensor 15. This sensor 15 may be, for example, a capacitive or an active-pneumatic sensor. The signal from the sensor is converted in an evaluation stage 16 and indicated for example in an instrument 17.
Fourier analyzers are particularly suitable for evaluating this signal. Since the basic frequency of the periodicity of the complete sliver is directly coupled with the frequency of the combing period, it is of advantage for the analyzing frequency to be controlled by the comber. This affords the further advantage of an arbitrarily narrow band width for the frequency band to be investigated and, hence, a further reduction in interfering frequencies. The object of this evaluation is to obtain a minimum of the output signal from the analyzer.
Specific examples of embodiments useful as evaluation stage 16 are described in U.S. Pat. No. 2,516,768, Re. 23,368 and 2,679,639. This latter patent describes a so-called "integrator" which is an analog computer and would serve in the present invention to average the electrical signal corresponding to the variable cross-section of the sliver determined by sensor 15.
FIG. 1 shows the guides around which the individual outputs are guided in the form of round pins 11, 12, 13 and 14. In one exemplary embodiment of the aforementioned U.S. Pat No. 3,958,305 and as shown in present FIG. 1, the phase position of each individual output or combing machine sliver is changed by arranging the guide pins eccentrically and arranging them for rotation about these eccentric axes.
Basically, the result expressed by the deflection of the indicating instrument in accordance with the present invention does not give any indication as to the origin of the residual periodicity. However, this can be changed for example by empirically turning one guide pin after the other and observing the effect upon the magnitude of the residual periodicity. If it increases, the same guide pin is turned in the other direction. If it falls, the further tests are conducted with the pin in this new position. This procedure can be repeated with each individual combing machine sliver until the residual periodicity cannot be reduced any further.
However, this basically complicated empirical approach to the optimum value can also be automated by the technique known among experts as wobbling.
FIG. 2 shows a system for wobbling the phase positions of the individual outputs in combination with a system for automatically regulating phase position. To this end, the eccentric guide pins 11, 12 and 13 are connected through gears 23, 24; 25, 26 and 27, 28 to drive systems, for example in the form of motors 19, 20 and 21, so that the eccentric pins rotate at a certain rotational speed as long as voltage is applied to the line 22 by switchgear 18.
One of the eccentric guide pins 14 has to remain undriven, because one combing machine sliver can be regarded as a referencephase sliver.
The gears 23, 24; 25, 26 and 27, 28, which are shown in the form of worm gears, are arranged in such a way that their rotational speeds are different. However, it is of advantage to select simple rotational speed ratios in order to obtain identical patterns or arrangements of the eccentric guide pins within reasonable time intervals.
The instrument 17 may be in the form of, for example, a contact instrument which closes a switching contact on reaching a certain minimum position. This switching contact acts on the switchgear 18 which keeps the drive systems 19, 20 and 21 under voltage until the instrument 17 has reached its minimum position. If, during production, the residual periodicity increases systematically to such an extent that the minimum contact of the instrument 17 is opened, the eccentric guide pins 11, 12 and 13 begin to rotate again until the minimum value is reached once again. Thus it will be appreciated that instrument 17 serves as a means for stopping the adjustment action provided by gears 23 to 28.
FIGS. 3 and 4 explain the effect of the eccentric guide pins rotating at different rotational speeds in the form of vector diagrams. In FIG. 3, all the vectors r 1 , r 2 , r 3 and r 4 are in phase, and the length of the resulting vector R is four times the length of an individual vector.
FIG. 4 shows the moment at which all four vectors (three of which rotate at different speeds from the starting position shown in FIG. 3) are in 90°, 180° and 270° phase displacement. The resulting vector R is O. Naturally, the lengths of the quantities symbolized by the vectors r 1 , r 2 , r 3 and r 4 show differences, in the same way as the respective phase positions cannot amount exactly to 90°. However, it is possible in this case, too, to determine a residual vector which corresponds to the residual periodicity which forms a minimum around a value 0, providing enough time is allowed for finding the optimum positions of the eccentric guide pin.
Although only a few embodiments of the present invention have been described above, it should be appreciated that many modifications can be made without departing from the spirit and scope of the invention. All reasonable modifications which are not specifically set forth are intended to be included within the scope of the present invention which is to be limited only by the following claims. | A plurality of combing machine slivers having periodically variable densities are combined in such a way that the density variations approximately compensate one another and a complete sliver having little density variation is formed. The relative phase positions of the respective combing machine slivers when assembled together are controlled in response to the periodicity of the complete sliver. | 3 |
BACKGROUND AND SUMMARY OF INVENTION
This invention relates to an excavating tooth assembly and more particularly, to an assembly featuring a novel lock arrangement for removably securing a point on an adapter.
Traditional excavating tooth locking devices depend on enclosure within centrally located apertures in the tooth components for development of dislodgement resistive forces. Until the development of the HELILOK® twist-on point (U.S. Pat. No. 4,335,532) virtually all commercial teeth used a combination of a rigid lock such as a pin and a resilient keeper such as a plug. Historically, the rubber plug operated through the lock to tighten the point on the nose of the adapter and these same tightening forces maintained the engagement of the plug with the locking pin to resist pin ejection. The drawback in this approach was that resistance to pin dislodgement diminished as the point/nose fit loosened through service--with resultant reduction in tooth tightening forces.
The above-mentioned '532 patent did not use centrally located apertures for containment but rather a U-shaped lock straddling the adapter and engaging rearwardly extending tongues on the point. This realized a significant increase in strength over preceding teeth. Relative to the '532 patent I have invented a new locking system therefor which offers several improvements and advantages over the U-shaped fastener.
The invention involves an externally mounted elongated shaped lock which provides a point tightening force through cooperative engagement with two vertically disposed ears connected by a ledge on one side of the adapter nose and with the lug on one ear of the point through spring-like deformation from its free shape. This lock is maintained in place by engagement with a retractable plug centrally located in the side of the adapter nose. The adapter nose ears project from the side of the nose a distance approximately equal to the thickness of the elongated lock. The connecting ledge provides a guide function when the lock is driven into place and then a secondary bearing function in operation of the tooth assembly to prevent overstressing of the lock. This ledge projects from the side of the nose a distance of approximately half the thickness of the elongated lock. The invention provides the following advantages and improvements:
1. Extended lock life through a unique stabilized wedge action;
2. Reduction of effort for lock removal;
3. Reduced cost;
4. No requirement for a dedicated lock removal tool; and
5. Increase in adapter nose life.
The instant invention is described in conjunction with an illustrative embodiment in the accompanying drawing, in which
FIG. 1 is a fragmentary side elevational view of a tooth embodying the invention;
FIG. 2 is a top plan view of the tooth of FIG. 1;
FIG. 3 is a sectional view along the line 3--3 of FIG. 1;
FIG. 4 is an enlarged sectional view of the keeper plug illustrated at the right-hand portion of FIG. 3;
FIG. 5 is an enlarged side elevational view of the locking pin seen in the left-hand portion of FIG. 1;
FIG. 6 is a front elevational view of the pin of FIG. 5;
FIGS. 7--9 are sectional views through the pin of FIG. 5 along the lines 7--7, 8--8 and 9--9 respectively;
FIG. 10 is a fragmentary perspective view of the adapter employed in the practice of the invention and featuring the right or "lockless" side;
FIG. 11 is a fragmentary perspective view of the adapter of FIG. 10 and featuring the left or "lock-equipped" side, and also illustrating the plug in exploded relation thereto;
FIG. 12 is a front end view of the adapter similar to the showing in FIG. 3; and
FIG. 13 is a sectional view taken along the line 13--13 of FIG. 2.
DETAILED DESCRIPTION
The instant invention find advantageous application in connection with the excavating tooth of the previously-mentioned co-owned U.S. Pat. No. 4,335,532 which has been marketed widely under the trademark HELILOK®. In certain instances, there has difficulty of removal of the U-shaped fastener. In any event, the lock of the instant invention reduces the fairly high force requirement required in the '532 patent for lock removal.
In the illustration given, the numeral 20 designates generally the inventive tooth assembly. As seen in FIGS. 1 and 2 the numeral 21 designates the point element. The point 21 is mounted on an adapter 22. More particularly, the adapter 22 has a nose 23 (see particularly FIGS. 10 and 11) which is received within a socket 24 (see FIGS. 1 and 2). The point 20 has a digging or earth engaging edge or bit 25 at the end thereof opposite the socket 24. Conventionally, the point 21 is installed on the adapter 22 by a lineal movement along the longitudinal center line or axis of the tooth 20.
As in the '532 patent, the point and adapter employ generally helical thread means for achieving the coupling between the point 21 and adapter 22. In the illustration given the threads or helical flutes 26 are provided on the exterior of the nose 23 (see FIGS. 10 and 11). In similar fashion, the nose 23 is equipped with a stabilized end part as at 27 and for additional details hereof, reference is hereby made to the '532 patent.
In the operation of the '532 construction (and here as well) the point 21 was positioned with its socket end in alignment with the forward end of the nose. Grooves (not shown) in the point were aligned with the threads 26 and installation was achieved by rotating the point 21 through approximately 45°. Thereafter, a generally U-shaped lock was inserted into the two side tongues 28 (see FIG. 2). These tongues 28 extend rearwardly of the point 21 and have slots 29 therein. The adapter nose has mating recesses 30 to receive the tongues 28. The tongues 28 on the point 21 enter the recesses 30 at the last stage of point rotation incident to mounting.
The lock generally designated 31 (see FIG. 3) of the instant invention differs significantly from that previously employed with the '532 patent construction, consisting in the illustrated embodiment of only a single pin as contrasted to the U-shaped lock previously employed. The pin or lock bar is designated 32 and is seen to be deformed as at 33 (see FIGS. 1 and 13) to provide a point tightening force.
The creation of this tightening force is facilitated by a variable width profile consisting of a "large radius", concave forward edge 34 and a "smaller radius", convex rear edge 35 (see FIG. 5), For example, the pin 32 for the size 67 HELILOK® is 5.9" long with the concave forward edge 34 being developed by a 22" radius and the rear edge or surface by a 16" radius. The cross sectional dimensions at the ends are approximately 0.75"× 0.80" with the larger dimension extending between the surfaces 34 and 35. At mid-length, this dimension is 0.870".
In installation of the pin 32, the forward edge 34 contacts a pair of vertically disposed ears 36, 37 which project from one side of the modified design HELILOK® nose (see FIGS. 1 and 11). The rear edge 35 contacts the lug 38 on one of the point tongues 28 (compare FIGS. 1 and 2). The lugs 38 are provided at the extreme rear of the tongues 28 and are partially defined by the slots 29.
During assembly the relatively narrower end width of the pin 32 (see FIGS. 5, 6 and 9 at 39) enters, without resistance, the available opening between the point tongue lug 38 and the ledge 40 (see FIG. 12) extending between the vertically disposed nose ears 36, 37. As the pin 32 is driven into this opening its rear edge 35 engages the point lug 38 such that lateral deformation of the pin 32 is induced. This elastic deformation creates a point tightening force against the point tongue lug.
It is the geometry of the forward edge relative to the rear edge of the pin that produces a wedge tightening affect on the point tongue lug. This geometry eliminates one of the negative aspects of a traditional straight taper wedge, which is the tendency to disassemble under load. With a straight taper wedge, there is always a component of tooth loading tending to dislodge the wedge. With the instant invention, there is no such component. This geometry may be considered as providing a stabilized wedge force by virtue of elimination of the dislodgement force component.
As indicated above, the pin 32 is beveled at one end as at 39--for engagement during assembly with the spring plug generally designated 41. As best seen in FIGS. 3 and 8 the pin 32 is equipped with a generally conically shaped side recess 42 which receives the end of a similarly shaped plug member 43 (see FIG. 4). The plug member 43 is equipped with an axially extending shank 44 about which a helical spring 45 is mounted.
Still further, the spring 45 and shank 44 are encapsulated with a shrouding means 46 which advantageously may take the form of self-skinning polyurethane rubber. This avoids problems of lock removal which sometimes were difficult because of frozen dirt which can pack around the spring in the assembly. Also, by encapsulating the spring 45 and shank 44 in the means 46 inward of the base 47 of the plug member 43, a unitary element 41.
The self-skinning shroud means 46 seals out clay and fines which hinder plug function and the shroud means is capable of great deformation without loss of resiliency through the fact that water is prevented from entering the foam cells.
The cooperative engagement of the pin with the plug 41 at the beginning of assembly is arranged to prevent accidental reverse assembly of the pin. As properly oriented for assembly the beveled end 39 of the pin 32 will engage the tip of the plug member 43 such that, when the pin is driven toward assembly, the total plug 41 is forced by a wedging action into the circular bore 48 (see FIG. 11) in the side of the adapter nose and against the pressure of spring 45. Because the conical tip 49 of the plug is joined to the flange bearing or base portion 47 of the plug by an intermediate cylindrical portion 50, this plug wedging action will not occur when the pin is positioned in a reverse orientation. In this instance, the blunt portion 51 (see FIG. 6) of the pin end will flatly contact the cylindrical portion of the plug tip so that assembly is prevented. Assembly of the pin upside down is prevented by the same means. The beveled end 39 is equipped with an integral guide 39a as seen in FIGS. 5 and 9 to assist the insertion of the pin 32.
Spring loaded locks have been disclosed in the prior art, for example, U.S. Pat. No. 2,635,366 but this suffers from the drawback of having the lock retention force operating in the same direction as the point mounting direction. Another prior art teaching that employs detent like means for mounting a point on the adapter is co-owned U.S. Pat. No. 4,577,423 but no springs are employed.
A commercially available locking system employs a central flex pin which forces two side pins into holes in the point sidewall, thereby giving four surfaces of point retention. However, the side pins have nothing to do with retaining the central flex pin in assembly.
Still another type of spring usage is seen in co-owned U.S. Pat. No. 4,501,079 which employs a very wide spring to achieve only secondary tightening capability to prevent rattling.
The adapter nose rear, top and bottom profiles are continuous uninterrupted surfaces as at 52 and 53 (see FIG. 10) made possible because the two ears 36 and 37 project only sidewardly. This optimizes the nose in resistance to fatigue failures in the area of the lock.
The ledge 40 joining the two vertically disposed nose ears 36, 37 and formed by the termination of the conically shaped nose is characterized by the same lateral alignment with the point tongue lug 38 as exists in the co-owned U.S. Pat. No. 4,335,532. This creates the same longitudinal shear loading on the pin as exists on the U-shaped lock, wherein a pin of comparatively small size and low cost is structurally adequate.
While in the foregoing specification a detailed description of an embodiment of the invention has been set down for the purpose of illustration, many variations in the details hereingiven may be made by those skilled in the art without departing from the spirit and scope of the invention. | An excavating tooth assembly including an adapter, a point equipped with rearwardly projecting tongues, and locking means including a vertical pin external of the adapter nose held in place by a shrouded spring loaded plug disposed perpendicularly to the line of mounting the point on the adapter, the pin haivng arcuate front and back surfaces for wedging engagement with laterally projecting ears on the nose and a laterally projecting lug on a point tongue. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application Ser. No. 61/021,472 filed Jan. 16, 2008 which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] One or more embodiments of the present invention generally relate to a system and method for detecting a fault isolation and leakage current for an inverter circuit in a vehicle.
[0004] 2. Background Art
[0005] It is known that in order to charge or use electrical devices that are not part of the vehicle (such as, but not limited to, cell phones, laptops, or vacuum cleaners) various aftermarket adapters are needed to be purchased so that such adapters can be plugged into a power outlet of the vehicle and into the electrical device to charge or use the electrical device. To charge and/or use such an electrical device in a vehicle, an aftermarket vehicle adapter is needed that includes a cable and a connector generally shaped in the form of a cylindrical connector to mate with a power outlet (e.g., cigar lighting receptacle) in the vehicle. The connector includes a retractable conductive pin that makes contact with a mating terminal positioned within the power outlet of the vehicle to enable power transmission therebetween. The adapter may include additional circuitry (e.g., inverter circuit) for converting the DC power to AC power so that the electrical device can operate or store power provided by the vehicle.
[0006] Original equipment manufacturers (OEMS) are attempting to obviate the need for vehicle occupants to have to purchase the aftermarket vehicle electrical adapter as described above. For example, OEMs are implementing a female prong connector within the vehicle that is capable of receiving a male prong connector in a similar manner to that invoked when connecting an electrical device to an electrical wall outlet of a home, a building, or other suitable establishment. OEMs are consistently on guard for the need to provide a safe connection for users that may come into contact with the female prong connector or other componentry that is utilized to provide for DC to AC conversion in the vehicle.
SUMMARY
[0007] An inverter system for a vehicle comprising a housing, a primary stage, a secondary stage and a fault detection circuit is provided. The primary stage is configured to receive a first voltage signal from an energy power source to generate a second voltage signal. The secondary stage is configured to generate a third voltage signal in response to the second voltage signal. At least one of the primary and the secondary stages define at least one resistance point for discharging leakage current responsive to generating the third voltage signal. The fault detection circuit is configured to electrically couple the primary stage and the secondary stage to provide the second voltage signal to the secondary stage and to measure a portion of the third voltage signal to determine whether the leakage current being discharged through the at least one resistance point is within a predetermined current range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The embodiments of the present invention are pointed out with particularity in the appended claims. However, other features of the various embodiments will become more apparent and will be best understood by referring to the following detailed description in conjunction with the accompany drawings in which:
[0009] FIG. 1 depicts an inverter system for use in a vehicle;
[0010] FIG. 2 depicts various internal resistance points of the inverter system;
[0011] FIG. 3 depicts an inverter system in accordance to one embodiment of the present invention;
[0012] FIG. 4 is a plot depicting a waveform which corresponds to non-isolation fault condition; and
[0013] FIG. 5 is a plot depicting a waveform which corresponds to one isolation fault condition.
DETAILED DESCRIPTION
[0014] Detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the one or more embodiments of the present invention.
[0015] In order to provide for DC to AC conversion in a vehicle so that an electrical device can operate from the high AC based voltage output, various safety measures can be employed to protect users that come into contact with a prong in a connector that is associated with providing the high AC based voltage to the electrical device. In a first measure, any components generally associated with the high AC based voltage (including the connector and the one or more of the prongs) are adequately isolated from the rest of the electrical network of the vehicle (e.g., ground connection to earth via a chassis connection through tires of the vehicle). Such isolation is adequate so long as various isolation resistance points about the DC to AC conversion system (or inverter system) are high.
[0016] A second measure requires that in the event a failure exists with respect to isolating the high AC voltage component from the rest of the vehicle network, such a high AC voltage is disconnected to prevent the risk of shocking the user. One or more embodiments of the present invention are directed toward protecting a user that may come into contact with the prong of the connector that is utilized to transfer the high AC voltage from the vehicle to the electrical device.
[0017] FIG. 1 generally illustrates an inverter system 10 for use in a vehicle. The system 10 comprises an energy source 12 and an inverter module 14 . The inverter module 14 generally includes a first connector 16 having prongs 18 a - 18 n therein for receiving a second connector (not shown). A user 20 may mate the second connector to the first connector 16 . In general, the inverter module 14 is configured to receive a DC voltage from the energy source 12 and to convert the DC voltage into an AC voltage output. The second connector is coupled to an electrical device. The electrical device may comprise a cell phone, laptop computer, vacuum cleaner, or other suitable device that requires A/C electrical power to operate.
[0018] The AC voltage output may be any one of, but not limited to, 100 Vac/50 Hz, 110 Vac/60 Hz, 200 Vac/60 Hz, 220 Vac/60 Hz, or 230 Vac/50 Hz depending on the country in which the vehicle will be used. In one example, the energy source 12 may be a vehicle battery that generates 12 Vdc. In another example, the energy source 12 may be a DC supply such as a voltage DC/DC stabilizer or converter that converts a high DC-based voltage to a DC voltage level suitable for input to the inverter module 14 . The energy source 12 is recognized to be any such device capable of providing a suitable input to the inverter module 14 .
[0019] The inverter module 14 includes a primary stage 24 and a secondary stage 26 . The inverter module 14 further includes a transformer 22 having a primary coil 22 a and a secondary coil 22 b. The primary stage 24 and the secondary stage 26 coact with each other to convert the DC voltage input into the AC voltage output. For example, the primary stage 24 may include a DC/AC converter (not shown) to convert the DC input voltage into a low AC voltage having a high frequency component. The secondary stage 26 converts the low AC voltage back into a high DC voltage (e.g., 300 V or other suitable voltage). The high DC voltage is input to a switching element that includes MOSFET(s), IGBT(s) or other suitable power devices to generate the desired AC voltage output. The above description of converting the DC voltage into the AC voltage output is known in the art and will not be described further. The secondary stage 26 is generally isolated (via various isolation elements) from the primary stage 24 due to the high voltage characteristics of the secondary stage 26 . The isolation elements include, but not limited to, separation mechanisms in printed circuit board (PCB) to separate tracks in primary and secondary stages 24 , 26 , galvanic isolation in the transformer 22 , optocouplers, or other suitable devices. The primary stage 24 may include the primary coil 22 a of the transformer 22 and the secondary stage 26 may include the secondary coil 22 b of the transformer 22 .
[0020] The inverter module 14 includes a housing 25 that is constructed of metal (other electrically conductive materials are contemplated). The primary stage 24 and the secondary stage 26 are generally positioned within the inverter module 14 . The first connector 16 may be positioned in a center stack area of an instrument panel in the vehicle. An insulated wiring cable may be coupled to the first connector 16 and the inverter module 14 to enable electrical communication therebetween.
[0021] The housing 25 may be situated so that contact is made with a surface in the vehicle that is sufficient to establish a suitable ground to earth. In one example, the housing 25 may be coupled to a vehicle chassis (e.g., see chassis connection 28 ). The chassis connection 28 is coupled to earth via wheels (not shown). The wheels may include a small resistance as represented by R wh .
[0022] A connection 27 is made between the housing 25 and a negative feed of the energy source 12 . As noted above, the secondary stage 26 is isolated from the primary stage 24 . Such isolation generally refers to the condition whereby minimal leakage current flows between the primary stage 24 and the secondary stage 26 while the inverter module 14 converts the DC voltage input into the AC voltage output. By isolating the secondary stage 26 from the primary stage 24 , such a condition also isolates the secondary stage 26 from the connection 27 of the negative feed, and the chassis connection 28 . If the secondary stage 26 is not properly isolated from the primary stage 24 , then a large amount of leakage current may flow between the primary stage 24 and the secondary stage 26 if the circuit is closed. Such a condition may harm the user 20 in the event the user 20 contacts the negative prong of the first connector 16 .
[0023] FIG. 2 depicts various internal resistance points (RP 1 , RP 2 , RP 3 , and RP 4 ) that may be present within the inverter system 10 . The ohmic values of the various internal resistance points RP 1 , RP 2 , RP 3 and RP 4 determine the amount of leakage current that flows between the primary stage 24 and the secondary stage 26 . It is to be noted that internal resistance points RP 1 -RP 4 are not to be construed as actual resistors that are implemented within the inverter module 14 for the purpose of converting the DC voltage input into the AC voltage output. Such internal resistance points RP 1 -RP 4 represent locations that may exhibit ohmic values between the primary stage 24 , the secondary stage 26 , and/or the housing 25 .
[0024] The resistance values of the internal resistance points RP 1 -RP 4 under normal operating conditions are high which indicates that the secondary stage 26 is isolated from the primary stage 24 . RP 1 may correspond to an internal resistance between the positive side of the primary coil 22 a and the positive side of the secondary coil 22 b of the transformer 22 . RP 2 may correspond to an internal resistance between a negative side of the primary coil 22 a and a negative side of the secondary coil 22 b. RP 3 may correspond to an internal resistance between the positive side of the secondary coil RP 3 and the ground (e.g., the metallic housing 25 that is coupled to the chassis connection 28 ). RP 4 may correspond to an internal resistance between the negative side of the secondary coil RP 4 and the ground (e.g., the metallic housing 25 that is coupled to the chassis connection 28 ).
[0025] In the event one or more of the resistance points RP 1 -RP 4 exhibit a low ohmic condition, such a condition may correspond to the secondary stage 26 not being isolated from the primary stage 24 . In such a case, an isolation fault is considered to exist and the leakage current that is passed from the secondary stage 26 to the primary stage 24 is high in the event the first connector 16 is mated with the second connector. Such an isolation fault may be caused due to one or more issues within the electronics in the primary or secondary stage 26 . A low ohmic condition exhibited by any one of the resistance points may correspond to an isolation fault. It is generally recognized that leakage current is passed from the secondary stage 26 to the primary stage 24 (and through the resistance points RP 1 -RP 4 ) while the high AC voltage output is delivered to the electrical device. When an isolation fault is not present, any such leakage current discharged through the resistance points RP 1 -RP 4 is considered to be negligible.
[0026] FIG. 3 depicts an inverter system 50 in accordance to one embodiment of the present invention. The system 50 includes a fault detection circuit 51 . The fault detection circuit 51 is generally configured to determine the amount of leakage current that flows between the secondary stage 26 and the primary stage 24 . The fault detection circuit 51 closes the circuit between the primary stage 24 and the secondary stage 26 to determine whether the leakage current is within a predetermined current range. In one example, the predetermined current range may correspond to a current value that is less than 5 mA. The particular current value(s) used to establish the predetermined current range may vary based on the desired criteria of a particular implementation. The fault detection circuit 51 includes a switching device 52 , a microcontroller 54 , and a voltage divider network (e.g., resistor R 1 and R 2 ). The microcontroller 54 measures the voltage across the resistor R 1 and/or R 2 to determine the amount of leakage current that flows from the secondary stage 26 to the primary stage 24 .
[0027] In operation, the microcontroller 54 is configured to control the switching device 52 (e.g., switch, relay, transistor, or other suitable mechanism) to close for a predetermined amount of time so that the microcontroller 54 measures the voltage across resistor R 2 (or resistor R 1 or both resistor R 1 and R 2 ) to determine if the measured voltage is within a predetermined voltage range. If the measured voltage across resistor R 2 is within the predetermined voltage range, the microcontroller 54 determines that the there are no isolation faults present at one or more of resistance points RP 1 -RP 4 . As such, any such leakage current flowing through the inverter module 14 is generally considered to be negligible (or with the predetermined current range) and may not shock the user 20 . If the measured voltage is not within the predetermined voltage range, then the microcontroller 54 determines that there is at least one isolation fault present and that the leakage current exceeds the predetermined current range. In this case, the microcontroller 54 may shut the inverter module 14 down and cease to convert the DC voltage input into the AC voltage output to remove the potential for the high leakage current to come into contact with the user 20 .
[0028] The microcontroller 54 may control an LED or other suitable mechanism to warn the user in response to detecting an isolation fault. In one example, the microcontroller 24 may be electrically coupled to other controllers about the vehicle via a data communication bus. Such a data communication bus may be implemented as, but not limited to, control area network (CAN), local interconnect network (LIN) or other recognized alternate. The microcontroller 54 may transmit a message over the bus to the other controllers so that the controller notifies the user of the isolation fault (e.g., cluster lighting telltale to warn the user).
[0029] The microcontroller 54 may control the switching device 52 to close and measure the voltage across the resistor R 2 after vehicle engine start-up thereby detecting the presence of a high leakage current condition (or isolation fault) (e.g., one or more of the ohmic values of the resistance points RP 1 -RP 4 is low). The microcontroller 54 shuts the inverter module 14 down in response to detecting the isolation fault before the user may experience a shock condition. It is generally contemplated that the microcontroller 54 may also control the switching device 52 to close and measure the voltage periodically at predefined intervals (e.g., every 10 seconds or suitable time frame) after engine startup.
[0030] In one example, the microcontroller 54 may calculate Vrms across the resistor R 2 with the measured voltage across the resistor R 2 . Vrms may correspond to an AC signal having a 5 V peak-to-peak with a DC offset of 2.5V. The microcontroller 54 may measure the voltage across the resistor R 2 for a period of 20 ms for an A/C output voltage at 50 Hz and a period of 16.6 ms for an A/C output voltage at 60 Hz. After the microcontroller 54 determines the Vrms for the measured voltage, the microcontroller 54 compares the Vrms against the predetermined voltage range. The voltage values in the predetermined voltage range may be in a root mean square format. It is recognized that the time period used by the microcontroller 54 to measure the voltage may include other values than those noted above.
[0031] In one example, the predetermined voltage range may correspond to a range of 0.78 Vrms and 1 Vrms. Meaning, that in the event Vrms for the measured voltage corresponds to a value between 0.78 Vrms and 1 Vrms, such a condition may indicate that there are no isolation faults present and that the leakage current is within the predetermined current range. Such a condition may also indicate that the total resistance of all of the resistance points RP 1 -RP 4 about the inverter module 14 is greater than or equal to 120 Kohms. If, on the other hand, the Vrms for the measured voltage is either less than 0.78 Vrms or greater than 1 Vrms, such a condition may indicate that there is an isolation fault present between the secondary stage 26 and the primary stage 24 and that the leakage current may be outside of the predetermined current range. The microcontroller 54 may shut down the operation of the inverter module 14 in the event such a condition was present. The particular values selected to establish the predetermined voltage range may vary based on the desired criteria of a given implementation.
[0032] The number of resistors which form the voltage divider network in the system 50 may vary and are not intended to be limited to those shown in FIG. 3 . The voltage divider network (e.g., resistor R 1 and R 2 ) may reduce voltage so that an analog/digital (A/D) converter (not shown) within the microcontroller 54 can read the measured voltage across the resistor R 1 and/or R 2 . It is contemplated that the microcontroller 54 may not include the A/D converter to read the voltage across the resistors R 1 and R 2 and that other suitable methods for reading the voltage may be employed.
[0033] As noted above, the secondary stage 26 receives the low DC voltage from the primary stage 24 . The secondary stage 26 converts the low AC voltage back into a high DC voltage and presents the high DC voltage to power switching element(s) to generate the desired AC voltage output. In another embodiment, the switching device 52 may be coupled to the various DC stages within the secondary stage 26 so that DC-based voltages may be measured across the resistor R 1 and/or R 2 to obtain a DC-based measurement as opposed to the to the root-mean square voltage format as described above. With respect to the root-mean square voltage format as described above, the resistors R 1 and R 2 are generally coupled to various devices within the secondary stage 26 that are associated with the AC voltage component.
[0034] FIG. 4 is a plot 60 depicting a measured waveform 62 which corresponds to non-isolation fault condition in accordance to one example of the present invention. Waveform 62 generally corresponds to the measured voltage across a single resistor (e.g., resistors R 1 or R 2 ). The waveform 62 is shaped in the form of a sinusoidal wave and that such a sinusoidal wave generally indicates that the various internal resistance points RP 1 -RP 4 exhibit a high resistance value (e.g., a measured voltage reading that is within the predetermined voltage range) thereby indicating that the leakage current is within the predetermined current range (e.g., less than 5 mn or other suitable current value).
[0035] FIG. 5 is a plot depicting a measured waveform 72 which corresponds to an isolation fault condition. Waveform 72 is an example of the measured voltage that may be an indicative of a risk of high leakage current (e.g., measured voltage not within predetermined voltage range). In such case, one or more of the internal resistor points RP 1 -RP 4 may exhibit a low resistance state. It is generally contemplated that other such electronics such as capacitor(s), diode(s) and/or inductor(s) included within the inverter module 14 may be combined with the resistors R 1 and/or R 2 to provide an alternate detection circuit to create a signature waveform that corresponds to a high leakage current condition.
[0036] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. | An inverter system for a vehicle comprising a housing, a primary stage, a secondary stage and a fault detection circuit is provided. The primary stage is configured to receive a first voltage signal from an energy power source to generate a second voltage signal. The secondary stage is configured to generate a third voltage signal in response to the second voltage signal. At least one of the primary and the secondary stages define at least one resistance point for discharging leakage current responsive to generating the third voltage signal. The fault detection circuit is configured to electrically couple the primary stage and the secondary stage to provide the second voltage signal to the secondary stage and to measure a portion of the third voltage signal to determine whether the leakage current being discharged through the at least one resistance point is within a predetermined current range. | 6 |
BACKGROUND OF THE NEW VARIETY
The present invention relates to a new, novel and distinct variety of nectarine tree, which has been denominated varietally as ‘Burnecthree’. The ‘Burnecthree’ Nectarine Tree produces an exceptionally high quality nectarine which is mature for harvesting and shipment in the mid-season. Still further, another unique aspect of the ‘Burnecthree’ is that it yields a very firm nectarine that exhibits high eating quality as compared with the other nectarine varieties which ripen at approximately the same time of the season.
ORIGIN OF THE NEW VARIETY
The present variety of nectarine tree was derived from an ongoing program of fruit and nut tree breeding. The purpose of this program is to improve the commercial quality of deciduous fruit and nut varieties and rootstocks by creating and releasing selections of prunus, malus and regia species. To this end, we make both controlled and hybrid crosses each year in order to produce seedling populations from which improved progenies are evaluated and selected. The nectarine seedling ‘Burnecthree’ was originated by us in 1994, and chosen from among a population of seedlings which resulted from a controlled cross pollination of the ‘Grand Diamond’ Nectarine Tree (U.S. Plant Pat. No. 4,095), which was used as the pollen parent, and the ‘Flame Glo’ Nectarine Tree (U.S. Plant Pat. No. 8,441), which was used as the seed parent. The resulting seed from this cross pollination was planted in the spring of 1995. The new variety was selected from among seedlings growing in experimental orchards located near the city of Fowler, Calif., County of Fresno, in the central San Joaquin Valley. The Nectarine Tree ‘Burnecthree’ was subsequently marked and noted as having exceptional characteristics. It has been subsequently evaluated during the 1996-1999 fruiting seasons. After the 1996 season, the ‘Burnecthree’ Nectarine Tree was selected for advanced evaluation and repropagation.
ASEXUAL REPRODUCTION OF THE NEW VARIETY
Scion wood from the original seedling of the Nectarine Tree, ‘Burnecthree’ was collected and grafted in the evaluation plot of the experimental orchard previously described onto two different and existing Nemared_(unpatented) rootstocks in February of 1997. Fruit from the resulting propagation has been subsequently evaluated for the 1998 and 1999 fruiting seasons. This latter evaluation clearly demonstrated that the repropagated trees were true to the characteristics of the original seedling in all observable respects.
SUMMARY OF THE NEW VARIETY
The ‘Burnecthree’ Nectarine Tree is characterized as to novelty by producing fruit which have a mid-season ripening date, and which is further of high quality, firm, and has an attractive exterior coloration. In this regard, the present variety of nectarine tree bears clingstone fruit which are ripe for commercial harvesting and shipment during approximately July 8 to July 15. These harvesting dates are approximately one week later than the harvest dates of the commercial freestone nectarine variety ‘Summer Grand’ Nectarine Tree (U.S. Plant Pat. No. 2,879). The present variety distinguishes itself from the Summer Grand Nectarine Tree, however, by producing fruit having a brighter and more extensive exterior coloration, improved flavor, and additionally, has a firmer flesh. Further, the ‘Burnecthree’ Nectarine Tree distinguishes itself from the Summer Grand Nectarine Tree in that the fruit of the ‘Burnecthree’ Nectarine Tree has an extended shelf life, after it is harvested, in relative comparison to the fruit of the Summer Grand Nectarine Tree. The subject variety differs from the ‘Grand Diamond’ in that ‘Burnecthree’ is a clingstone fruit and has much more luster in its external finish than does the fruit of the ‘Grand Diamond’. The subject variety also differs from the ‘Flameglo’ nectarine in that the ‘Burnecthree’ fruit is generally larger and does not have a predominate pistil point which consistently appears on the fruit of the ‘Flameglo’.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing is a color photograph of a characteristic twig bearing typical leaves; several leaves showing both the dorsal and ventral coloration thereof; and several mature fruit showing their external coloration sufficiently matured for harvesting and shipment. Additionally, one fruit of the subject variety is dissected in the equatorial or cheek plane to illustrate the flesh and stone characteristics.
DETAILED DESCRIPTION
Referring more specifically to the pomological details of this new and distinct variety of nectarine tree, the following has been observed under the ecological conditions prevailing at the orchards previously described, and which are located near the town of Fowler, county of Fresno, state of California. Observations were made of the original seedling tree on its own root during the growing years of 1996-1999. All major color code designations are by reference to The R.H.S. Colour Chart (1995 Third Edition) provided by The Royal Horticultural Society of Great Britain.
Tree:
Size.— Generally — Average to above average as compared to other common nectarine cultivars.
Productivity.— Productivity with respect to pounds per acre is not available. This trait is highly dependent on cultural practices and is not distinctive of the variety.
Form.— The original seedling was trained in a central leader configuration with a moderate spread in the crown of the tree. The tree is considered upright to upright spreading in form.
Height.— The original seedling had a height dimension of 3.86 m at the end of the 1999 growing season.
Width.— The original seedling tree had a width of 2.1 m at the end of the 1999 growing season.
Current season growth.— The current season growth for the new variety was approximately 0.79-1.0 m.
Regularity of bearing.— Regular, and considered hardy under typical Central San Joaquin Valley climatic conditions.
Trunk:
Thickness.— Approximately 61.2 mm in diameter when measured at a distance of approximately 15.24 cm above the soil level, at the end of the 1999 growing season.
Bark texture.— Considered moderately rough with numerous folds of papery scarf skin being present.
Lenticels.— Numerous flat, oval lenticels are present. The lenticels range in size from approximately 3.0 to 7.0 millimeters in width and from approximately 1 to 2 millimeters in height.
Lenticels color.— Tan Brown (RHS Greyed-Orange Group 173 D).
Bark coloration.— Variable, but it is generally considered to be a grey-brown (RHS Greyed-Orange Group 174 A).
Branches:
Size.— Considered medium for the variety.
Diameter.— The branches have a diameter of 38.1 mm when measured during the 3 rd year after grafting.
Surface texture.— Average, and appearing furrowed on wood which is several years old.
Crotch angles.— Variable between about 41.0° to 46.0° from the horizontal axis for scaffold limbs. This is not distinctive of the variety however.
Current season shoots.— Surface Texture — Substantially glabrous.
Internode length.— Approximately 2.2 to 2.4 cm.
Color of mature branches.— Medium brown, (RHS Greyed Orange Group 175 C to 177 B).
Current season shoots.— Color — Light green, (RHS Yellow Green Group 144 C), with some reddish-brown coloration appearing on exposed exterior shoots (RHS Greyed Red Group 181 B). The color of the new shoot tips is considered a bright and shiny green (RHS Green Group 143 B).
Leaves:
Size.— Considered average for the species. Leaf measurements have been taken from vigorous upright current season growth at approximately midshoot.
Leaf length.— Approximately 176 to 188 millimeters.
Leaf width.— Approximately 48 to 51 millimeters.
Leaf thickness.— Approximately 1 to 2 millimeters.
Leaf base shape.— Slightly oblique.
Leaf form.— Lanceolate.
Leaf tip form.— Acuminate.
Leaf color.— Dark green (RHS Green Group 132 C).
Leaf texture.— Glabrous.
Lower surface color.— Light green, (RHS Yellow Green Group 146 B).
Venation.— Pinnately net veined.
Mid - vein.— Color — Light yellow green, (RHS Yellow Green Group 153 B).
Leaf margins.— Form — Considerate crenate, and occasionally doubly crenate. Uniformity — Considered generally uniform.
Leaf petioles.— Size — Considered medium. Length — Approximately 6 to 9 millimeters. Diameter — Approximately 1.5 to 2 millimeters. Color — Pale green, (RHS Yellow Green Group 150 C).
Leaf glands.— Size — Approximately one to two millimeters in height and two to three millimeters in width. Numbers — Generally 1-2 per side. Occasionally two per side. Type — Reniform and small. Color — Greenish brown, (RHS Grey Brown Group 199 C).
Leaf stipules.— Size — Approximately 6 to 9 mm in length; 1.0 mm in width. Number — Typically 2 per leaf bud and up to 6 per shoot tip. Form — Lanceolate in form with a serrated margin. Color — Green (RHS 135 A) when young, but changing to a yellow-brown (RHS Greyed-Orange Group 174 A) color with advancing senescence. The stipules are considered to be early deciduous.
Flowers:
Flower buds.— Generally — The floral buds are considered to be medium in size (16.0 mm long and 9.0 mm wide), plump to slightly pointed in form, and slightly appressed, relative to the bearing shoot.
Flower buds.— Color — The bud scales are gray-brown, (approximately RHS Greyed Orange Group 177 B). The buds are considered hardy under typical central San Joaquin Valley climatic conditions.
Hardiness.— No winter injury has been noted during the several years of evaluation in the Central San Joaquin Valley. The current variety has not been intentionally subjected to drought or heat stress and therefore this information is not available.
Blooming time.— Considered slightly earlier than average in relation to other nectarine cultivars commonly growing in the Central San Joaquin Valley. Date of full bloom was observed on Mar. 4, 1998.
Flower type.— The variety is considered to be a showy type flower.
Flower diameter.— Flower diameter at full bloom is approximately 38 to 45 millimeters.
Bloom quantity.— Considered abundant.
Flower bud frequency.— Normally 1 to 2 buds appear per node, although 1 bud per node is more common.
Petal size.— Generally — Considered medium-large for the species. Length — Approximately 17 to 22 millimeters. Width — Approximately 16 to 20 millimeters.
Petal shape.— Broadly ovate.
Petal count.— Nearly always 5.
Petal texture.— Glabrous.
Petal color.— Light pink when young (approximately RHS Red Purple Group 69 C), and with advancing senescence changing to a very pale pink (RHS Red Purple Group 68 B). The lower portion of the flower petal is typically darker that the apical portions and exhibits a dark pink coloration (RHS Red-Purple Group 64 B).
Petal claw.— Form — The claw is considered truncate in shape and has a medium size when compared to other similar varieties. Length — Approximately 1.5 to 2 millimeters. Width — Approximately 1 millimeter.
Petal margins.— Generally — Considered variable, from nearly smooth, to moderately undulate.
Petal apex.— Generally — The petal apices appear slightly domed.
Flower pedicel.— Length — Considered medium-short, and having an average length of approximately 2.0 to 3.0 millimeters. Diameter — Considered average, approximately 2 millimeters. Color — Bright green (RHS Yellow Green Group 144 D).
Floral nectaries.— Color — Dull orange, to an orange-gold color (approximately RHS Greyed Orange Group 168 B). The color of the nectaries become increasingly dull and slightly darker with advancing senescence.
Calyx.— Surface Texture — Generally glabrous, with some slight ribbing being occasionally evident. Color — A dull red, (approximately RHS Greyed Red Group 184 A).
Sepals.— Surface Texture — The surface has a medium length, wooly, and gray (RHS Greyed-Purple Group 183 D) colored pubescence. Number — Generally 5 per flower. Size — Average, and ovate in form. Typically 4.0 mm wide and 6.0 mm long. Color — A dull red, (approximately RHS Greyed Red Group 178 A).
Anthers.— Generally — Average in size. Color — Red to reddish-orange dorsally, (approximately RHS Greyed Purple Group 187 D). Pollen production — Pollen is abundant, and has a yellow-gold color, (approximately RHS Orange 26 A).
Filaments.— Size — Varaible in length, approximately 14 to 16 millimeters. Color — White, (RHS Red Purple Group 69 D), and darkening with advanced maturity.
Pistil.— Generally — Average in size. Length — Approximately 15 to 17 millimeters, including the ovary. Color — Considered a very pale green, at mid-bloom, (approximately RHS Yellow Green Group 151 D). Surface Texture — Glabrous.
Fruit:
Maturity when described.— The present variety of fruit is described, as it would be found in its firm ripe condition at full commercial maturity. In this regard, the fruit of the present variety was first picked on approximately Jul. 8, 1998. The date of last pick of the same fruit in 1998 was approximately Jul. 15, 1998 under the ecological conditions prevailing in the San Joaquin Valley of Central California.
Size.— Generally — Medium in size, and considered moderately uniform. Average Cheek Diameter — Approximately 75 to 78 millimeters. Average Suture Diameter — Approximately 75 to 79 millimeters. Average Axial Diameter — Approximately 74 to 77 millimeters. Fruit Weight — This is highly dependent on agricultural practices, and therefore is not distinctive of the present variety.
Fruit form.— Generally — Globose in its lateral aspect. The fruit is generally uniform in symmetry and having a rounded form when viewed from the apical aspect.
Fruit suture.— Generally — The suture appears as a thin line, which extends from the base to the apex, and which appears slightly deeper, basally, within the stem well, and apically on both sides of the pistil point. No apparent callousing or stitching exists along the suture line.
Suture.— Color — The suture normally is the same color as the underlying blush, both where the orange-yellow background color, (RHS Orange Group 24 C) and the red orange color, (RHS Red Group 46 A to 46 B) occur.
Ventral surface.— Form — Considered uniform.
Stem cavity.— Size — Considered moderately for the species.
Width.— Approximately 19-21 millimeters.
Length.— Approximately 27-30 millimeters.
Depth.— Approximately 10 to 11 millimeters.
Form.— Considered narrowly oval.
Fruit base.— Generally — Considered truncate to slightly oblique in form, and uniform.
Fruit apex.— Generally — Considered depressed and usually recessed below the height of the apical shoulders.
Fruit stem.— Generally — Considered medium in length, approximately 9 to 10 millimeters.
Diameter.— Approximately 3 to 4 millimeters.
Color.— Generally a pale yellow-green, (approximately RHS Yellow Green Group 145 B).
Fruit skin.— Generally — Considered average in thickness. Surface Texture — The variety has a very glabrous surface. Skin Acidity — Considered neutral.
Tenacious to flesh.— Yes at commercial maturity.
Tendency to crack.— Not observed.
Skin color.— Generally — Variable, with approximately 80% to 90% of the fruit surface covered with a brilliant crimson red blush.
Blush color.— The blush color is generally more prevalent apically. This red blush color ranges from a dark red, (RHS Red Group 46 A and B) to an orange red, (RHS Orange-Red Group 33 B), with many degrees of shading and blending occurring between these colorations.
Skin ground color.— This is generally present in variable percentages covering approximately 10% to 20% of the fruit's surface, which has a yellow-golden color, (RHS Yellow Orange Group 22 A to 24 C).
Flesh color.— Generally — Considered varaible, having a yellow-orange color in a range, (RHS Yellow Orange Group 21 C to 21 A).
Flesh fibers.— Generally — Present, numerous, fine and light colored. These fibers are present throughout the flesh.
Stone cavity.— Red, (approximately RHS Red Group 45 B) to a yellow orange, (approximately RHS Yellow Orange Group 18 B).
Flesh texture.— Generally — The flesh is considered firm and fine at commercial maturity. The flesh texture is considered non-melting.
Ripening.— Generally — The fruit of the present variety ripens evenly.
Flavor.— Considered very sweet and having moderate acidity. The flavor is considered both pleasant and well balanced.
Aroma.— Pleasant and abundant.
Eating quality.— Generally — Considered very good to excellent and well above average when compared to other common commercial varieties.
Stone:
Attachment.— Generally — The stone is considered to be a clingstone at full commercial maturity.
Stone size.— Generally — Considered medium for the species.
Length.— Approximately 32 to 35 millimeters.
Width.— Approximately 24 to 27 millimeters.
Thickness.— Approximately 23 to 24 millimeters.
Fibers.— Generally — A few medium length fibers are attached along the entire surface area of the stone.
Stone form.— Generally — The stone is considered rounded to slightly oval.
Stone base.— The stone is generally considered truncate.
Base angle.— The base angle of the stone is variable, but occasionally is considered oblique to the stone axis.
Hilum.— Generally — Considered medium in size, and relatively well defined. The hilum is approximately 5 to 7 millimeters long and approximately 3 to 4 millimeters wide. Form — Considered oval.
Apex.— Shape — The stone apex is raised and has an acute tip.
Stone shape.— Considered variable. The stone is normally equal, although occasionally it may appear nearly unequal.
Stone surface.— Surface Texture — Generally, considered medium in roughness and exhibits substantial pitting laterally. Substantial grooving is apparent over the apical shoulders. Surface pitting is prominent, generally, and is present more frequently basally. Ridges — Numerous fine ridges are present basally and converge towards the base of the stone.
Ventral edge.— Width — Considered medium in size, and prominent, and having a dimension of approximately 5 to 7 millimeters when measured at mid-suture. The wings are most prominent over the basal area.
Dorsal edge.— Full, heavily grooved, and having jagged edges. The dorsal edge is moderately eroded over the apical shoulder.
Stone color.— The color of the dry stone is approximately a light to medium brown, (RHS Orange Red Group 34 C).
Tendency to split.— No splitting noted.
Kernel.— Form — Oval. Length — Approximately 16.0-19.0 mm. Width — Approximately 12.0-14.0 mm. Thickness — Approximately 5.0-6.0 mm. Pellicle — Pubescent. Color — RHS Greyed-Orange Group 172 B.
Use.— The subject nectarine variety Burnecthree is considered to be a nectarine of mid-season maturity, which produces a very firm, highly attractive colored fruit which is useful for both local, long distance, and export shipping.
Keeping quality.— Fruit has stored well up to 20 days after harvest at temperatures of about 1° C.
Resistance to insects and disease.— No particular susceptibilities were noted.
Shipping quality.— Well above average.
Although this new variety of nectarine tree possesses the described characteristics noted above, as a result of the growing conditions prevailing in the central part of the San Joaquin Valley of central California, it is to be understood that variations of the usual magnitude and characteristics incident to changes in growing conditions, fertilization and pruning and pest control are to be expected. | A new and distinctive variety of nectarine tree denominated varietally as ‘Burnecthree’, and which is characterized as to novelty by a date of maturity for commercial harvesting and shipment of approximately July 8 to July 15, under the ecological conditions prevailing in the San Joaquin Valley of central California. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally concerns fluid pressure brake and analogous systems and more particularly concerns multiple fluid receiving points involving front and rear brake pressure modifying.
2. Discussion of the Prior Art
Generally, brake pressure distribution (BPD) valves predeterminately control pressurized fluid to vehicle brakes to vary vehicle brake torque distribution dependent on vehicle deceleration levels. Valves of this type are for the purpose of providing substantially equal pressure distribution to the front and rear brakes when the brake system is operating below a certain predetermined pressure. This type of valve is compatible with a brake system having front and rear axle drum brakes.
Due to the use of shoe return springs, drum brakes require an initial pressure to overcome the opposing forces of the shoe return springs before any braking action occurs. Disc brakes generally do not have such return springs and therefore do not require the initial pressure to overcome such spring forces. As a result, when exposed to the same applied pressure, disc brakes will initially respond to applied pressure faster than drum brakes. Therefore, in a hybrid braking system, such as one including front axle disc brakes and rear axle drum brakes, equal pressure distribution below certain predetermined pressures is undesirable since the faster initial response to pressure application of the disc brakes would result in an initial imbalance of braking force between the front and rear brakes. That is, the front axle disc brakes would initially respond to applied pressure prior to a similar response by the rear axle drum brakes thus creating the possibility of initial front disc brake application prior to the rear drum brake application. Such imbalance could cause premature front axle lock-up on low friction road surfaces and could also cause a higher front brake wear rate.
To overcome these undesirable effects, it would be beneficial to provide unequal brake pressure distribution below certain predetermined pressures by providing a valve capable of initially delaying or restricting the pressure application to the front disc brakes while permitting unrestricted pressure application to the rear drum brakes to overcome the opposing force of the return springs. The desired result would be substantially simultaneous application of both the front disc and rear drum brakes.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a brake pressure distribution valve for predeterminately controlling braking pressure resulting in unequal brake pressure distribution below certain predetermined pressures by providing a valve capable of initially delaying or restricting the pressure application to the front disc brakes while permitting unrestricted pressure application to the rear drum brakes. The foregoing is accomplished by providing a housing having a cavity formed therein. Inlet and outlet ports are formed in the housing to permit fluid to enter and exit the cavity. A metering seal is mounted in the cavity between a first cavity portion adjacent the inlet port and a second cavity portion adjacent the outlet port. A first fluid pressure responsive member is resiliently mounted in the cavity for relative movement into and out of engagement with the metering seal. A second fluid pressure responsive member extends through the first member for relative and concerted movement therewith. A first passage is normally open and extends through the first member for fluidly interconnecting the first and second cavity portions. A second passage is normally closed and is operable upon concerted movement of the first and second fluid responsive members for fluidly interconnecting the first and second cavity portions. The second fluid pressure responsive member carries a check valve member for sealingly closing the first passage upon relative movement between the first and second fluid pressure responsive members thus holding off pressure distribution to the front brakes. The valve may be used in a vehicle brake system of the type including a master cylinder, front disc brakes, rear drum brakes and conduit interconnecting the master cylinder with the front and rear brakes. The valve may be interconnected with conduit between the master cylinder and the front brakes.
Other advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like parts are marked alike:
FIG. 1 is a diagrammatic illustration of a brake system including the novel valve of this invention;
FIG. 2 is a cross-sectional side view of the novel valve of this invention;
FIG. 3 is an exploded partial cross-sectional side view of a specific portion of the novel valve of this invention; and
FIG. 4 is a graphical illustration of a pressure curve resulting from use of the novel valve of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 generally illustrates a portion of a vehicle brake system designated 10 including brake system components such as master cylinder 11 and brake pedal 12 operably connected thereto. Brake fluid in the master cylinder is conducted to front disc brakes 13a, 13b via conduit 17, warning valve 15, conduit 16, brake pressure distribution valve 14 and branch conduits 18a, 18b. Brake fluid is similarly conducted to rear drum brake cylinders 19a, 19b via conduit 20, warning valve 15, conduit 21 and branch conduits 22a, 22b.
In FIG. 2, the novel brake pressure distribution valve of this invention is generally designated 14. The valve includes housing 28 having threaded inlet port 30 and threaded outlet ports 32, 34. Also, housing 28 includes cavity 29 containing first, second and third fluid pressure responsive piston members 36, 38, 40, respectively. Cavity 29 includes first cavity portion 29a adjacent inlet port 30, second cavity portion 29b adjacent outlet ports 32, 34, and third cavity portion 29c. Metering seal 42 is located generally between first and second cavity portions 29a, 29b, respectively. Sealing diaphragm 44 is generally located between second and third cavity portions 29b, 29c, respectively. A tophat shaped valve element 46 is carried by second fluid pressure responsive member 38. First resilient member or spring 48 is compressed between first piston 36 and metering seal 42 to exert forces thereon. Second resilient member or spring 52 is compressed between first piston 36 and diaphragm 44 for exerting forces thereon. Third resilient member or spring 54 is compressed between third piston 40 and an end cap 180 for exerting forces thereon. A first fluid passage 56 interconnects first and second cavity portions 29a, 29b, respectively, when fluid passes through bore 36i formed in member 36. A second fluid passage 58 interconnects first and second cavity portions 29a and 29 b, respectively, when first fluid pressure responsive member 36 and metering seal 42 are separated by fluid passing therebetween. First, second and third fluid pressure responsive members 36, 38 and 40, respectively, and valve element 46 are mounted in cavity 29 and each is provided for either independent or concerted relative movement.
More specifically now, valve 14 comprises housing 28 preferably formed of aluminum and including main cavity 29 formed therethrough having its longitudinal axis interconnecting first end 28a and second end 28b. Cavity 29 generally includes three cylindrical portions designated first cavity portion 29a adjacent first end 28a, relatively reduced diameter second cavity portion 29b formed adjacent first portion 29a, and third portion 29c formed between second portion 29b and second end 28b.
Threaded inner peripheral portion 29d of first cavity portion 29a is formed immediately adjacent first end 28a. First cavity portion 29a is separated from second cavity portion 29b at shoulder 29e. Second cavity portion 29b is separated from third cavity portion 29c at flange 29f. Peripheral groove 29g is formed in cavity 29 adjacent second end 28b. Inlet bore 30a intersects cavity 29 at first portion 29a. Outlet bores 32a, 34a intersect cavity 29 at second portion 29b. Bores 90, 92 are formed through housing 28 having axes transverse to the axis of cavity 29. The bores are provided for mounting housing 28 by the use of bolts or the like.
Annular aluminum sleeve 93 is provided in cavity portion 29a with a first end 93a and a second end 93b. Radially directed annular groove 93c is formed in sleeve 93 for mounting rubber O-ring 102 therein in sealing engagement with cavity portion 29a. Annular rubber metering seal 42 is mounted in sleeve 93 adjacent second end 93b. Sleeve 93 also includes a plurality of radially directed bores 93d formed therein.
Annular aluminum first fluid pressure responsive member or piston 36 is provided in cavity portion 29a within sleeve 93. First end 36a of piston 36 terminates adjacent first end 93a of sleeve 93. Second end 36b of piston 36 protrudes past second end 93b of sleeve 93 and into second cavity portion 29b. Radially extending annular flange 36c adjacent second end 93b is provided for cooperative association with metering seal 42. Spring member 48 is compressed between piston 36 and metering seal 42. Spring 48 is preferably of tinned music wire and urges metering seal 42 into position with sleeve 93. A plurality of radially directed bores 36d are formed in piston 36 similar to those formed in sleeve 93. Rubber valve seat 122 is situated in abutting relationship with piston 36. Axially directed bores 36e, 36i join to extend from first end 36a to second end 36b. Radially directed annular retainer ring groove 36f is formed in the piston 36 and is axially spaced between first end 36a and radial bores 36d.
Piston member 141 is preferably of aluminum and is generally cylindrical including first end 141a and second end 141b which includes axially directed annular blind counterbore 141c formed therein. A plurality of radially directed bores 141d are formed to intersect with blind bore 141c. Steel retainer ring 147 is positioned in groove 36f and retains second end 141b of member 141 in abutting relationship with valve seat 122. Aluminum end cap or plug 154 is generally cylindrical and includes first end 154a and second end 154b. Outer annular peripheral portion 154c is threaded for mating engagement with similarly threaded peripheral portion 29d of housing 28. Annular groove 154d is provided in cap 154 for mounting rubber O-ring 160 therein in sealing engagement with housing 28. Second end 154b includes axially directed bore 154e for mounting annular rubber seal 162 and axially directed bore 154f is for accommodating first end 141a of member 141 in sealing engagement with rubber seal 162. Axially directed bore 154g vents bore 154f to atmosphere. Bores 154h are formed in first end 154a to accommodate a well-known spanner wrench used to threadedly position cap 154 in bore 29. Substantially flat, washer-like steel ring 150 is sandwiched between second end 154b of end cap 154 and first ends 93a and 36a of sleeve 93 and piston 36 respectively.
Piston 38 is an elongated cylindrical shaft-like member of varying diameters along its longitudinal axis. Piston 38 is preferably of stainless steel. First end 38a of piston 38 is of a first diameter for accommodating a floating-fit relationship with tophat shaped check valve element 46 for relative or concerted movement therewith. Annular groove 38j is formed into piston 38 for accommodating steel retaining ring 132. A portion 38c of piston 38 extends from first cavity portion 29a through bore 36i of piston 36 in relatively movable relationship therewith. Flange 38d is formed on piston 38 in second cavity portion 29b. A further portion 38e of piston 38 extends from flange 38d and terminates at enlarged diameter portion 38f. The enlarged diameter portion 38f terminates at annular groove 38g for accommodating steel retaining ring 138. A further portion 38h of piston 38 extends from groove 38g through third cavity portion 29c and terminates at nub 38i formed on the piston at its second end 38b.
Second end 36b of piston 36 protrudes beyond metering seal 42 into second cavity portion 29b where washer-like steel spring retainer 170 is axially urged into abutment with flange 36c of piston 36 by spring 52 preferably formed of tinned music wire. Annular rubber diaphragm 44 is seated in cavity portion 29b. Spring 52 urges bell-shaped steel spring retainer 172 into contact with diaphragm 44 which in turn urges diaphragm 44 into sealing engagement with housing flange 29f. Bell-shaped retainer 172 engages portion 38c of piston 38. Diaphragm 44 sealingly engages reduced diameter portion 38e of piston 38. A brass clamp ring 174 maintains diaphragm 44 in sealing engagement around piston 38.
Third piston 40 is slidably engaged around portion 38f of piston 38 and is also slidably engaged within housing flange 29f. First end 40a of piston 40 is adjacent diaphragm 44 and second end 40b engages retainer ring 138, retained in annular groove 38g, when relative movement occurs between pistons 38 and 40. Tinned music wire spring 54 urges steel retainer ring 178 into second end 40b of piston 40 and also into abutment with housing flange 29f.
Aluminum end cap 180 is generally cylindrical and includes first end 180a and second end 180b interconnected by central annular bore 180c. Annular groove 29g is provided to accommodate retainer ring 182 for retaining cap 180 in third cavity portion 29c. Spring 54 urges cap 180 into contact with retaining ring 182. Extended portion 38h of piston 38 extends through bore 180c of end cap 180. Rubber boot 184 is sealingly engaged with cap 180 and with extended portion 38h of piston 38 adjacent nub 38i.
In operation, with the valve 14 assembled as illustrated in FIG. 2 and connected in the vehicle brake system of FIG. 1, it can be seen that fluid enters inlet port 30 at an initial pressure designated P(in) and flows through bore 30a into first cavity portion 29a. Initially fluid can flow along first path 56 from first cavity portion 29a past bores 93d, 36d, 141d, past tophat valves 46, through bore 36i to second cavity portion 29b and thus to outlet ports 32, 34 at a pressure designated P(out). Fluid communication through passage 58 between first portion 29a and second portion 29b is blocked due to the sealing engagement of metering seal 42 and first piston 36. As fluid pressure increases it acts on diaphragm 44 which is connected to piston 38. At this point P(in) = P(out) as illustrated on the pressure curve of FIG. 4 by line O-A.
When the pressure acting on the effective area of diaphragm 44, FIG. 2, is sufficient to move piston 38 to the right as designated by the arrow 51 to partially draw first end 38a to the right as viewed in the drawing, this permits tophat valve 46 to engage seal 122 thus closing first path 56 and closing off fluid communication between cavity portions 29a, 29b. The closing pressure of valve 46 can be predetermined by the stiffness of rubber diaphragm 44, and is generally desired to be some value below 15 psi. At this point the rate of increase in P(in) is greater than the rate of P(out) which is negligible as illustrated on the pressure chart of FIG. 4 as the line A-B. This closing action of valve 46 temporarily holds off fluid pressure from the front brakes.
As inlet pressure P(in) builds in first portion 29a the outlet pressure P(out) remains substantially constant until P(in) overcomes the force of springs S 1 and S 2 or 48, 52. The force exerted by spring 48 is intended to be only that magnitude necessary to assure the positioning of metering seal 42 against flange 36c to maintain a sealing relationship therebetween. When P(in) overcomes the forces of springs S 1 and S 2 or 48, 52 then first piston 36 will move to the right thus opening second path 58 between metering seal 42 and flange 36c thus re-establishing fluid communication between first and second portions 29a, 29b respectively. An increase in P(in) is now accompanied by a proportional increase in P(out). At this point, the proportional pressure increases of P(in) and P(out) are illustrated on the pressure curve of FIG. 4 as line B-C and it can be seen that the rate of change of P(out) is increasing in relation to P(in).
P(out) will continue to increase in accordance with the above-stated relationship with P(in) until the output pressure overcomes the force of spring S 3 or 54 and moves piston 40 toward abutable engagement with retainer ring 138 fixedly mounted on piston 38. At this point, the proportional pressure increases of P(in) and P(out) are illustrated on the pressure curve of FIG. 4 as line C-C' and it can be seen that the rate of change of P(out) has further increased in relation to P(in). By referring to FIG. 3, the width of the gap between piston 40 and ring 138 is the controlling factor for the position of point C' on FIG. 4 and it has been determined that decreasing the gap width will shorten the line C-C' whereas increasing the gap width will lengthen the line C-C'.
Once piston 40 engages ring 138 (at point C') the pistons 38 and 40 act to move to the right in unison. At this point, the proportional pressure increases of P(in) and P(out) are illustrated on the pressure curve of FIG. 4 as line C'-D and it can be seen that the rate of change of P(out) has still further increased in relation to P(in).
Eventually P(out) becomes equal to P(in). This condition is generally referred to as the pressure blend point (point D on the chart of FIG. 4). At input pressures above the blend point, the input/output relationship will be a 1/1 ratio. Upon release or decreasing input pressure, P(out) will follow P(in) on a 1/1 ratio as illustrated by line DA since direct communication exists in the reverse flow direction due to the capability of the fluid to pass through second passage 58 past the metering seal 42 and through the first passage 56 via bore 36i past one-way tophat shaped check valve 46.
The foregoing has described a novel brake pressure distribution valve for holding off distribution of fluid pressure to front brakes in proportion to fluid pressure distributed to the rear brakes. The valve may be used in a vehicle brake system in cooperation with a master cylinder, front disc brakes and rear drum brakes.
Modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | A brake pressure distribution valve distributes fluid pressure to front brakes in proportion to fluid pressure distributed to rear brakes, and in addition, "holds off" the pressure distribution to the front brakes for delayed distribution thereto. The valve includes a housing having a cavity formed therein. Inlet and outlet ports permit fluid to flow into and out of the cavity. A first piston engages a metering seal to normally close one fluid passage and to cut off fluid communication between inlet and outlet ports. Another fluid passage is normally open to establish fluid communication between the inlet and outlet ports. Due to a fluid pressure buildup, a closing member is actuated to close the other passage thus holding off pressure distribution to the front brakes. As the fluid pressure buildup continues the one passage opens to re-establish fluid communication between the inlet and outlet ports. The valve may be used in a vehicle brake system in cooperation with a master cylinder, front disc brakes and rear drum brakes. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application which is based upon and claims priority from prior U.S. patent Ser. No. 11/117,276, filed on Apr. 27, 2005, now U.S. Pat. No. ______, the entire disclosure of which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of semiconductor devices. More specifically, the present invention relates to a semiconductor multiplexing device that generates an electronically scannable conducting channel with two oppositely formed depletion regions. The multiplexing device has numerous applications. For example, the multiplexing device could be used to address multiple bits within a memory cell, or to connect nano lines to micro lines within a minimal space or could be used to build a nanoscale programmable logic array or to perform chemical and/or biological sensing at the nanoscale (molecular) level.
BACKGROUND OF THE INVENTION
[0003] Conventional memory devices are limited to mostly 1 bit at the intersection of a wordline (WL) and a bitline (BL) in a memory array. For example, DRAM devices are limited to 1 bit per intersection, which corresponds to the presence of only one capacitor at each node. Similarly, FLASH devices have at most 2 bits per cell, in a multibit or multilevel configuration. These 2 bits can be detected based on the magnitude and direction of the current flow across the cell.
[0004] However, conventional memory devices are not capable of easily accommodating more than two memory bits at every crosspoint intersection. It would therefore be desirable to expand the access capability in memory devices to select or read multiple bits at every memory area or crosspoint that is normally desired by one memory wordline and bitline.
[0005] One problem facing conventional semiconductor lithographic techniques is the ability to electrically interconnect nano-scaled lines or patterns (on the order of 1 nm to 100 nm) and micro-scaled lines or patterns (on the order of 90 nm or a feature that could be typically defined by semiconductor processes such as lithography). Such connection is not currently practical, as it requires a significant interconnect semiconductor area, which increases the cost and complexity of the manufacturing process or the final product.
[0006] It would therefore be desirable to have a multiplexing device or an addressing device that establishes selective contact to memory cells, logic devices, sensors, or between nano-scaled lines and micro-scaled lines within a minimal space, thus limiting the overall cost and complexity of the final product.
[0007] The need for such a multiplexing device has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
[0008] The present invention satisfies this need, and presents a multiplexing device capable of selectively addressing multiple nodes or cross-points, such as multiple bits within a volatile or non-volatile memory cell. This multi-node addressing aspect of the present invention uses the fact that wordline and bitline voltages can be varied in a continuous fashion, to enable the selection or reading of multiple states at every crosspoint.
[0009] The present multi-node addressing technique allows, for example, 10 to 100 bits of data to be recorded at a single node, or in general to access bits of data that are of the order of 100 times more densely packed than conventional lithographically defined lines. As used herein, a node includes for example the intersection of a wordline and a bitline, such as a memory wordline and bitline.
[0010] The multiplexing devices selectively generates a thin, elongated, semiconducting (or conducting) channel (or window) at a desired location within a substrate, to enable control of the width of the channel, from a first conducting sea of electrons on one side of the substrate to a second conducting sea of electrons on the other side of the substrate.
[0011] In one embodiment, the multiplexing device generates an electronically scannable conducting channel with two oppositely formed depletion regions. The depletion width of each depletion region is controlled by a voltage (or potential) applied to a respective control gate at each end of the multiplexing device.
[0012] In another embodiment, the depletion width is controlled from one control gate only, allowing the access to the memory bits for both the reading and writing operations to be sequential. Other embodiments are also contemplated by the present invention.
[0013] If the depletion width is controlled at both ends of the multiplexing device, along the same axis, the conducting channel can be small (e.g., sub 10 nm) to enable random access to the memory bits. This embodiment is applicable to random access memories, such as SRAM, DRAM, and FLASH, for embedded and standalone applications and to programmable logic arrays.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
[0015] FIG. 1 is a schematic illustration of an exemplary multiplexing device of the present invention, comprising a scannable conducting channel having a relatively narrow width, shown in a first position within a scanning region;
[0016] FIG. 2 is a schematic illustration of the multiplexing device of FIG. 1 , showing the scannable conducting channel with a relatively wider width, in a second position within the scanning region;
[0017] FIG. 3 is a schematic illustration of another embodiment of the multiplexing device of FIGS. 1 and 2 , wherein the scannable conducting channel connects conducting lines, such as nano-scaled lines, on one side of the multiplexing device to electrodes on the opposite side of the multiplexing device;
[0018] FIG. 4 is a schematic illustration of yet another embodiment of the multiplexing device of FIG. 3 , wherein the scannable conducting channel connects conducting lines, such as nano-scaled lines, on one side of the multiplexing device to other conducting lines, such as nano-scaled lines, on the opposite side of the multiplexing device;
[0019] FIG. 5 is a schematic illustration of still another embodiment of the multiplexing device of FIG. 4 , wherein the scannable conducting channel connects conducting lines, such as nano-scaled lines, on one side of the multiplexing device to other conducting lines, such as micro-scaled lines, on the opposite side of the multiplexing device;
[0020] FIG. 6 is a schematic illustration of another embodiment of the multiplexing device of the previous figures, wherein the scannable conducting channel is curvilinearly (non-linearly) controlled, to connect non-coaxially (or coplanarly) disposed lines on both sides of the multiplexing device;
[0021] FIG. 6A is a schematic illustration of another embodiment of the multiplexing device of FIG. 6 , illustrating two discrete depletable regions separated by a transition region therebetween;
[0022] FIG. 7 is a schematic illustration of a further embodiment of the multiplexing device of the previous figures, wherein the scanning region is formed of a plurality of discrete regions;
[0023] FIG. 7A is a schematic illustration of a further embodiment of the multiplexing device of FIG. 7 , showing alternative embodiments of the discrete regions;
[0024] FIG. 8 is a schematic illustration of still another embodiment of the present invention, exemplifying a three-dimensional configuration comprised of a plurality of stackable multiplexing devices;
[0025] FIG. 9 is a block diagram illustrating a serial connectivity of a plurality of multiplexing devices of the previous figures;
[0026] FIG. 10 is a perspective view of an exemplary multi-node cross-point array configuration using a plurality of multiplexing devices of the previous figures, illustrating a two-dimensional architecture;
[0027] FIG. 11 is a schematic illustration of another exemplary multiplexing device of the present invention that is similar to the multiplexing device of FIG. 1 , where the depletion region is controlled by a single electrode;
[0028] FIG. 12 is a schematic illustration of the multiplexing device of FIG. 11 , wherein the scannable conducting channel connects conducting lines, such as nano-scaled lines, on one side of the multiplexing device to electrodes on the opposite side of the multiplexing device;
[0029] FIG. 13 is a schematic illustration of the multiplexing device of FIG. 1 , where the depletion region is controlled by applying a reverse bias to a p-n (or p+-n or n+-p junction);
[0030] FIG. 14 is a schematic illustration of another embodiment of the multiplexing device of FIG. 7A , showing alternative embodiments of the intermediate regions;
[0031] FIG. 15 is a schematic illustration of a semiconductor-on-insulator (e.g., SOI) MOSFET that shows the effects of a floating polysilicon region in the multiplexing device of FIG. 14 ;
[0032] FIG. 16 is an isometric, schematic illustration of the multiplexing device of FIG. 14 , rotated about its side; and
[0033] FIG. 17 is an isometric view of a multiplexing array formed of an array of multiplexing devices of FIG. 16 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] FIGS. 1 and 2 illustrate an exemplary multiplexing device 100 of the present invention. The multiplexing device 100 comprises a conducting channel 110 that is controllably scannable within a scanning region 106 . A first gate oxide layer 104 is disposed intermediate the scanning region 106 and a first control gate 102 , at one end of the multiplexing device 100 . At the opposite end of the multiplexing device 100 , a second gate oxide layer 114 is disposed intermediate the scanning region 106 and a second control gate 116 .
[0035] When suitably biased by a potential V 1 , the first control gate 102 generates a first depletion region 108 in the scanning region 106 . Similarly, when the second control gate 116 is suitably biased by a potential V 2 , it generates a second depletion region 112 in the scanning region 106 . The first and second depletion regions 108 , 112 interact to generate the conducting channel 110 .
[0036] The width w 1 of the first depletion region 108 is regulated by the potential V 1 and the doping concentration in the scanning region 106 . Similarly, the width w 2 of the second depletion region 112 is regulated by the potential V 2 and the doping concentration in the scanning region 106 . As a result, the width and the position of the conducting channel 110 can be very precisely controlled. FIGS. 1 and 2 illustrate the conducting channel 110 at two different positions along the scanning region 106 , and having different widths.
[0037] In a structure that is suitable for the formation of multiplexing device 100 , the first and second control gates 102 and 116 , respectively, are formed of conductive layers. As used herein a conductive layer can be formed of any suitable conductive or semiconductive material. For example the conductive layer can be formed of copper, tungsten, aluminum, a silicided layer, a salicided layer, a semiconductive layer, or a conductive layer, such as metallic materials, polysilicon, silicon germanium, metallic composites, refractory metals, conductive composite materials, epitaxial regions, amorphous silicon, titanium nitride, or like conductive materials. Preferably, the conductive layers are formed of polysilicon layers that are doped with dopant atoms. Dopant atoms can be, for example, arsenic and/or phosphorus atoms for n-type material, or boron atoms for p-type material.
[0038] Although the first and second control gates 102 and 116 can be lithographically defined into two distinct sections that are oppositely disposed relative to the scanning region 106 , as illustrated in FIG. 1 , it should be clear that the first and second control gates 102 and 116 could be disposed at different positions relative to the scanning region 106 . In particular, while the multiplexing device 100 is illustrated as having a generally rectangular shape, it should be clear that multiplexing device 100 could assume various other shapes, such as circular, oval, square, and various other shapes. Some of these alternative designs for the multiplexing device 100 could require the allocation of the first and second control gates 102 and 116 at various positions that are not necessarily opposite.
[0039] The two distinct sections of the first and second control gates 102 and 116 can be of a different conductivity type, for example: one section can be n-type while the other section can be p-type dopants or the two regions could have different metals. Known or available masking and ion implanting techniques can be used to alter the doping of portions of conductive layers.
[0040] The first and second control gates 102 and 116 can have the same or different widths. The width of each control gate can, for example, exceed 1000 angstroms. The voltages V 1 and V 2 applied to the first and second control gates 102 and 116 , respectively, can vary between approximately 0 and +/−100 volts.
[0041] A dielectric first gate oxide layer 104 is formed intermediate the first control gate 102 and the scanning region 106 . Similarly, a dielectric second gate oxide layer 114 is formed intermediate the second control gate 116 and the scanning region 106 . As used herein a dielectric layer can be any insulator such as wet or dry silicon dioxide (SiO 2 ), hafnium oxide, silicon nitride, tetraethylorthosilicate (TEOS) based oxides, borophospho-silicate-glass (BPSG), phospho-silicate-glass (PSG), boro-silicate-glass (BSG), oxide-nitride-oxide (ONO), oxynitride materials, plasma enhanced silicon nitride (p-SiN x ), a spin on glass (SOG), titanium oxide, or like dielectric materials or composite dielectric films with a high k gate dielectric. A preferred dielectric material is silicon dioxide.
[0042] The scanning region 106 can be formed of any suitable, depletable material. In this exemplary illustration, the scanning region 106 is formed of a depletion region, such as silicon or polysilicon layer that is lightly doped with either an n-type dopant, or a p-type dopant. In this exemplary embodiment, the scanning region 106 is doped with an n-type dopant. The width of the scanning region 106 could exceed 5 nm. The various components of regions and layers of the multiplexing devices described herein, could be made using, for example, known or available methods, such as, for example, lithographic processes.
[0043] In operation, by varying the voltages V 1 and V 2 on the first and second control gates 102 , 116 , respectively, the conducting channel 110 is controllably scanned along the directions of the scanning arrows A and B, up and down the central column of the multiplexing device 100 . In the present exemplary embodiment, the width, w (e.g., w 1 , w 2 ) of the depletion regions 108 , 112 is determined by the following equation:
w =(2) 1/2 λ n ( v | ) 1/2
where λ n is the extrinsic Debye length of the conducting channel 110 ; v | is defined by (q*(V bi +V)/kT)−2 where V bi is the built-in potential and V is the applied voltage. For an n-concentration of 10**16/cc the maximum depletion width is on the order of 1 micron.
[0044] FIG. 2 is a schematic illustration of the multiplexing device of FIG. 1 , showing the scannable conducting channel 110 with a relatively wider width, in a second position within the scanning region 106 .
[0045] FIG. 3 illustrates another multiplexing device 200 according to an alternative embodiment of the present invention, wherein the scannable conducting channel 110 connects conducting lines 201 , such as nano-scaled lines 202 through 210 (e.g., having a width between approximately 5 angstroms and 1,000 angstroms), on one side of the multiplexing device 200 , to one or more electrodes 228 on the opposite side of the multiplexing device 200 . To this end, the multiplexing device 200 further includes a source 226 , a first oxide layer 222 , and a second oxide layer 224 .
[0046] In this exemplary embodiment, the first oxide layer 222 is in contact with the first control gate 102 and the first gate oxide layer 104 . Similarly, the second oxide layer 224 is in contact with the second control gate 116 and the second gate oxide layer 114 . The source 226 is formed intermediate the first oxide layer 222 and the second oxide layer 224 , in contact with the scanning region 106 , and the electrode 228 . Layers 222 and 224 serve to isolate the gate regions 102 and 116 from the electrode ( 228 ) and source ( 226 ).
[0047] The source 226 can be formed of a silicon or polysilicon layer that is doped with either an n-type dopant, or a p-type dopant. The source 226 could be formed of any conductive or semiconductive material that forms an electrical contact to the scanning region 106 and electrode 228 . In this exemplary embodiment, the source 226 is doped with an n+-type dopant. In operation, the conducting channel 110 is generated as explained earlier in connection with FIGS. 1 and 2 , and is scanned across the scanning region 106 to establish contact with the desired line, for example line 204 , allowing the source 226 to inject electrons through the conducting channel 110 , into the selected line 204 .
[0048] In FIG. 3 , the source 226 has an inner surface 236 that is illustrated as being generally flush with the oxide layers 222 , 224 . It should however be understood that the inner surface 236 A of the source 226 could alternatively be recessed relative to the oxide layers 222 , 224 , as shown in a dashed line. Alternatively, the inner surface 236 B of the source 226 could extend beyond the oxide layers 222 , 224 , as shown in a dashed line.
[0049] FIG. 4 illustrates another multiplexing device 300 according to the present invention. Multiplexing device 300 is generally similar in construction to the multiplexing device 200 of FIG. 3 , but is designed for a different application. The scannable conducting channel 110 of the multiplexing device 300 connects conducting lines 201 , such as nano-scaled lines 202 - 210 , on one side of the multiplexing device 300 , to other conducting lines 301 , such as nano-scaled lines 302 - 310 , on the opposite side of the multiplexing device 300 .
[0050] In this exemplary embodiment, the lines 301 are coaxially aligned with the lines 201 , so that the conducting channel 110 interconnects two aligned lines, such as lines 204 and 304 .
[0051] FIG. 5 illustrates another multiplexing device 400 according to the present invention. Multiplexing device 400 is generally similar in construction to the multiplexing device 300 of FIG. 4 , but is designed for a different application. The scannable conducting channel 110 connects conducting lines 401 , such as nano-scaled lines 402 - 405 , on one side of the multiplexing device 400 to other conducting lines 411 , such as micro-scaled lines 412 - 415 , on the opposite side of the device 400 (e.g., having a width that exceeds approximately 100 angstroms).
[0052] FIG. 6 illustrates another multiplexing device 500 according to the present invention. Multiplexing device 500 is generally similar in construction to the multiplexing devices 100 , 200 , and 300 of FIGS. 1-3 , but will be described, for simplicity of illustration, in connection with the design of multiplexing device 300 of FIG. 4 . The scannable conducting channel 510 is curvilinearly (non-linearly) controlled, to connect non-coaxially (or coplanarly) disposed lines 201 , 301 on both sides of the multiplexing device 500 .
[0053] In order to effect this curvilinear conducting channel 510 , the multiplexing device 500 is provided with four control gates 502 , 503 , 504 , 505 that are arranged in pairs, on opposite sides of the scanning region 106 . In this specific example, the control gates 502 , 504 are disposed, adjacent to each other, on one side of the scanning region 106 , and are separated by an insulation layer 512 . Similarly, the control gates 503 , 505 are disposed, adjacent to each other, on the opposite side of the scanning region 106 , and are separated by an insulation layer 514 .
[0054] Potentials can be applied independently to the control gates 502 - 505 , to generate a first depletion region 508 and a second depletion region 512 , so that the conducting channel 510 is curvilinear. To this end, control gates 502 and 503 are paired, so that when a potential V 1 is applied to the control gate 502 and a potential V 2 is applied to the control gate 503 , a first portion 520 of the conducting channel 510 is formed. Similarly, when a potential V′ 1 is applied to the control gate 504 and a potential V′ 2 is applied to the control gate 505 , a second portion 522 of the conducting channel 510 is formed.
[0055] Portions 520 and 522 of the conducting channel 510 are not necessarily co-linear, and are interconnected by an intermediate curvilinear section 524 . As a result, it is now possible to connect line 207 to line 305 even though these two lines are not co-linearly disposed. Other lines on opposite (or different) sides of the multiplexing device 500 could be interconnected by the conducting channel 510 , by independently scanning the first and second portions 520 , 522 of the conducting channel 510 , along the arrows (A, B) and (C, D), respectively.
[0056] While FIG. 6 illustrates only four control gates 502 - 505 , it should be clear that more than four gates can alternatively be used.
[0057] FIG. 6A illustrates another multiplexing device 550 according to the present invention. Multiplexing device 550 is generally similar in construction to the multiplexing device 500 of FIG. 6 . Similarly to FIG. 6 , the scannable conducting channel 510 is curvilinearly (non-linearly) controlled, to connect non-coaxially (or coplanarly) disposed lines 201 , 301 on both sides of the multiplexing device 550 . However, the switching device 550 comprises two discrete depletion regions 551 , 552 that are separated by an intermediate, electrically conducting transition region 555 .
[0058] In order to effect the curvilinear conducting channel 510 , the multiplexing device 500 is provided with four control gates 562 , 563 , 564 , 565 that are arranged in pairs, on opposite sides of the scanning regions 551 , 552 , wherein each pair of control gates is separated from the other pair by the intermediate transition region 555 . In this specific example, the control gates 562 , 564 are disposed, adjacent to each other, and are separated by the intermediate transition region 555 , while the control gates 563 , 565 are disposed, adjacent to each other, on the opposite side of switching device 550 , and are separated by the intermediate transition region 555 .
[0059] Potentials can be applied independently to the control gates 562 - 565 , to generate the first depletion region 551 and the second depletion region 552 , so that the conducting channel 510 is curvilinear. To this end, control gates 562 and 563 are paired, so that when a potential V 1 is applied to the control gate 562 and a potential V 2 is applied to the control gate 563 , a first portion 520 of the conducting channel 510 is formed. Similarly, when a potential V′ 1 is applied to the control gate 564 and a potential V′ 2 is applied to the control gate 565 , a second portion 522 of the conducting channel 510 is formed.
[0060] The switching device 550 further includes a plurality of gate oxide layers 572 , 573 , 574 , and 575 that separate the control gates 562 , 563 , 564 , and 565 from their respective depletion regions 551 , 552 .
[0061] While FIG. 6A illustrates four control gates 562 - 565 and one the intermediate transition region 555 , it should be clear that more than four gates and one intermediate transition region 555 can be successively used to form the switching device 550 .
[0062] FIG. 7 illustrates yet another multiplexing device 600 according to the present invention. Multiplexing device 600 is generally similar in construction to any of the previous multiplexing devices of FIGS. 1-6 , but will be described, for simplicity of illustration, in connection with the design of multiplexing device 200 of FIG. 3 . FIG. 7 illustrates the feature that the scanning region 616 could be continuous or formed of a plurality of discrete sub-regions, such as sub-regions 606 , 608 , 610 with boundaries 607 , 609 therebetween.
[0063] FIG. 7A illustrates a further multiplexing device 650 according to the present invention. Multiplexing device 650 is generally similar in construction to multiplexing device 600 of FIG. 7 . The scanning region 656 of multiplexing device 600 is formed of a plurality of discrete sub-regions, such as sub-regions 676 , 677 , 678 , with intermediate regions 680 , 681 , 682 therebetween. The intermediate regions 680 , 681 , 682 serve the function of extending the depletion regions 676 , 677 , 678 and further isolating the conducting channels from each other.
[0064] While only three intermediate regions 680 , 681 , 682 are illustrated, it should be clear that one or more intermediate regions may be formed. In this particular embodiment, the intermediate regions 680 , 681 , 682 are generally similar in design and construction, and are dispersed along the scanning region 656 . In another embodiment, the intermediate regions 681 , 682 are disposed contiguously to each other. The spacing between the intermediate regions 680 , 681 , 682 and the widths of all the regions in the embodiments described herein, could be changed to suit the particular applications for which the multiplexing devices are designed.
[0065] Considering now an exemplary intermediate region 681 , it is formed of two semiconductor layers 690 , 691 with an intermediate layer 692 having a high dielectric constant material that is sandwiched between the semiconductor layers 690 , 691 . According to another embodiment, the intermediate layer 692 is made of a semiconducting material that is different from that of layers 690 and 691 to form a quantum well structure.
[0066] Intermediate region 682 includes an intermediate region 699 that is generally similar to the intermediate region 692 . Alternatively, the intermediate regions 692 , 699 could have different work functions than the work function of semiconductor layer 691 so as to produce a quantum well function.
[0067] FIG. 8 illustrates another multiplexing device 700 of the present invention, exemplifying a three-dimensional configuration. Multiplexing device 700 is comprised of a plurality of stackable multiplexing devices, such as multiplexing devices 100 , 200 , 300 , 400 , 500 , 600 , that can be different or similar. Each of these stackable multiplexing devices can be independently controlled as described in connection with FIGS. 1-7 .
[0068] According to this embodiment, one, or a group of multiplexing devices 100 , 200 , 300 , 400 , 500 , 600 can be selected by applying suitable depletion potentials V 3 , V 4 , to two outer electrodes 703 , 704 , respectively. Once the multiplexing device or a group of multiplexing devices 100 , 200 , 300 , 400 , 500 , 600 is selected, the selected multiplexing device or a group of multiplexing devices 100 , 200 , 300 , 400 , 500 , 600 is operated individually, as described earlier. In addition, a high-K insulation layer (e.g., 711 , 712 , 713 , 714 , 715 ) is interposed between two contiguous multiplexing devices (e.g., 100 , 200 , 300 , 400 , 500 , 600 ).
[0069] FIG. 9 illustrates another multiplexing device 800 of the present invention, exemplifying the serial connectivity of a plurality of multiplexing devices, such as multiplexing devices 200 , 300 , 400 . Each of these serially connected multiplexing devices 200 , 300 , 400 can be independently controlled, and the output of one multiplexing device used to control the accessibility of the subsequent multiplexing device.
[0070] FIG. 10 is a perspective view of an exemplary multi-node cross-point array 900 using at least two multiplexing device, e.g., 200 , 300 whose respective outputs are selected as described above, onto output lines 201 , 301 , are selected as described above. The selected outputs are processed (collectively referred to as “processed outputs”), as desired, by for example, operational devices 950 . The processed outputs can be used directly, or, as illustrated in FIG. 10 , they can be further fed to one or more multiplexing devices, e.g., 400 , 700 , resulting in outputs that are fed to respective output lines 400 , 700 .
[0071] The operational devices 950 could be, for example, memory cells, logic devices, current-driven or voltage-driven elements, such as light emitters, heat emitters, acoustic emitters, or any other device that requires addressing or selective accessibility.
[0072] As an example, the operational device 950 can include a switchable element that is responsive to current change or voltage change, or phase change, resulting in change of resistance or magneto-resistance, thermal conductivity or change in electrical polarization. Alternatively, the operational devices can include a carbon nano tube, a cantilever, a resonance driven device, or a chemical or biological sensor.
[0073] FIG. 11 is a schematic illustration of another exemplary multiplexing device 1100 according to the present invention. The multiplexing device 1100 is generally similar in design and operation to the multiplexing device 100 of FIG. 1 , and comprises a conducting region 1112 that is controllably scannable within a scanning region 106 . The gate oxide layer 104 is disposed intermediate the scanning region 106 and the control gate 102 , at one end of the multiplexing device 1100 . At the opposite end of the multiplexing device 1100 , an insulator layer, such as an oxide layer 1114 , is disposed contiguously to the scanning region 106 . It should be clear that the insulator layer 1114 is optional.
[0074] The depletion region 1108 is controlled by applying a potential V 1 to the control gate 102 , in order to generate the conducting region 1112 . An important feature of the multiplexing device 1100 is to control the width w of the depletion region 1108 using a single control gate 102 . Unlike the multiplexing device 100 , the undepleted region 1112 of the multiplexing device 1100 is not necessarily a small region. It could, in some cases, encompass the entire scanning region 106 under the control gate 102 and the gate oxide 104 . As further illustrated in FIG. 12 , the multiplexing device 1100 enables concurrent multibit sequential programming.
[0075] FIG. 12 is a schematic illustration of the multiplexing device 1100 of FIG. 11 , wherein the scannable conducting channel 110 connects conducting lines, such as nano-scaled lines 201 , on one side of the multiplexing device 1100 to electrodes (or to a micro line) on the opposite side of the multiplexing device 1100 . Since the multiplexing device 1100 comprises a single control gate (or electrode) 102 , many nano-scaled lines 201 could be selected for any value of the control gate potential V 1 . This requires a serial access scheme as compared to a random access scheme used by the embodiments of FIGS. 1-8 .
[0076] FIG. 13 is a schematic illustration of a multiplexing device 1300 that is similar to the multiplexing device 100 of FIG. 1 , but without the two gate oxide layers 104 , 114 . In the previous embodiments, the depletion regions 108 , 112 were comprised, for example of a depletion region of a Metal Oxide Semiconductor (MOS) system. However, the depletion regions 108 , 112 of the multiplexing device 1300 of FIG. 13 form two p+-n junctions (or alternatively one p+-n junction) with the adjacent control gates 102 , 116 , respectively. In an alternative embodiment, the depletion regions 108 , 112 form two n+-p junctions (or alternatively one n+-p junction) with the adjacent control gates 102 , 116 , respectively.
[0077] By applying potentials V 1 and V 2 to the p+ regions (control gates 102 and 116 ), a conduction channel 110 could be formed in around the middle of the scanning region 106 . One of the advantages of this multiplexing device 1300 is that the breakdown voltages of p-n junctions can be higher than the gate oxide breakdown voltages. This means that higher voltages could be applied to the control gate 102 , 116 . This could also mean that the scanning region 106 could be bigger. In an alternative embodiment, the multiplexing device 1300 could be formed of a single control gate, such as control gate 102 .
[0078] In yet another embodiment, the depletion regions 108 , 112 of the multiplexing device 1300 are formed by Schottky barriers (Metal—semiconductor regions), wherein the first and second control gates 102 and 116 are formed of a metal material. The depletion width in the Schottky barrier is controlled much the same way as the depletion width in a p-n junction.
[0079] Similarly to the illustration of FIG. 3 , it is possible to select nano-scaled lines 201 by applying appropriate potentials V 1 and V 2 to the first and second control gates 102 , 116 , respectively, and connect it to the micro-scaled line or source 226 . Alternatively Schottky barriers (metal-n or metal-p) regions may be used to do the connection as well.
[0080] FIG. 14 is a schematic illustration of another multiplexing device 1400 according to the present invention. The multiplexing device 1400 is generally similar in function and operation to the multiplexing device 650 of FIG. 7A , and shows an alternative embodiment of the intermediate regions 1480 , 1481 , in order to illustrate an exemplary instance of nano-pillar addressing.
[0081] In this embodiment, the semiconducting depletion regions 676 , 677 , 678 are physically separated through a combination of dielectrics (e.g., oxide/nitride/high-K) and electrode/semiconducting regions that are referred to as intermediate regions 1480 , 1481 . This allows a reduction in the leakage between the bits and extends the range of the maximum depletion region possible. This may also allow low voltage operation. Though only three semiconducting depletion regions 676 , 677 , 678 and two intermediate regions 1480 , 1481 are shown for illustration purpose only, it should be clear that a different number of regions could alternatively be used.
[0082] Each semiconductor depletion region 676 , 677 , 678 is bounded by at least one thin dielectric layer, e.g., 690 , 691 , which is preferably but not necessarily composed of an oxide in order to passivate the sidewalls and to guarantee good electrical properties. Sandwiched between layers 690 and 691 in each intermediate region 1480 , 1481 is a high-K dielectric material 1491 , 1492 , respectively. This minimizes the voltage drop between the intermediate regions 1480 , 1481 while maintaining isolation. The high-K dielectric material 1492 could be any dielectric with a reasonable dielectric constant, wherein a higher dielectric constant provides better electrical properties.
[0083] Each of the intermediate regions 1480 , 1481 further comprises two side insulation regions on opposite ends of the high-K dielectric material 1491 , 1492 . More specifically, intermediate region 1480 further comprises two side insulation regions 693 , 695 , and intermediate region 1481 further comprises two side insulation regions 694 , 696 . Side insulation regions 693 - 696 isolate the high-K dielectric material 1491 , 1492 from the semiconducting depletion regions 676 , 677 , 678 .
[0084] Alternatively, each of the dielectric layers 690 , 691 comprises a thin dielectric material, typically oxide, that bounds the semiconducting depletion regions 676 , 677 , 678 . However, the intermediate regions 1480 , 1481 between the dielectric layers 690 , 691 are filled with a semiconducting material or a metal material to form regions 1491 , 1492 . Each of the regions 1491 , 1492 is preferably floating and its potential depends on the capacitive coupling of the different control electrodes 102 , 114 to these regions 1491 , 1492 .
[0085] This design is desirable for the following reasons. A heavily doped semiconductor or metallic region further minimizes the applied voltage requirements. In addition, the work function difference between the electrode/semiconductor region 1492 and the semiconductor region results in an inversion layer (thin layer of electrons) at the interface of the semiconducting depletion regions 676 , 677 , 678 . This allows the multiplexing device 1400 to work via the depletion of the inversion layer charge as opposed to a charge resulting from ionized dopant atoms, and therefore minimizes dopant fluctuation effects. In this case, insulation regions 693 - 696 are required to prevent shorting of the electrodes (i.e., 1491 , 1492 ) to the various semiconducting depletion regions 676 , 677 , 678 and to keep it electrically isolated. This effect is further illustrated in FIG. 15 using the example of a simple MOS device 1500 .
[0086] As further illustrated in FIG. 7A , the multiplexing device 1400 of FIG. 14 , wherein the scannable conducting channel 110 could be connected to conducting lines, such as nano-scaled lines 201 , on one side of the multiplexing device 1400 to electrodes (or micro lines) on the opposite side of the multiplexing device 1400 .
[0087] FIG. 15 illustrates the effect of including floating polysilicon/electrode regions ( 1491 and 1492 in FIG. 14 or 1525 in FIG. 15 ) in semiconducting structure 1500 . Structure 1500 is generally formed of a silicon on insulator (SOI) wafer with a thin (e.g., less than approximately 100 nm) silicon region on top of an insulator (oxide). The MOS device includes an n-channel device with n+ source regions 1505 and drain regions 1510 . The gate 1525 is formed of n+ polysilicon material. At zero bias gate, the potentials of the source 1505 and drain 1510 develop an inversion layer 1507 in the channel of semiconductor region 1515 . This inversion layer 1507 is generated because of the work function difference between the gate 1525 and the silicon/semiconductor 1515 . This work function difference causes the bands in the silicon 1515 at zero gate voltage to bend in much the same way as a transistor with positive applied bias. This inversion charge in the addressing scheme may be depleted in much the same way as dopant charge. One way to think about the transistor in FIG. 15 is that it emulates a negative threshold voltage transistor.
[0088] Referring now to FIG. 16 , it illustrates a multiplexing device 1600 according to the present invention. Multiplexing device 1600 is generally similar to multiplexing device 1400 of FIG. 14 , but is rotated about its side. Multiplexing device 1600 comprises a plurality of nano-pillars 1676 , 1677 , 1678 , 1679 that are interposed between the first control gate 102 , the second control gate 116 , and intermediate regions 1610 , 1615 , 1620 . The intermediate regions 1610 , 1615 , 1620 are generally similar in construction and operation to the intermediate regions 1480 , 1481 of FIG. 14 . While four nano-pillars 1676 , 1677 , 1678 , 1679 are illustrated, it should be clear that a different number of nano-pillars can be selected. A plurality of oxide/dielectric layers 1686 , 1687 , 1688 surround the intermediate regions 1610 , 1615 , 1620 to isolate them from the nano-pillars 1676 , 1677 , 1678 , 1679 , and the operational devices 1635 , 1645 .
[0089] Arrows C indicate the direction of the electrical currents flowing through one or more nano-pillars 1676 , 1677 , 1678 , 1679 selected by depletion, as described earlier. While the direction of the current is shown in the current direction, it should be clear that the current could alternatively flow in the opposite direction. The current flows between the two electrodes 1602 , 1604 , through operational devices 1635 , 1645 (denoted earlier as operational devices 950 ).
[0090] FIG. 17 shows a multiplexing array 1700 that is formed of an array of multiplexing devices 1600 of FIG. 16 , with the electrodes 1602 , 1604 , the operational devices 1635 , 1645 , and the control gates 102 , 116 removed for clarity of illustration. The plurality of multiplexing devices 1600 are separated and insulated by a plurality of insulation layers 1705 . The insulation layers 1705 are preferably, but not necessarily formed of oxide layers, and could alternatively be made of the same material as the intermediate region 1610 . While only four multiplexing devices 1600 are illustrated, it should be clear that a different number of multiplexing devices 1600 can alternatively be used.
[0091] It is to be understood that the specific embodiments of the present invention that have been described are merely illustrative of certain applications of the principle of the multiplexing device. Numerous modifications may be made to the multiplexing device without departing from the spirit and scope of the present invention. | An electronically scannable multiplexing device is capable of addressing multiple bits within a volatile or non-volatile memory cell. The multiplexing device generates an electronically scannable conducting channel with two oppositely formed depletion regions. The depletion width of each depletion region is controlled by a voltage applied to a respective control gate at each end of the multiplexing device. The present multi-bit addressing technique allows, for example, 10 to 100 bits of data to be accessed or addressed at a single node. The present invention can also be used to build a programmable nanoscale logic array or for randomly accessing a nanoscale sensor array. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 11/498,849, filed on Aug. 3, 2006, the contents of which are hereby incorporated by reference.
BACKGROUND
The present disclosure relates to concrete construction, and more particularly, but not exclusively, to a dowel bar assembly for connecting adjacent concrete slabs.
The construction of concrete surfaces is commonly accomplished by forming a plurality of adjacent concrete slabs that are separated by expansion joints. In some applications, the concrete slabs may support heavy loads, such as loads exerted by equipment on aircraft runways, taxiways, and parking aprons. The heavy loads that are supported by an individual concrete slab can cause vertical movement of the slab with respect to adjacent slabs. To prevent this damaging movement, the load may be distributed through load bearing dowels that extend between adjacent slabs across expansion joints. These dowels are typically formed from a ductile material, such as steel or fiberglass, which transmits the load and provides additional reinforcing structure. Different techniques exist for installing such dowel bars into a concrete slab.
One of the typical methods for installing dowel bars is to create a dowel bar assembly or apparatus that includes wire side rails for supporting a dowel bar in place prior to the pouring of a concrete slab. Typically, a dowel bar assembly is positioned in an area where two concrete slabs will abut one another. An expansion member may be mounted on the dowel bar assembly, and commonly delineates the respective edges of the concrete slabs. A first concrete slab is then poured along one side of the expansion member, partially covering the dowel bar assembly. A second concrete slab is subsequently poured along a second side of the expansion member, covering the other side of the dowel bar assembly. Therefore the two concrete slabs are separated by an expansion joint and connected together by the dowel bars to help distribute heavy loads across both of the concrete slabs.
Joining the wire side rails to the dowel bar is usually time consuming and costly. The wire rails are usually made of steel and susceptible to corrosion. Often, the corrosion spreads from the wire rails to the dowel bar. Previously, attempts to control the corrosion were made by coating the dowel bar with epoxy. However, commonly the side frame is welded to the epoxy coated dowel bar, and such welds enable corrosion to enter into the dowel bar even with the epoxy coating since the weld areas are not coated. Therefore, one drawback to this method of forming concrete slabs is increased corrosion. In addition, another drawback is the time consuming and costly method of constructing the dowel bar assembly. Furthermore, if the assembly is constructed at a factory, transport and storage of the devices becomes difficult and costly as well.
Therefore, many needs remain in this area of technology.
SUMMARY
In one aspect of the dowel bar assembly there is an apparatus for combining adjacent concrete slabs. The apparatus includes a dowel having an end portion for placement into a concrete slab. The apparatus also includes an end cap having an open end for receiving the dowel end portion. The end cap has a hood extending at least partially around the dowel receiving end of the end cap and positioned transverse to the longitudinal axis of the dowel. The hood defines a curved channel. The apparatus also includes a side frame having at least one wire received in the curved channel of the end cap.
Another aspect of the dowel bar assembly includes an end cap for placing on a dowel. The end cap includes a central portion defining a recess for receiving an end of the dowel, the central portion having a first end, a second open end for receiving the end of the dowel, and an outer surface. The end cap also includes a hood surrounding the defined recess and defining a curved channel around at least a portion of the outer surface of the central portion.
Yet another aspect of the dowel bar assembly includes an end cap for connecting a side frame having a first cross wire and a second cross wire to a dowel. The end cap includes a receiving portion defining an interior area for receiving an end of the dowel. The end cap also includes a supporting portion integrally formed with the receiving portion for supporting the side frame. The supporting portion also includes a first wire support for supporting the first cross wire and a second wire support for supporting the second cross wire. The first and second wire supports are arranged substantially parallel to each other.
A further aspect of the dowel bar assembly includes an end cap for connecting a dowel to a side frame. The end cap includes a tubular central portion having a first end and a second end, where at least one of the ends is an open end for receiving the dowel and the tubular central portion defines an outer peripheral surface. The end cap also includes a first sleeve coupled to the central portion and positioned along a first tangent of the outer peripheral surface of the tubular central portion for receiving a portion of the side frame. In addition, the end cap includes a second sleeve coupled to the central portion and positioned along a second tangent of the outer peripheral surface of the tubular central portion for receiving a differing portion of the side frame. The second tangent is placed on an opposite side of the outer peripheral surface of the tubular central portion from the first tangent. The end cap also includes a resilient protrusion coupled to the central portion for receiving a further differing portion of the side frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary dowel bar assembly that is partially embedded in abutting concrete slabs.
FIG. 2A is a perspective view of one end of the dowel bar assembly of FIG. 1 , with the side frame decoupled from the end cap of the assembly.
FIG. 2B is a perspective view of one end of the dowel bar assembly of FIG. 1 , with the side frame coupled to the end cap of the assembly.
FIG. 3A is a cross-sectional side view of the end cap of the dowel bar assembly of FIG. 1 , with the side frame partially coupled to the end cap.
FIG. 3B is a cross-sectional side view of the end cap of the dowel bar assembly of FIG. 1 , with the side frame completely coupled to the end cap.
FIG. 4 is a rear perspective view of the end cap of the dowel bar assembly of FIG. 1 .
FIG. 5 depicts a plurality of dowel bar assemblies in a stacked arrangement.
FIG. 6A is a perspective view of a first alternative aspect of a dowel bar assembly holding a side frame.
FIG. 6B is an exploded perspective view of the first alternate aspect of FIG. 6A .
FIG. 6C is a cross-sectional side view of the end cap of the dowel bar assembly of FIG. 6A , with the side frame completely coupled to the end cap.
FIG. 6D is a cross-sectional side view of a variant of the end cap of the dowel bar assembly of FIG. 6A , with the side frame completely coupled to the end cap.
FIG. 7 is a perspective view of an end cap for a second alternative aspect of a dowel bar assembly.
FIG. 8 is a perspective view of an end cap for a third alternative aspect of a dowel bar assembly.
FIG. 9A depicts a plurality of dowel bar assemblies having the end caps of FIG. 8 stacked upon each other.
FIG. 9B is a cross-sectional side view of the stacked dowel bar assemblies of FIG. 9A .
FIG. 10 is a perspective view of an end cap for a fourth alternative aspect of a dowel bar assembly.
FIG. 11 is a perspective view of an end cap for a fifth alternative aspect of a dowel bar assembly.
DETAILED DESCRIPTION
The descriptions contained here are meant to be understood in conjunction with the drawings that have been provided.
FIG. 1 illustrates an exemplary dowel bar assembly 30 . The dowel bar assembly 30 assists in preventing vertical movement of the concrete slabs 32 a , 32 b (collectively designated 32 ). The concrete slabs 32 abut each other along an expansion member 34 that is placed between the two abutting concrete slabs 32 . The expansion member 34 can be made from different materials known by those skilled in the art. For example, in some aspects the expansion member 34 is made of a rubber, cork, fiberglass or various other types of resilient materials. In other aspects, the expansion member 34 is a cardboard or similar type material, such as those used in sidewalk blocks. The expansion member 34 usually either expands or contracts to fill in the area between the abutting concrete slabs 32 during changes in temperature. Extending through the expansion member 34 and out of one of the concrete slabs 32 is at least one dowel bar 36 . In the illustrated aspect, three dowel bars 36 are illustrated projecting out of the concrete slab 32 . Those skilled in the art will readily recognize that any number of dowel bars 36 can be used as may be required to transfer loads between adjacent concrete slabs. The dowel bars 36 of the illustrated aspect are shown to be cylindrical. In other aspects, however, other shapes can be used. For example, a rod with a square cross-section or even hexagonal cross-section can be used. Similarly, a variety of materials can be used for the dowel bar 36 . The dowel bar 36 can be formed from a metal material or a fiberglass material, to name a few. In some aspects, a material having anticorrosion properties, such as a coating of epoxy, may be used to prevent corrosion of the dowel bar 36 due to moisture. FIG. 1 illustrates that the dowel bar 36 extends out of the concrete slab 32 a into the other concrete slab 32 b across expansion joint 34 . In this way, the concrete slabs 32 are coupled together and a heavy load placed on one of the concrete slabs 32 a , 32 b will be spread more uniformly across both concrete slabs 32 . Each dowel bar 36 includes an end portion 38 that is sized to receive an end cap 40 . Each end cap 40 is placed on the end portion 38 of the dowel bars 36 to provide a structure for coupling a side frame 42 to the dowel bar 36 . In the illustrated aspect, the side frame 42 is constructed of two main components. The first component is a curved connection wire 44 that connects to the end cap 40 . The other component is a cross wire assembly 46 , which combines successive ones of the curved connection wire 44 together. In the illustrated aspect, there are two cross wires 46 a and 46 b . FIG. 1 illustrates that the concrete slabs 32 cover the dowel bar assembly 30 after the concrete has been poured and therefore completely buries the dowel bar assembly 30 therein.
Referring now to FIG. 2A , the assembly of the side frame 42 into the end cap 40 is illustrated. The end cap 40 includes a channel 48 that runs below the dowel bar 36 . The channel 48 is designed to receive the cross wire assembly 46 of the side frame 42 . The arrow in FIG. 2A indicates that the channel 48 receives the cross wire assembly 46 . The end cap 40 also includes a curved channel 50 that is designed to receive the curved connection wire 44 of the side frame 42 . In the illustrated aspect, the curved channel 50 is substantially U-shaped, however, in other aspects the curved channel 50 may have other shapes. The channel 48 is positioned transverse to the longitudinal axis of the dowel bar opposite the curved channel 50 . This connection of the curved connection wire 44 and the curved channel 50 is described in more detail hereinbelow with reference to FIGS. 2B and 3B . The curved channel 50 is defined by a hood 52 formed generally around the periphery of the dowel bar 36 . The hood 52 includes a resilient protrusion 54 that is used to lockingly engage the curved connection wire 44 when it has been inserted into the curved channel 50 . This is illustrated in more detail in FIG. 3B . The side frame 42 includes a curved portion 56 that is received by the curved channel 50 and is surrounded by the hood 52 when it is inserted into the curved channel 50 . The cross wires 46 and the curved connection wire 44 are coupled together using welds 58 so that the side frame 42 is provided in a pre-assembled condition.
Referring now to FIG. 2B , the attachment of a side frame 42 to the end cap 40 is illustrated. FIG. 2B illustrates the side frame 42 in a first state 60 in phantom. In this first state 60 the upper cross wire 46 a is inside of the channel 48 . After the side frame 42 has been inserted into the channel 48 it can be rotated from the first state 60 illustrated in phantom to the second state 62 illustrated in solid. Upon rotating the side frame 42 around the pivot point created by the first channel 48 the curved portion 56 of the curved connection wire 44 is placed into the curved channel 50 and is lockingly engaged inside of the curved channel 50 . To lock the curved portion 56 , the resilient protrusion 54 first bends in an upward direction and then snap fits around the curved portion 56 of the curved connection wire 44 . This configuration allows assembly of the dowel bar 36 and the side frame 42 prior to forming the concrete. The side frame 42 provides a stand for suspending the dowel bars 36 off of the ground so that they will be placed into the interior of a concrete slab.
Referring now to FIG. 3A , a cross-sectional view of the end cap 40 illustrates the first state 60 of the side frame 42 . In this state, the channel 48 receives the cross wire 46 a and the side frame 42 is positioned at an angle to a generally vertical plane P coincident with the longitudinal axis of the channel 48 . The design of the channel 48 allows the cross wire 46 a to rotate easily within the channel 48 so that the side frame 42 can be easily connected to the end cap 40 . FIG. 3B illustrates the dowel bar assembly 30 after the side frame 42 has been moved to the second state 62 . In this state, the side frame 42 has rotated around a pivot point created by the combination of the cross wire 46 a and the channel 48 . This places the curved portion 56 of the curved connection wire 44 into the curved channel 50 by deflecting the resilient protrusion 54 upwards to allow the curved portion 56 to slide into the curved channel 50 . The resilient protrusion 54 is biased towards the interior of the end cap 40 and therefore locks down around the curved portion 56 of the curved connection wire 44 once it has been completely enclosed inside of the curved channel 50 . Again, the position of the side frame 42 is at an angle to the plane P through the channel 48 . This forms a stable base out of the side frame 42 for holding the dowel bars 36 steady while the concrete is being poured. Those skilled in the art will recognize that the side frame 42 can be positioned in a range of angles from the plane P depending on the orientation of the curved channel 50 and the end cap 40 . FIGS. 3A and 3B also illustrate that the end cap 40 has an open end 64 that is designed to receive the dowel bar 36 . In addition, FIGS. 3A and 3B illustrate that a first wall 66 and a second wall 68 define the channel 48 . Those skilled in the art will recognize that channel 48 can be formed in different manners in different aspects of the dowel bar assembly.
FIG. 4 illustrates that the end cap 40 has a central portion 70 that includes a first end 72 for covering the end portion 38 of the dowel bar 36 . The open end 64 receives the dowel bar 36 and an outer surface 74 surrounds the end portion 38 of the dowel bar 36 when inserted. The hood 52 substantially surrounds the first end 72 and defines the curved channel (not shown) generally around at least a portion of the periphery of the outer surface 74 . The open end 64 of the central portion 70 of the end cap 40 provides access to a recessed area 76 defined by the inner surface 78 of the central portion 70 . The inner surface 78 includes a plurality of ribs 80 around its periphery for facilitating a friction fit to the end portion 38 of the dowel bar 36 to snugly hold the end cap 40 in place. The ribs 80 have a first portion 81 that has a first height for engaging the outer surface of the dowel bar 36 . The ribs 80 may also have a second portion 82 that has a second height greater than the first height for engaging the end portion 38 of the dowel bar 36 to limit the insertion of dowel bar 36 into the recessed area 76 .
Referring now to FIG. 5 , a plurality of dowel bar assemblies 30 are shown stacked one upon each other. Therefore, the dowel bar assemblies 30 can be pre-assembled prior to shipment and conveniently stacked upon each other so to minimize the amount of space occupied, or assembled in one area of a construction site and stacked until needed.
Referring now to FIGS. 6A and 6B , one alternative aspect of an end cap 40 W is illustrated. In FIGS. 6A and 6B identical reference numerals are used to described similar parts with the addition of a W suffix indicating that the parts are similar but slightly different as will be readily apparent from the figures. The end cap 40 W includes a first section 83 that slides over the end portion 38 of the dowel bar 36 . The first section 83 slides into contact with a second section 84 of the end cap 40 W and locks with the second section 84 of the end cap 40 W through the use of the dual resilient protrusions 85 on opposite sides of the dowel bar 36 . The curved portion 56 W of the curved connection wire 44 W is restrained between the second section 84 and the first section 83 . The end cap 40 W, like end cap 40 , has a hood 52 W around the periphery of the outer surface of the end cap 40 W that defines a curved channel 50 W for receiving the curved portion 56 W of the curved connection wire 44 W. In addition, the end cap 40 W has a channel 48 W for receiving a cross wire 46 W. Reference to FIG. 6B illustrates that the channel 48 W is only bound by one wall 68 W instead of two walls like in the end cap 40 of FIG. 4 . FIG. 6B illustrates additional detail of the end cap 40 W. The end cap 40 W has the first section 83 that is lockingly engaged into place by the resilient protrusions 85 on either side of second section 84 . The resilient protrusions 85 may include gripping ridges 86 that grip an outer portion 88 of the first section 83 and allow the first section 83 to be positioned in a plurality of locations longitudinally along the axis of the dowel bar 36 . The inner portion 90 of the first section 83 has an interior surface 92 that defines ribs 94 . Accordingly, when the second section 84 is slid over the end portion 38 of the dowel bar 36 the second section 84 can easily slide back and forth. Then when the curved connection wire 44 W is desired to be connected to the end cap 40 W, the curved connection wire 44 W is slid over the end portion 38 of the dowel bar 36 and into the curved channel 50 W of the second section 84 . Then the first section 83 is slid over the end portion 38 of the dowel bar 36 and snapped into place using the resilient protrusions 85 . Simultaneously, the ribs 94 of the first section 83 friction fit the first section 83 to the dowel bar 36 and keeps the entire end cap 40 W and side frame 42 W in stable connection with dowel bar 36 . This design of the end cap 40 W reduces the tolerances needed in the manufacture of the side frame 42 W, lowering manufacturing costs and assisting assembly.
Referring now to FIG. 6C , a cross-sectional view of the end cap 40 W illustrates how the first section 83 contacts the second section 84 of the end cap 40 W and locks to the second section 84 through the dual resilient protrusions 85 on opposite sides of the dowel bar 36 . Resilient protrusions 85 may include a series of gripping ridges 86 that grip an outer portion of the first section 83 and allow the first section 83 to be positioned in a plurality of locations longitudinally along the axis of the dowel bar 36 . Second section 84 may compress first section 83 as first section 83 is positioned more closely to second section 84 along the axis of the dowel bar 36 , enhancing the friction fit of the first section 83 to the dowel bar 36 . Resilient protrusions 85 may also be manually disengaged from first section 83 to permit end cap 40 W to be repositioned or otherwise removed as necessary.
Referring now to FIG. 6D , a cross-sectional view of a variant of the end cap 40 W illustrates how the first section 83 may contact the second section 84 of the end cap 40 W and lock to the second section 84 without the use of resilient protrusions. A portion of the inside surface of second section 84 and a portion of the outside surface of first section 83 may be formed with complementary gripping ridges 89 that are brought into mutual engagement when the first section 83 is slid into contact with the second section 84 . Second section 84 may compress first section 83 as first section 83 is advanced toward second section 84 along the axis of the dowel bar 36 , enhancing the friction fit of the first section 83 to the dowel bar 36 . The positioning of gripping ridges 89 on complementary surfaces of the first section 83 and the second section 84 additionally shields the connection and provides an effective one-way locking mechanism.
Referring now to FIG. 7 , another alternative aspect of an end cap 40 X is illustrated. Once again, similar parts are designated with identical reference characters with the addition of the X symbol to indicate that the parts are similar to the reference characters already used with readily apparent differences. The end cap 40 X includes a central portion 96 having a first end 98 that is closed and a second end 100 that is open. The second end 100 is designed to be able to receive the end portion 38 of the dowel bar 36 . The end cap 40 X includes a first sleeve 102 for receiving a first connection wire 44 a X and a second sleeve 104 that for receiving a second connection wire 44 b X. In the illustrated aspect, the first sleeve 102 and second sleeve 104 are integrally formed with the central portion 96 of the end cap 40 X. Those skilled in the art, however, recognize that in other aspects the sleeves can be coupled to the central portion 96 in other manners. The second sleeve 104 is positioned along a tangent of the dowel bar 36 and the first sleeve 102 is positioned along an opposite tangent of the dowel bar 36 that arranges the connection wires 44 a X and 44 b X substantially parallel to one another. In addition, the central portion 96 also has a resilient protrusion 106 for coupling to the cross wire 46 X. The cross wire 46 X and the connection wires 44 a X and 44 b X are pre-welded together to form side frame 42 X so that assembly is simple. The end cap 40 X is simply placed over the end portion 38 of the dowel bar 36 and then the connection wires 44 a X and 44 b X are slid into the first and second sleeve 102 , 104 . Next, the resilient protrusion 106 is clipped around the cross wire 46 X.
Referring now to FIG. 8 , another alternative aspect of an end cap 40 Y is illustrated. Once again, similar parts are designated with identical reference characters with the addition of the Y symbol to indicate that the parts are similar to the reference characters already used with readily apparent differences. The end cap 40 Y includes a connecting portion 108 that is designed to form an interior area for receiving an end portion 38 of the dowel bar 36 . In addition, the end cap 40 Y includes a supporting portion 110 that is integrally formed with the connecting portion 108 . The supporting portion 110 supports the side frame (not shown). The supporting portion 110 has a first wire support 112 and a second wire support 114 formed therein. In the illustrated aspect, the wire supports 112 , 114 are channels formed in the supporting portion, however, in other aspects of the dowel bar assembly other structures are used. The wire supports 112 , 114 lie within the apron 116 of the end cap 40 Y. The apron 116 includes a plurality of apertures 118 designed to lighten the weight of the supporting portion 110 , to allow concrete to easily flow therethrough, and to assist with stacking the dowel bar assemblies 30 Y as illustrated in FIGS. 9A and 9B . In the illustration, the first wire support 112 includes two clamp pairs 120 arranged substantially parallel to each other that are designed to clamp around a portion of the side frame (not shown), such as a cross wire (not shown). Each clamp pair may be formed of resiliently opposed clamping members, however, other aspects may use other structure to clamp around a portion of the side frame. In addition, the second wire support 114 may also include two claim pairs 112 which are also designed to clamp around a portion of the side frame (not shown). The supporting portion 110 may also include base members 124 designed to support the entire dowel bar assembly 30 Y upon the ground surface prior to the pouring of the concrete. The end cap 40 Y eliminates the need to have connection wires (not shown) having a curved portion and simply allows the dowel bar 36 to be connected to a cross wire (not shown).
Referring now to FIG. 9A , the stackability of the dowel bar assembly 30 Y is illustrated. FIG. 9A illustrates that one supporting portion 110 rests on top of another dowel supporting portion 110 and the connecting portion 108 of one dowel bar assembly 30 Y passes through the largest one of the apertures 118 of another dowel bar assembly 30 Y.
Referring now to FIG. 9B , a cross-sectional view provides additional detail of the stacking illustrated in FIG. 9A . This view illustrates clearly that the connecting portion 108 extends through an aperture 118 and supports the apron 116 along a support surface 126 . Therefore, in some situations it is preferable to pre-assemble the dowel bar assembly 30 Y prior to shipping to the construction site. The stackability of these dowel bar assemblies 30 Y facilitates ease in transporting these dowel bar assemblies 30 Y.
Referring now to FIG. 10 , an alternative aspect of an end cap 40 Z is illustrated. As in the earlier aspects, like numerals are used to refer to like parts and similar parts are designated with a Z symbol. The end cap 40 Z includes a removable top 128 that includes guide rails 130 that help it to slidingly engage the bottom portion 132 of the connecting portion 108 Z. This design allows an end portion 38 of a dowel bar 36 to be inserted into the connecting portion 108 Z. Then the end cap 40 Z can be snugly attached to the end portion 38 of the dowel bar 36 by sliding the top portion 128 so that the guide rails 130 interact with the bottom portion 132 to snap the top portion 128 over the dowel bar 36 . Like in the aspect shown in FIG. 8 , the end cap 40 Z includes a supporting portion 110 Z that includes a first wire support 112 Z and a second wire support 114 Z arranged substantially parallel to each other. These wire supports 112 Z, 114 Z each include their own respective pars of clamps 120 Z and 122 Z. In addition, they also include the base members 124 Z and an apron 116 Z to connect all of the pieces together. Accordingly, the cross wires 46 a Z, 46 b Z are coupled to the supporting portion 110 Z and the dowel bar 36 is connected to the connecting portion 108 Z to create the assembly.
Referring now to FIG. 11 , an alternative aspect of an end cap 40 V is illustrated. As in the earlier aspects, like numerals are used to refer to like parts and similar parts are designated with a V symbol. As in FIG. 10 , this aspect has a connecting portion 108 V and a supporting portion 110 V, however, the design of the connecting portion 108 V is different. The connecting portion 108 V includes an upper half 134 and a lower half 136 for surrounding the dowel bar 36 received in the lower half 136 . In the illustrated aspect, the halves 134 , 136 are clasps, however those skilled in the art will recognize that other structures are used in other aspects of the dowel bar assembly. The upper half 134 and the lower half 136 are joined together using a living hinge 138 . A living hinge 138 is used in the illustrated aspect, however, those skilled in the art will recognize that other types of hinge mechanisms for connecting the upper half 134 to the lower half 136 can be used in other aspects. The living hinge 138 allows the first tab 140 of the upper half 134 to lockingly engage with the second tab 142 of the lower half 136 . Accordingly, the upper half 134 locks around the end portion 38 of the dowel bar 36 when the dowel bar 36 is received by the lower half 136 . Similarly, like the other aspects shown in FIGS. 8 and 10 , the supporting portion 110 V includes a first wire support 112 V and a second wire support 114 V arranged substantially parallel. In addition, the end cap 40 V also includes first clamp members 120 V and second clamp members 122 V. Also, a set of apertures 118 V and base members 124 V may be used with the apron 116 V to form the supporting member 110 V.
This has been a description of the present invention and one preferred mode of practicing the invention, however, the invention itself should only be defined by the appended claims. | An apparatus for combining adjacent concrete slabs including a dowel, an end cap, and a side frame. The end cap has a hood defining a curved channel extending at least partially around a dowel receiving end. The side frame has at least one wire received in the curved channel. Also, an end cap having an integrally formed supporting portion including first and second wire supports for supporting substantially parallel side frame cross wires. Also, an end cap including first and second sleeves positioned along opposing tangents of the outer peripheral surface of the end cap for receiving differing portions of a side frame, and further including a resilient protrusion for receiving a further differing portion of the side frame. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This Regular Patent Application (RPA) refers to Provisional Patent Application (PPA) Docket Blurt1 60/363,506 dated Mar. 8, 2002.
FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to software systems, specifically systems designed to deliver customer service over the worldwide web and other networks.
The present invention relates generally to Customer Relationship Management (CRM) applications and more specifically it relates to an audio message driven customer interaction queuing system (AMDCIQS) for audio-enabled web pages in a retail or customer support context. More generally, the system may include message types such as audio (primarily voice), video, text (email and SMS (short Messaging Service)) and fax. More specifically, this system primarily allows web page visitors to utter questions into a browser-resident voice recorder application akin to a Walkie-Talkie, queues these questions along with the originating web page URL and user data before distributing them to customer service agents. These Agents can then research the question, using the web page as reference, and respond with an audio (or other) message, played upon the recorder application by the User after some brief service interval.
2. Description of the Prior Art
It can be appreciated that CRM applications have been in use for years, and have become a natural melting pot for traditional telephony customer interaction and newly emerging web contact paradigms such as email, Voice Over Internet Protocol (VoIP), web call-back request, and text chatting. Of these, voice applications are of particular interest in this discussion, but the other channels offer insight into the customer service equation as their service characteristics become germane to this invention.
The main problem with conventional CRM web applications is that their support for voice interaction is unsatisfactory, and voice interaction remains the channel preferred by customers and the most effective and proven channel for sales and support. Existing web-oriented customer service involves a compendium of textual and visual self-help material designed to deflect extraneous call traffic from call centers. When interaction is actually desired by customers on the web, their options include sending email to the vendor, asking for an immediate call back from the vendor, text chatting with customer support agents, or opening a VoIP voice session with an agent. The weaknesses of each of these methods appear in this discussion.
Email contact into CRM applications is managed on the user side through web-forms and/or email programs designed to help users isolate issues for discussion, and frequently targets groups within the vendor using the To: address to aid in triage of incoming service requests. In the vendor system, an ERMS or Email Response Management System aggregates the incoming email traffic, performs routing analysis over the mail, and routes them to service queues. In the contact center, managers devise staffing models to address this traffic in addition to the more prevalent voice traffic that besets the typical contact center. Service Level Agreements, or SLAs for email contacts vary widely, from as little as a few minutes for an automatically generated “receipt” response, to days or weeks. On average, the response cycle exceeds 24 hours. The net effect of this has been to damage the customer's expectation for timely service on this channel best characterized as a text message driven system.
Web Call Back is a second common form of customer interaction on websites and involves the voice medium. The drawbacks of this approach are threefold however. First, the User needs to wait for a call back, which can take a variable amount of time. The User generally receives no notification of expected wait time, further undermining the expectation for timely or “worthwhile” service. Second, the User may need to drop the ISP connection to the Internet in order to receive the call. This is likely to disrupt the context for the question, and is likely to result in no transaction whatsoever. The third weakness of this approach is that the staffing model required to support web call back is identical to an out-dialing telemarketing application. As such, because the calls are real time and have indeterminate length, the model for staffing a center to field such calls is expensive. Add to that the expense of traditional call center infrastructure, and the attractiveness of this contact channel diminishes.
Text-chatting customer interaction shares some of the same weaknesses as Web Call Back from a staffing perspective. The primary weakness of this approach is that the staffing model required to support text chat is identical to an out-dial telemarketing application. As such, because the conversations are real time and have indeterminate length, the model for staffing a center to field such calls is expensive. Another problem with text chat is that it requires text entry for users which is a frequent barrier to usage. A third problem with it is the User must wait in a queue before receiving service, further diminishing the User's excitement impulse to establish contact.
VoIP is the last form of current customer interaction over the web and shares the queuing weaknesses of the approaches above as well as their expensive staffing models since it is connection oriented. This means that users on either end of a connection must participate at the same time, unlike a messaging application. Additionally, VoIP infrastructure is expensive to acquire and manage. Finally, and most fatefully, the quality of VoIP remains a problem for most users. Even with the quick saturation of broadband services into the consumer market, underlying limitations of shared Internet communications without Quality of Server (QoS) guarantees makes VoIP unreliable and unsatisfying for everyone. VoIP voice fidelity is generally so bad that the pay-services for VoIP suffer due the prevalent belief it is inherently free because of its poor quality. For these reasons, the adoption curve for VoIP has been disappointing, even though it will ultimately be a useful contact channel. The horizon for this usefulness is still several years away at earliest. QoS issues aside, VoIP will always necessitate an expensive staffing model and infrastructure to support. And regardless of network performance improvements, any connection-oriented service technology forces customers to “queue” before asking their questions.
Though there has been no application to date of Instant Messaging technology for CRM, it is worth mentioning as it most closely resembles aspects of the invention under discussion here. Instant Messaging allows users to send text to one another, and permits audio and video real-time streaming. These applications, however, function in a peer-to-peer mode (even though intermediated by a host server) in which users seek out specific other users. What has not happened, though, is the application of this mode of interaction for N:1 (N to one) customer service, and more particularly, not for voice. It is the combination of the last two features that drives a portion of the novelty of this application.
While these devices may be suitable for the particular purpose to which they address, they are not as suitable for voice-enabled web customer service as is the technology represented here. The net result of the above discussion is a pastiche of customer dissatisfaction and customer service organization frustration.
On the customer side, the interaction is marked by inconvenience, waiting, unnatural interaction paradigms employing text input and general technical obstacle. The result is diminished excitement on the part of consumer, reduced patience with inhumane technology solutions that solve nothing, drive frustration, and ultimately, undermine the transaction itself
On the customer service organization side, center managers are frustrated at mounting expenses from increasing staffing models, new infrastructure costs that deliver under whelming performance, and burnt out customer service agents. The net result of the overload and expense pressure is a retreat from solving the problem.
In these respects, a voice message driven customer interaction queuing system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of voice-enabled web pages in a retail or customer support context, allowing web page visitors to utter questions into a browser-resident recorder application akin to a Walkie-Talkie. These questions are then queued along with originating web page information and user data and distributed to customer service agents. Agents can then research the question using the web page as reference, and respond with an audio (or other) message.
3. Objects and Advantages
To ease the acronym burden in this discussion, AMDCIQS is hereafter replaced with the name “Blurt”, the inventor's name for the technology herein described. In view of the foregoing disadvantages inherent in the known types of CRM applications now present in the prior art, the present invention (Blurt) provides a new audio message driven customer interaction queuing system with the following advantages:
The primary feature of Blurt is the ability of the Blurt player to operate without the need to queue with customer service and wait for an agent before satisfying the customer's desire to ask a question. This results in the following advantages:
(a) Users can immediately record messages (of various media types) at the moment of conception. (b) Users can issue messages spontaneously into a customer service organization without waiting for agents to become available first. (c) Disruption is minimized to user routine. (d) Impulse contact is enabled. (e) Contact model is simplified for user.
A second primary feature of Blurt is that it is not connection-oriented, relying on messages as a medium of exchange versus persistent real-time telecom sessions (connections). The connectionless feature leads to a several advantages in the customer service center hosting Blurt:
(a) Load balancing for service requests. (b) Reduced staffing requirements in service center. (c) Audio fidelity improvement of messages (versus VoIP). (d) Elimination (or avoidance) of expensive infrastructure (VoIP switches, ACDs and PBX switches).
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new voice message driven customer interaction queuing system that has many of the advantages of the CRM applications mentioned heretofore and many novel features that result in a new voice message driven customer interaction queuing system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art CRM applications, either alone or in any combination thereof.
This system can be used to voice-enable web pages in a retail or customer support context, allowing web page visitors to utter questions into a browser-resident recorder/player application akin to a Walkie-Talkie. It then allows customers to continue browsing the website or shopping while customer service formulates their answer. Finally, it allows the user to receive the answer and listen to it on the radio-like device. This response cycle is designed to occur in less than about 2 minutes, which is usually less time than spent navigating a traditional call center phone menu. The ease of use, immediacy, instant familiarity with the device paradigm, and quick response time combine to make it easier for people to make a buying decision or to get help when they need it, thereby increasing transaction success rate.
The following business objectives succinctly list the high-level key issues addressed by the invention:
(a) The primary business objective is to increase on-line sales effectiveness by targeting causes for transaction abandonment. (b) A second primary business objective is to enable spontaneous customer voice contact via the web order to establish sales opportunities and exploit the web sales channel (c) Another business objective is to increase voice quality of web-transmitted voice such that the channel becomes acceptable to agents and customers (d) Another business objective is to enable impulse contact from customers in order to establish sales opportunities (e) Another business objective is reducing call center staffing expenses (f) Another business objective is to reduce infrastructure and PSTN toll service costs. (g) Another business objective is to relieve the “real time” constraints placed upon customer service organizations and the expense that results
The technical process behind the invention addresses these needs. It allows web page visitors to utter questions into a browser-resident recorder application that visually resembles and functions like a Walkie-Talkie. These questions are queued with originating web page information and user data and distributed to customer service agents. These agents then research the question using the web page as reference, and respond with an audio message. The web page visitor plays the response upon the browser-resident player.
It should be noted that this voice message driven interaction paradigm applies to non-web applications as well. Traditional telephone customer service operations could employ this message-driven model as well, employing the back-end queuing function described above to achieve similar cost economies in the customer service operation to those described here in the web context.
The following technical objectives support the stated business objectives:
(a) A primary object of the present invention is to provide a voice message driven customer interaction queuing system that will overcome the shortcomings of the prior art devices. (b) Another object is to provide a voice message driven customer interaction queuing system that enables voice message driven customer interaction queuing for persons desiring voice-oriented customer service on websites. (c) Another object is to provide a voice message driven customer interaction queuing system that allows web site visitors to utter questions into a browser-resident recorder application akin to a Walkie-Talkie 2-way radio, and send these messages to customer service for timely handling. (d) Another object is to provide a voice message driven customer interaction queuing system that offers a method for email-style store and forward service delivery for audio messages with a brief service interval (less than 1 minute message roundtrip is possible), supported by a reduced staffing model compared to that for connection-oriented call-handling contact centers. (e) Another object is to provide a voice message driven customer interaction queuing system that queues audio questions along with originating web page URL and user information and then distributes these messages and supplemental data to customer service agents, (f) Another object is to provide a voice message driven customer interaction queuing system that allows customer service agents to respond to questions with audio messages and route these answers back to the users initiating contact. (g) Another object is to provide a server-side agent selection process for distribution of messages based upon topic of the originating URL, user data, availability of agent, work load of agent, and immediate prior history servicing the specific customer. (h) Another object is to leverage platform-independent development tools that facilitate cross-platform portation of the invention. (i) Another object is to develop DBMS independent architecture through the elimination of DBMS specific implementation features such as stored procedures and triggers. (j) Another object of the invention is to create an architecture easily assimilated into either IT infrastructure of an end customer, or into the product suite architecture of a vendor in the CRM or CTI space. (k) Another object is to provide continuity of service to the customer by assigning subsequent customer messages to the same agent until the session is concluded. (l) Another object is to provide an administrative facility for the creation, management and deletion of agent accounts, user data profiles, and message management. (m) Another object is to provide a voice message driven customer interaction queuing system that offers high voice quality by using client-side multi-media codec services for voice messages transported via the Internet. (n) Another object of the invention is to provide a system that compresses voice into acceptably small files for transfer in an acceptably timely manner over a slow speed dialup connection at 28.8 kbps. (o) Another object of the invention is to provide a user interface that downloads to the client browser in an acceptably timely manner over a slow speed dialup connection at 28.8 kbps. (p) Another object of the invention is to provide a user interface that immediate taps into familiar user expectations by using a “Walkie-Talkie-like” interface requiring minimal explanation to operate successfully. (q) Another object of the invention is to provide a user interface with toy-like appeal that encourages usage by leveraging user curiosity. (r) Another object is to provide a voice message driven customer interaction queuing system that works independently of the variable quality of interne transport resulting from network latency (transport delay) and jitter (variation in latency), thereby increasing voice fidelity dramatically.
Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages be within the scope of the present invention.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated.
SUMMARY OF THE INVENTION
In accordance with the present invention, an Audio Message Driven Customer Interaction Queuing System generally comprises client, server and agent elements designed to allow users to spontaneously create and issue messages into a web-based customer service facility without queuing beforehand.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 shows high-level elements of the Blurt service delivery process.
FIG. 2 is a Blurt software component view showing the core elements of the Blurt Client, Blurt Server, and Blurt Agent.
FIG. 3 is a high-level flowchart of the software process for Users to send messages to Agents, and the response path for Agent messages returning to Users.
FIG. 4 is a Blurt System View with high-level process flow indicated.
FIG. 5 is a flowchart of the client software process for the “Record” operation of the Blurt client.
FIG. 6 is a flowchart of the client software process for the “Review” operation of the Blurt client.
FIG. 7 is a flowchart of the client software process for the “Play” operation of the Blurt client.
FIG. 8 is a flowchart of the client software process for the “Send” operation of the Blurt client.
FIG. 9 is a Blurt Server and DBMS architecture diagram with rough process flow.
FIG. 10 is a screen capture depicting the Blurt Client embedded in a web page.
FIG. 11 is a screen capture depicting the Blurt Agent browser interface with embedded Blurt Client.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the attached figures illustrate an audio/voice message driven customer interaction queuing system, which comprises client, server and agent elements.
By way of introduction, this discussion refers to 3-party and 2-party service models. In a 3-party model, a server brokers interaction between Users and Agents. In a 2-party model, User-Agent interaction occurs directly.
From the overall service level, the preferred 3-party service architecture functions in the following manner: A User visiting a blurt-enabled website creates an audio message using the Blurt Client ( FIG. 1 , 10 , 15 , 50 ). The user then sends the message using the Blurt Client ( FIG. 1 , 50 ) to the Blurt Server ( FIG. 1 , 30 ). The Blurt Server then determines availability and selects an Agent ( FIG. 1 , 40 ′) to field the message, and distributes the message to the Agent. The Agent sees the User web page that originated the message ( FIG. 1 , 40 ′, 15 ′, 15 ) and can manage multiple concurrent User dialogs by viewing the Connection Management area ( FIG. 1 , 40 ′, 15 ′, 25 ). The Agent records responses to the User questions using the Blurt Client ( FIG. 1 , 40 ′, 15 ′, 50 ′) and sends the message back to the Blurt Server ( FIG. 1 , 30 ). The Blurt Server then sends the response on to the User's Blurt Client for playback ( FIG. 1 , 10 , 15 , 50 ).
From the software component level, the preferred 3-party software architecture functions in the following manner: A User visiting a blurt-enabled website creates an audio message using the Blurt Client ( FIG. 2 , 50 , 51 , 52 , 53 ). A Flash object ( FIG. 2 , 50 ) drives JavaScript ( FIG. 2 , 51 ), which in turn controls an ActiveX object ( FIG. 2 , 52 ). The ActiveX object employs a Codec ( FIG. 2 , 53 ) to capture and store audio files, and sends these to the Blurt Server JSP page ( FIG. 2 , 99 ) and Java Servlets ( FIG. 2 , 100 , 101 , 102 ), which handle disposition of the messages. The Blurt Server then assigns the message to an Agent and transfers the message to the Agent's Client ( FIG. 2 , 50 ′, 51 ′, 52 ′, 53 ′). The Agent controls playback using the Flash object ( FIG. 2 , 50 ′) in a manner similar to the User side, driving JavaScript ( FIG. 2 , 51 ′), which in turn controls, an ActiveX object ( FIG. 2 , 52 ′). The ActiveX object employs a Codec ( FIG. 2 , 53 ′) to retrieve and play the audio message, and to capture his response to the User's question, and to send the response back to the Blurt Server ( FIG. 2 , 99 , 100 , 101 , 102 ). The Blurt Server then sends the response on to the User's Blurt Client for playback ( FIG. 2 , 50 , 51 , 52 , 53 ) in a manner similar to Agent playback.
From the overall system level, the preferred 3-party architecture functions in the following manner: A User visiting a Blurt-enabled site creates an audio message using the Blurt Client ( FIG. 4 , 50 , 51 , 52 , 53 ). The ActiveX portion of this client manages the collection and posting ( FIG. 4 , connector 2 ) the message to the Blurt Server. On the server side this is handled by the postmessage servlet ( FIG. 4 , 101 ). This servlet establishes a connection with the DBMS ( FIG. 4 , 103 ) and creates a session ( FIG. 4 , connector 3 , 45 ) and resulting profile if this is a new contact ( FIG. 4 , 43 ). The message is stored in the DBMS ( FIG. 4 , 44 ) to await assignment to an agent, or forwarding to an agent if this is part of an existing session. The Blurt Server Bean Explorer classes embedded in JSP processes ( FIG. 4 , 102 , 99 ) then assess the new contact ( FIG. 4 , connector 4 ) and identify an available agent for assignment of the message, or the incumbent agent for the session. If an incumbent has since become unavailable, the JSP process selects a new agent. It then instructs the get message Servlet ( FIG. 4 , 100 ) to retrieve the message ( FIG. 4 , connector 5 ) from the DBMS ( FIG. 4 , 103 , 44 ) and deliver it to the selected agent for playback ( FIG. 4 , connector 6 ) on the Blurt Client ( FIG. 4 , 50 ′, 51 ′, 52 ′, 53 ′). Once the Agent has completed recording an audio response, the Blurt Client ActiveX control ( FIG. 4 , 52 ′) posts the message ( FIG. 4 , connector 7 ) to the postmessage servlet ( FIG. 4 , 101 ), which in turn inserts it into the DBMS 103 ( FIG. 4 , connector 8 ). The getmessage servlet ( FIG. 4 , 100 ) then notices the assignment, retrieves it ( FIG. 4 , connector 9 ) and delivers the message to the User ( FIG. 4 , connector 10 ) for playback on the Blurt client ( FIG. 4 , 50 , 51 , 52 , 53 ).
As for more specific details of architecture and operation, the preferred invention consists of the following elements:
The Blurt Client resides in a standard browser on a Personal Computer (PC). The Blurt Client comprises a Macromedia Flash interface driving JavaScript and an ActiveX control and uses standard or custom audio encoding/decoding codecs. The Blurt Server comprises Java Servlets, Enterprise Java Beans, a web and application server and generic database technology. The Blurt Agent consists of a standard browser structured into areas for displaying the User Web Page, Active Connections for the Agent, and the Blurt Client for message playback and recording.
The Blurt Client appears embedded in web pages “enabled” with the Blurt technology. Variations on the Blurt client involve alternatives in each of its components.
The Flash GUI portion of the Blurt Client may be replaced with a Java applet resident in a browser, or as a Java application running outside of a browser on a user desktop. In the event of a Java application, the service model can assume a standard client-server architecture (2-party) and facilitate direct messaging to a host. The Flash GUI may also be replaced by JavaScript, thereby reducing the need for a Flash player in the browser. This reduces GUI functionality however, impacting usability. The JavaScript portion of the Blurt client may be replaced using VB script or another scripting language. Each of these alternatives, however, impacts the userbase, as their ubiquity on User platforms is not assured.
The ActiveX portion of the Blurt Client may be replaced by Java. Java, however, is not as efficient to integrate with Windows audio services and could impact codec operation. Java would, however, promote cross platform operation, and would thereby increase user acceptance. The ActiveX portion of the Blurt Client may be replaced by next generation Microsoft .NET elements. This is a desirable alternative to the instantiation used in reduction to practice, which occurred 13 Feb. 2002. .NET will reduce security-screening issues at client download time, thereby enhancing usability.
In the Codec portion of the Blurt Client, one may substitute a custom codec and include it in the download package at Client download time. This would aid in cross-platform compatibility, but will increase download size, thereby impacting adoption.
Functionally, the Blurt Client may operate in 3-party mode, or 2-party peer-to-peer mode. Reduction to practice focused upon 3-party mode. In either 3-party or 2-party mode, the Blurt Client functions identically from the user perspective. In 3-party mode, messages route to a server, where the server may distribute the message to multiple agents by applying an assignment availability algorithm, or to specific single users with no assignment analysis required. In 2-party mode, User messages route to a single predefined specific user directly. The User may not direct the message routing as this would disrupt the N: 1 service model, where N users employ a tool to communicate with 1 Agent. There is no provision for User addressing to allow for addressing to arbitrary recipients. Transport for 2-party Blurt may employ SMTP, or a specially developed light transport client designed expressly for this purpose.
Blurt Client message handling currently employs encoding voice and using HTTP for file transfer. This transfer could alternately employ FTP or another file transfer protocol with no effective difference, other than potential diminished performance. Due to communication delay in file transfer, the preferred method of message handling involves encoding and immediate streaming of said file to the server to reduce perceived transmission time. Blurt Client streaming functionality thus changes the Send command to an implicit “approve and post” command for the message file as it has already, or is already, in transit upon command issuance. Alternative message handling could involve immediate streaming of audio prior to an encoding step, but the resulting file size of the stream would be prohibitive and defeat the gains of early transfer. Alternative message handling could also employ SMTP-style file transfer to effect file transfer to the destination; this would be problematic, however, as variations in User platform configuration may reduce broad applicability.
The Blurt Server consists of Java Servlets, Enterprise Java Beans, a Tomcat server, and generic database technology. It executes JSP pages and business logic related to managing the availability of agents and assignment of user-originated messages that include audio, URL data and user data elements. User messages may include, text, fax and video as well. The server also manages audio responses from the Agent, routing, then delivering them to the originating User's Blurt Client for playback on the User PC.
The Blurt Server may also be implemented with alternate technologies for dynamic page creation and delivery, including ASP, .NET or ColdFusion. These products are not open-source, however, impacting the cost of delivery for the system. The Blurt Server may also employ alternate web and application server technologies including, but not limited to IBM's WebSphere, WebLogic, and Microsoft IIS. These alternatives do not offer substantive advantages to the Blurt Server function, but may suit customers of Blurt due to pre-existence in customer infrastructure.
Functionally, the Blurt Server may operate in 2 modes in a 3-party service model, or be omitted from the system with a modified Blurt Client performing peer-to-peer 2-party communication in a 2-party model. In the 3-party model, messages route to a server, where the server may distribute the message to multiple Agents by applying an assignment availability algorithm (mode 1), or to specific single users with no assignment analysis required (mode 2). In the 2-party model, User messages route to a single pre-defined specific Agent directly. The User may not direct the message routing as this would disrupt the N: 1 service model, where N users employ a tool to communicate with 1 Agent. Transport for 2-party Blurt may employ SMTP, or a specially developed light transport client designed expressly for this purpose.
The Blurt Agent consists of a standard browser segmented into areas comprised of the User URL area, the Connection Management area, and the Blurt Client area. These are the basic elements required to enable a rich customer service delivery process.
The Blurt Client area consists of a screen area displaying the Blurt Client player, which is comprised of Macromedia Flash, JavaScript and ActiveX, with reliance upon supplemental codecs for audio record and playback. These codecs may be added to this system by the Operating System itself (as in the case of Windows), or via custom development.
The User URL area consists of a screen area in which the User URL that accompanied the user message is expanded to show the agent from where the message originated in the Blurt enabled website.
The Connection Management area consists of graphical icons indicating user sessions currently assigned to the Agent, and which Customer is in focus in the User URL area undergoing service delivery.
The Blurt Agent may assume innumerable realizations as the core elements may recombine as desired by customers. Each of the core elements may be realized using various technologies, thereby creating a large combination of possible instantiations in varied configurations.
The Blurt Client, comprised of an ActiveX Control ( 52 ), a Flash interface ( 50 ), and JavaScript ( 51 ) working with a supplemental codec ( 53 ), is connected among its components as follows:
The Flash Interface ( 50 ) of the Blurt Client collects user input in the form of button key presses and mouse hovering. The Flash Interface ( 50 ) passes these events to JavaScript ( 51 ), which in turn pass the events to an ActiveX Control ( 52 ). The ActiveX Control ( 52 ) then may interact with Operating System Audio services, supplying an audio file to play, or instructing it to capture audio stream from an input device such as a microphone. The ActiveX Control ( 50 ) may also interact with Blurt Server ( 30 ) components getmessage ( 100 ) and postmessage ( 101 ), and may execute HTTP Put, Post and Get commands for transportation and retrieval of audio files, User URL and other User data. The Blurt Client connectivity applies to both User and Agent instantiations of the Blurt Client.
The Blurt Server ( 30 ) connectivity consists of Java Servlets interacting with Enterprise Java Beans ( 102 ), a web server (Tomcat) server acting as a JSP container ( 99 ) and generic database technology ( 103 ).
The Java Servlets are comprised of getmessage ( 100 ) and postmessage ( 101 ) and interact with the ActiveX Control ( 52 ) of the Blurt Client. The Java servlets ( 100 , 101 ) also feed the JSP ( 99 ) logic that assigns and delivers user-data-enhanced-messages to agents, and accepts their responses. The Java servlets ( 100 , 101 ) also interact with subordinate DBMS technology ( 103 ) employing JDBC to insert and retrieve records into the database.
The Blurt Server JSP pages ( 99 ) interact with the Java servlets to accept and push content to Users and Agents.
On the User Side, the Server ( 30 ) pushes audio responses created by Agents, using HTTP ( 55 ) to communicate with the User Side browser ( 15 ). The Server ( 30 ) also communicates through the ActiveX Control ( 52 ), and indirectly to JavaScript ( 51 ), and indirectly to the Blurt Client Flash interface ( 50 ) to manage playback-control-button states, display message information on the Blurt Client Interface ( 50 ) for presentation to the User, and to push audio content to the client.
On the Agent Side, the Server ( 30 ) employs HTTP to push User URL data to the Agent User URL area ( 26 ), and to push Connection Management information to the Connection Management area ( 25 ) of the Agent browser. The Server also interacts with the Agent instance of the Blurt Client ( 50 ′) in the Blurt Client Frame of the Agent browser in the manner described above, with the distinction that the server responds to Agent Play requests for User input by updating the Connection Management area, and by retrieving content corresponding to the User URL, and displaying said content in the User URL area ( 26 ) of the Agent browser.
Variations on Blurt interprocess communication would derive from two sources, those being alternate development technology, or alternate Blurt topology in service of 2-party versus 3-party models.
Regarding alternate technology, the Flash GUI ( 50 ) portion of the Blurt Client may be replaced with a Java applet resident in a browser, or as a Java application running outside of a browser on a user desktop, or as a JavaScript browser application. This might include RPC-style communication, FTP interaction, and other functional equivalents for use in a conventional client-server model.
If the Flash GUI were indeed replaced by JavaScript or a Java Applet, this would eliminate the need for a Flash plug-in in the browser. Interprocess communication would thus rely upon Java messaging. The JavaScript portion of the Blurt client may be replaced using VB script or another scripting language.
In the event of Java Application or other conventional non-web oriented model, interprocess communication depends upon the design of said tools. Each of these alternatives, however, impacts the userbase, as their ubiquity on Windows platforms is not assured.
As suggested, another alternate instantiation alluded to above arises from the 2-party communication model (versus the 3-party model motivating most of this discussion). This service structure implements N: 1 messaging, where N Users may message 1 and only 1 Agent. This is in contrast to the 3-party model that enables multiple Agents to service an arbitrary number of Users. This application is most likely in small businesses such as sole proprietorships, or in small professional practices. The reason this architecture becomes 2-party is that no server is necessary to perform the assignment to the single Agent. This affects connectivity in the following manner: Blurt may then implement a light mail client or leverage a pre-existing mail client on the User and Agent PCs such as MS Outlook Express to perform the file transport function.
The ActiveX portion of the Blurt Client may be replaced by Java. Java, however, is not as efficient to integrate with Windows audio services and could impact codec operation. Java would employ Java messaging to talk to other components. The ActiveX portion of the Blurt Client may also be replaced by next generation Microsoft .NET elements. This is a desirable alternative to that used in reduction to practice in the Blurt Prototype that operated successfully end-to-end-to-end Feb. 13, 2002. Details of this .NET strategy are emerging as of this writing, however, and did not appear to be available for development.
In the Codec portion of the Blurt Client, one may substitute a custom Codec and include it in the download package at Client download time. This would eliminate Windows API calls to the Audio system, replacing them with API calls of the Codec.
The Blurt Server ( 30 ) may also be implemented with alternate technologies for dynamic page creation and delivery, including ASP, .NET or ColdFusion. The Blurt Server may also employ alternate web and application server ( 99 ) technologies including, but not limited to IBM's WebSphere, WebLogic, and Microsoft IIS. These would employ the interprocess communications peculiar to each platform
Functionally, a Blurt System may operate in 3-party mode, or 2-party peer-to-peer mode. Reduction to practice focused upon 3-party mode. In either 3-party or 2-party mode, the Blurt Client functions identically from the user perspective.
In 3-party mode, messages route to a server, where the server may distribute the message to multiple agents by applying an assignment availability algorithm, or to specific single users with no assignment analysis required (e.g. a service brokerage between providers and consumers).
Additional variations upon 3-party and 2-party themes assume somewhat academic options entirely motivated by the desire to circumvent the protection this patent application seeks. Some of these include a 3-party system that includes peer-to-peer file transfer of audio and related data initiated but not mediated by a server. Additionally, 3-party solutions could employ SMTP or FTP as a means for file transfer, but do not represent innovation and are again designed to avoid claims herein. Other variations could include conversion of Blurt audio messages into telephony streams directed into a voice mail system or other telephony infrastructure. While this innovation does employ an alternate path, it relies upon the fundamental claim here of premeditated voice message queuing in a customer interaction queuing context, thus infringing claims herein.
Blurt message handling on the client currently employs encoding voice and using HTTP for file transfer. This transfer could alternately employ FTP or another file transfer protocol with no effective difference, other than potential diminished performance. Due to communication delay in file transfer, the preferred method of message handling involves encoding and immediate streaming of the file to the server to reduce perceived transmission time. Blurt Client functionality thus changes the Send command to an implicit “approve and post” command for the message file as it has already, or is already, in transit upon command issuance. This innovation provides marginal transfer time improvement, however, as Blurt generates small audio files, and the inclusion of streaming logic would increase download package size and retard initial client download, diminishing the improvement accordingly in a tradeoff. Alternative message handling could involve immediate streaming of audio prior to an encoding step, but the resulting file size of the stream would be prohibitive and defeat the gains of early transfer. Alternative message handling could also employ SMTP-style file transfer to effect file transfer to the destination; this would be problematic, however, as variations in User platform configuration would reduce broad applicability.
Several additional alternatives present themselves in the realization of Blurt, each being inspired by the innovation presently under examination in this document. These alternatives are in scope for Blurt development, only delayed by race to reduce the core concept to practice, which has occurred.
Some of these innovations include analyzing other User Data and User URL to accomplish routing in the Blurt Server logic. This would allow call centers to triage messages and deliver them to subject experts. Further enhancements along this line would involve speech to text analysis and key word spotting within the audio stream to accomplish the same purpose. Other innovations at the same logic step of the service cycle would facilitate business logic controllable by the host of the system such as “Business Day” rules, versus off hour rules, and auto-audio responses generated during relevant times to manage user expectations when the service is likely to be delayed.
In addition to routing innovation, complementary applications may develop as enabled directly by this core innovation. These are fully anticipated here and claimed, including 3-party incident billing systems, 3-party subscription billing systems, and two party equivalents. Additional applications claimed include ASP hosted 3-party solutions in a service bureau configuration for all variations of systems above and related billing systems.
Additional innovations in the client pertinent to security are also claimed. These may include user authentication and voice encryption, or the employment of digital signatures to establish user identity.
Additional innovations enriching the communication stream are also claimed. These include bundling attachments with messages to aid in the dialog or for other purposes, and creation of a spontaneous customized portal for Users or Agents which house relevant material.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
FIGURE REFERENCE NUMERALS
Number
Item
10
Customer PC
15
Customer browser originating web page
15′
Agent browser
20
Communication network
25
Agent browser connection management area
26
Agent browser User URL Area
30
Service host server
35
Service Host LAN
40′
Agent PCs
43
Profiles
45
Sessions
47
Messages
50
Customer Flash GUI
50′
Agent Flash GUI
51
JavaScript Customer
52
ActiveX Control Customer
53
Media Codec Customer
51′
JavaScript Agent
52′
ActiveX Control Agent
53′
Media Codec Agent
55
HTTP or alternate transfer protocol
99
Java Server Pages (JSP) Container
100
getMessage Java Servlet
101
postMessage Java Servlet
102
Enterprise Java Beans
103
Data Base Management System (DBMS) | This application is for an audio message-driven customer interaction queuing system for retail, help desk or any public web page in a support context, allowing web page visitors to utter questions into a browser-resident recorder application similar to a Walkie-Talkie. These questions then queue along with originating web page information and are distributed to customer service agents. These agents can then research the question, using the web page as reference, and respond with an audio message, played upon the recorder application by the user after some brief service interval. The invention includes client, server and agent elements. The Client resides in a standard browser on a PC. The Client as initially instantiated consists of a Macromedia Flash interface driving an ActiveX control and JavaScript using audio encoding/decoding codecs. The Server consists of Java Servlets, Enterprise Java Beans, a web and application server and generic database technology. The Agent consists of a browser partitioned into areas to accommodate customer URL viewing, Connection Management (to service multiple customers concurrently), and a Client for message playback/record/send functions. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is arc welding apparatus, and more particularly, circuits for controlling the arc voltages applied by arc welding apparatus.
2. Brief Description of the Prior Art
Arc welding apparatus are well known in the prior art. The quality of the weld is dependent upon maintenance of a proper arc length and voltage. It is desirable that a welding apparatus compensate for changes in welding parameters, introduced by workpiece variations and the like. For example, the workpiece may vary in thickness or resistance, and unless the arc voltage is compensated for such variances, the weld will not be uniform in it characteristics.
In my co-pending application entitled "Welding Apparatus," Ser. No. 372,193 filed Apr. 26, 1983, an apparatus is described for mounting the welding electrode on a fixture which is servo operated to move the electrode in relation to the workpiece. While servo positionable electrodes per se are not new, the servo circuits employed in the past have suffered the disadvantages of oversensitivity to variations in arc voltage, such that the electrode will oscillate or "hunt" for the electrode position at which the nominal arc voltage is obtained. This excessive "hunting" is of course deleterious to the weld.
Accordingly, a need exists for an arc voltage control circuit which maintains the arc voltage within a proper range about the nominal voltage, without excessive servo "hunting."
SUMMARY OF THE INVENTION
The present invention comprises a novel circuit adapted to sense variations in the arc voltage from the nominal arc voltage, and to compensate for such variations only if the variations are outside a predetermined "deadband" range, by gradually accelerating the servo movement until the arc voltage is within range, and then quickly decelerating and stopping the servo movement.
The preferred embodiment of the improved circuit consists generally of (i) an arc voltage detector and (ii) a preset arc reference voltage generator, each coupled to a (iii) voltage comparator for generating an error signal, (iv) a deadband error comparator circuit for determining conditions when the error signal exceeds a predetermined deadband range and providing a control signal determined by the difference between the error signal, the deadband reference, and a servo gain factor, (v) a motor servo circuit which is operative to generate, in the presence of a control signal, a ramp signal having a predetermined and selectable acceleration slope characteristic for gradually accelerating the servo motor until the control signal is nulled, and a deceleration slope characteristic having a relatively small time constant for stopping motor operation in a relatively short time interval, and (vi) a motor drive circuit responsive to the output of the motor servo circuit.
The circuit achieves correction of the arc voltage without the deleterious overshooting or "hunting" characteristic of prior art equipment. Once the nominal voltage range has been attained, the servo motor is rapidly decelerated and stopped.
Other features and advantages are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are schematic drawings illustrating the circuitry of the preferred embodiment of the present invention.
FIG. 5 is a block diagram of the functional elements of the preferred embodiment when operating in the automatic servo mode.
FIG. 6 is a graph illustrating the servo circuit output as a function of time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention comprises a novel arc voltage control circuit for an arc welding apparatus. The following description of the invention is provided to enable any person skilled in the welding apparatus art to make and use the present invention, and sets forth the best mode presently contemplated by the inventor for carrying out his invention. Various modifications, however, to the preferred embodiment, will be readily apparent to those skilled in the art, and generic principles defined herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and novel features described herein.
The present invention is related to the apparatus described in my co-pending application, entitled "Welding Apparatus," Ser. No. 372,193 filed Apr. 26, 1982 wherein is described my invention relating to the automatic retraction of the welding electrode above the surface a predetermined distance to initiate the welding procedure. As is described in that application, the welding electrode is mounted in a servo motor-driven fixture, which is operable to move the electrode toward or away from the workpiece. Prior to commencing the welding operation, the operator initiates a downward movement of the electrode, which "jogs" downward until the welding electrode contacts the workpiece, whereupon a micro-switch is engaged, the servo motor is reversed, and the electrode jogged upwardly a predetermined distance for the start of the welding. Reference is made to my copending application for further description of the specific mechanism for positioning the electrode. In accordance with the present invention, once the electrode has been prepositioned and the welding voltage attained, automatic torch positioning apparatus is engaged to maintain an approximately constant welding voltage by variation of the position of the torch relative to the workpiece.
Referring now to FIG. 5, a block diagram of the preferred embodiment when operating in the automatic servo mode is illustrated. The absolute value of the actual welding voltage is detected by detector 100, and compared with the present arc voltage value by comparator 190. The error signal 192 from comparator 190 will either be a positive or negative voltage, depending upon the value of the actual arc voltage relative to the preset arc voltage. Error signal 192 is compared at the deadband-error comparator 120 with the deadband preset value. The preset value represents the range in the error signal magnitude about which no servo correction will be made. That signal will be at ground potential unless the error signal magnitude is greater than the preset deadband value. When the magnitude of the error signal is greater than the deadband, the output 142 represents a difference signal between the deadband preset value 119 and the product of a servo gain factor and the difference between the error signal 192 and the deadband preset value. Control signal 142 is coupled into motor servo circuit 150. Circuit 150 controls motor drive circuit 200, which in turn drives motor 420. Circuit 150 generates a ramp signal, in the presence of output 142, of either positive or negative slope depending upon the polarity of output 142, which controls motor drive circuit 200. The ramp signal causes the servo motor to rotate in the appropriate direction to move the electrode so as to reduce the error signal. The ramp signal causes the motor to slowly accelerate from the stopped position to a clamped maximum speed. Once the error signal has been reduced to a value within the deadband range, the ramp signal quickly returns to a null level at a fixed, relatively steep rate so as to stop motor operation.
Referring now to FIG. 1, a schematic of some of the components of the circuit outlined in block form in FIG. 5 is shown. The subcircuit outlined in phantom line 100 corresponds to the arc voltage detector shown in FIG. 5. Similarly, subcircuits 120 and 150, also outlined in phantom line in FIG. 1, correspond respectively to the deadband-error comparator circuit and motor servo circuit shown in FIG. 5. The inputs to circuit 100 are delivered at nodes A and B, respectively, from the torch 10 and workpiece 20 connections illustrated in FIG. 3. The voltage between the torch 10 and workpiece 20 is filtered by capacitors 12 before being provided to circuit 100. Circuit 100 acts as an absolute value detector, providing at its output a positive voltage signal representative of the absolute magnitude of the filtered arc voltage. While the operation of circuit 100 will be readily apparent to those skilled in the circuit art, it is noted that, for positive arc voltages, diode 106 is back biased, allowing gain resistor 108 to operate so that amplifier 104 is in an amplifying mode. Resistors 102, 108, 110 and 118 are nominally 20 Kohm resistors, and resistor 112 a 10 Kohm resistor.
Op amp 114 acts as an inverting summing amplifier, summing and inverting the voltages developed across resistor 110 and resistor 112. For example, with a +10 volt input at node A, the voltage at node 101 will be inverted at approximately -10 volts, and the voltage across resistor 110 will be +10 volts due to the differences in the values of resistors 110 and 112. The input at op amp 114 will be at -10 volts and when inverted, the voltage output at node 119 will be at +10 volts, i.e., the same as the input voltage.
For negative arc voltage inputs to circuit 100, e.g., -10 volts, diode 106 will conduct, leaving the voltage at node 109 at approximately ground, while the voltage drop across resistor 110 will leave at approximately -10 volts, therefore, with the inverting action of the amplifier 114, a voltage of +10 volts will be presented at node 119. The circuit 100 will operate with rectifying action due to capacitor 116 and the input capacitors filtering the arc voltage.
The output at node 119 is representative of the absolute magnitude of the actual arc voltage. The operator, however, is able to set a nominal or preset arc voltage by the use of digital voltmeter 50 and potentiometer 70, as shown in FIG. 3. Thus, with relay contact 60 in the voltage preset mode, a 12 volt supply voltage +V is coupled through potentiometer 70, through DVM calibration potentiometer 65 to the DVM, with the voltmeter monitoring the potential as developed on the wiper of potentiometer 70. By manipulating potentiometer 70, the operator may preset the desired voltage, which will depend upon the welding parameters, e.g., the workpiece material and the like. During welding operation, the digital voltmeter 50 is coupled through relay contact 60 and node D to monitor the level of the output of circuit 100, the actual arc voltage.
The preset voltage level is continuously coupled through node C and resistor 190 (nominally 20 Kohm) to provide a reference level to the "plus" input of op amp 190. Op amp 190 corresponds to the comparator 190 shown in FIG. 5. The output of circuit 100 is coupled through resistor 194 (nominally 20 Kohm) to the "minus" input of comparator op amp 190. Feedback resistor 196 (nominally 20 Kohm) provides feedback between the minus input and the output of comparator 190. Resistor 198 (nominally 20 Kohm) couples the "plus" input of comparator 190 to ground. Comparator 190 provides an output or error signal at node 199 equivalent to the difference between the reference voltage at node C and the signal at node 119, i.e., the absolute actual arc voltage. Error signal 199 is coupled through switch 180 to a second comparator circuit 120.
Circuit 120 operates to provide a null output when the error signal is zero or within a range of the preset deadband voltage. This deadband voltage is set by the position of potentiometer 170 by the operator. Resistors 170 and 172 comprise a 1K potentiometer and 1.4 Kohm resistor, respectively. Thus, the operator is able to adjust the deadband voltage from 0 to about 4.5 volts. This deadband voltage is provided to the "plus" input of amplifier 122 and is also inverted by amplifier 174, and then provided to the "plus" input of amplifier 124 in circuit 120. Resistors 176 and 178 comprise 20 Kohm resistors in the preferred embodiment. The operation of circuit 120, when the error voltage at node 199 is greater than the deadband voltage, is to provide the following output signal at node 131: ##EQU1## where E output=the voltage at node 131
E DB =preset deadband voltage
R 126 , R 127 , R 136 =values of resistors 126, 127 and 137
E r =error signal at node 119.
This output voltage is thus a function of the deadband voltage, the error signal, and a gain factor determined by the values of resistors 126, 127 and 136. Resistors 136 and 126 are nominally 2 Kohm and 100 Kohm resistors, respectively, and potentiometer 172 a 200 Kohm potentiometer. Thus, for these resistive values, the gain factor will theoretically range from zero to about 33.
The resultant output signal at node 131 provides the input to motor servo circuit 150. Circuit 150 includes amplifiers 152 and 166 being coupled together through feedback resistor 158 (nominally 20 Kohms) and zener diode limiters 154 and 156. These zener diodes have a nominal reverse bias breakdown voltage of 4 volts. The output of amplifier 152 is coupled to the "plus" input of amplifier 166 through variable resistor 165, which in the preferred embodiment is nominally a 500 Kohm potentiometer. The "plus" input to amplifier 156 is also coupled to the "minus" supply voltage (nominally -12 volts) through capacitor 167, nominally a 100 microfarad capacitor. The output of amplifier 152 is also coupled to the "plus" input of amplifier 166 through the resistor and diode network comprising resistors 184 and 185 (nominally 2 Kohm resistors) and to diodes 158, 160, 162 and 164. (It is noted that reference herein to a "minus" input to an op amp is to the inverting input, while reference to the "plus" input is to the noninverting input.)
Circuit 150 operates in the following manner. When a positive output signal is provided at node 131, the output of amplifier 152 will be driven to its saturated "minus" voltage. Capacitor 167 will be charged away from zero potential through variable resistor 165. The diodes do not provide a current path for charging capacitor 167, since a path of less resistance is available through diode 167 (or diode 162, for negative voltages) to ground. In a similar fashion, with a positive output voltage at node 131, the output of amplifier 152 will be at its saturated positive voltage. Once again, the only current path for charging capacitor 167 is through variable resistor 165. Since amplifier 166 is configured as a unity gain follower, while capacitor 167 is being charged, the amplifier 166 output will be a ramp signal whose slope is determined by the time constant of capacitor 167 (nominally a 100 microfarad capacitor) and potentiometer 164 (nominally a 500 Kohm potentiometer). Thus, the operator can vary the time constant by adjustment of potentiometer 165, thereby varying the time delay before actuation of the servo motor to correct the arc voltage. This ramp signal is fed back to amplifier 152 through resistor 158 (nominally 20 Kohms) and the zener diode limiter circuit to the "minus" input of amplifier 152. This feedback, as well as the output of op amp 166, is of course limited to ±4 volts, the zener reverse bias breakdown voltage. The output of circuit 150 is fed through switch 182 through node K to motor drive circuit 200 (see FIG. 2).
The motor drive circuit 200 is divided into circuit 200a (FIG. 2) and 200b (FIG. 4). Circuit 200a includes op amps 202, 218 and 228. Amplifiers 202 and 218 operate in a complimentary fashion to drive complimentary transistor pairs 410, 412 and 402, 404, which power the servo motor 420.
The output from servo circuit 150 is coupled through node K to the "minus" input of amplifier 202. The signal at node 211 is coupled through node R to the emitters of complimentary transistor pair 410, 412 (FIG. 4). The node 211 signal is also coupled through resistor 208 (nominally 10 Kohm) to the "minus" input to amplifier 218. Resistors 206, 207, 214 and 216 each have nominal 1 Kohm values. The output of amplifier 202 is coupled through resistor 206 and node 209 to the bases of complimentary transistors 410, 412.
The signal at node 213 is coupled through node T to the emitters of complimentary transistor pair 402, 404. The output of amplifier 218 is coupled through resistor 216 and nodes 216 and U to the bases of the complimentary transistors 402, 404.
Feedback to circuit 200a is taken from nodes 403 and 411 (FIG. 4) through nodes R and T and resistors 206 and 210 (nominally 10 Kohms) to the "minus" inputs of amplifiers 202 and 218, respectively (FIG. 2). Taking the feedback from the emitters of the drive transistors eliminates any effect of the forward bias voltage drops of these transistors.
Resistors 224 and 226 are nominally 2 Kohms, and resistors 220 and 224 comprise 20 Kohm resistances. The output of amplifier 228 is coupled to node 233 and through potentiometer 230 to the "plus" input of amplifier 202 and to ground.
Circuit 200a receives the output from servo circuit 150. Assuming that the signal consists of a ramp signal with positive slope, the ramp will be inverted at nodes 211 and 209 by amplifier 202, and coupled to the emitters and bases, respectively, of transistors 410 and 412. There will be a positive voltage drop across resistor 207 from node 211 to node 209. Therefore, the signal applied to the bases of transistors 410, 412 will be positive with respect to the signals applied to the emitters. NPN transistor 410 will be biased "on," and PNP transistor 412 biased "off."
Still assuming a positive ramp voltage input to circuit 200a, the inverted ramp at node 211 is presented to amplifier 218, configured as a unity gain inverting amplifier. Thus, the voltage at signal node 213 will be positive with respect to that at node 215, biasing NPN transistor 404 "off" and PNP transistor 402 "on." Thus, a current path has been established, from the +V supply voltage, through transistor 410, resistor 422, the motor 420 armature, and transistor 402 to the negative supply voltage. As the ramp input signal to circuit 200a increases, so will the drive current through the motor, thereby accelerating the motor speed as the ramp increases.
Op amp 228 senses the current through the motor armature and its output provides IR compensation to the "plus" input of amplifier 202. This positive feedback serves to compensate for heat losses in the motor windings, and also to current limit the current through the motor, by providing a feedback current at the "minus" input of op amp 202 opposite to the control signal through node K. This current feedback flows through potentiometer 232 and network 900.
For negative ramp signals at node K, the operation of motor drive circuit 200 is reversed. Transistors 410 and 402 will be biased "off" and transistors 412 and 404 biased "on." A positive reference voltage will be presented to amplifier 202. Current flow through the motor, and the direction of motor operation, will be in the reverse direction.
The servo motor will raise or lower the electrode, thereby either lowering or raising the actual arc voltage and correcting the control signal at node 131. As the motor operates and accelerates, the error signal and the control signal will become smaller in an exponentially increasing fashion. Once the control signal nulls and the control signal at node 131 opens, the output of amplifier 152 will no longer be driven to a saturated condition, and the capacitor 167 will discharge to ground potential either through diode 158 and resistor 184, or diode 160 and resistor 185, depending upon the polarity of the charge on capacitor 167 at node 169. One of diodes 164 will clamp the discharge level to ground, as it will be biased "on" once the voltage on node 169 approaches the diode "biased on" voltage drop.
A current path to charge or discharge capacitor 167 always exists through variable resistance 165. During discharge operation through 2 Kohm resistance 184 or 185, this path is of negligible effect. Thus, servo control circuit 150 operates to provide a motor control signal which ramps up on down in the motor accelerating mode, at a rate dependent upon the capacitor 167-resistor 165 time constant. In a motor decelerating mode, the signal discharges to nearly the ground potential, thereby stopping motor operation, at a rate dependent upon the capacitor 167-resistance 184 or 185 time constant, and the control signal decay to a null due to the electrode positioning. Since resistors 184 and 185 are 2 Kohm resistors, and resistor 165 is a 500K potentiometer, the deceleration mode time constant will, for significant resistance settings of resistor 165, be substantially shorter. This causes the motion to quickly stop once the error voltage has been nulled, thereby minimizing the possibility of a position overshoot. An exemplary waveform of the signal at node K is shown in FIG. 6, illustrating the acceleration mode during interval T1 node and deceleration mode during interval T2.
Having described the operation of the circuitry shown in block diagram form in FIG. 5, the overall operation of the circuitry disclosed in FIGS. 1-4 will now be generally described. The operator initiates operation by placing switch S1 (FIG. 3) in contact with contact 22, a "jog downward" position. With S1 continuously held in this position, the electrode is carried downward by operation of motor 420 until the electrode contacts the workpiece, causing micro-switch S2 to close, initiating an upward movement to the electrode to a predetermined distance away from the workpiece. Once the electrode has reached this predetermined distance, which may be adjusted by potentiometer 305 (nominally 1 Megohm potentiometer), the operator may release switch S1 and initiate the arc voltage firing. Once the arc voltage is in range, a delay timer is initiated to allow the arc to stabilize. Upon elapsement of the delay timer, an autorelay is tripped which closes switches 180 and 182, coupling the deadband comparator 120 motor servo circuit 150 into operation. The operator may always switch from automatic servo operation to manual operation by closing switch S3, de-energizing the autorelay and opening switches 180 and 182. Even when servo circuit 150 is in operation, its output signal may be overridden in the presence of a lockout signal from the welding power supply presented across terminals 324 and 326 (FIG. 3).
While the operation of the circuit will be apparent to those skilled in the art, placing switch S1 in the "jog down" mode couples node N to node J (FIG. 3). A manual control signal is provided through NAND gate 600, diode 601, NAND gate 602, amplifier 604, jog speed settiing resistor 606 (50 Kohm potentiometer), and diode 608 to amplifier 202 of motor drive circuit 200a. (If S1 is in the "jog upward" mode, node M is activated, and a control signal passes through NAND gates 622 and 624, diode 626, 20 Kohm resistor 614, is inverted by amplifier 604 (resistance 616 and 612 are nominally 18 Kohm and 100 Kohms respectively), and thence through potentiometer 606 and diode 610 to the "minus" input of amplifier 202.
As the electrode jogs downward, it will contact the workpiece, closing micro-switch S2. Capacitor 630, which will have been charged to the positive supply voltage (nominally 12 volts) through 20 Kohm resistor 307 and 1 megohm resistor 305, will be discharged to ground and held there so long as switch S2 is closed. Thus, a capacitor 630 couples the "plus" input of amplifier 632 to ground, while the "minus" input is coupled to a +6 volt source. With the "plus" input grounded, the amplifier 632 output immediately switches from +12 volts to -12 volts, tripping flip-flop arrangement 640 (comprising NAND gates 636 and 638). Flip-flop 650 inhibits downward motion of the electrode while in this preset mode. The low output from amplifier 632 also forces an upward movement of the electrode, through NAND gates 652 and 654. Thus, a positive polarity signal is provided by network 640 through diode 642, to NAND gate 602, resulting in a negative polarity signal being provided to amplifier 202, and immediately reversing the direction of motion direction from a downward to an upward direction.
As the electrode raises above the workpiece, microswitch S2 opens, and capacitor 630 commences to charge to the positive supply voltage level, its charging rate being determined by the sum of resistances 305 and 307 and the value of capacitor 630 (nominally 20 microfarads). Once the capacitor charges to +6 volts, the polarity of the output of amplifier 632 switches from negative to positive, turning off the upward movement of the electrode through gates 652, 654 and 624. The control signal to the motor drive circuit 200a will be extinguished, and the motor stopped.
Another feature of the disclosed circuit is shown in FIG. 1. In-range arc voltage detection circuit 700 receives the detected arc voltage from circuit 100. The circuit provides an output when the arc voltage is in range, i.e., approximately 5 volts to 50 volts. Resistors 708 and 710 are 5 Kohm and 0.5 Kohm resistors, respectively, resistor 712 a 7 Kohm resistor, resistor 714 and 11.4 Kohm resistor, and resistor 706 is a 10 Kohm resistor.
Amplifier 720, with 10 Kohm resistor 722 and 20 microfarad capacitor 724, and a +6 volt source coupled to the "minus" input, comprises an antichatter filter or timer to provide an approximately 150 millisecond delay, to accommodate any oscillators in the arc voltage which would otherwise take the arc voltage out of the 5-50 volt range.
Once the delay is timed out, transistor 726 is turned on, diode is forward biased, starting timer circuit 740, which is configured to provide up to ten-second delay (depending upon the setting of potentiometer 748) before timing out and providing a low signal at node A4. Capacitor 736 is a 100 microfarad capacitor, resistors 744 and 744 are 10 Kohm resistors, and the breakdown voltage of zener diode is six volts.
Once timer 740 times out, transistor 750 will be turned off, and transistor 752 turned on energizing autorelay K1, thereby closing switches 180 and 182. The circuit will be in the automatic control mode. Manual jogging of the electrode will be inhibited in this automatic mode, due to the input states at NAND gates 622 and 600.
Another feature of the present circuit is sudden change detector 800, which detects sudden large (increasing) changes in the arc voltage, such as occurs in a weld burn-through condition. Upon detection of a sudden large change, the electrode is jogged upwardly automatically to a retracted position, triggered by action of flip-flop 640.
The disclosed circuit also uses a signal from the welding power supply indicating a low current mode operation to disable automatic servo action. The low current mode typically occurs to allow the workpiece to cool down. The supply signal triggers photocoupler 980 (FIG. 1) causing the servo circuit output to be disabled to prevent an erroneous electrode movement caused by the low current condition. | An improved control circuit is disclosed for controlling the arc voltage of welding apparatus. The circuit includes an automatic servo control circuit operative to gradually start the electrode positioning motor in the presence of an error signal indicating that the arc voltage is not at the desired level, to accelerate the motion of the positioning motor until the error signal is nulled and then quickly decelerate the motor to minimize electrode overshoots. The improved circuit is operative to prevent electrode servo "hunting" and results in improved welding operation. Other features and improvements are disclosed. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ergonomically designed container and package system.
2. Description of the Related Art
Multiple use container and composite packaging systems have been utilized in order to facilitate the storage and transport of a variety of materials. Often the container is used as the primary means for containing the material such that the material is sealed within the container. These materials may include wet or dry goods and may come in a variety of dimensions. In some cases, the packaging system may further comprise an external box for housing the container. The box may be used to provide additional strength and/or protection and often provides a packaging that is more suitable for stacking and transport. The external box also provides a surface that is suitable for advertising and describing the product contained therein.
Both the container and the packaging system may be used for the purpose of storing a material from the point of manufacture until it is delivered to its subsequent end use. Furthermore, the container in a package combination results in a configuration that is easily stackable for storage and transport in multiple unit stacking configurations.
However, the conventional containers available suffer from the drawback that they are not susceptible to being both stackable as well easily handled by a user for both carrying and pouring. Additionally, when the size and weight of the container is increased, this drawback may become even more problematic. Furthermore, most composite packaging systems require that the container be withdrawn from the box in order to access the contents contained therein. This is especially problematic when the spout must be accessed in order to pour contents from the container. Thus, the container, during use, loses the benefits associated with the box portion of the packaging system, e.g., the ability to be conveniently stacked.
Therefore, there is a need for an improved container that provides for better ergonomic handling during both pouring and carrying. Additionally, there is a need for a packaging including a container in a box, wherein the container may remain in the box during use.
SUMMARY OF THE INVENTION
Accordingly, an aspect of the present invention is to provide a container having top, a bottom, sides extending from the top to the bottom having a front side and a back side, a spout for inserting and removing contents from the container, a first handle portion on the top and extending generally in a direction front to back, a second handle portion on the top and extending in a direction transverse to the first handle portion.
Furthermore, the container may have a manual grip on the bottom of the container for supporting the container from the bottom.
According another aspect of the present invention, the spout may be disposed on or near the front top side of the container and the second handle portion may be disposed toward the backside. The first handle portion and the second handle portion may be connected to form a “T”-shape.
According to another aspect of the present invention the second handle portion in the direction transverse to the first handle portion may be shaped so as to be grasped by a thumb. Preferably, the second handle portion may range from two to four inches and, most preferably, three inches.
According to another aspect of the present invention, the manual grip on the bottom is formed by an indentation on the bottom of the container. Alternatively, this grip may be formed by a protrusion or both a recess and a protrusion.
According to another aspect of the present invention, a packaging is provided, having a container in a box, the container including: a top, a bottom, sides extending from the top to the bottom and having a front side and a back side, a spout for inserting and removing contents from the container, a first handle portion on the top and extending generally in a direction front to back, a second handle portion on the top and extending in a direction transverse to the first handle portion, and a manual grip on the bottom of the container. The the box may have has a top cover, a bottom cover and side portions extending from the top cover to the bottom cover that include at a front side and a back side, one or more openings on the top cover that expose the spout for pouring the contents of the container and for accessing the second handle portion so that the second handle portion can be manually grasped while remaining inside in the box, and an opening in the bottom cover that expose the bottom grip.
According to another aspect of the invention, there is a method of using the foregoing container and packing.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and aspects of the present invention will become more apparent by describing non-limiting exemplary embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a perspective view of a container according to a non-limiting exemplary embodiment of the present invention.
FIG. 2 is a side view of the container of FIG. 1 .
FIG. 3A is a bottom view of the container of FIG. 1 .
FIG. 3B is a profile view of the container bottom of FIG. 3A .
FIG. 4 is a perspective view illustrating features of the second handle portion according to a non-limiting exemplary embodiment of the present invention.
FIG. 5 is a perspective view of a box according to a non-limiting exemplary embodiment of the present invention.
FIG. 6 is a bottom view of the bottom of a box illustrating a bottom opening according to a non-limiting embodiment of the present invention.
FIG. 7 is a view of the bottom of a box illustrating a bottom opening and a push-up portion according to another non-limiting exemplary embodiment of the present invention.
FIG. 8 is a perspective view of a packaging comprising a container and a box according to a non-limiting exemplary embodiment of the present invention.
FIGS. 9 and 10 are side views of a portion of the bottom of the packaging illustrating the pushup portion and recess portions of the bottom of the packaging.
FIG. 11 illustrates a person pouring contents from the packaging of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The container and packing system according to non-limiting exemplary embodiments of the present invention will now be described more fully with reference to the accompanying drawings.
Referring to the exemplary embodiment shown in FIG. 1 , a container 1 is shown having a top 2 and a bottom 3 connected by sides 4 that extend from the top 2 to the bottom 3 . The container 1 includes a spout 7 that permits filling or dumping of the contents. Also located on the top 2 is a first handle portion 8 that extends from the spout 7 located near the front side 5 of the container 1 and a second handle portion 9 extending transverse to the first handle portion. In this embodiment, the second handle portion 9 is also shown connected to the first handle portion 8 on an end opposite the spout 7 . This embodiment also includes, as shown in FIG. 3 , a grip 10 on the bottom 3 of the container 1 .
The container may be made of plastic, which can be blow molded into various configurations, however, any material suitable for containing a particular kind of content may be used.
To facilitate handling in a variety of positions, the first handle portion 8 , the second handle portion 9 and the bottom grip 10 , are included. For use in a carrying position, the first handle portion 8 is formed in an elongated fashion, which extends from the front side 5 to the back side 6 and provides for a space between the first handle portion 8 and the top 2 of the container for inserting a hand. Thus, a user may slip his fingers through the first handle portion 8 to lift the container 1 . Additionally, when used in a pouring position, such as when tilted forward, the second handle portion 9 is provided and extends in a direction transverse to the first handle portion. This facilitates handling when the container is tilted off vertical, such as when emptying the contents of the container 1 . This second handle portion 9 may be utilized in tandem with the bottom grip 10 so that the container 1 may be gripped using two hands when tipped to pour the contents from the container 1 . These handle and grip configurations provide for stable and secure handling, especially when the container is heavy.
In the exemplary embodiment shown in FIG. 4 , the second handle portion 9 provides a forward facing surface 11 that extends from the top of the container 1 and provides a gripping surface to facilitate tipping the container 1 forward to pour out its contents. A portion of the first handle portion 8 , where it connects with the second handle portion 9 , may be necked down to form a narrowed neck portion 12 . This tapered or necked down portion improves finger reception when gripping the second handle portion 9 and its forward facing surface 11 . The forward facing surface 11 may also be formed with a curved profile as shown in FIG. 4 to further improve gripping.
The second handle portion 9 may have a width that is convenient for gripping around its side by the thumb and over the top by the remaining fingers. For example, the width of the second handle portion W 2 preferably ranges from one-fourth to three-quarters of the width of the container W c . More preferably, the width of the second handle portion W 2 ranges from one-third to one-half the width of the container W c . In inches, the width of the second handle portion W 2 may range from 2-4 inches and, preferably, about three inches.
The bottom grip 10 , similar to the second handle portion 11 , may be formed for gripping the container 11 when it is tilted for pouring. A recess 13 in the bottom, as shown in FIGS. 3A , 3 B and 9 , may be used to form this bottom grip. Alternatively, as best shown in FIG. 3B , the bottom grip 10 may formed by a protrusion on the surface or by combining both a recess and a protrusion.
Containers having these features may be advantageous when handling specific volumes of heavy fluids or materials.
In another preferred embodiment of the invention, the container 1 is enclosed within a box 14 to create a packaging system 26 as shown in FIG. 8 . The box 14 , as illustrated in FIGS. 5 , 6 and 7 , for example, includes a top cover 19 , a bottom cover 22 and a plurality of sides 23 . In the embodiment of FIG. 5 , the sides are shown joined to each other by vertical chamfered corners 24 . The container is further fitted with openings to permit access to the spout 7 and the handling portions. In particular, a top opening 15 permits access to the spout 7 , the first handle portion 8 and the second handle portion 9 , while the bottom grip 10 is accessible via a bottom opening 17 as illustrated, for example, in FIG. 6 . However, access to these portions may be provided by more than one opening if desired.
Additionally, to improve the ergonomics of the packaging system, the box 14 may include a notch section 16 in the front 21 of the box 14 for exposing a portion of the neck 25 of the spout 7 . This notch section 16 improves access to the spout 7 and also prevents the contents, when being poured from the container 1 , from entering the inside of the box 14 . The top opening 15 in this embodiment may also extend to the end of the first handle portion 8 to expose the narrowed neck portion 12 . Thus, the second handle portion 9 , while positioned under the top cover 19 , is accessible for handling when pouring the contents from the container 11 .
Referring to FIGS. 9 and 10 , while the bottom cover can be fitted with a bottom opening 17 to provide access to the bottom grip 10 , a push-up portion 18 may also be included to provide an ergonomically improved grip. As shown in FIG. 10 , the bottom opening 17 may comprise both an opening and a perforated portion, which defines the push-up portion 18 . Alternatively, the push-up portion may merely constitute a flap that covers a portion of bottom opening 17 . In operation, when the push-up portion 18 is pushed into recess 13 a slightly larger surface is formed for grasping and the box edge become smooth due to the fold 27 .
This packaging system provides unique features that permit use of the above-described container 1 without removal of the container from the box 14 . The box 14 is configured to permit access to the spout 7 for removing a lid or the like, and permits access to all the potential grasping points so that the packaging system 26 may be carried or used to pour contents from the container 1 . Furthermore, the packaging system 26 provides a strong, stackable package for continual use until all the contents of the container 1 are consumed.
Another feature of this embodiment provides that both the container 11 and the box are fitted with chamfered corners 24 , 28 to improve the strength and stackability of the packaging system 26 . With regard to strength improvements, the chamfered corners 24 , 28 make the package less susceptible to structural damage from blows directed at the corners of the box 14 . Furthermore, the chamfered corners 24 facilitate the adjacent stacking of multiple packaging systems on either a pallet or a warehouse space. Moreover, the improved structural characteristics permit more weight to be stacked vertically above each packaging system 26 . The chamfered corners 24 , 28 also provide a unique surface for displaying advertisements and the like.
Illustrated in FIG. 11 is a method for using the packaging system 26 . In order to empty contents from the container 1 , a user may grab the second handle portion 9 with one hand. Then the user may grab the bottom grip 10 with the other hand. Now in order to tilt the container 1 to empty the contents, the user pushes upwards on the bottom grip 10 , which causes a titling of the container 1 and a subsequent pouring of the contents therefrom.
While this invention has been particularly shown and described with reference to exemplary embodiments thereof, the above description should be considered in as illustrations of the exemplary embodiments only and are not for purposes of limitation. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention. | A packing that includes a bottle and/or a bottle and box combination wherein the container may have a first handle portion, a second handle portion, and a bottom grip portion. The first handle portion can extend in a front to back direction and the second handle portion can extend in a transverse direction to the first handle portion. The bottom grip may include a protrusion and recess on the bottom of the container. The box can be configured to have openings to provide access to the first and second handle portions such that the container need not be removed from the box to utilize the contents contained therein. The box may also include a bottom opening and a push-up portion to provide access to the bottom grip portion. | 1 |
This application is filed within one year of, and claims priority to Provisional Application Ser. No. 61/734,590, filed Dec. 7, 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to Wireless Signal Collection Systems and, more specifically, to a Method and System For Optimizing The Efficiency of SIGINT Collection Systems on Mobile Platforms with Limited Bandwidth Connections.
2. Description of Related Art
Over recent years, Government and Military mobile (air or ground-based) signals intelligence (SIGINT) platforms have increasingly had to deal with more and more challenges. These challenges include denser signal environments, wider frequency range targets, frequency-hopping targets, and even communications signals appearing on traditional microwave frequency bands (frequency ranges formerly only used only for radar type signals). These increased challenges have resulted in increasing the raw output of existing SIGINT collection systems to the point where it is now infeasible to send back the resulting large amounts of data in real time for control/command center processing.
The air-ground, or ground-air-ground links used to link the mobile platforms to the control/command centers have limited wireless communications bandwidths. Furthermore, due to the cost and complexity, it is impractical to increase these bandwidths. Thus, in order to keep up with changing RF environments, vast increases in the efficiency of the SIGINT collection techniques are needed
More advanced approaches must be researched and adopted to increase the efficiency of SIGINT collection. Clear innovations and next generation advancements in DSP, wideband digital scanning, high speed processing and datastream optimization algorithms are required to handle these modern challenges.
What is needed is a method and system to automatically adjust to varying bandwidth downlinks. The data throughput restrictions will be dealt with by adaptively prioritizing (and then throttling) the collected SIGINT datastreams to match the maximum allowable bandwidth at any moment, in real-time. This will completely maximize the mobile platform's downlink capability, no matter what the available bandwidth is. It will create SIGINT platform efficiencies heretofore not experienced and would extend the lifespan of the existing fleet of signals intelligence gathering aircraft/vehicles/ships. What is needed are unique approaches, unique techniques and algorithms for SIGINT platforms that can allow them to: automatically scan the RF spectrum with extreme speed, ignore whitespace regions, automatically focus and filter signals, and to have advanced signal-of-interest (SOI) prioritization algorithms based on real-time feedback from the datalink subsystem. Such a digital signal processing system would thus create far richer collected datasets.
SUMMARY OF THE INVENTION
In light of the aforementioned problems associated with the prior devices, methods and systems, it is an object of the present invention to provide a Method and System For Optimizing The Efficiency of SIGINT Collection Systems on Mobile Platforms with Limited Bandwidth Connections. In order to optimize the data uplink efficacy of the conventional mobile signal intelligence collection, the system and method should be implementable in legacy signal collection systems. The resultant system should first reduce potential upload bandwidth by eliminating whitespace in collected signals. Next, the system should ignore collectable signals based on signals frequency or angle of arrival so as to identify energy of interest. Next, the system should score and attribute a priority to each energy of interest, now known as signals of interest. The system should then increase collection bandwidth on all signals of interest based on the score, priority and availability of resources. Finally, in real time, and based on SOI score and priority and the availability of downlink resources, the collected signal data should be downlinked to the SIGINTcontrol center. The system must automatically and adaptively reduce the demands on the mobile links. The invention described in this patent application answers all these needs while at the same time having minimal operations & maintenance costs, and being scalable (i.e. can be mounted on a variety of mobile platforms such as all ground vehicles, ships, large airframes, aircraft pods, and even UAV's). The system and method described herein will allow unprecedented airborne/shipborne/& vehicular SIGINT collection that will increase performance and ultimately reduce costs for the U.S. Government.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:
FIG. 1 is a block diagram of a conventional mobile SIGINT collection system;
FIG. 2 is a block diagram of the system of FIG. 1 having the method and system of the present invention implemented therein;
FIG. 3 is a flowchart describing the steps of the preferred optimized collection and reporting system of the present invention; and
FIG. 4 is a flowchart summarizing the steps of the system of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Method and System For Optimizing The Efficiency of SIGINT Collection Systems on Mobile Platforms with Limited Bandwidth Connections.
FIG. 1 shows the prior art system. Signals are received by the standard SIGINT system tuner(s) 2 . The analog IF output is then sent to a standard digitizer (i.e. A/D converter) 3 . Typically, this digitizer is followed by a DSP chipset or FPGA subsystem. The subsystem digitizes and then processes the data so it can be sent to the Datalink subsystem 4 . The data that is sent to the Datalink subsystem is non-optimized, large blocks of digital SIGINT data. But the datalink subsystems always have some bandwidth limitation whereby only certain amounts of data can be transmitted reliable. What happens in the case of downlink overload is that SIGINT data blocks must be dumped 102 so that gaps are created in the data transmitted downstream. Sometimes this dumped data is stored locally, but not always. In any case, the SIGINT collection operation is non-optimized.
FIG. 2 outlines the Invention as described herein. As can be seen, the Invention 100 is software/firmware based. It places a unique set of algorithms into the standardized Digitizer Hardware 3 , such that they run in serial with the conventional digitizer processes. A telemetry output 106 of the Datalink subsystem is taken, which tells in real-time what the present allowable BW of the downlink is. This number is then feed back into the algorithms of the Invention 100 , thereby helping to optimize the entire process.
FIG. 3 outlines the signal block diagram of the Invention. The algorithms for high efficiency collection and optimization are shown in detail.
FIG. 4 describes the optimization method of the present invention in terms of operational steps that are non-specific as to the specific hardware conducting the steps.
Operation
Current SIGINT platforms perform brute force collection processes. The total amount of data that can potentially be collected cannot possibly be transmitted by the downlink due to limited realistic bandwidths. The following sections provide a summary of the technical approaches & techniques of this Invention intended to create a reliable real time Signal of Interest (SOI) collection system.
1) Perform High Efficiency Scanning, Detection, and Identification of SOI's: The algorithms to Scan, Detect, and Identify SOI's consist of a number of DSP routines implemented in HDL code. In order to process the incoming frequency spectrum the tuners analog IF is first digitized by an A/D converter. The resulting data stream is then timestamped and split up in small frequency segments (bins) with help of an FFT. Every bin will only at most cover a few KHz in order to maintain good frequency resolution and high sensitivity. The bin data is then processed first by an algorithm that automatically calculates and stores the noise floor for every bin. This noise floor then provides the basic reference point (i.e. threshold) for the triggering of the next algorithm that detects any and all peaks in the spectrum. At the same time, the bandwidth of any new detected energy is calculated from the peak information, and is reported to an algorithm that allocates digital drop converters (DDC's). A label is then created containing all the detected characteristics of the new energy. Together with the additional information (such as a priority frequency list), a score is then calculated and used as an item to compare priority for the further recordings and downlink bandwidth allocations.
2) Perform High Efficiency Filtering of SOI's: For every SIGINT system there is a pool of Digital Down Converters (DDC's). Every DDC consists of a Numeric Controlled Oscillator to tune the DDC to the desired IF frequency, and in addition contains down samplers and filters that can be set to all bandwidths of interest. All the DDC functions are implemented in HDL code. When in use, every DDC has a priority score allocated with its task. In the case where all DDC's are already in use, this priority score is compared with any newly detected Energy-of-Interest (EOI).
3) Perform High Efficiency Techniques to Minimize Collected I/Q of SOI's: In order to not waste downlink and recording bandwidth, it is important to accurately allocate the required bandwidth for a new EOI. This is accomplished by observing the actual occupied bandwidth and then adding an additional amount to that. When the decision is made regarding the correct bandwidth, the input to the DDC is switched to a lookback memory that allows capture of the new SOI from the first moment the new energy was detected. The lookback memory is normally about 2 or more seconds long so that there is plenty of time to for the system to observe the signals before the decisions need to be made about what DDC bandwidth should be allocated. This lookback observation is conducted without losing any of the information from the SOI. The DDC bandwidth is then set and the I/Q stream from the DDC is recorded on a digital recorder. This recorder is normally constructed with a number of solid state drives or conventional disk drives of sufficient size to record a complete mission.
4) Perform High Efficiency Techniques to Prioritize and Throttle Downlink Streams: Some SOI's must be immediately sent down to operators, generally because they are emanating from suspected enemy forces. Therefore, in addition to being recorded, the I/Q stream or the demodulated audio together with meta data (such as center frequency and occupied DDC channel bandwidth) can be transmitted over a downlink. In order to manage the bandwidth of the downlink an additional set of priorities such as frequencies of special interest are calculated and compared with the already ongoing data channels on the downlink.
The priorities of the actual SOI's on a downlink channel can be changed by an operator at any time. If an operator decides that the content of a channel is not of real interest, then he can manually free up the downlink channel space. In addition to the selected DDC's I/Q data, the downlink also contains all the frequency bins that are scanned during the search for new energy. In order to conserve downlink bandwidth, all white space is first removed, and the update rate is reduced to a few times per second. The update rate can be set by the operators. Channels on the downlink or SOI's currently recorded are marked in different colors. Also, the local operator display unit can be made to display a waterfall depicting any part of the spectrum. This gives a picture of the entire frequency spectrum.
DETAILED DESCRIPTION
The system and method [ 100 ] will yield high efficiency scanning, detection, and optimization of the data downlinks for airborne SIGINT applications. The precise methods included in the Invention [ 100 ] are split into seven (7) distinct sub-processes:
Sub-process #1—Whitespace Scanning (Noise Riding Threshold) Algorithm
Sub-process #2—Automatic Energy-of-Interest (EOI) Detection & Optimization Algorithm
Sub-process #3—EOI Prioritization & Scoring Algorithm
Sub-process #4—Automatic DDC Allocation & Storage Optimization Algorithm
Sub-process #5—Automatic Signal-of-Interest (SOI) Algorithm
Sub-process #6—SOI Prioritization & Scoring Algorithm
Sub-process #7—Downlink Data Throughput Optimization Algorithm
FIG. 3 shows a detailed block diagram showing where the sub-processes will be placed on any generic SIGINT collection platform. The algorithms of the sub-processes will allow the conventional platform to drastically increase SIGINT collection efficiency, and optimize its' output to a data downlink so that it does not exceed the bandwidth requirements of the air-ground, ground-air, or ground-air-ground links.
Sub-process #1—Whitespace Scanning (Noise Riding Threshold) Sub-process 10 : This algorithm begins by scanning a wide instantaneous bandwidth region of RF spectrum output from a tuner 12 (or tuners). Alternatively, the tuners can be Direction Finding receiver(s). It then digitizes and performs Fast Fourier Transformations of that region into frequency bins 14 . The Algorithm then continuously performs noise riding calculations on every single frequency bin 16 . In this way, a noise threshold can be automatically or manually set so that, for example, only signals that appear at several dB above the noise floor trigger the collection. This greatly enhances the system's ability to sort out the unwanted signals and focus all collection on areas of the RF spectrum where there is traffic. Right away this algorithm will eliminate all white space and help to enhance the collection efficiency of the system.
Sub-process #2—Automatic Energy-of-Interest (EOI) Detection & Optimization Sub-process 20 : This algorithm inspects every bin in the received IBW and compares the level with the current noise floor, such a subprocess is called the Peak Detection Calculation 22 . After that is done, the angle of arrival (AoA) is calculated for every frequency bin 24 . Then a decision point is made, if the peak is part of a list of pre-determined frequencies to ignore, or pre-determined AoA's to ignore 26 . If either of those criterions are met, the signal is discarded from further processing. If the signal level meets the trigger criteria it will be noted as an Energy-of-Interest (EOI) 28 . The Line of Bearing (LoB) of the new energy is also noted. The center frequency is then calculated for the EOI and the BW measurement made 29 .
At the same time a time the data comes through the Sub-process #2, an averaged picture of the entire spectrum with the current bin spacing is generated and stored into a FIFO 42 which is also used in Sub-process #4. Because of the large sampling reduction made on the spectrum this will require very little storage space. Any part or the entire spectrum picture can also be sent down to the operators at any time.
Sub-process #3—EOI Prioritization & Scoring Sub-process 30 : This algorithm assigns a score to all new EOI 32 . This score is formed by mission tables containing frequency ranges of high interest, low interest, or no interest. Occupied bandwidth is calculated and the LoB of the EOI can also be part of the priority scoring.
Sub-process #4—Automatic DDC Allocation & Storage Optimization Sub-process 40 : This algorithm maintains control over allocation of DDC resources. If free DDC channels are available it will assign and set a DDC at the center frequency of the new energy and allocate a bandwidth covering twice the measured bandwidth of the EOI. Collection of the I/Q stream of the Signal-of-Interest (SOI) 44 then commences. If no DDC channels are available it will compare the priority score of the EOI with the score of all the already allocated DDC channels. If a lower scored channel is found it will be replaced by the new EOI. A log is maintained for all new EOI events that can later be analyzed for further enhancements of the priority criteria's.
Sub-process #5—Automatic Signal-of-Interest (SOI) Collection Sub-process 50 : The SOI data is then assembled with metadata 54 . The I/Q from the DDC channels together with all metadata like Frequency, BW, LoB and time stamps are forwarded to a recording pool 52 that contains a bank of solid state or convention disk media without requiring any operator intervention. The data to the DDC is fetched from a FIFO look back memory 42 so no part of the new signals information is missed because of decision processing time.
Sub-process #6—SOI Prioritization & Scoring Sub-process 60 : SOI's occurring at frequency ranges of high interest or with other attributes of interest are considered for instant down streaming to the operators. Those SOI's are allocated an additional score that are used for the downlink prioritization 62 .
Sub-process #7—Downlink Data Throughput Optimization Sub-process 70 : This algorithm maintains control over allocation of downlink resources. If sufficient free downlink bandwidth is available it will assign downlink space for any SOI's DDC channel. If sufficient downlink bandwidth is not available it will compare the scoring 72 on the currently allocated downlink channels and decide if any or how many channels have lower priority. If the system is set to fully automatic it will replace the lower priority channels with higher priority. An over view picture of all the allocated DDC′ with all metadata is sent down to the operators every time the picture changes. From that picture any operator can intervene and change the downlink score priorities in order to be able to check any DDC channels that not currently have enough priority to be allocated downlink space.
The final optimized data is then transmitter through the Datalink Subsystem 80 to the ground processing center or control center. Real time, fluctuating air-to-ground, or ground-to-air status messages of the downlink BW status 82 are the feedback loop to Sub-process #7 to provide closed loop control for the invention [ 100 ].
DIAGRAM REFERENCE NUMERALS
10 Whitespace Scanning (Noise Riding Threshold) subsystem
12 Scan and Measure an Instantaneous Bandwidth Region of RF Spectrum from Tuner
14 Digitize/FFT the Region into Frequency Bins
16 Noise Riding Calculations for every FFT Bin
20 Automatic Energy-of-Interest (EOI) Detection & Optimization subsystem
22 Peak Detection Calculations for every FFT Bin
24 Calculate Angle of Arrival (AoA) on every Frequency Bin
26 Peak in the Ignore List of Freq or in the Ignore List of AoA?
28 Peak Determined to be New Energy-of-Interest (EOI)
29 Calculate Center Frequency and Bandwidth (BW) of EOI
30 EOI Prioritization & Scoring subsystem
32 Calculate EOI's Digital Down Converter (DDC) Priority # By Generating a Scoring Table (User Priority Frequency List, BW, AoA, etc.)
34 DDC with Lower Priority Available To Be Tasked?
40 Automatic DDC Allocation & Storage Optimization subsystem
42 FIFO Lookback
44 Allocate DDC and Begin Collecting I/Q Stream of SOI
50 Automatic Signal-of-Interest (SOI) Algorithm
52 Digital Recorder
54 Assemble the SOI Metadata for the file Header and send the I/Q data to the recorder
60 Sub-process #6—SOI Prioritization & Scoring Sub-process
62 Calculate SOI's Downlink Priority Number Score based on factors like: (Priority Frequency List and Modulation output from Recognizer)
70 Sub-process #7—Downlink Data Throughput Optimization Sub-process
72 With Score and BW, Calculate Which SOI I/Q Streams Will be Sent Through The Downlink Based Upon A Real-Time Optimization Technique
80 Air-to-Ground Datalink Subsystem With Tracking, Telemetry, & Control
82 Real-Time, Fluctuating Air-to-Ground Data BW of Downlink
FIG. 4 is presented in order to convey understanding of the method of the invention in terms of sequential steps not restricted to a particular hardware arrangement. The preferred method for optimizing the operation of Mobile SIGINT collection systems 200 commences with the system first reducing the potential data upload (i.e. between the mobile collection station and the central control station) volume by eliminating “whitespace” 202 . The potential data upload volume will then be reduced by eliminating the collection of signals having frequencies that lie within blocked (or not-of-interest) ranges 204 . Potential upload volume is also reduced by eliminating the collection of signals having angles of arrival within particular range(s) (e.g. to avoid collecting signals from friendly forces) 206 .
The remaining signal data is considered to be Energy of Interest, and is prioritized based on bandwidth, pre-existing or real-time user-assigned priority, among other factors 208 . If applicable, available DDC's may be reallocated to the EOI based on the assigned priority 210 . The ongoing collection of these “Signals of Interest” is held in buffer memory 212 , while simultaneously scoring and prioritizing these Signals of Interest 214 . The buffered SOI data is then downlinked to the control center from the mobile collection station (e.g. aircraft) based on the real-time priority of the SOI's 216 .
Each SOI package that is downlinked includes a time-stamped sequence number that is a unique identifier for the package, as well as documenting the time of transmission. Once each SOI package is received and processed, command center will uplink the sequence number to the mobile collection station 218 . The air-to-ground datalink subsystem [ 80 ] uses the elapsed time between the transmission of the SOI package and the receipt of the sequence number to determine what the available data bandwidth (throughput) of the downlink is, and responsively adjusts the rate of data downlink 220 . This throttling back of the downlink rate responsive to the real-time bandwidth capacity of the downlink, while the command center operator is processing the received SOI data is of extreme value when coupled with the prior-described optimization steps.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A Method and System For Optimizing The Efficiency of SIGINT Collection Systems on Mobile Platforms with Limited Bandwidth Connections that is implementable in legacy signal collection systems. The resultant system first reduces potential upload bandwidth by eliminating whitespace in collected signals. Next, the system ignores collectable signals based on signals frequency or angle of arrival so as to identify energy of interest. Next, the system score and attributes a priority to each energy of interest, now known as signals of interest. The system then increases collection bandwidth on all signals of interest based on the score, priority and availability of resources. Finally, in real time, and based on SOI score and priority and the availability of downlink resources, the collected signal data is downlinked to the SIGINTcontrol center. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. provisional application Ser. No. 60/899,629, filed Feb. 6, 2007, the entire contents of which is incorporated herein in its entirety by reference.
FIELD
The present invention relates generally to temperature and pressure transducers and more particularly to transducers that shift a frequency of a reflected signal based on a response to temperature or pressure.
BACKGROUND
In operations, piping can extend hundreds or thousands of feet below ground to a well through a harsh downhole environment. Devices have been used for monitoring downhole conditions of a drilled well so that an efficient operation can be maintained. These downhole conditions include temperature and pressure, among others. A pressure sensor implemented in this environment should be configured operate within the potentially difficult environmental conditions. Likewise, a temperature sensor implemented in this environment should have a response that is relatively insensitive to changes in pressure.
SUMMARY
A device in accordance with an embodiment includes a pressure sensor having a first conductor plate that includes a first layer formed on a first substrate. The first layer has a high coefficient of thermal expansion relative to the first substrate. The pressure sensor also has a second conductor plate that includes a second layer formed on a second substrate. The second layer has a high coefficient of thermal expansion relative to the second substrate. A hermetic seal is located at the edges of the first and second conductor plates. The first and second conductor plates are fixed relative to one another, and a gas is retained in an adjustable gap between the first and second conductor plates.
A device in accordance with an embodiment includes a temperature sensor having a first conductor plate that includes a first layer formed on a first substrate. The first layer has a first coefficient of thermal expansion relative to the first substrate. The temperature also includes a second conductor plate having a second layer formed on a second substrate. The second layer has a second coefficient of thermal expansion relative to the second substrate. An adjustable gap is located between the first conductor plate and the second conductor plate, and a vent is formed in at least one of the first conductor plate and the second conductor plate.
A system in accordance with another embodiment includes a an enclosure having a signal generator for generating an electromagnetic energy signal, an oscillating component for generating a ringing signal based on the electromagnetic energy, a component for adjusting a frequency of a ringing signal in response to a change in pressure applied thereto, and a processor for correlating the adjusted frequency to a pressure at the enclosure.
A system in accordance with another embodiment of the invention includes an enclosure having a signal generator for generating an electromagnetic energy of signal, an oscillating component for generating a ringing signal based on the electromagnetic energy, an element for adjusting a frequency of an electromagnetic signal based on a temperature in the enclosure, and a processor for correlating the adjusted frequency to the observed temperature of the enclosure.
A method in accordance with an embodiment of the invention includes using a system having a capacitor with a first plate and a second plate, retaining a gas in a gap between the first and second plates, generating a signal having a predetermined frequency, shifting the frequency of the generated signal based on a warping of at least one of the first plate and the second plate due to a pressure of the gas retained between the first and second plates, and correlating the shift in frequency to a pressure value.
A method in accordance with an embodiment of the invention includes using a system having a capacitor with a first plate having a first coefficient of thermal expansion and a second plate having a second coefficient of thermal expansion and a vent provided in at least one of the first and second plates. The method includes generating a signal having a characteristic frequency, shifting the characteristic frequency of the signal based on a bending of at least one of the first plate and the second plate due to temperature, wherein the bending adjusts a gap between the first plate and the second plate, and correlating the shift in frequency to a temperature value.
A method in accordance with another embodiment includes bonding a first layer having a high expansion coefficient to a second layer having a low expansion coefficient to form a first plate, forming a first dielectric layer on the first layer of the first plate, bonding a third layer having a high expansion coefficient to a fourth layer having a low expansion coefficient to form a second plate, forming a second dielectric layer on the third layer of the second plate, mounting the first plate and the second plate such that the first and second dielectric layers are adjacent, and sealing edges of the mounted plates so that a gas is retained between the first and second plates.
A method in accordance with another embodiment includes bonding a first layer having a high expansion coefficient to a second layer having a low expansion coefficient to form a first plate, forming a first dielectric layer on the first layer of the first plate, bonding a third layer having a high expansion coefficient to a fourth layer having a low expansion coefficient to form a second plate, forming a second dielectric layer on the third layer of the second plate, forming a vent in at least one of the first plate and the second plate, mounting the first plate and the second plate such that the first and second dielectric layers are adjacent and a gap is established between the plates, and bonding edges of the first plate and second plate together.
In accordance with another embodiment of the invention, a machine-readable medium includes machine-executable instructions for performing the methods or operating the systems described herein.
DESCRIPTION OF THE DRAWINGS
Embodiments will be described in greater detail in reference to the drawings, wherein:
FIG. 1 illustrates a pressure sensor in accordance with an embodiment;
FIG. 2 illustrates a temperature sensor in accordance with an embodiment;
FIG. 3 illustrates a second temperature sensor in accordance with an embodiment;
FIGS. 4A-4E illustrates a method of manufacturing a pressure sensor in accordance with an embodiment;
FIGS. 5A-5E illustrates a method of manufacturing a temperature sensor in accordance with an embodiment;
FIG. 6 illustrates an overview of a system for measuring pressure in an enclosure in accordance with an embodiment;
FIG. 7 is an overview of a telemetry system for measuring temperatures in an enclosure in accordance with an embodiment; and
FIG. 8 is a flowchart of a method of measuring temperature or pressure in accordance with an embodiment.
DETAILED DESCRIPTION
FIG. 1 illustrates a pressure sensor 100 in accordance with an embodiment. The pressure sensor 100 includes a first conductor plate 102 and a second conductor plate 104 .
The first conductor plate 102 includes a substrate 106 and a metal layer 108 formed on the substrate 106 . The metal layer 108 is formed from a metal that has a coefficient of thermal expansion (CTE 2 ) that is greater than the coefficient of thermal expansion (CTE 1 ) of the substrate 106 . A dielectric layer 110 is formed on the metal layer 108 .
The second conductor plate 104 includes a substrate 112 and a metal layer 114 formed on the substrate 112 . The metal layer 114 is formed from a metal that has a coefficient of thermal expansion (CTE 4 ) that is greater than the coefficient of thermal expansion (CTE 3 ) of the substrate 112 . A dielectric layer 116 is formed on the metal layer 114 .
The first conductor plate 102 is mounted on the second conductor plate 104 such that the dielectric layer 110 of the first conductor plate 102 is adjacent to the dielectric layer 116 of the second conductor plate 104 . A hermetic seal 118 is formed at the edges of the first conductor plate 102 and the second conductor plate 104 such that the first and second conductor plates 102 and 104 are fixed relative to one another. The first conductor plate 102 and the second conductor plate 104 are fixed relative to one another such that a gap (G) between approximately one to twenty thousandths of an inch (0.001″-0.020″) is established between the plates. A gas is retained in the gap between the conductor plates 102 and 104 . Conductive (e.g., metallic) leads 120 and 122 are connected to the first conductor plate 102 and the second conductor plate 104 , respectively. The leads 120 and 122 enable the pressure sensor 100 to connect to external circuitry.
The first metal layer 108 of the first conductor plate 102 has a coefficient of thermal expansion (CTE 2 ) that is greater for the coefficient of thermal expansion (CTE 4 ) of the second metal layer 114 of the second conductor plate 104 . Moreover, to respond to pressure changes of the surrounding environment, the gas retained between the conductor plates 102 and 104 can be an inert gas such as nitrogen or argon. It should be readily apparent that any gas may be retained in the gap based on the desired response. The gas can be selected based, for example, on its propensity to provide a reproducible and predictable response to pressure changes of the surrounding environment.
The substrates 106 and 112 of the first conductor plate 102 and the second conductor plate 104 , respectively, may be formed of an insulating material having a coefficient of thermal expansion that is substantially equal to zero (0). The insulating material of which the substrates 106 and 112 is formed should be resilient and capable of insulating and providing structural integrity to the pressure sensor 100 for use in harsh environments. A suitable material for forming as substrates 106 and 112 is carbon fiber fabric, however, it should be readily apparent that the choice of materials is not limited to this selection.
The metal layers 108 and 114 of the conductor plates 102 and 104 , respectively, are formed from a material having a high coefficient of thermal expansion relative to the material of the respective substrates 106 and 112 . Materials known to provide good performance in use as the metal layers 108 and 114 include copper and stainless steel, for example, however, the metal layers 108 and 114 are not limited solely to these materials and may be formed of any metal having a coefficient of thermal expansion that provides the desired response. For low coefficient of thermal expansion materials, metals such as iron-nickel alloys may be suitable. For example 36FeNi (sold under the trade name Invar) or FeNi42 may be suited to low coefficient of thermal expansion applications. Likewise a ceramic material such as Zerodur may be useful in this regard. Where it is necessary to have an insulative property, the metallic alloys may be coated or covered in an insulating material.
During operation, the pressure sensor 100 responds to external pressure by adjusting the size of the gap between the conductive plate 102 and 104 based on the bending (e.g., degree of warpage) of at least one of the respective conductor plates. The gas retained in the gap acts as a spring to move the conductive plates 102 and 104 further apart at lower external pressures and compresses the conductive plates 102 and 104 closer together at higher external pressures. When the metal layers 108 and 114 are formed of a metal such as copper, for example, that has a high coefficient of thermal expansion, the metal layers 108 and 114 also experience bending (e.g., warpage) due to changes in temperature. This bending can be a exhibited by an inward or outward bowing of the respective metal based on temperature. The substrates 106 and 112 , when formed from carbon fiber material, for example, have a lower coefficient of thermal expansion and are thus more stable with respect to changes in temperature than the copper of metal layers 108 and 114 . In this case, the substrates 106 and 112 can counteract the temperature related warpage of the metal layers 108 and 114 , respectively, and reduce the effects of external temperature changes on pressure monitoring. As will be appreciated, the same effect may be achieved by providing both a substrate and a conductor layer having low coefficient of thermal expansion. By selection of relative thicknesses of each layer in addition to proper material selection, the device can be made to be relatively more sensitive to pressure than to temperature.
FIG. 2 illustrates a temperature sensor 200 of an embodiment. The temperature sensor 200 includes a first conductor plate 202 and a second conductor plate 204 .
The first conductor plate 202 includes a substrate 206 and a metal layer 208 formed on the substrate 206 . The metal layer 208 has a substantially higher coefficient of thermal expansion (CTE 2 ) than the coefficient of thermal expansion of the substrate 206 (CTE 1 ). A dielectric layer 210 is formed on the metal layer 208 .
The second conductor layer 204 includes a substrate 212 and a metal layer 214 formed on the substrate 212 . The metal layer 214 has a substantially higher coefficient of thermal expansion (CTE 4 ) than the coefficient of thermal expansion of the substrate 212 (CTE 3 ). A dielectric layer 216 is formed on the metal layer 214 .
A vent 218 is formed through the first conductor plate 202 such that the vent 218 extends from an outer surface of the substrate 206 , through the metal layer 208 , to an outer surface of the dielectric layer 210 . The vent 218 provides an escape path for any gas that is retained between the conductor plates 202 and 204 . By providing an escape path for the gas, the vent 218 ensures that external pressure has relatively little influence on the temperature response of the sensor 200 .
The first conductor plate 202 and the second conductor plate 204 are mounted such that the dielectric layers 210 and 216 are adjacent. Furthermore, the conductor plates 202 and 204 are mounted such that a gap (G) between one and twenty thousandths of an inch (0.001″ to 0.020″ or lesser or greater as desired) is established therebetween. Metal leads 220 and 222 are attached to the first conductor plate 202 and the second conductor plate 204 , respectively. These metal leads enable the temperature sensor 200 to be connected to external circuitry.
The substrates 206 and 212 , the metal layers 208 and 214 , and the dielectric layers 210 and 216 may be formed from the same materials as described above with respect to the corresponding components of the pressure sensor 100 .
During operation, as the temperature of the surrounding environment increases, the metal layers 208 and 214 bend (e.g., warp) inwardly to reduce the size of the gap (G). The degree of warpage of metal layers 208 and 214 can be directly related to the coefficient of thermal expansion associated with each respective layer. Additionally, the coefficient of thermal expansion and the thickness of the substrates 206 and 212 can also determine the degree of warpage of the metal layers 208 and 214 .
FIG. 3 illustrates a temperature sensor 300 of an embodiment. Temperature sensor 300 includes a conductor plate 302 having a substrate 306 , a metal layer 310 , and a dielectric layer 314 . The temperature sensor 300 also includes a conductor plate 304 having a substrate 308 , a metal layer 312 , and a dielectric layer 316 . The conductor plates 302 and 304 are implemented through the same materials and employ the same characteristics as described above with respect to the temperature sensor 200 of FIG. 2 . In addition to these components, the temperature sensor 300 also includes a vent 318 in the conductor plate 302 and a vent 320 in the conductor plate 304 . The vent 318 extends from an outer surface of substrate 306 to an outer surface of dielectric layer 314 . The vent 320 extends from an outer surface of substrate 308 to an outer surface of the dielectric layer 316 .
During operation, the temperature sensor 300 responds to external temperatures in the manner as described above with respect to temperature sensor 200 of FIG. 2 . The use of the additional vent 320 can further reduce or eliminate effects of external pressure by enabling an additional path of escape for any gas retained between the conductor plates 302 and 304 .
FIGS. 4A through 4E illustrate a process of manufacturing a pressure sensor of an embodiment. In FIG. 4A , the metal layer 108 is formed on the substrate 106 . The metal layer 108 may be bonded to the substrate 106 through any known processes, including lamination through an epoxy resin and explosive bonding, for example. In FIG. 4B , the dielectric layer 110 is formed on the metal layer 108 . Both conductive plates of the pressure sensor are formed in the previously described manner. FIG. 4C illustrates the conductive plate 104 having the metal layer 114 and dielectric layer 116 formed sequentially on the substrate 112 . Those of ordinary skill in the art will appreciate that conductive plates 102 and 104 may be formed through the same or a similar process.
In FIG. 4D , the first conductive plate 102 is mounted on the second conductive plate 104 such that a gap (G) between approximately one and twenty thousandths of an inch (0.001″ to 0.020″, or less or greater as desired) is established between the dielectric layers of each plate. In FIG. 4E , the two plates are hermetically sealed together at their edges to create a pressure vessel. At the time the two plates are hermetically sealed, air or a gas can be deliberately trapped in the gap (G) between the plates. Alternatively, the air or gas can be injected into the cavity between the plates.
FIGS. 5A through 5E illustrate a process of manufacturing a temperature sensor of an embodiment. In FIG. 5A , a metal layer 208 is bonded to the substrate 206 . The metal layer 208 may be bonded to the substrate 206 through processes including but not limited to, for example, lamination using an epoxy resin, and an explosive bonding process. In FIG. 5B , a dielectric layer 210 is applied and formed on the metal layer 208 .
In FIG. 5C , a second conductor plate 204 may be formed in a manner similar to that previously discussed with respect to the first conductor plate 202 . For this reason, the process of forming the second conductor plate 204 will not be discussed in greater detail.
In FIG. 5D , a vent 218 is formed in the first conductor plate 202 . The vent 218 is formed by drilling a small hole from the outer surface of the substrate 206 through the metal layer 208 , to an outer surface of the dielectric layer 210 . It should be readily apparent that this same process may be used to form a vent 218 in the second conductor plate 204 .
In FIG. 5E , the first conductor plate is mounted onto the second conductor plate such that a gap (G) between approximately one and twenty thousandths of an inch (0.001″ to 0.020″, or lesser or greater as desired) is established between the two plates. The edges of the two plates are fixedly attached to one another but not sealed so that any influence of pressure is canceled.
The materials used to construct the pressure and temperature sensors should be properly balanced to achieve a desired response to changes in the pressure and temperature of the environment. For example, the thickness of the substrate determines the effectiveness of the substrate in canceling the warping effect of an associated metal layer. Layers may be formed of varying thicknesses and/or have a multilayered structure. Additionally, the substrates of the pressure or temperature sensor may be constructed such that one or both of the conductive plates warp in response to the external temperature or pressure. In an embodiment, the warping or active conductive plate is formed on a substrate having a thickness that enables the plate to effectively warp or bow based on the external pressure or temperature to achieve the desired response. For example, the substrate of the active plate may be formed from a single 0.011″ thick carbon fiber fabric. The non-warping or inactive plate is multilayered or otherwise formed at a thickness that restricts the ability of the inactive plate to bow. For example, the substrate of the non-active plate may be formed from a single or multi-layer carbon fiber fabric having a total thickness of 0.033″.
FIG. 6 illustrates an embodiment of a system 600 for measuring pressure in an enclosure (E).
The enclosure (E) may be implemented in numerous shapes and sizes and may be a partial or full enclosure. The enclosure (E), as illustrated, is a representation of a full enclosure that is a high temperature and/or high pressure vessel. By way of example, the temperature within the enclosure may reach up to 600° F.
The high temperatures and pressures realized in the enclosure (E) may be generated by any of numerous industrial applications such as drilling, manufacturing, or construction operations, for example. Those of ordinary skill in the art will appreciate that high temperatures and pressures of the enclosure (E) may also be generated through the innate environmental conditions experienced by the enclosure (E) itself.
The system 600 includes a device, such as a signal generator 602 , for generating an electromagnetic signal or an electromagnetic pulse (EMP). The frequency of the signal can be in a range that includes, but is not limited to, RF frequencies such as 3 Hz-30 GHz, or lesser or greater as desired. The signal is communicated to the enclosure (E) through a suitable medium such as cabling, conductive piping, or over-air, for example.
The system 600 also includes a device, such as the capacitive sensor 100 , for adjusting the frequency of the signal based on the pressure of the enclosure. The capacitive sensor 100 can be included in a resonant circuit 604 .
The resonant circuit 604 includes means such as an antenna 606 for receiving the RF signal. The resonant circuit 604 also includes means, such as an inductor 608 , for connecting the resonant circuit 604 to the antenna 606 . The resonant circuit 604 also includes a circuit resistance 610 and circuit inductance 612 which represent the impedance of circuit casing. The resonant circuit 604 receives the RF signal through the antenna 606 , and rings at its natural frequency. The capacitive sensor 100 senses the pressure of the enclosure, and modulates the frequency induced in the resonant circuit 604 . The capacitive sensor 100 modulates the frequency by bending (e.g., warping) at least one of the first plate and the second plate relative to the pressure exerted on the gas that is retained in the gap (G) between the plates, by the enclosure (E). The modulated frequency can be processed to provide a measure of the pressure of the enclosure. That is, the vibration frequency induced by the RF energy is modulated by the sensed pressure of the enclosure, and this modulation of the frequency can be processed to provide a measure of the characteristic.
The system 600 also includes a device, such as a correlator 614 , for correlating the modulated frequency to the observed pressure of the enclosure. Those skilled in the art will appreciate that the correlator 614 may be a processor or computer device. The correlator 614 can be programmed to process the modulated vibration frequency to provide a measurement of the sensed characteristic. The measurement can, for example, be displayed to a user via a graphical user interface (GUI). The correlator 614 can perform any desired processing of the detected signal including, but not limited to, a statistical (e.g., Fourier) analysis of the modulated vibration frequency. Commercial products are readily available and known to those skilled in the art for performing suitable frequency analysis. For example, a fast Fourier transform that can be implemented by, for example, MATHCAD available from Mathsoft Engineering & Education, Inc., or other suitable product to deconvolve the modulated ring received from the resonant network device. The processor can be used in conjunction with a look-up table having a correlation table of modulation frequency-to sensed characteristics (e.g., temperature, pressure, and so forth) conversions.
FIG. 7 illustrates an embodiment of a system 700 for measuring temperature in an enclosure (E).
The system 700 includes a signal generator 702 , a capacitive sensor 200 and, a correlator 714 . It should be readily apparent that the signal generator 702 , and the correlator 714 are similar to the corresponding elements, as illustrated in the embodiment of FIG. 6 .
The capacitive sensor 200 adjusts the frequency of the RF signal resonant circuit based on the temperature of the enclosure. The capacitive sensor 200 can be included in a resonant circuit 704 . It will be appreciated that the resonant circuit 704 may be similar to the corresponding element as illustrated in the embodiment of FIG. 6 and likewise includes an antenna 706 , inductor 708 , circuit resistance 710 , circuit inductance 712 . The capacitive sensor 200 adjusts the frequency of the resonant circuit 704 by bending (e.g., warping) at least one of the first plate and the second plate relative to the temperature of the enclosure (E).
FIG. 8 is a flowchart that illustrates an embodiment of a method of measuring temperature on pressure in an enclosure. To measure pressure, the method is implemented using the system 600 having a pressure sensor 100 as discussed above. To measure temperature, the method is implemented using the system 700 having a temperature sensor 200 as discussed above.
As shown in FIG. 8 at 800 , a signal generator generates an electromagnetic signal or an electromagnetic pulse (EMP) at a frequency between, for example, 3 Hz and 30 GHz. The resonant circuit 604 , 704 receives the signal ( 802 ). The capacitive sensor 100 , 200 of the resonant circuit 604 , 704 adjusts the frequency of the received signal by bending (e.g., warping) at least one of the first plate and the second plate in response to pressure or temperature depending on the application ( 804 ). The bending of the plates adjusts the spacing of the gap between the plates, thereby changing the capacitance of the capacitive sensor 100 , 200 .
The receiver 602 , 702 receives the signal ( 806 ) and the correlator 608 , 708 uses a look-up table to correlate the modulation of the frequency to an observed pressure or temperature value ( 808 ).
While the invention has been described with reference to specific embodiments, this description is merely representative of the invention and is not to be construed as limiting the invention. Various modifications and applications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims. | Methods for making and systems employing pressure and temperature sensors are described. Embodiments include a capacitive element including a first conductor plate and a second conductor plate. Each plate includes a conductor layer formed on a substrate. In a pressure sensor embodiment, seal is positioned at or near the edges of the conductor plates, and a gas retained in a gap defined between the plates. In a temperature sensor embodiment, the gap defined between the plates is in fluid communication with the external environment. | 4 |
This application claims priority from U.S. Provisional Application No. 60/408,022, filed Sep. 4, 2002.
FIELD OF THE INVENTION
The present invention relates to the production of polyolefin-based adhesive resins, and particularly to an improved process for producing polyolefin-based adhesive resins.
BACKGROUND OF THE INVENTION
Conventional polyolefin-based adhesive resins for bonding to or bonding together polyolefins and polar materials such as nylon, ethylene vinyl alcohol copolymer, metals and the like, are made using multiple step processes. First, an olefin, such as ethylene, commonly in gaseous form, is polymerized or co-polymerized with other monomers to form a polyolefin and extruded into pellets as a finished form.
Second, at least some polyolefin thus prepared must be further chemically reacted with a chemical having a polar functional group to provide a modified (“grafted”) polyolefin having a polar functionality (herein referred to as a “graft”). One way of performing this step is to visbreak the polyolefin in the molten state under conditions of high shear and/or temperature, in the presence of the polar monomer, to cause formation of free radicals that then react with the polar monomer. Another way is to dissolve the polyolefin in a solvent along with the polar monomer in the presence of a peroxide catalyst or other suitable catalyst that facilitates chemical grafting of the monomer onto the polyolefin in solution. Either process results in a polyolefin grafted with a polar monomer. The graft copolymer thus prepared is then typically pelletized in an extruder.
Third, the graft copolymer is typically melt-blended with an additional quantity of polyolefin to dilute the graft copolymer to a desired concentration, and to provide a polyolefin-based adhesive resin that has processing and physical properties suitable for the end use application. The mixing is usually performed by melting the polyolefin pellets and the graft pellets above the melting point of the two components and mixing the melted materials to desirably obtain a homogenous product. This additional melt blending is yet another expense. The polyolefin-based adhesive resin thus prepared is then pelletized from an extruder.
There is a need for a less expensive, less complicated process for producing polyolefin-based adhesive resins. There is also a need for a better quality polyolefin-based adhesive resin.
An example of a process for producing polyolefin-based adhesive resin is described in U.S. Pat. No. 4,487,885, issued Dec. 11, 1984. The process described therein utilizes a major amount of polyolefin polymer or polymers, which, as described above, has been formed by polymerizing an olefin or olefins and extruded into pellets as a finished form. The pelletized polymer or polymers are next mixed with graft and heated to above the melting point of the components under high shear. A heated extruder may be used to accomplish the latter step, and the melt mixed product can be recovered in the form of pellets. As noted in the patent, the product of the process may consist of from about 70–99.5 wt. % of polyolefin, e.g. polyethylene, and about 0.05–30 wt. % of the graft.
While conventional processes for producing polyolefin-based adhesive resins have been found to be useful, there are several disadvantages inherent in those processes. For example, in heating and shearing the polymerized polyolefin, e.g. polyethylene, usually in the form of pellets, above its melting point, imperfections, usually in the form of gelled polymer, are formed with each such heat history. The least amount of such imperfections is desired so that the adhesive resin when applied to a substrate will be continuous and without visible and/or functional imperfections.
Additionally, the conventional processes described above are costly due to the additional equipment and the energy required to first polymerize the olefin monomer, pelletize the polyolefin, and then melt and mix the formed polyolefin and graft material to form the adhesive product.
Thus there is a need for an improved process for producing polyolefin-based adhesive resins which reduces the amount of imperfections, such as gelled polymer, of the polyolefin material by eliminating one melt processing and extrusion step after the polymerization. There is also a need for a process that reduces the time, energy and equipment required to produce the desired polyolefin-based adhesive resins.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an improved process for producing polyolefin-based adhesive resins.
Another object of this invention is to provide a process for producing polyolefin-based adhesive resins that reduces the amount of imperfections in the produced adhesive resin.
Another object of this invention is to provide a process for producing polyolefin-based adhesive resins that improves properties, such as optical properties in thin films of the produced adhesive resin as compared to polyolefin-based adhesive resins produced by heretofore conventional processes.
Still another object of this invention is to provide an improved process for producing polyolefin-based adhesive resin that reduces the time, energy and equipment required to produce the adhesives as compared to conventional processes for such production.
These and other objects and advantages of the present invention will be apparent from the following description.
As explained above, in heretofore known processes the polyolefin that is graft polymerized to form a polyolefin-based adhesive resin is exposed to at least two, and often three, melt extrusion and pelletizing steps before it can be sold for commercial use. Additional polyolefin used in the resin is exposed to two melt extrusion and pelletizing steps, once following synthesis of the polyolefin and once while mixing the polyolefin with the graft copolymer. The present invention is directed to a process that eliminates at least one of the melt processing and extrusion steps for the polyolefin-based adhesive resin, and to an improved polyolefin-based adhesive resin thus prepared.
In accordance with the present invention, a process is provided that advantageously eliminates the need for reheating and melting of polyolefin polymer and reduces imperfections due to such reheating and melting of polymer, in producing polyolefin-based adhesive resins. The term “polyolefin” is defined as including homopolymers and copolymers of olefin monomers having from 2–12 carbon atoms. Examples of suitable polyolefins include without limitation high density polyethylene (linear ethylene polymers having a density of at least 0.945 grams/cm 3 ), branched low density polyethylene (branched ethylene polymers having a density of about 0.900 to about 0.944 grams/cm 3 ), linear low density polyethylene (linear ethylene-alpha olefin copolymers having a density of about 0.870 to about 0.944 grams/cm 3 and including a C 3 to C 12 alpha-olefin comonomer), polypropylene homopolymers, propylene-ethylene copolymers, butene-1 homopolymers and copolymers, and the like. The term “polyolefin” also includes copolymers of olefins such as ethylene with vinyl acetate, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate, acrylic acid, methacrylic acid, acid terpolymers and the like, which contain at least 50% by weight ethylene.
The process comprises polymerizing an olefin, mixture of olefins or mixture of olefins and other monomers, where preferably the olefin or olefins have from about 2 to 8 carbon atoms, for example by polymerizing at least one olefin monomer mixture using a conventional reactor process, and mixing the polymerization product with a graft and either with or without another component, such as an adhesion promoting resin, preferably elastomer, and more preferably a thermoplastic elastomer, or a metallocene catalyzed polyolefin, in a heated extruder or other heated mixing device at a temperature above the melting point of the components to obtain the desired grafted polyolefin-based adhesive resin.
The process may be utilized to produce adhesives based on any olefin to produce corresponding polyolefin-based adhesive resins of such polyolefins, for example, high density polyethylene (HDPE), polypropylene, and the like, and copolymerizations in a single or more than one polymerization reactors, in series or in parallel. In the case of polyethylene as a polyolefin, the olefin monomers include ethylene and less than 50% of one or more other monomers, which may include alkenes, for example, propylene, butene-1, hexene-1, 4-methyl pentene-1, octene-1, and other unsaturated aliphatic hydrocarbons; also, ethylenically unsaturated esters, such as vinyl acetate, methyl acrylate, ethyl acrylate and butyl acrylate.
“Graft” as heretofore defined is understood to include any of the functional polymeric compositions or other structures as described in U.S. Pat. Nos. 3,658,948; 3,697,465; 3,862,265; 3,868,433; 4,087,587; 4,087,588; 4,487,885; 5,070,143 and others.
In accordance with the invention, a polyolefin is synthesized by a conventional process. The polyolefin from the reactor is fed to a mixing device, such as a mixing extruder, where it is combined with a graft copolymer in pellet or powder form that has been separately produced, prior to pelletizing to form a polyolefin-based adhesive resin. The graft copolymer can be the reaction product of a thermoplastic polymer and a polar monomer, and may be produced according to a known technique. As described, the polyolefin is melt blended with the graft copolymer in a mixing device, preferably a mixing extruder, to yield a polyolefin-based adhesive resin. The adhesive resin is discharged from the mixing device, preferably a mixing extruder, through a die having multiple openings, and is cooled and pelletized.
The process of the invention reduces the number of melt extrusion and pelletizing steps for the ungrafted polyolefin portion of the adhesive from two to one. The only melt extrusion and pelletizing seen by the polyolefin occurs in the reactor's existing in-line mixing device after synthesis of the polyolefin, after it is blended with the graft copolymer. This reduction in melt mixing and melt extrusion history is significant because the polyolefin (excluding the graft copolymer) often constitutes 80–99% of the polyolefin-based adhesive resin.
Polyolefin-based adhesive resins produced according to the invention have less degradation, less crosslinking and better (whiter) color than conventional polyolefin-based adhesive resins having more extensive heat histories. Films produced using the improved polyolefin-based adhesive resin, tend to have better optical properties, including increased clarity, less haze and/or less gels. The polyolefin-based adhesive resin of the invention is also less expensive to manufacture.
The polyolefin-based, grafted copolymer adhesive resin obtained by the process of the present invention is particularly useful in a variety of applications, particularly for bonding to materials or bonding materials together, for example such materials as polyolefins, polyamides, polyvinyl alcohol, ethylene vinyl alcohol copolymer, metals, glass, wood and/or paper, and other substrates, particularly polar substrates; and in fabrication processes, such as powder coating, rotational molding, film-forming processes using standard cast film and blown film extrusion and coextrusion processes; application to multiple substrates using thermal lamination, extrusion lamination, and extrusion and coextrusion processes including blow molding, sheet extrusion, and pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred embodiment, the process of the present invention is desirably performed by polymerizing ethylene with other olefin monomers according to known polymerization techniques, and mixing the raw product of the polymerization with a graft as heretofore described. The olefin monomer mixture may have the composition of primarily ethylene with less than 50% of other alkenes as heretofore described.
In accordance with a particular embodiment of this invention, the polyolefin is fed to a mixing extruder immediately following synthesis. A graft copolymer that has been separately manufactured, is added to the same mixing extruder and is blended with the polyolefin prior to pelletizing. The graft copolymer may be based on the same or different polyolefin as the synthesized polyolefin, and is desirably based on a similar polyolefin. The graft copolymer may also be based on a thermoplastic elastomer, such as an ABA block copolymer having polystyrene end blocks and an olefin or diolefin midblock. Such elastomers are described in U.S. Pat. No. 5,070,143, the disclosure of which is incorporated by reference. The resulting graft polyolefin-based adhesive resin is then extruded through a die having multiple openings and is cooled and pelletized.
The polyolefin-based adhesive resin produced according to the embodiment may include from about 0.05 to about 30% by weight of the graft copolymer, preferably from about 1 to about 20% by weight of the graft copolymer, and most preferably from about 2 to about 15% by weight of the graft copolymer. Additional adhesion-promoting resins, such as thermoplastic elastomers, may also be added and blended with the polyolefin and graft copolymer at this stage. When used, the thermoplastic elastomer may constitute from about 1 to about 30% by weight of the polyolefin-based adhesive resin. The balance of the polyolefin-based adhesive resin is substantially the polyolefin that was just synthesized. The polyolefin may constitute from about 50 to about 99.9% by weight of the polyolefin-based adhesive, preferably from about 70 to about 99% by weight, and most preferably from about 85 to about 98% by weight.
The graft copolymer is a copolymer of a polyolefin or thermoplastic elastomer as described above, and a polar comonomer. The term “polar comonomer” refers to organic molecules (e.g. monomers) having a carboxyl, hydroxyl, anhydride or other oxygen functionality. When grafted onto polyolefins and/or thermoplastic elastomers, these monomers exhibit polar attraction to, and under certain conditions may chemically react with, polar surfaces of polyolefins, polyamides, polyvinyl alcohol, ethylene vinyl alcohol copolymer, metals, glass, wood and/or paper and other substrates. Suitable polar monomers include without limitation carboxylic and dicarboxylic acids and their anhydrides, for instance maleic acid, fumaric acid, maleic anhydride; 4-methylcyclohex-4-ene-1,2 dicarboxylic acid and its anydride; tetrahydrophthalic acid and its anhydride; x-methylnorborn-5-ene-2,3 dicarboxylic acid and its anhydride; norborn-5-ene-2,3 dicarboxylic acid and its anhydride; maleo-pimaric acid and its anhydride; bicyclo(2.2.2) oct-5-ene-2,3-dicarboxylic acid and its anhydride; 1, 2, 3, 4, 5, 8, 9, 10-octahydronaphthalene-2,3-dicarboxylic acid and its anhydride; 2-oxa-1,3,-diketospiro (4.4)non-7-ene, bicyclo(2.2.1)hept-5-ene-2,3-dicarboxylic acid and its anhydride; nadic anhydride, methyl nadic anhydride, himic anhydride, and methyl himic anhydride. Other suitable polar monomers are described in U.S. Pat. Nos. 3,873,643 and 3,882,914, the disclosures of which are incorporated by reference.
In the embodiment of the invention described above, the graft copolymer can be produced using a conventional process. Conventional grafting processes include without limitation a) processes where the polyolefin or thermoplastic elastomer is reacted with the polar comonomer in the presence of sufficient heat and shear to visbreak the molten polymer and form free radicals which react with the monomer, b) processes where the molten polyolefin or thermoplastic elastomer is reacted with the polar monomer in the presence of heat and a catalyst, such as a peroxide catalyst, and c) processes where the polyolefin or thermoplastic elastomer is reacted with the polar monomer in a suitable solvent, in the presence of a catalyst. An exemplary process for preparing a graft copolymer is described in U.S. Pat. No. 4,087,587, the disclosure of which is incorporated by reference. The graft copolymer may include from about 85 to about 99.999% by weight of the base polymer and from about 0.001 to about 15% by weight of the grafted polar monomer, preferably from about 95 to about 99.99% by weight of the polyolefin and from about 0.01 to about 5% by weight of the grafted polar monomer; preferably from about 97 to about 99.9% by weight of the polyolefin and from about 0.1 to about 3% by weight of the grafted polar monomer.
EXAMPLE
In this example, ethylene and butene gases were introduced into the polymerization reactor of a commercial large-scale polyethylene manufacturing system. The mixture was polymerized in the reactor using a suitable Zeigler-Natta catalyst, forming an ethylene-butene copolymer, commonly referred to as linear low density polyethylene (LLDPE). The LLDPE polymerization product with a density of 0.918 g/cc was then discharged from the reactor in the form of a powder and fed into an accumulator bin in line with the reactor, and then was combined with graft as the LLDPE was transported into a continuous mixer. The graft was a high density polyethylene grafted with maleic anhydride. Maleic anhydride content, based on combined weight of the polymers, was 0.2%. The LLDPE powder and the graft copolymer were heated to a temperature of approximately 400–450 degrees F. and subjected to shear mixing. Following mixing, the mixture was pelletized as it exited the mixer. Six-185,000 pound lots of pelletized polyolefin-based adhesive resin were thus produced by the process of the present invention. This experiment was performed by Equistar Chemicals, LP using a large-scale polyethylene manufacturing facility (480 million pounds per year capacity).
COMPARATIVE EXAMPLE
For comparative purposes, LLDPE, which had been previously manufactured in the reactor and pelletized, was mixed with the same graft copolymer as noted above in the same proportions, in a continuous mixer heated to a temperature of approximately 400–450 degrees F. and subjected to shear mixing. The mixture was pelletized as it exited the mixer. This pelletized product is utilized as the CONTROL in the following tests.
Test 1
To determine the amount of undesirable gelled polymer in the adhesive product, pellets of adhesive produced above in accordance with the present invention, referred to as Lots 1–6, and pellets of CONTROL produced as described above, were separately introduced into a single screw extruder, and extruded into a blown 3 mil monolayer film. The amount of gelled polymer in the films of Lots 1–6 and of the CONTROL were determined by counting the number of gelled polymer or gels in a given area of the film and normalizing the count for a 50 square foot area by a laser gel scanner. The following counts were found:
Gel Count
Lot 1
2582
Lot 2
2360
Lot 3
2499
Lot 4
2206
Lot 5
1930
Lot 6
2177
Lots 1–6
2292
(averaged)
CONTROL
3423
Thus, TEST 1 shows the desired reduction in the amount of imperfections due to gelled polymer in polyolefin-based adhesive resin produced in accordance with the present invention as compared to the amount of imperfections due to gelled polymer of polyolefin-based adhesive resin produced under the heretofore known conventional processes.
The optical properties of films prepared as in TEST 1 were evaluated as noted in the following tests:
Test II
Haze, i.e., the clarity of films, in this case of films of 2 mil thickness prepared as noted above, was determined in accordance with ASTM Test No. D-1003, as follows:
Haze %
Lot 1
7.8
Lot 2
7.4
Lot 3
7.5
Lot 4
7.8
Lot 5
7.6
Lot 6
7.6
Lots 1–6
7.6
(averaged)
CONTROL
10.2
Test III
The gloss of 2 mil films as noted above was determined in accordance with ASTM Test No. D-2457, with the following results:
Gloss Units
Lot 1
68.8
Lot 2
69.8
Lot 3
70.5
Lot 4
67.9
Lot 5
70.0
Lot 6
69.1
Lots 1–6
69.4
(averaged)
CONTROL
62.7
Test IV
Transparency of 2 mil films as noted above was determined in accordance with ASTM Test No. D1746, as narrow angle scatter (“NAS”) as follows:
NAS, %
Lot 1
71.9
Lot 2
72.5
Lot 3
72.4
Lot 4
73.1
Lot 5
75.1
Lot 6
73.8
Lots 1–6
73.1
(averaged)
CONTROL
66
Test V
Degradation of polyolefin-based adhesive resin produced in accordance with the present invention as compared to that of polyolefin-based adhesive resin produced in accordance with heretofore known processes was demonstrated by measuring the yellowness of 2 mil films prepared as noted above in accordance with ASTM Test No. D1925, with the following results:
Y1 - (Yellowness) Rating
Lot 1
2.5
Lot 2
2.5
Lot 3
2.2
Lot 4
2.1
Lot 5
1.9
Lot 6
1.9
Lots 1–6
2.2
(averaged)
CONTROL
6.0
The above tests demonstrate the improvement in the reduction of imperfections and degradation upon producing polyolefin-based adhesive resins in accordance with the process of the present invention, as well as the improvement in the optical properties of the films of the adhesive, as compared to polyolefin-based adhesive resins produced according to heretofore known conventional methods. The above testing was performed by Equistar Chemicals, LP.
While the embodiment of the invention described herein is presently preferred, various modifications and improvements can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated by the appended claims, and all changes that fall within the meaning and range of equivalents are intended to be embraced therein. | A method for producing polyolefin-based adhesive resins having improved physical and optical properties and the improved adhesive resins thereby produced, eliminates at least one reheating and melting of polyolefin polymer, comprises polymerizing a monomer composition of at least one olefin, mixing the polymerization product without pelletizing the polyolefin polymer with at least one graft polymer or copolymer in a heated mixing device at a temperature above the melting point of the components, and recovering the resulting polyolefin-based adhesive resin. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is claiming priority of Chinese Application No. 200610060873.7 filed May 29, 2006, entitled “A Method of Communicating for a Communication Apparatus” which application is incorporated by reference herein in its entirety.
BACKGROUND
[0002] The present disclosure relates to communication techniques, especially a method and a system of communication for a communication apparatus.
[0003] As shown in FIG. 1 , a fiber access point-to-multi-point optic network includes a central office optical line terminal (OLT), at least one splitter, a plurality of remote apparatus optical network terminals (ONTs), and the associated fiber. The central office apparatus and optical splitters are connected together with the fiber, which forms the backbone of the optical network. The splitters are connected to each remote apparatus with a plurality of branching optical fibers.
[0004] In a passive optical network (PON), the transmission of data streams between the office-side OLT and the remote apparatus ONT is implemented by creating a schedule between the central office OLT and every terminal apparatus ONT. The central office OLT assigns bandwidth grants for upstream data to every terminal apparatus ONT according to the bandwidth requirements of every terminal apparatus. By granting bandwidth to every terminal apparatus ONT, the scheduling for upstream transmission traffic for the terminal apparatus ONT is achieved.
[0005] In order to guarantee the quality of service of the transmissions, the terminal apparatus ONTs need to classify the services according to their priorities and transmit each service with a reference to its priority. However, in an actual network application, an OLT connects to different vendors' terminal apparatus ONTs. Since there no standard for service classification in the terminals, different service classification methods are deployed in the different vendors' terminal apparatus when implementing the service classification. For example, in some vendors' terminals, the service classification is developed using a virtual local area network (VLAN) method, while other vendors implement the Institute of Electrical and Electronics Engineers (IEEE) 802.1p service classification method in their terminals. Even if the different vendor apparatuses adopted the same classification method, the classification method strategy would likely be different. For instance, “voice service=VLAN1” and “data service=VLAN2” are used in some vendors' terminal apparatus, while “voice service=VLAN5” and “data service=VLAN6” are used in other vendors' terminal apparatus. In such a case, the central office apparatus OLT should configure and process the different terminal apparatus using a common classification strategy so as to realize the communication between central office OLT and the different terminal apparatus. For terminal apparatus that adopt the VLAN service classification method, the central office apparatus configures their service using a common classification strategy. For example, “voice service” would be configured as VLAN 1 and “data service” would be configured as VLAN 2 . For terminal apparatus which adopt the 802.1p service classification method, “voice service” would be configured as COS 7 and “data service” would be configured as COS 5 . Whenever a new terminal apparatus is linked to the OLT or there are some changes to the terminal apparatuses that are linked to OLTs, the operators are required to reconfigure the terminal apparatuses. Thus, the work efficiency is very low and the manual configuration is prone to suffer errors.
SUMMARY
[0006] An embodiment of the present disclosure provides a method and a system of communication for a communication apparatus to solve problems like low work efficiency or error-suffering configuration that occur when different terminals are linked to communication networks.
[0007] An embodiment of the present disclosure provides a method of communication for a communication apparatus, comprising following steps:
[0008] an optical network terminal (ONT) sending an information frame upstream to an optical line terminal (OLT); and
[0009] the OLT receiving the information frame, obtaining information about the ONT from the information frame and processing the information frame received from the ONT with the information about the ONT.
[0010] An embodiment of the present disclosure also provides a system of communication for a communication apparatus, which includes the central office apparatus and the terminal apparatus connected to the central office apparatus through the splitters, the system comprising:
[0011] An interconnected apparatus, the interconnected apparatus connected to the central office apparatus, the terminal apparatus information from the transmitted information frames are gathered by the interconnected apparatus; using the gathered terminal apparatus information configuration data table, the terminal information is stored in the data table; the information frames are received from the central office apparatus by the interconnected apparatus and the information frames transmitted by terminal apparatus are processed using the information frame processing method in the data table.
[0012] By receiving the transmitted information frames from the terminal apparatus, the central office apparatus automatically obtains the terminal apparatus information from the information frames; the central office apparatus configures the processing method for the terminal information automatically according to the terminal apparatus information, to thereby improving the data processing efficiency and correctness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a component diagram of an embodiment of the PON.
[0014] FIG. 2 is the network composition diagram of an embodiment of the present disclosure.
[0015] FIG. 3 is the message time sequence for an embodiment of the present disclosure.
[0016] FIG. 4 is diagram illustrating an implementation of the different terminal service by the central office apparatus OLT for an embodiment of the present disclosure.
[0017] FIG. 5 is the service processing procedure diagram for an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0018] The embodiment of the present disclosure will be detailed described with reference to the following drawings.
Embodiment 1
[0019] As shown in FIG. 2 , the terminal service management apparatus is added to the present PON. The terminal service management apparatus is involved in:
[0020] 1. Gathering and storing various terminal apparatus ONT information; and
[0021] 2. Configuring the service classification method for each terminal apparatus.
[0022] As shown in FIG. 3 , when the terminal apparatus ONT is successfully activated and registered to the network, the central office apparatus OLT assigns an apparatus identifier ID. In addition, the terminal apparatus ONT will automatically transmit the manufacturer information, terminal sequence number, terminal type, service classification supported by the terminal, and other terminal attribute information to the terminal service management apparatus through a management information channel build-up between the central office OLT and terminal apparatus ONT. The terminal service management apparatus then queries the inner build-up terminal apparatus processing method table: if there is no relative information for the terminal in the terminal service management apparatus, the transmitted information should be stored into the terminal apparatus processing method table in the terminal service management apparatus; otherwise, the information should be discarded (not shown in the FIG. 3 ).
[0023] After the terminal service management apparatus receives the transmitted information for the registering terminal apparatus, the service configuration information is sent out for the successfully registered terminal apparatus through the management information channel build-up between the central office OLT and the terminal apparatus ONTs using the service classification method supported by the terminal apparatus (such as the VLAN or the 802.1p service classification method).
[0024] Referring to FIG. 4 , the scheduling procedure for the central office apparatus OLT to execute to different kinds of terminal apparatus ONTs is described in detail below.
[0025] When the central office apparatus OLT schedules the upstream data using the bandwidth requirement information transmitted from the various terminal ONTs, the central office apparatus OLT distinguishes the information frames transmitted from the different terminal apparatus ONTs from the received upstream data. The service processing module in the office side apparatus OLT also obtains the terminal apparatus identifier ID assigned by the central office apparatus. The service processing module then finds the corresponding terminal type from the mapping table using the terminal apparatus ID. The terminal service management apparatus determines the processing method for the corresponding terminal apparatus ONT service classification from the terminal apparatus processed method table using the terminal's adopted method type, such as the VLAN method or the 802.1p method. Using the service classification method, the received information frames are processed according to the service classification method. The central office apparatus OLT transmits the processed information frames according to the network side service classification requirements, and uses the common classification strategy to convert the service classification, or nests the service identifier (adds another service classification identifier) to all of the received service information. For example, the service classification processing methods for different terminals, such as VLAN and 802.1p, are switched by the central office apparatus OLT into one having a common classification strategy, such as only the VLAN service classification method, or added another service classification identifier based on the original classification. The information frames are processed by the OLT apparatus and sent to the network connected to the central office apparatus.
[0026] Referring to the FIG. 4 and FIG. 5 , the embodiment of the present disclosure is clarified in detail below.
[0027] In the central office OLT, the implementation procedure for using a common classification strategy to convert the service identifiers to terminals having different types of service identifiers is as follows.
[0028] When network terminal ONT (A) and ONT (B) are activated and registered successfully with the office-side apparatus OLT, the office-side apparatus OLT assigns the terminal identifiers ID(A), ID(B) to the terminals ONT (A) and ONT (B) respectively, and builds up the management information channels to terminals ONT (A) and ONT (B). Network terminals ONT (A) and ONT (B) automatically send the manufacturer information (vendor number), type (a multimedia terminal or a data terminal), service classification method (the service identifier is the VLAN method or the 802.1p COS method) supported by the terminal, and other attribute information (such as the line rate and physical interface) for the network terminals to the terminal service management apparatus through the management information channel build-up between the central office OLT and the terminal apparatus ONTs. The terminal service management apparatus stores and processes the information for the network terminals ONT (A) and ONT (B). At the same time, the terminal service management apparatus configures the service to each network terminal, ONT (A) and ONT (B), through the central office apparatus OLT, using the service classification method supported by the network terminals ONT (A) and ONT (B). If terminal ONT (A) supports the VLAN service classification, the service classification may be configured as voice service=VLAN 1 and data service=VLA 2 . If terminal ONT (B) supports the 802.1p service classification, the service classification should be configured as voice service COS=7 and data service COS=6. Through the service configuration of each network terminal ONT(A) and ONT(B), uniformity of the service classification of network terminals ONT(A) and ONT(B) and the central office apparatus is preserved.
[0029] After the service configuration of the network terminals ONT(A) and ONT(B), the central office apparatus OLT adjusts the upstream data of network terminals ONT(A) and ONT(B) respectively according to the bandwidth requirements of network terminals ONT(A) and ONT(B). The network terminals ONT (A) and ONT (B) then transmit their information frames upstream to the central office apparatus OLT using the information frames' position guaranteed by the central office apparatus OLT and the amount of information transmitted.
[0030] When the central office apparatus OLT receives the upstream information frames transmitted from the network terminals ONT (A) and ONT (B), the central office apparatus OLT obtains the identifiers ID(A) and ID(B) for the network terminals ONT (A) and ONT (B) respectively. Using the identifiers for the network terminals ONT (A) and ONT (B), the central office apparatus OLT looks up the mapping table and obtains the terminal types for the corresponding network terminals ONT (A) and ONT (B). Using the terminal type for the network terminals ONT (A) and ONT (B), the central office OLT looks up the service classification method supported by the network terminals ONT (A) and ONT (B) in the terminal service management apparatus database. Using the service classification for the network terminals ONT (A) and ONT (B), the central office apparatus OLT classifies the service traffic transmitted from the network terminals ONT(A) and ONT(B), and converts the service identifiers for the network terminals ONT (A) and ONT (B) into the service classification identifiers for the central office apparatus side. Specifically, the data service identifier VLAN 2 for ONT (A) is converted into the VLAN 7 for the central office OLT side, and the data service identifier COS 6 for ONT (B) is converted into the VLAN 7 for the central office OLT side. In addition, the voice service identifier VLAN 1 for ONT (A) is converted into the VLAN 9 for the central office OLT side, and the voice service identifier COS 7 for ONT (B) is converted into the VLAN 9 for the central office OLT side. The converted information is then stored into the different PRIs for the information queues. For example, the voice service is sent to the high priority queue and the data service is sent to the low priority queue. The processed information frames are then sent into the networks connected to the central office apparatus.
[0031] In the central office OLT, the implementation of the nested service identifiers to the terminals identified by the different types of service identifiers is as follows.
[0032] The early implementation process is the same as in the first embodiment. The only difference is that the processing method for the terminal service identifiers is distinguished at the central office OLT.
[0033] When the central office OLT receives the data streams from the network terminals ONT (A) and ONT (B), the central office OLT nests the network terminals' service stream identifiers into another service identifier. For example, a central office end voice service identifier VLAN 5 is added to the voice service identifier for network terminal ONT (A), and a central office end data service identifier VLAN 7 is added to the data service identifier for network terminal ONT (B). Then, these nested service traffics are stored into different PRI queues: the voice service is sent to the high priority queue and the data service is sent to the low priority queue. The processed information frames are then sent into the networks connected to the central office apparatus.
[0034] Besides an automatically configuration, the relationship mapping table between the terminal apparatus identifier IDs and the terminal type in the central office apparatus can be configured by manual input through the added terminal apparatus.
[0035] In an embodiment, the terminal service management and service processing apparatus can be made up of an interconnected apparatus. Indeed, the interconnected apparatus can be realized through other methods and meanwhile the terminal management apparatus and service processing apparatus can be split into even smaller apparatuses.
Embodiment 2
[0036] A service processing module and the mapping table for the terminal apparatus identifier ID and processing method may be added into the central office apparatus. The mapping table may include a two-field terminal apparatus identifier ID and the corresponding processing method for the terminal. The mapping table can be configured manually or automatically (as described in the first embodiment). The service processing module may receive the information frames transmitted from the terminals, get the terminal apparatus identifiers from the information frames, determine the mapping table for the terminal apparatus identifiers and processing methods, and process the information frame using the processing method in the mapping table.
[0037] As described above, the embodiments are only some of the implementations of the present disclosure. However, as will be appreciated by those skilled in the art, various modifications may be made to the aforementioned embodiments without departing from the scope of the present disclosure. Therefore, the scope of the present disclosure is in accordance with the scope of the following claims. | A method of communicating for a communication apparatus, which includes: a terminal apparatus transmitting the information frames to a central office apparatus; the central office apparatus receiving the information frames and obtaining the terminal apparatus information from the information frames; the central office apparatus processing the information frames transmitted from the terminal apparatus, using the terminal apparatus information obtained from the information frames; whereby communication between the central office apparatus and the terminals of different vendors is implemented. | 7 |
RELATED APPLICATION
This application is a Non-provisional application based on Provisional application S. No. 60/306,217, filed Jul. 18, 2001, and on which priority is claimed.
FIELD OF INVENTION
This invention relates to silicon carbide discontinuous fibers, which are substantially free of whiskers, and methods for their manufacture.
BACKGROUND OF INVENTION
Silicon carbide whiskers are known in the art. Articles manufactured employing such whiskers are also known to be good to excellent absorbers of microwave energy, particularly low energy microwave energy, e.g., about 2.45 GHz and about 1000-3000 watts. These whiskers are commonly 1-3 microns in diameter and 10-200 microns long.
Silicon carbide whiskers, however, suffer problems relating to their potential carcinogenicity. More specifically, these whiskers, which are very small, readily inhaled, difficult to contain against dispersion into the ambient environment, among other undesirable characteristics or properties, are both difficult and expensive to manufacture and/or to be formed into a product which is useful. One proposed specific use for silicon carbide whiskers is in the fabrication of a filter for carbonaceous or organic components of a gaseous discharge stream, such as, for example, a filter for the exhaust system of a diesel engine.
Due to their small size, e.g., many times smaller than cellulose paper-making fibers which commonly are of about 7-20 microns diameter and about 50-1000 microns length, these whiskers also are unsuitable for use in the well-known and relatively inexpensive paper-making processes for forming the whiskers into a sheet, which can subsequently be formed into a pleated filter paper product, for example.
Heretofore, it has been proposed to produce silicon carbide fibers, as opposed to whiskers, to serve as heating elements in a microwave field. However, certain of these methods produce spun continuous filaments which must be cut to produce discontinuous fibers. This method is expensive and time-consuming. Moreover, cutting of the filaments tends to expose their cut ends to oxidation or other deleterious degradation. Also, it has been proposed to produce silicon carbide fibers which are somewhat free of whiskers, but the method employed requires an initial step of producing carbon fibers which are thereafter converted to silicon carbide. However, these fibers do not heat rapidly in a low energy (e.g., 2.45 MHz) microwave field. None of these known methods provides a cost-efficient and environmentally friendly means for the manufacture of substantially whisker-free silicon carbide fibers which are individually on the order of the size not materially less that the size of cellulose paper-making fibers, hence suitable for use in the manufacture of desired geometrical shapes.
SUMMARY OF INVENTION
The present invention comprises silicon carbide fibers of an individual size equal to or not substantially less than the size of cellulose paper-making fibers and which are substantially free of whiskers. On one embodiment, the fibers are formed employing cotton fibers, preferably chopped cotton fibers. The chopped cotton fibers are carbonized in an inert atmosphere at a temperature of between about 700° C. and about 1200° C. These fibers, in water, are blended with calcium oxalate monohydrate mixed in hot methanol, ferrous sulfate, and fumed silica, and thereafter dried with heating. This mix is loaded into graphite tubes and heated at an elevated temperature for a time sufficient to effect the principal reaction of:
SiO 2 +3C═SiC+2CO Eq.1
and resultant conversion of the fibers of the mix to silicon carbide. The process yields about 25% by weight of the original weight of carbonized cotton fibers. The vast majority of the discontinuous silicon carbide fibers are of a size approximating the size of cellulose paper-making fibers. Other components of the process product include smaller silicon fibers and/or particulates of non-fibrous geometry. This product is readily suspended in a slurry which is suitable as one of the feed materials for a slurry employed in a substantially conventional papermaking process, employing conventional and well-known paper-making equipment. In the slurry there may be included other ceramic fibers or additives, for example, as desired. The product obtained employing the paper-making process and equipment comprises a self-supporting sheet of discontinuous silicon carbide fibers which are intertangled in the manner of cellulosic fibers and additives found in a conventional paper product. The sheet product so produced has been found to be foldable, such as pleated on a pleating machine, to form a filter medium comprising principally silicon carbide fibers and, in certain circumstances, lesser quantities of entrapped silicon carbide particulates of non-fibrous geometry.
Importantly, the silicon carbide fibers of the present paper-like product obtained is strongly susceptible to relatively low-energy microwave energy and thus may be heated to a temperature of about 800 degrees C. in less than about 15 seconds. At such temperature, common organic materials entrapped in a silicon carbide fiber filter, for example, are combusted and converted to environmentally friendly products.
BRIEF DESCRIPTION OF DRAWING
The single FIGURE is a photographic representation of silicon carbide fibers admixed with silicon carbide non-fibrous particulates as produced by the process of the present invention.
DETAILED DESCRIPTION OF INVENTION
In accordance with a preferred embodiment of the present invention, a quantity of cleaned, bleached and fully carbonized, cotton fibers, of about 10 microns in diameter, chopped to lengths approximating the length of, or longer than, cellulosic paper-making fibers, e.g., to between about 0.1 and about 4 millimeters in length are admixed, preferably in typical liquid-solids V-blender, equipped with an intensifier and a liquidus bar, with ferrous sulfate suspended in water, calcium oxalate monohydrate suspended in hot methanol or hot water, and low density (e.g., fumed) silica, until homogenized. The homogeneous mixture is dried, preferably at about 300 degrees F. This dry mix is loaded into suitable closed containers, such as semi-porous graphite tubes, which, in turn are loaded into a furnace which preferably is preheated to at least about 1450 degrees C., i.e. below about 1750 degrees C. where the formation of whiskers and particulate silicon carbide forms, for about one hour. The silicon carbide fibers formed within the tubes is recovered for further processing. Such further processing, in accordance with one embodiment, comprises formation of silicon carbide fibrous sheet material, employing convention cellulosic paper-making processes and equipment. The silicon paper-like product may be formed into any of various geometrical shapes, including pleating and incorporation into a regeneratable filter for carbonaceous products contained in a gas stream.
Carbonized cotton fibers, as opposed to carbonized PAN fibers or other organic carbonized fibers, is an important aspect of the present invention. For reasons not known with certainty, all non-cotton carbonized fibers known and available to the present inventor fail to yield the desired silicon carbide fibers, as opposed to whiskers. As noted, the useful cotton fibers should be cleaned and bleached cotton fibers which have been carbonized. Examples of suitable carbonized cotton fibers are those available from E & L Enterprises, Inc. of Oakdale, Tenn., or Aerospace Enterprise, Inc. of Gardner, Me. and identified as AEI 1000 degree C. carbonized cotton fibers. Raw, non-carbonized cotton fibers have been found to exhibit unacceptable mixing characteristics in the present invention even when added to the mix in relatively smaller proportions of a mixture of carbonized and raw cotton fibers.
For use in the present invention, the cotton fibers are chopped following their carbonization to individual fiber lengths of between about one-eighth to about one-half inch. The silicon carbide fibers produced from these cotton fibers retain the morphology of the carbonized cotton fibers. As noted, however, a small percentage of the carbonized cotton fibers end up as short silicon carbide fibers or particulates of silicon carbide. These particulates, however, are of insubstantial significance in the present invention in that, in a papermaking process, such particulates pass through the screen and/or are captured within the formed sheet where they can serve the beneficial function of enhancing the formation of the sheet material.
In the present process, a quantity of the carbonized chopped cotton fibers and water are loaded into a conventional rotary blender or V-blender which preferably is provided with an intensifier and liquidus bar. One suitable blender is a Littleford Model FM-130 rotary blender having a 3 cubic foot capacity. Using this blender, preferably only one-half this capacity is employed. Blending commonly takes place within one to five minutes, using the intensifier. V-blender of the common laboratory type are also acceptable.
To the mix of cotton fibers and water, there is added, via the liquidus bar of the blender, ferrous sulfate and calcium oxalate monohydrate, followed by fumed silicon dioxide powder. The order of addition of the ingredients of the desired mix is not critical, but preferably, the carbonized cotton fibers are initially introduced into the blender, followed by the addition of the calcium oxalate, followed by the addition of the ferrous sulfate, and finally, addition of the low density silica. Preferably, the calcium oxalate monohydrate is suspended in hot methanol and added to the blender via the liquidus bar. Similarly, the ferrous sulfate is suspended in water and also added to the blender via the liquidus bar. The silicon dioxide powder is added in the dry powder form to the blender.
In a preferred mixture, there is employed 31.6 parts of carbonized cotton fibers, 0.4 parts of calcium oxalate monohydrate, 12.5 ml of a solution of 25 mg Fe++/ml water (in the form of ferrous sulfate; equivalent of 0.0036 gm Fe) and 68.2 parts of fumed silicon carbide.
The quantity of cotton fibers in the mix may vary between about 25 and about 35 parts; the calcium oxalate may vary between about 0.3 and about 0.6 parts; the ferrous sulfate may vary between about 10 and about 25 ml of the noted suspension; and the silicon oxide may vary between about 66 and about 70 parts. Preferred results are obtained when the mix is mixed to homogeneity. In particular, homogeneity of the dispersion of the ferrous sulfate within the mix is important in ensuring conversion of the fibers to silicon carbide. Further, it is of importance in the present invention that the mix be free of any significant amount of a whisker growth component, such as boric oxide.
Drying of the mixture may be carried out by dispensing the mix from the blender into flat pans, for example, and heating the mixture in the pans within an oven at 300 degrees F.
The dried mix is thereafter loaded into semi-porous graphite closed containers for conversion of the fibers of the mix to silicon carbide. In a preferred embodiment, the mix within a tube is heated as rapidly as possible to a temperature of about 1700 degrees C. In a preferred embodiment, this activity is carried out by preheating an oven to a temperature of 1700 degrees C. and, after expulsion of air from the mix in the tube by means of a brief (e.g. 45 minutes) argon purge, the tube with its mix contents is moved into the preheated oven, having an inert atmosphere, and held therein for between about one and about 5 hours. Preferably, the residence time within the oven is about two hours.
Employing the process of the present invention, there is achieved substantially 100% conversion of the fibrous material to silicon carbide, with a yield of between about 20% and 30% of the original weight of the carbonized cotton fibers. As may be seen from the single FIGURE, the vast majority of the silicon carbide fibers produced are of a size approximating the size of cellulosic paper-making fibers. The remainder of the mix comprises relatively small amounts of silicon carbide particulates and/or shorter silicon carbide fibers. The product so produced contained an insignificant quantity (e.g., less than 1%) of silicon carbide whiskers. Microscopic examination of the product showed silicon carbide fibers having individual diameters of about 5-25 microns in diameter and lengths of between about 100 and about 3,000 microns.
The product produced by the present invention was formed into a sheet employing conventional paper-making techniques. This paper was thereafter pleated employing a conventional pleating machine, preferably which the sheet was captured between first and second cellulosic paper sheets. The pleated sheet was formed into a filter geometry and tested for susceptibility to microwave radiation, employing a conventional household microwave oven of 2.45 GHz (about 600 watts). It was found that the product produced by the present invention consistently was heated in this oven to greater than 700 degrees C. within about 30 seconds. | Method for producing discontinuous silicon carbide fibers, useful as heating elements in a low-energy microwave field, from discontinuous carbonized cotton fibers employing an admixture of carbonized cotton fibers, a metal salt promoter, calcium oxalate monohydrate, and low-density silicon dioxide. The admixture, in a dry state, is introduced into a preheated oven at about 1450 to 1750 degrees C. for between about one and five hours. Silicon carbide fibers and a sheet formed from the fibers are disclosed. | 3 |
FIELD OF THE INVENTION
The present invention relates to a connector assembly including an interconnectable socket connector and header connector. More particularly, the present invention relates to a connector assembly for electrically connecting an electronic apparatus housed in a socket connector to a header connector.
BACKGROUND OF THE INVENTION
In establishing electrical connection between various components, especially in the electronics environment, socketing has long been used as an expedient. Socketing entails providing a pair of connectors which are matable. One connector of the pair typically houses an electronic apparatus while the other connector of the pair is mounted and electrically secured to an object to which connection is desired such as a printed circuit board. Where connection is desired between an electronic apparatus and a printed circuit board, the first connector is usually referred to as a socket connector while the second connector is usually referred to as a header connector.
In addition to providing ease of interconnectability, the socket connector is also used to provide physical protection to the electronic apparatus housed therein. Socket connectors may be constructed which totally enclose an electronic apparatus housed therein to prevent external contaminants from adversely affecting the electrical performance of the apparatus. However, in certain extremely harsh environments, such as those found in the engine compartment of an automobile, merely covering the electronic apparatus may be insufficient protection.
The art has seen the use of encapsulation techniques where the electronic apparatus is encapsulated or potted, with a curable potting compound. The potting compound is typically provided in a fluid state, which after being poured around the electronic apparatus, hardens or cures to a solid state, thereby providing an environmental seal around the electronic apparatus. Socket connectors, which support such electronic apparatus, must be also capable of containing a curable potting compound in such a manner that complete encapsulation of the electronic apparatus is achieved.
In order to facilitate mass production of such socketed connectors, the socket connector should support the electronic apparatus in such a manner that it is relatively easy to completely encapsulate with potting material.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a connector assembly for electrically connecting an electronic apparatus to a printed circuit board.
It is a further object of the present invention to provide a socketable connector assembly which permits the matable interconnection of electronic components.
It is a still further object of the present invention to provide a connector assembly for electrically connecting an electronic apparatus supported in a socket connector to a header connector supported on a printed circuit board, and which permits the encapsulation of the electronic apparatus supported in the socket connector.
In the efficient attainment of these and other objects, the present invention provides a connector assembly for electrically connecting an electronic apparatus to a printed circuit board. The assembly includes a socket connector and a matable header connector. The socket connector includes an insulative open-sided container which is capable of retaining a curable potting compound. A plurality of electrical contacts are supported by the container having first ends within the container which engage and support the electronic apparatus. Opposed second ends of the contacts extend exteriorly of the connector. Means is provided for supporting the electronic apparatus in a position within the container to permit the electronic apparatus and the first ends of the contacts to be surrounded by the potting compound. A cover is supportable over the container to enclose the potted electronic apparatus. The header connector is securable to the printed circuit board and includes an insulative housing and plural electrical terminals electrically engageable with the socket contacts to establish electrical connection therebetween.
As more particularly shown by way of the preferred embodiment, the socket connector includes an open-sided container having a bottom wall and an upstanding side wall extending around the perimeter of the bottom wall. A support platform extends from the bottom wall of the container to support the electronic apparatus in a position spaced from the bottom wall to permit the potting compound to flow therearound. The first ends of the contacts in the socket connector are positioned at a location spaced from the bottom wall and the side wall to help support the electronic apparatus in a position where the potting compound can easily flow therearound.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in exploded perspective view, the socket connector of the connector assembly of the present invention.
FIG. 2 is a perspective showing of a header connector of the connector assembly of the present invention.
FIG. 3 shows an electrical contact used in the socket connector shown in FIG. 1, attached to an electronic apparatus.
FIG. 4 shows the socket contact and the electrical apparatus shown in FIG. 2, supported by a housing of the socket connector of FIG. 1.
FIG. 5 shows partially in section, the assembled socket connector of FIG. 1.
FIG. 6 shows partially in section, the assembled socket connector of FIG. 5 inverted and connected to the header connector shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electrical connector assembly 1 of the present invention is shown in FIGS. 1 and 2. Connector assembly 1 includes a socket connector 10 shown in FIG. 1 and an intermediate header connector 12 shown in FIG. 2. Socket connector 10 is formed of a suitable electrically insulative plastic material and as shown in FIG. 1 includes a lower housing 14 and an upper cover 16. Lower housing 14 is generally rectangular in shape having a planar bottom wall 18 and an upstanding side wall 20 extending about the perimeter of bottom wall 18. The upper surface of lower housing 14 is open thereby forming an open-ended container which is closed by cover 16. Lower housing 14 and side wall 20 define and internal cavity 21.
Socket connector 10 further includes plural electrical contacts 22, one of which is shown in FIG. 1. Contacts 22 are positioned on lower housing 14 in a manner which will be described in further detail hereinbelow.
Cover 16 is also generally rectangular in shape, having a planar upper wall 24 and a depending side wall 26 extending perimetrically around upper wall 24. Cover 16 is constructed to fit over lower housing 14 to enclose cavity 21 thereof. Cover 16 includes an upwardly extending portion 28, which permits accommodation of contacts 22 as will be described in further detail hereinbelow. Cover 16 also includes a latch 30 mounted on side wall 20. Latch 30 is manually operable to secure and lock socket connector 10 to header connector 12, as will be described in further detail hereinbelow.
Referring additionally to FIG. 3, socket connector 10 is designed to house an electronic apparatus 32 which may include a printed circuit board 34 upon which are mounted various electronic devices 36. Electrical contacts 22 are used to establish electrical connection with electronic apparatus 32. Contacts 22 are elongate members formed of suitably electrically conductive material, and include a first end conventionally formed into a pin receiving socket 38. Each contact 22 further includes an elongate central portion 40 extending from socket 38 to a connecting clip element 42 at the opposite end thereof. Clip element 42 is used to engage an edge 34a of printed circuit board 34. Clip element 42 includes upper and lower fingers 44 which engage opposed surfaces of printed circuit board 34 about edge 34a. Fingers 44 typically electrically engage metallic traces (not shown) on the surfaces of printed circuit board 34 to establish electrical connection therebetween. Central portion 40 of contact 22 includes an angled transition region 46 which horizontally spaces clip element 42 from socket 38.
In the present embodiment, it is contemplated that socket connector 10 will employ eight contacts 22. The contacts 22 are spaced along edge 34a of printed circuit board 34. The clip elements 42 of contacts 22 secure contacts 22, both mechanically and electrically to printed circuit board 34. It of course may be appreciated that a socket connector may be constructed which could support a various number of contacts 22 as may be needed for a particular application.
Referring now to FIG. 4, the electronic apparatus 32 and contacts 22 which are secured thereto, are inserted into lower housing 14. Socket contact 22 includes a wall engaging portion 48, shown in FIG. 3, which clips onto an upper edge of 20a of side wall 20. The engagement of each of contacts 22 with the upper edge 20a of side wall 20 secures the contacts thereto and also fixably supports electronic apparatus 32 within cavity 21 of lower housing 14.
Contacts 22 are constructed so that central portion 40 thereof extends down toward bottom wall 18, but terminates in clip element 42 at a location spaced from bottom wall 18. Thus, as shown in FIG. 4, clearance is provided between printed circuit board 34 and bottom wall 18. Additionally, as shown in FIGS. 1 and 4, lower housing 14 includes a platform 50 extending upwardly from bottom wall 18 at a location spaced from contacts 22. Platform 50 includes a board bearing surface 52, which is substantially parallel to bottom wall 18 and which supports an edge 34b of printed circuit board 34 opposite to edge 34a. Platform 50 helps support printed circuit board 34 within cavity 21 at a location spaced from bottom wall 18. In addition, as particularly shown in FIG. 4, transition region 46 of contact 22 disposes clip element 42 at a location spaced inwardly from side wall 20. This provides a clearance between clip element 42 and side wall 20. Further, board bearing surface 52 of platform 50 is spaced inwardly from side wall 20. Thus, as positioned in FIG. 4, printed circuit board 34 is positioned centrally within cavity 21 spaced from side walls 20. By spacing printed circuit board 34 away from both bottom wall 18 and side all 20 of lower housing 14, clearance is provided on all sides of printed circuit board 34 which permits complete encapulsation of electric apparatus 32.
Referring now to FIG. 5, an electronic apparatus 32, including printed circuit board 34, is spaced both vertically and horizontally away from bottom wall 18 and side wall 20 of lower housing 14, a potting compound 56 may be poured into cavity 21 of lower housing 14 to completely surround electronic apparatus 32 as well as clip elements 42 of contacts 22 which engage printed circuit board 34. Potting compound 56 is of the type which is commonly used and commercially available in the electronics industry to environmentally seal electronic components. It is typically provided in a fluid state so that it may be poured into cavity 21 of lower housing 14, to flow completely around electronic apparatus 32 and clip elements 42 of contacts 22. The potting compound 56 is permitted to cure to a hardened state whereby the electronic apparatus as well as its electrical connection to contacts 22, are environmentally sealed.
Once potting compound 56 hardens or cures, cover 16 may be placed over lower housing 14 to enclose the potted electronic apparatus 32. As shown in FIG. 1, lower housing 14 and cover 16 may include cooperative key element such as a rib 58 on lower housing 14 and a slot 59 on cover 16 to provide keyed-matability between cover 16 and lower housing 14. Extending portion 28 of cover 16 accommodates extending sockets 38 of contacts 22, securely retaining contacts 22 within socket connector 10. Extending portion 28 includes openings 55 adjacent sockets 38 to permit electrical connection to sockets 38.
Referring now to FIGS. 2 and 6, the connection of socket connector 10 to header connector 12 is shown. Header connector 12 includes an elongate insulative body 60, having a central cavity 62 of like shape to that of extending portion 28 of cover 16 which is received therein. The shape of extending portion 28 and cavity 62 provides a keying feature preventing improper connection of socket connection 10 to header contacts 12. Header connector 12 includes a plurality of pin-type contact terminals 64 in number corresponding to the number of contacts 22 in socket connector 10. Header connector 12 includes a latch receiving member 66, which comprises a tapered lead-in portion 67 and a securement portion 68. Latch receiving member 66 is engageable with latch 30 to lock socket connector 10 to header connector 12.
As shown in FIG. 6, header connector 12 is typically mounted to a further printed circuit board 65 in conventional fashion. Socket connector 10 is inverted from its position shown in FIG. 5, so that it may be connected to header connector 12 mounted on printed circuit board 65. Extending portion 28 of cover 16 supporting contacts 22 is inserted into cavity 62 of header connector 12. Electrical connection is established between terminal 64 and socket 38 of each of contacts 22 in conventional pin and socket fashion. Latch 30 engages lead-in portion 67 and snaps into securement portion 68 to lock socket connector 10 to header connector 12. Latch 30 may be manually released so that socket connector 10 may be removed from header connector 12.
Socket connector 10 provides an environmental seal to electronic apparatus 32, and therefore may be used in harsh environments such as the engine compartment of an automobile to establish electrical connection between sophisticated electronic components now being used in automobiles.
Various changes to the foregoing described and shown structures would now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims. | A connector assembly for electrically connecting an electronic apparatus to a printed circuit board includes a matable socket connector and head connector. The socket connector includes a lower housing which supports the electronic apparatus and which is capable of containing an insulative curable potting compound. A plurality of electrical contacts is supported by the lower housing in electrical engagement with the electronic apparatus. A cover is supportable over the lower housing for enclosing the housing. The electronic apparatus is supported within the socket connector in position so that the curable potting compound may completely surround the electronic apparatus providing an environmental seal. The socket connector is insertable into the header connector supported on the printed circuit to establish electrical connection therebetween. | 7 |
This is a continuation-in-part of U.S. patent application Ser. No. 422,887 made by the present applicant and filed Sept. 24, 1982, now abandoned.
FIELD OF THE INVENTION
This invention relates to a system to accumulate potential energy and, in particular, to such a system of the type adapted to harness multiple sources of energy including those of variable input, such as from the wind, the sun or the water.
DESCRIPTION OF THE PRIOR ART
The competitive production of power from the wind, the sun and also in many cases also from the water, is hampered in particular by the large seasonal, daily and even hourly variations in the amount of such energy that is available at any time.
OBJECTS OF THE INVENTION
It is a general object of the present invention to provide a system of the above type, which is constructed and arranged to reduce the effect of the variable input of such sources of renewable energy.
It is another object of the present invention to provide a system of the above type, which may be driven by about any kind or number of energy-responsive machines.
It is a more specific object of the present invention to provide a system of the above type, in which potential energy is accumulated during the peak portions to be released during the energy deficient portions of the cycles of operation.
Still another object of the invention is to provide a system of the above type, in which variable rotary input power is converted into substantially constant output.
It is a further object of the present invention to provide a system of the above type, which is of simple, inexpensive and efficient construction and operation and which can be each assembled and disassembled for intallation at various locations.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will be better understood with reference to the following detailed description of a preferred embodiment thereof, which is illustrated, by way of example, in the accompanying drawings, in which:
FIG. 1a is a cross-sectional view of a major portion of a potential energy accumulating plant forming part of a first embodiment of the present invention, showing a rotor assembly in dotted lines;
FIG. 1b is a cross-sectional view of a pumping unit in combination with the remainder of the plant thus complementarily illustrating, in cooperation with FIG. 1a, a potential energy accumulating system with variable input-regulated output according to the present invention;
FIG. 2 is a view of a weight lifting assembly forming part of FIGS. 1a and 1b, in combination, and illustrating the weight lifted position;
FIG. 3 is a side elevation view of a scissor link forming part of the weight lifting assembly;
FIG. 4 is a cross-sectional view of dual weight passages at the upper end of the weight lifting assembly, as seen along line 4--4 in FIG. 1a;
FIG. 5 is a cross-sectional view of a dual weight passage and gate at the lower end of the weight lifting assembly, as seen along line 5--5 in FIG. 1a;
FIG. 6 is a top plan view of the potential energy accumulating plant according to a second embodiment of the invention;
FIG. 7 is an outline and schematic view of the plant illustrated in details by FIGS. 1a and 1b;
FIG. 8 is a cross-sectional view of a plant forming part of another embodiment of the invention;
FIGS. 9, 9a, and 9b are schematic illustrations of three different types of turbines that are usable in cooperation with the pumping unit of FIGS. 1b and 7, and that would provide variable drive to it;
FIGS. 10 and 11 are schematic elevations of two different types of solar energy units that can be used to provide the variable drive to the pumping unit; and
FIGS. 12 to 16 inclusive are schematic elevation views of water-actuated units that can also be used to drive the pumping unit of FIGS. 1b and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrated system (see FIG. 7, 1a and 1b) comprises pumping unit 10, a drive unit to actuate the pumping unit and a potential energy accumulating plant 11 that is connected to the pumping unit to be hydraulically or pneumatically operated by the latter.
The pumping unit 10 comprises a body 12 carried by legs 13. A planetary gear system is mounted into one face of the body 12 and includes a sun gear 14 fixedly attached on an axle 15, planet gears 16, and a ring gear member 17. The latter is rotatably mounted by ball bearings, as shown, in a circular cavity in one side of the body 12. The ring gear member 17 is provided with a socket 18 axially projecting outward thereof and arranged to be driven by a stud axle 19 of a driving element. That stud axle is secured in the socket 18 by a setscrew 20. Thus, any rotation of the stud axle 19 is transmitted to the ring gear member 17 and to the sun gear 14 and axle 15. A cam 21 is mounted on the end of the axle 15 in a central chamber 22.
A pair of pistons 23 are slidably mounted in a pair of radial piston chambers positioned radially outward relative to the central chamber 22. There is a series of pairs of pistions 23 and chambers equally angularly arranged in a circle. Each piston 23 is provided with a piston rod 24 having its head projecting in the central chamber to be engaged by the cam 21. The latter is arranged to alternatively engage the heads of the pistons 23 and to outwardly displace the same alternatively radially outwardly in its piston chamber against the bias of the corresponding return spring 25. Each piston chamber is provided with an inlet and an outlet apertures and check valves 26, 27 mounted in them respectively. The inlet apertures are interconnected by an outlet passage 29. The inlet passage 28 and the outlet passage 29 are connected by fluid lines or tubes 30 and 31 to an inlet manifold 32 and an outlet manifold 33, respectively. Those manifolds 32 and 33 allow to connect two or more pumping units in parallel one with the other to supplement each other. For instance, a second pumping unit, not shown, would be connected by fluid lines 30' and 31' to the corresponding manifolds 32 and 33. For instance, two or more pumping units 10 could be actuated by two different driving elements, such as a wind turbine for one and a solar energy apparatus for the other, as shown hereinafter.
The plant 11 is operated by the fluid pressure produced by one or more pumping units 10. The plant 11 can be used to drive, for instance, a rotor assembly 35 to operate, for example, an electric generator.
The rotor assembly 35 includes an endless conveyor that extends downwardly from the outlet end 36 of an upper ramp or trough 67 to a lower inlet end 37 of a lower return ramp or trough 66. The endless conveyor includes an endless belt 38 to which are secured shelves or plates 39. The latter are arranged to carry weights in the form of balls 40 that are dropped on them on one side of the endless conveyor to rotate the latter. Appropriate means transmit the rotation of the endless conveyor to any load, such as an electric generator. Rotor assembly 35 can be eliminated, and balls 40 allowed to drop freely, or otherwise to do useful work, such as stone crushing.
The weight lifting circuit comprises a weight lifting assembly formed of a pair of weight or ball lifting mechanisms mounted side by side and operated by a common actuation system.
As shown in FIGS. 1a, 4, and 5, the weight lifting assembly defines a lower entry and an upper exit for the balls 40. Each ball lifting mechanism includes a receptacle 46 that is pivotally connected to a bracket 47 and a scissor link unit 48. The latter includes a plurality of scissor links 49 that are articulated one to another. The lower end 50 of each scissor link unit 48 is secured in fixed position relative to the housing of the plant. The upper end of each scissor link unit 48 carries the bracket 47 to displace the latter and the receptacle 46 up and down with it. An actuator member 51 is connected to the lower scissor link 49 to upwardly expand the same and to expand the upper end of the scissor link unit at a greater distance compared to the lower scissor link. The actuator member 51 is attached at one end of a cable 52 at the other end of which a counterweight 53 is attached. The cable 52 passes over a pulley such that the counterweight 53 balances the weight of the actuator member 51 and the corresponding scissor link unit, bracket 47 and receptacle 46.
A common actuation system for the two weight lifting mechanisms is operatively connected to the corresponding actuator members 51. The common actuation system includes a pair of cylinders with each a piston 54 slidable in it. Each piston 54 is provided with an axial projection 55 that is fixedly attached to the corresponding actuator member 51 to bodily displace the latter with its piston. Each piston 54 is downwardly biased by a return spring 56 to expel the fluid from its cylinder. A fluid inlet passage 57 and a fluid outlet passage 58 are formed in the plant 11 under the pistons 54, are connected to the manifolds 32 and 33 by tubes 59 and 60 respectively, and communicate with each cylinder. The pair of fluid inlet passages 57 of the two cylinders are interconnected one with the other, and so are the two outlet passages 58. A double valve is provided for each cylinder to selectively close either one or the other of the corresponding inlet passage 57 or outlet passage 58. For that purpose, each of the two double valves is provided with a valve element 61 and a valve element 62, respectively. Each double valve includes a stem 63 that upwardly projects and is downwardly biased by a return compression spring 64. An arm 65 is pivoted above each piston 54 and arranged to upwardly displace the corresponding double valve upon engagement by the corresponding piston when the latter arrives at its innermost or topmost position, as shown in FIG. 2. When this occurs, the valve element 61 stops the supply of fluid into the cylinder through the inlet passage 57 and opens the outlet passage 58 to expel the fluid from the cylinder under the action of the corresponding return spring 56. It can thus be seen that, when one piston 54 moves upward, the other moves downward and the fluid that is expelled from one cylinder compensates or balances the fluid that is pumped into the other cylinder; and the fluid lines and elements can thus form a substantially closed system.
As can be seen in FIG. 3, the small displacement or extension of the lower scissor link 49 is converted into a much larger displacement of the upper end of the scissor link unit and, thus, of the corresponding receptacle 46 that lifts a ball 49 to the exit end of the ball lifting mechanism from the lower entry.
The weight lifting circuit includes the lower trough 66 and the upper trough 67. The loweer trough 66 forms a ramp downwardly sloping from the outlet of the endless conveyor 35 to the lower entry of the ball lifting mechanisms. The upper trough 67 slopes in the opposite direction from the upper exit of the ball lifting mechanisms to the upper outlet end 36.
A swing gate 68 (FIGS. 1a and 5) is pivoted at the entry of the ball lifting mechanisms and is Y-shaped in cross-section to operatively pivot transversely between the dual inlet passages 69. The swing gate 68 is pivoted from one side to the other by each ball 40 that rolls by. This is done by the ball engaging one of its sides and pivoting it, so that the next ball will engage the other side, and so on alternatively. Thus, the ball lifting mechanisms will alternatively be loaded and will lift a ball to unload it at the upper exit by tilting of the receptacles 46 upon abutment with the projection 70 at the upper end of each ball lifting mechanism.
The loading of a ball on each receptacle 46 is controlled by a first and second spaced-apart flap gate 71a, 71b pivotally connected to a transverse bar 72 extending under trough 66. Bar 72 is also pivotally connected to the ramp at 72a intermediate gates 71a, 71b.
The first gate 71a is nearer to receptacles 46 than the second gate 71b. The bar 72 also includes at the end thereof, adjacent bracket 47, a coiled spring 73 fixedly connected thereto and downwardly extending. Spring 73 biases gate 71a upwardly through the wall of ramp 66, while biasing retraction of gate 71b under the lever action.
Before a ball 40 is loaded in receptacle 46, the downwardly moving bracket 47 presses the end of bar 72 against spring 73. Thus, gate 71a retracts, and gate 71b protrudes upwardly, preventing other balls 40 from falling in the latter receptacle 46.
When receptacle 46 is lifted, it allows another ball 40 to engage in a position in beteen gates 71a and 71b, since ramp 66 is inclined, and since the bias of spring 73 will retract gate 71b and extend gate 71a, through the ramp 66 and thereinto.
Everything is done automatically, simply by the weight of balls 40, and the displacement of receptacle 46.
The upper exit (FIGS. 1a and 4) is divided by a partition 74 into dual exit passages 75 registering with the two ball lifting mechanisms, respectively.
As best seen in FIG. 1a, spaced-apart pivoted regulating gates 45 and 76 are positioned at the upper inlet end of the endless conveyor 35, and are arranged to intercept the balls 40 and hold them in the ramp 67 and, thus, to form a waiting station for them.
The operating mechanism of gates 45, 76 is quite similar to that of gates 71a, 71b. Gates 45, 76 are pivotally connected to a transverse bar 120, through corresponding arms 121, 122. Bar 120 is itself pivotally connected to ramp 67 through arm 123, located between arms 121, 122. A coil spring 124 also biases gate 76 to protrude within ramp 67, while it biases gate 45 to become retracted.
When a shelf 39 becomes in registry with bar 120, it will temporarily abut the free end thereof, wherein the bar will pivot on its central axis 120a against the bias of spring 124. This will extend gate 45 and retract gate 76. When the shelf 39 releases bar 120, the latter pivots to its initial position, and gate 45 retracts and gate 76 is extended.
The balls 40 thus timely roll down to fall onto the shelves 39. If no rotor 35 is used, then the falling balls may be used for othr types of work. the ramp 67 may be arranged to store any desired number of balls 40 to hold a good reserve at the waiting station. However, by using multiple types of power inputs, the number of balls 40 stored at the waiting station can be reduced.
Thus, the generation of power may be sustained despite interruption of the pump and lifting mechanism for lack of sufficient wind, sunshine, and/or fluid energy to operate the machine driving the stud axle 19.
FIG. 6 specifically discloses a potential energy accumulating system having a plurality of pumping units 10 and weight lifting mechanisms located in casing 46a and each including long buckets 46 each lifting, for instance, three balls 40. Each pumping unit may be driven by a different power source. One of these units, at 10', may be activated by large animals drawing the legs L of the unit when the animals are guided to walk around the unit 10'. One unit 10 may be driven by electric motor 34 fed by a conventional electric power grid during periods of low demand. Any number of units 10 may be provided with fluid feed and return lines 30 to 30"", 31 to 31""to feed manifolds 33a, 33b and return manifolds 32a and 32b.
The essential difference found in the embodiment of FIG. 6 is the shape of the upper ramp 67, now a multi-ramp 67', including a rear-enlarged portion 75a, an intermediate circular portion 75b, and a number of front legs 36a. Within circular portion 75b of ramp 67 there is axially connected thereto a distributor disc 75c, having a depending circular skirt 75d extending toward portion 75b. Skirt 75d forms a wide inlet 75e always communicating with portion 75a for constantly receiving balls 40, and a narrow outlet 75f for the passage of successive balls 40. Disc 75c may be rotated by a crank wheel 130, operated by a handle 131, and actuating a bevel gear 132 meshing with radial teeth 133 on disc 75c.
Rotation of disc 75c aligns outlet 75f with any selected leg 36a to allow selective distribution of balls 40 into legs 36a. Each leg 36a may be associated with a rotor assembly having fingers instead of shelves 39 to pass between fingers 36b at the outlet of legs 36a.
In the embodiment of FIG. 8, the solid balls 40 are replaced by a liquid. The troughs are in the form of basins 140, 141 capable of containing a liquid, such as water W thereinto, and being at the bottom and top portion respectively of the system. The receptacles of the weight-lifting mechanism are replaced here by water-tight water buckets 46', activated in the same manner as before. However, release of determined amount of water W from lower basin 140 into a bucket 46' is done through prior engagement of water within a cylindrical valve 142 pivotable about its central axis.
The valve 142 rotatively engages a recess 140a of basis 140 and is pivotable through a link 144 eccentrically pivoted to valve 142 at 142a and pivoted at its other end to a transverse lever 145 located under basin 140.
Lever 145 is similar to bar 72 in its relation with bracket 47, and has an inner end 145a pivoted to the frame. Valve 142 includes two wall openings 146a, 146b opposite one to the other. When a water bucket 46', seated on its bracket 47, is lowered during its cycle, bracket 47 pivots arm 145 downwardly against the bias of the spring 147. This draws link 144 therewith, and rotates valve 142 counterclockwise. The water trapped within valve 142 may exit through outlet opening 146a, toward bucket 46', while inlet opening 146b is now over the water-line.
Basin 141 also includes a cylindrical valve 150 housed within the walls thereof and under the body of water W of the same. Valve 150 is sealingly rotatable and also includes two peripheral top and bottom openings 150a, 150b. Opening 150a may become in registry with a basin drain hole 151 and opening 150b may become in registry with a lowermost outlet duct 152, but not at the same time.
Rotation of valve 150 is operated by the movement of shelves 39 (see FIG. 1a) (now water-holding buckets) that each temporarily abut on a lever 153 to downwardly pivot the same about pivot axis 153a. Lowering lever 153 draws down link 154 pivotally connected at 155a to the wall of valve 150. The bias of spring 156 returns bar 153 to its initial position. As shown in FIG. 8, lowering link 154 rotates valve 150 counterclockwise.
Since the volume of water W transferred to each bucket 46' is less than half the capacity of valve 142, whereas the volume of water escaping through outlet duct 152 is equal to the inner volume of valve 150, one needs larger buckets for collecting the water of upper basin 141 than the buckets 46' collecting the water from basin 140. However, the arrangement of valve 150 could be similar to that of lower valve 142.
As may now be seen from FIGS. 9 to 16 inclusive, a good variety of machines operated by renewable energy and characterized by a variable output may be connected to drive the pumping unit 10. It must be noted that any number of such machines may be connected to any number of pumping units 10 to produce a fluid flow through the manifolds 32, 33 to the afore-described weight lifting mechanisms.
FIGS. 9, 9a, 9b respectively illustrate three types of horizontal axis rotatable turbines; a wind propeller 91, a wind paddle wheel 92, and a water turbine blade 93 wherein the horizontal output axle is to be drivingly connected to the stud axle 19 of FIG. 1b.
FIG. 10 and 11 illustrate two types of solar energy actuated machines 94 and 95, whose output shaft is connected to the stud axle 19. The machine 94 includes a bi-metal blade 96 whose displacement in response to the sun rays 97 reflected by, for example, a mirror M, is transmitted to the stud axle 19 by a rod 98 and an arm 99. The machine 95 includes a bi-metal coil 100 whose reaction to the sun rays 97 reflected by mirrow M, is converted into rotation of its coiled portion and, thus, of the stud axle 19 to which it is attached by an arm 101.
FIG. 12 illustrates a machine 102 that is operated by waves 103 of a body of liquid. The latter fills a bucket 104 that is pivotally mounted on an arm 105. The bucket 104 is upwardly biased by springs 106, 107, and the arm 105 is connected to the stud axle 19.
As can be seen, the liquid fills the bucket 104 and rotates the stud axle 19. Bucket 104 then empties for successive cycles. The stud axle 19 thus rotates back and forth, producing pumping by the unit 10 due to the planetary gear system in the pumping unit.
In the machine 110 of FIG. 14, intermittent undergound spurts of liquid or gas move the bell-shape cap 111 up and down to reciprocally rotate the stud axle 19.
In FIG. 15, a plurality of floating pads 112 are connected by arms 113 to rotate the axles 114 in accordance with the tide.
In FIG. 16, the stud axles 19 are rotated by rocking of a boat 115. This is done through the relatively pivotal displacement of the arms 116 attached to the floats 117 and to the stud axle 19.
From the above description, it is clear that the system of the present invention can use several different energy sources to actuate the pumping units 10 or 10'. Therefore, these sources may be such that the peak of their respective power output will occur at different times, to therefore enable to store a minimum of balls 40 or a minimum volume of water at the waiting station in the upper trough. Therefore, such a waiting station need not be of very large capacity so much so that non-variable energy sources can also be used to drive the pumping units in case of failure to obtain power from the variable energy sources.
The system of the invention can be made of separable parts adapted to be easily taken apart and reassembled at another location. The lower trough system could be located in an undergound gallery of an abandoned mine with the upper trough on the ground and with the weight lifting mechanism in one shaft and the outlet and inlet ends of the upper and lower troughs in register with another mine shaft. The system can be situated so as to take advantage of the topography of the soil. Also, the scissor link units can be positioned upside down with the actuating piston 54 at the upper end and the receptacle 46, or water bucket 46', at its lower end. | This potential energy accumulating system is of the type adapted to harness multiple sources of energy, including those of non-variable input such as from fuel and those of variable input, such as from the wind, the sun, the geothermal steam, animal power or the water. The system is characterized by being made to reduce the effect of the variable input of such sources of energy by stocking the same in the form of potential energy, releasable under kinetic form, and by being compatible to be coupled to and driven by any kind or number of machines operated by variable and non-variable energy sources. This system includes a closed circuit arrangement to use and accumulate the potential energy of relatively heavy balls or bodies of water, and to mechanically regulate the output so as to compensate the variations in the energy input. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus of receiving and decoding signals in an apparatus for coding and transmitting video and sound signals in a CATV system, pay TV system or the like, and more particularly to the decoding of sourd signals.
2. Description of the Prior Art
In a pay TV system or the like, video and sound signals are transmitted by coding so as not to be accessed by nonsubscribers, and they are decoded by subscribers, so that normal picture and sound may be reproduced. Regarding this video and sound coding means, various methods had been proposed so far, but they have had their own problems.
For example, the method of always inverting black and white colors of the video signal only, the method of compressing the synchronizing signal, and the method of inverting the synchronizing signal were easy to decode, and the signals were easilly accessed illegally. The method of eliminating the synchronizing signal was unstable in the picture because the jitter of the reproduction synchronizing signal was left over. The method of eliminating the color burst signal was inaccurate in the phase of the reproduction color burst signal and unstable in reproducing colors.
Or, of the methods of coding sound signals, the method of scrambling a PCM sound signal was broad in the bandwidth when another sound carrier was used and was unsuited to an FM broadcast such as satellite broadcasting system, and its decoding unit was expensive. In the method of transmitting sound by plurality carriers and changing them over randomly, the decoding unit was complicated, and it was difficult to balance the stereo sound reproduction.
Object of the Invention
It is hence an object of this invention to present a television sound signal processing apparatus which is hard to access illegally and excellent in the quality of reproduced sound. It is another object of this invention to present a television sound signal processing apparatus capable of eliminating the accumulation of errors when decoding delta-encoded sound signals.
BRIEF SUMMARY OF THE INVENTION
In the television sound signal processing apparatus of the present invention, a digitized delta-encoded sound signal superposed in the horizontal blanking period of television signal, and a standard digital signal of said sound signal superposed in the vertical blanking period are received, and the reference signal of that field is compared with that of one field before, and, when their difference is greater than a predetermined value, the decoded value of the delta-encoded signal immediately before that reference signal is employed as the standard value for the delta decoding of the sound signal.
Furthermore, the reference signals in the field superposed in the vertical blanking period and the fields immediately before and after it are stored continuously for the portion of two fields, and the standad value of the field indicated in the preceding field and that of the present field received in that field are compared, and when they are different and the standard value of the preceding field is correct, the value immediately before that field is used as the standard value for the decoding of the sound signal of that field.
Moreover, the majority value of reference signals transmitted repeatedly by three or more times (by an odd number) within a same horizontal blanking period of a vertical blanking period is used as the standard value for delta decoding of sound signal of the field.
In the television sound signal processing apparatus of this invention, a sound signal of a television signal is sampled and converted into a form of a multivalue digital signal, and its uncompressed digital signal is sent in a certain period while, in the other period, a digital signal is received for the portion of change expressing the difference from the sample value of the sound signal in one horizontal blanking period before being sent into a horizontal blanking period, and, assuming the value of the uncompressed digital signal to be standard value x and the value of the next compressed digital signal to be Δx, the value Δx of the subsequent compressed digital signal is added to the immediately preceding value to process a signal every time as x=y+Δx, and an uncompressed digital sound signal is obtained, which is converted to an analog sound signal.
Furthermore, when an uncompressed digital sound signal is sent in the vertical blanking period once in every field, this digital value x is taken as the reference, and the signals are processed every time as x=y+Δx in relation to the subsequent compressed digital signal value Δx to obtain a digital sound signal in a compressed state, which is converted to an analog sound signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the outline of the television sound signal processing apparatus in one of the embodiments of the present invention;
FIG. 2 is a waveform diagram of signals in the horizontal blanking period of the same apparatus;
FIG. 3 is a waveform diagram of signals in the vertical blanking period in the same apparatus;
FIG. 4 is a block diagram of a sound signal composite circuit of the same apparatus;
FIG. 5 is a block diagram representing the synchronous reproducing circuit of the same apparatus;
FIG. 6 is a flowchart showing the synchronous reproducing procedure of the circuit shown in FIG. 5;
FIG. 7 is a waveform diagram of sound data signals in the same apparatus;
FIG. 8 is a block diagram illustrating the processing signal of the same sound data signals;
FIG. 9 is a waveform diagram showing the reference sound signal in the same apparatus;
FIG. 10 is a waveform diagram of sound data signals, and
FIG. 11 is a block diagram showing the processing circuit of sound data in the same apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention are described below while referring to the accompanying drawings.
In the embodiments, the whole signal processing and overall operation are accomplished by the whole circuits of FIG. 4. Reproducing of the synchronous signals and generating of the sampling clocks and gate pulses for the signal processing of the circuits of FIG. 4 are accomplished by the circuits of FIG. 5 as shown by the flowchart in FIG. 6. Furthermore, by using these clocks and pulses, reproducing the standard sound signal and the delta decoding of the sound data are accomplished by the circuits of FIG. 8. The circuits of FIGS. 6 and 8 each compose parts of the circuits of FIG. 5 respectively.
Delta encoded sound data is contained in the television signal is as shown in FIG. 2 and the shaded areas in FIG. 3, and the details of the sound data is shown in FIG. 7. Furthermore, delta encoded sound data and the standard sound value signal are shown in FIG. 9, and the details of the standard sound value is shown in FIG. 10.
Furthermore, additional operation of these embodiments, i.e. accurate reproduction of the standard sound value is accomplished by the circuit of FIG. 11.
One of the present embodiments is illustrated in conjunction with FIG. 1, wherein numeral 1 denotes the tuner of a televison receiver; element 2 is a VIF circuit; element 3 is a detecting circuit; element 4 is a circuit to reproduce synchronizing signals, and element 5 is a circuit to invert or not to invert the video signal on the basis of the data processing result of a data processing circuit 6. This data processing circuit 6 is intended to process the data, and convert a digital sound signal into an analog signal, and deliver a discriminating signal (changeover signal) to invert or not to invert the video signal. Numeral 7 is a circuit to form an RF output signal (VHF) using the sound and image normalized as the inputs in an RF remodulation circuit.
FIG. 3 shows the signals in the former part of the vertical blanking period, wherein φ 20 is the composite synchronizing signal of the television signal, φ 21 is the horizontal blanking signal in the first field, φ 22 is the output signal of the detecting circuit 3 in the first field, φ 23 is the horizontal signal in the second field, φ 24 is the output signal of the detecting circuit 3, φ 25 is the vertical synchronizing signal, φ 26 is the signal which is produced at the front edge of the horizontal blanking signal of 4H, and φ 27 is the signal which is produced at the front edge of the horizontal blanking signal of 267H.
The output of the detecting circuit 3 lacks a horizontal synchronizing signal and a vertical synchronizing signal as shown in FIG. 2 φ 1 , FIG. 3 φ 22 and φ 24 , and vertical trigger signal V T and horizontal trigger signal H T are inserted instead. The shaded areas φ 22 and φ 24 in FIG. 3 are in same composition as t 2 to t 6 in FIG. 2 φ 1 , i.e.--the data of t 2 to t 6 transmitted at the shaded areas of φ 22 and φ 23 . The polarity of the video signal is repeatedly inverted and noninverted at random intervals in the horizontal scanning line unit or screen unit. When the polarity of color burst signal is changed, however, hue deviation or other problems may occur. Therefore, the color burst signal is not inverted.
Hereunder the reproduction of the synchronizing signal is described. First, the outline of the operation is mentioned by referring to FIG. 5. If a synchronous reproduction is to be effected, the output of a buffer 8 is sliced in a slicing circuit 12 and shaped into a binary signal, and is sampled in a sampling circuit 13 to store sound data at every H in a buffer memory 18, while the delta-encoded signal is decoded in a delta decoder 19 as is described below by referring to FIGS. 7-9 and transferred into a buffer memory 20, whose output is D-A converted at a speed of 2 f H by a D/A converter 21, and two outputs for right and left are obtained using the high quality sound of a sampling rate 2 f H and maximum frequency f H as the output of D/A converter 21.
On the other hand, the data of 5H to 7H, 268H to 270H in FIG. 3 are written into a buffer memory 14, read out, and decoded in a decoder 15, and a signal is provided to control whether or not the video signal is inverted, while a pulse to control the inverting period is formed in an inverting changeover circuit 16 and supplied to a synthesizing circuit 10. The output of a clamp circuit 9 is inverted in an inverting amplifier 17, whose output is also supplied to the synthesizing circuit 10, and the output of the synthesizing circuit 10 is changed over whether the output of clamp circuit 9 or the output of the inverting amplifier 17 is supplied, by the output of the inverting changeover circuit 16. The output of the inverting changeover circuit 16 is also supplied to the inverting amplifier 17, and the output of the inverting amplifier 17 is suppressed when inversion is not required, and the crosstalk is lessened in the synthesizing circuit 10. When the output of the synthesizing circuit 10 is clamped in a clamp circuit 11, an ordinary video signal is obtained.
The synchronous reproduction is described in details below in conjunction with FIG. 5. The procedures of synchronous reproduction and data processing are shown in FIG. 6. Numeral 22 in FIG. 5 is a detecting circuit for detecting vertical trigger signal V T and horizontal trigger signal H T ; element 23 is a reproducing circuit for reproducing color subcarrier f sc ; element 24 is a circuit for effecting a PLL (phase locked loop) of 12f sc and f sc of a VCO (voltage controlled oscillator); element 26 is a 1/5 divider; element 27 is a 1/3 divider, and element 28 is a 1/455 divider of the output of the 1/3 divider 27, that is, 4f sc , whose output is 2f H . Numeral 29 is a 1/2 divider, whose output is f H , and element 30 is a 1/525 divider of 2f H , whose output is about 60 Hz. Numeral 31 is an equalizing pulse generator, and element 32 is a generator of the vertical synchronizing signal. Numerals 28 through 32 are known circuits commonly used as the synchronizing board for synchronizing TV signals. Numeral 23 is a sampling clock forming circuit, and when the data transmission rate is 6/5f sc , a sampling clock is formed by using 12/5f sc of the output of the 1/5 divider 26. The output of the sampling clock forming circuit 33 is supplied to a data sampling processing circuit 6 to be sampled, and the data is processed. Numeral 6A is a sound reproducing circuit for forming analog sound. Numeral 34 is a burst gate forming circuit for forming a burst gate from the output of the 1/2 divider 29. In a synchronous reproducing circuit 35, cmposite synchronizing signals are formed from the outputs of dividers 29, 31, 32, and the composite synchronizing signal output of this circuit 35 and the output of a video clamping and inverting circuit 36 are synthesized in a video synthesizing circuit 37, and a video signal is formed. The video clamping and inverting circuit 36 clamps the video signal and inverts the video signal for a required period according to the output of the data sampling processing circuit 6.
Thereafter, in the procedure as shown in FIG. 6, the synchronizing signal is established, and the data is processed, and the sound is processed.
Parameters of the sound signal and information data are shown in Tables 1 and 2, in which the sound signals in the horizontal blanking period are indicated.
FIG. 7 shows the details of the sound data T 2 to T 6 to φ 1 of FIG. 2.
As evident from Table 1 and FIG. 7, the sound data which is transmitted from the transmitter in every horizontal blanking period is as shown in FIG. 2. φ 1 is comprised of a total 46 bits comprising 44 bits for two samples of each of the right and left sound signal respectively and 2 bits for phase synchronizing, i.e. 1, 0 provided before it. In FIG. 7, based on the fall of the first bit of φ 12 , 45 clocks are generated by timing control circuit 40 thereafter from 0 to 44. Further, 440 clocks for the 440 bits of the data as shown in FIG. 9 T 34 to T 39 (also as shown in FIG. 10) are generated. When the phase of φ 13 is adjusted so that the 1/5 divider 26 may be reset at the first bit of φ 12 , the time for φ 12 settles within the portion of one cycle of 12f sc , that is, about 23 ns (±11.5 ns).
An example of sampling and sound signal processing circuit is shown in FIG. 8. The output of the buffer 8 is sliced in a slicing circuit 38, and a binary waveform as shown in FIG. 7 φ 12 is obtained. On the other hand, in a timing control circuit 40, gate pulses containing a portion of sound signal (t 2 to t 6 in FIG. 2) are generated by using the output signal of the 1/2 divider 29 and 1/525 divider 30.
As the output signal of the 1/2 divider 29 is f H signal which is synchronized to the horizontal trigger signal H T and the output signal of the 1/525 divider 30 is f V signal which is synchronized to the vertical trigger signal V T , the gate pulses are generated by using the pulse generating circuits, for example, multivibrators or counters, which are triggered by the outputs of the dividers 29 and 30 in the timing control circuit 40. The gate pulses are applied to an AND gate 39, and only the sound signals and data are extracted and supplied to D terminal of D flip-flop 41. When the flip-flop 41 is clocked by FIG. 7 φ 13 and 440 clocks, the data can be sampled. The fall of t 42 is detected by the output of the AND gate 39, and clocks 0 and 44 and 440 clocks are generated as stated above.
The buffer memory 43 is controlled by control signal generated in the timing control circuit 40 by using the f sc , f H and f V signal so that the output of the D flip-flop 41 may be fed to the buffer memory 43 only for the portion of 44 bits of 1 to 44. A control signal for writing into the sound data is generated in the timing control circuit 40 by using of the f sc , f H and f V signal and sent from the timing control circuit 40 to the buffer memory 42 so that data for the portion of 440 bits may be stored. This data of 440 bits is the sound or information data as shown in Table 2, and is transmitted in T 34 to T 39 as shown in FIG. 9. This data is picked-up by the D flip-flop 41 by using the 440 clocks and is supplied to the buffer memory 42. When the sound data in FIG. 3 is received in the VBL, uncompressed L and R digital values (for example, 14 bits each) thereof are stored in the buffer memory 42, and are transmitted to an arithmetic circuit 44 a short time later by addressing the buffer memory 42 of the addesses of the sound data. Said 14 bits will be corrected if there is an error of 1 to 2 bits or more.
In FIG. 9, if there are 2×14 bits (including an error correction code) in T 34 to T 35 , the error should be corrected from T 35 to T 42 . This is effected in a circuit attached to the buffer memory 42 by using the parity check method.
On the other hand, the data of T 32 to T 33 is stored in the buffer memory 43 somewhat later (for example, 1 μs) than T 33 . The data of T 32 to T 33 represents the delta-encoded sound signal which is shown in FIG. 7. Supposing this time to be T 33 +ΔT, the data of a 0 to a 10 and the previous data, the previous data is the uncompressed L and R digital values (14 bits each) which was received in previous VBL and stored in the buffer memory as described above, are arithmetically operated by the arithmetic circuit 44 for delta decoding under the control signal from the timing control circuit 40 within, for example, 1 μs, from T 33 +ΔT. When the operation and error correction are done in hard logic, both operations can be processed within 1 μs each. The result of this arithmetic operation is D-A converted by the D-A converter 45 and stored in memory L 1 of 47. Furthermore, the data of c 0 to c 10 is compared with the previous data, and the result is D-A converted and stored in memory R 1 of 49. Numerals 47 through 50 are analog memories.
It is sufficient when the above operations be done within about 1/2H, and when the error correction circuit and arithmetic operation circuit are composed in hard logic as mentioned above, 11 bits of memories L 1 , R 1 may be cmpletely processed within several to ten microseconds. The time of delivering the data L 1 , R 1 of T 3x in FIG. 9 is nearly in the middle of 1H (common to each H). Therefore, there is an allowance of about 26 μs between T 33 and T 3x , and the safe margin is sufficient if the above processing time is assumed to be about 10 μs. From T 3x , processing of b 0 to b 10 , d 10 to d 10 is effected. They are delivered from memory L 2 of 48 and memory R 2 of 50, at T 3y in 1/2H after T 3x .
The timing control circuit 40 is controlled by the f H signal from the 1/2 divider 29 and the f V signal from the 1/525 divider 30, and provides the output having low and high level alternatively changing the level in every 1/2 f H , i.e. low level in T 3x to T 3y and T 4x to T 4y , high level in T 2y to T 3x and T 3y to T 4x .
The output of each memory of 47 to 50 is alternately delivered from AND gates 51 to 55 or OR gates 53, 56. That is, in T 3x to T 3y , since the output of timing control circuit 40 is at low level, the output of the inverter 46 becomes high level, and AND gates 51, 54 are made to conduct, so that the contents of memories 47, 49 may be taken out as L and R sounds, respectively. In T 3y to T 4x , since the output of timing control circuit 40 is at high level, the AND gates 52, 55 are made to conduct, and the outputs of memories 48, 50 becomes L and R outputs. The operation is the same for other Hs.
The sound data received at time T 34 to T 35 in FIG. 9 is processed for error correction by buffer memory 42 until T 39 , and is fed to an arithmetic operation circuit 44 at T 42 , and are directly D-A converted. Thus, the converted data sent within T 34 to T 35 in FIG. 9 is delivered from D-A converter 45 to memory 47, 49 to reproduce the sound for duration of T 4x to T 4y . At this time, 11 bits each of L 1 , R 1 of T 42 to T 43 are not used because the uncompressed data sent in T 34 to T 35 is used for the first sample of the sound in every field. Thereafter, taking this value of the first sample as the starting sound value for each field, only the changed value of the sound from the starting sound value is successively added or subtracted to accomplish the delta decoding under the control signal from the timing control circuit 40 as described above. Meanwhile, if the first one bit of 11 bits is treated as a code, the remaining 10 bits are increments of decrements for delta decoding. Therefore, it is possible to follow up the changes of 60 dB. By using processing digital sound signals, the standard value can be transmitted once in every field correctly by adding an error correction code even in a so-called digital encoding of 11 bits, so that the sound signals are sufficiently excellent and resistance to noise.
Numerals 57, 58 in FIG. 8 are parts of signal processing circuit used in a so-called teletext receiver or the like, and 57 is a bus buffer and 58 is a CPU. That data in the VBL after 4H in FIG. 3 is processed in these bus buffer 57 and CPU 58, of which composition is known, being similar to that of a so-called teletext receiver.
An accurate reproduction of the standard value of sound is described below while referring to FIGS. 9 to 11. The actual sound data in FIG. 9 is assumed as shown in FIG. 10. At φ 100 , the preceding 32 bits are composed of 24 repetitive bits of 1 and 0 of clock run (CR) and 9 bits of framing code. The next 384 bits consist of three sets of sound data of 128 bits each, having the same content, comprising 64 bits of information and 64 bits of check code as in φ 100 . This takes the form of source BCH (Bose-Chandhuri-Huffman) code, one of well-known error correction codes, and can correct random and burst error within 10 bits. The final 24 bits of φ 100 are CRC (Cyclic Redundancy Check) codes, one of well-known error correction codes. The information of 64 bits consists of the portion of two fields each for L and R, 2×2×14=56 bits, and 8 bits of additional data. The 8-bit data may be used as required, and CRC may not be necessarily used.
The flow of signal is explained in FIG. 11. Numeral 57 is an analog gate, and gate pulses comprising T 34 to T 39 in 4H in FIG. 9 are generated in the timing control 40, and the output of video buffer 8 is gated. If any data of the same number of bits is wholly superposed, for example, up to 21H in VBL, gate pulses including T 34 to T 39 (440 bits) are delivered every H from the timing control circuit 40 from 4H to 21H and 267H to 284H, and are applied to a gate 57. The output of the gate 57 is converted into a binary value in the slicing circuit 38, and is gated by the output of the timing control circuit 40 at AND gate 39'. The AND gate 39', different from the gate 39 in FIG. 8, is made to conduct if the gate 57 conducts in other periods than the horizontal blanking period. In the horizontal blanking period, the parts except buffer memory 42, bus buffer 57, and CPU 58 in FIG. 8 will operate as stated above. A sampling circuit 41' , different from the 41 in FIG. 8, is a shift register having an S-P converting function.
On the other hand, the output of gate 57 is applied to (Band Pass Amplifier) 58 of 6/5f sc , and the part of clock run-in in FIG. 10 φ 101 appears as a sine wave. This is used to control the phase of the output of VCO 59 of 12/5f sc . Numeral 60 is a phase shifter, and the phase of the output of VCO 59 is matched with the phase of the output of BPA 58 by the output of BPA 58, that is, the rise or fall of the output of the phase shifter 60 is adjusted to the middle of each bit of received φ 101 , and after the clock run period, phase information is not received but is held until the clock run of next horizontal scanning period or clock run of next field. Thus, since at least 1H can be sufficiently maintained within a same phase, a clock synchronized with data can be formed in the phase shifter 60. The circuit of phase shifter 60 is an analog one, and its output is shaped into pulses in a shaping circuit 61, and supplied into a clock generating circuit 62. The clock is supplied from the clock generating circuit 62 into the sampling circuit 41', and when a framing code appears in the output of the sampling circuit 41', it is detected in FC detecting circuit 41F, and the subsequent 440-32=408 clocks are supplied into the sampling circuit 41', and 408 bits in 1H are sampled, and supplied into a latch circuit 42L. In the latch circuit 42L, the output of the sampling circuit 41' is latched by every 8 bits, and is supplied into the buffer memory 57. Data for the portion of two fields is stored in the buffer memory 57.
Writing of data into the buffer memory 57 and reading-out the data from the buffer memory 57 are controlled by W/R processing circuit 63. The contents in the buffer memory 57, that is, the data in the corresponding field (the portion of three times of L 100 , R 100 in FIG. 10 φ 102 ) of 2×56×3 bits for the portion of two fields, are compared. Since the same data is stored three times, the majority is determined by comparison, and L 101 , R 101 are determined. If not determined, the L 100 , R 100 stored in the previous field are used. The L 101 , R 101 are held up to the next field.
These processing are done by the high speed CPU 64 or hard logic. The time available for processing is about 40 μs at maximum of T 39 to T 4x in FIG. 9, but is is necessary to finish somewhat before T 4x .
The output of the CPU 64 is stored in the buffer memory 65, and supplied to the arithmetic operation circuit 44 before T 4x to be used as the standard value at the time of T 4y , and is also D-A converted and stored in memories 47, 49 before T 4x . Thus, sine the standard values of L and R are obtained once in every field without being compressed, the operation returns to a normal state within one field if a malfunction occurs during delta decoding.
In FIG. 10, incidentally, error correction, three times of majority decision, and forwarding of data in previous field are mentioned to take place simultaneously, but is is the same ir they are done separately. Or, at φ 102 , only L 100 and R 100 may be used and the remaining 28 bits may be used in other data. When effected as in FIG. 10, if φ 102 skips in one field, the value in the previous field may be used. In delta decoding system, errors may be accumulated, but in this system, the data returns to the correct value within one field
EFFECT OF THE INVENTION
Thus, this invention presents a processing circuit for delivering sound of high quality containing reproduced image, which is hard to be illegally accessed, in decoding encoded sound signals. It is another advantage that the decoding circuit is suited to LSI and is practical.
TABLE 1______________________________________Item Numerical value______________________________________Data transmission rate ##STR1##Max. frequency component of 4,295,454 Hzdata (fundamental wave)One-bit width of data Approx. 116.402 nsecSound data per 1H 46 bitsRight sound data 22 bits (2 samples)Left sound data 22 bits (2 samples)Start bit 2 bitsSound sampling rate 2f.sub.H ≈ 31.468 kHzSound max. frequency component f.sub.H ≈ 15.734 kHzNo. of bits per one sound sample 11 bitsModulation method of digital Delta encodingsound signalInitializing period of sound One fieldsignalInitializing data of sound 16 bitssignal______________________________________
TABLE 2______________________________________Item Numerical value______________________________________Transmission speed of information data ##STR2##One-bit width of information Approx. 116.4 nsdataNo. of information data 440 bits (55 bytes)pieces per 1HInformation data superposing 440 × 0.1164 ≈ 51.22 μsperiod (within 1H)Bit period 10101010101010 (2 bytes)Frame period 11100101 (1 byte)______________________________________ | A television sound signal processing apparatus receives a digitized delta-encoded sound signal superposed in a horizontal blanking period and a digital signal showing the standard value of the sound signal superposed in a vertical blanking period, and then compares the reference signal of this field with that of one field before, and, when the difference is greater than a predetermined value, employs the decoded value of the delta encoded signal immediately before that reference signal as the standard value for the delta decoding of the sound signal. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a facsimile apparatus for transmitting various information necessary for maintenance and control of electronic apparatus, such as facsimile apparatus and copier installed in office, through general public circuits networks.
2. Description of the Related Art
The facsimile apparatus is recently increasing in the type capable of forming images on plain paper by employing a copying process. The rate of troubles occurring in the mechanism employing such copying process is high. It is desired to strengthen the service organization for maintenance and control due to the necessity of periodic overhaul for maintenance of performance, and in particular quick and accurate countermeasures are keenly demanded in order to recover from troubles promptly.
In the conventional method of maintenance and control, generally, the facsimile apparatus itself detects its own condition, and indicates the nature of trouble or coming of replacement timing of specific parts by its display or the like, or displays the nearly empty state of consumable parts (indicating the consumable parts are about to end) to tell the user. The user recognizes the state, and if judging it necessary to call serviceman, it is reported to the maintenance service station assigned for maintenance and control of the facsimile apparatus by telephone or other means.
Such telephone communication, however, gives rise to the following problems.
(1) The user cannot do his own work when explaining the trouble, and loses time.
(2) The user may misunderstand the trouble message, and wrong information may be transmitted to the maintenance service station.
(3) The user may not notice the trouble message, and in such a case a minor trouble may be promoted to a major trouble.
(4) The maintenance service station sends the serviceman by preparing necessary repair parts after receiving the report from the user, and prompt countermeasure is difficult.
It is hence lately proposed to do maintenance and control in a method in which the user side facsimile detects its own operating state, converts the detected data to communication information, sends it automatically (or according to a transmission request from the maintenance service station) to a maintenance service station. The station receives the transmitted communication information, converts it, for example, into character information and prints out to recognize the operating state of the user side facsimile. (See, e.g., Japanese Patent Application Hei. 1-302749).
When executing such method of maintenance and control, in the first place, the user must install the facsimile apparatus possessing such function for transmitting the operating state. Then the serviceman goes to the office of the user to agree to a contract, and negotiates the term of the maintenance control for the facsimile apparatus with the user. Upon agreement, the serviceman manually sets the opening information for activating the function on the facsimile apparatus having the function of automatic transmission of the operating state.
The opening information includes what maintenance function should be selected, that is, what type of information is to be sent to the maintenance service station, information about the subscribed facsimile apparatus such as the apparatus name, subscriber's name and number, and the telephone number of the maintenance service station, that is, the information transmission destination.
In this facsimile apparatus, only the information about the operating state of the apparatus detected according to the function selected and set by the opening information is automatically transmitted to the maintenance service station. Accordingly, in the event of a trouble failing to transmit automatically to the maintenance service station, or a trouble out of the scope of the maintenance control service, the user must report to the maintenance service station by telephone or other means, and hence the same problems as mentioned above may occur.
SUMMARY OF THE INVENTION
It is hence a primary object of the invention to present a facsimile apparatus capable of transmitting information about the operating state to the control device if the operating state is not detected.
It is another object of the invention to present a facsimile apparatus capable of manually transmitting the information about the operating state to the control device.
To achieve the above objects, the invention presents a facsimile apparatus comprising:
facsimile communication means for transmitting and receiving image data through a public circuit network,
means for recording image data in recording paper,
means for reading the document optically and converting into image data,
means for detecting the operating states of at least the facsimile communication means, recording means and reading means, and
operating state transmitting means for transmitting the information about the detected operating state to a control device for controlling the operating state through a public circuit network, thereby transmitting the information about the operating state to the control device automatically when the operating state is detected, wherein the apparatus further comprises
information input means for receiving the information to be transmitted to the control device, and
input information transmitting means for transmitting the information received by the information input means to the control device.
In the invention, the recording means records the information entered by the information input means in recording paper.
Also in the invention, the facsimile apparatus comprises a memory for storing the information received by the information input means.
According to the invention, the information to be transmitted entered through the information input means is transmitted to the control device by the input information transmission means, Thus, to the control device, not only the information about the operating state to be detected by the operating slate detecting means, but also the information about the operating state not detected by the operating state detecting means is also transmitted. Therefore, in the event of a trouble out of the scope of the maintenance control service, for example, by the key input operation by the operator, the information about the trouble may be transmitted to the maintenance service station.
Also according to the invention, the information entered by the information input means is recorded in recording paper through recording means. Therefore, the user of the facsimile can easily recognize the information transmitted to the control device.
Moreover, according to the invention, the information entered through the information input means is stored in the memory. Therefore, in the facsimile apparatus possessing the display means, for example, if not able to record by the recording means, the stored information can be shown in the display means. Furthermore, by reading out the information stored in the memory as required, the information may be recorded in the recording paper when it becomes possible to record by recording means.
Thus, in the invention, even the information other than the information about the operating state detected by the operating state detecting means can be transmitted to the control device. Therefore, if a trouble out of the service scope of maintenance control should occur, the information may be transmitted to the maintenance service station without report by telephone or the like, so that the convenience and utility of the facsimile apparatus may be enhanced.
Also according to the invention, the information to be transmitted is printed out in recording paper by the recording means. Therefore, the user of the facsimile apparatus can easily recognize what information has been transmitted.
Moreover according to the invention, the information to be transmitted is stored in the memory, may be displayed as desired, for example, in display means. Therefore, the user of the facsimile apparatus can easily recognize what information has been transmitted.
The invention also presents a facsimile apparatus comprising:
communication means for transmitting and receiving various signals including image data through a public circuit network,
means for recording image data in recording paper,
reading means for reading the original optically and converting into image data,
operating state detecting means for detecting the operating state of at least the communication means, recording means and reading means, and
operating state transmitting means for transmitting the information about the detected operating state through a public circuit network to a control device for controlling the operating state, thereby transmitting the information about the detected operating state automatically to the control device when the operating state is detected, wherein the apparatus further comprises
information input means for receiving the information to be transmitted to the control device,
input information transmission means for transmitting the information entered through the information input means to the control device, and
control means for inactivating means other than the communication means after transmission of the information by the input information transmission means.
The invention is characterized by the control means which activates the inactivated means when receiving a predetermined cancel signal from the control device by the communication means.
The invention is also characterized by the control means which stores the information showing that the cancel signal from the control device has been received.
According to the invention, the information entered through the information input means is transmitted to the control device by the input information transmission means. That is, to the control device, the information not detected by the operating state detecting means or the information not transmitted automatically can be transmitted. At this time, the control means inactivates other means than the communication means after the information is transmitted to the control device. Accordingly, for example, if the information transmitted to the control device is the information about troubles of various means of the facsimile apparatus, problems of causing new troubles can be eliminated by disabling the defective facsimile apparatus by the control means.
Moreover, according to the invention, the means inactivated by the control means can be activated by receiving a predetermined cancel signal from the control device by the communication means. Hence, if the facsimile apparatus is disabled due to trouble or the like, by making it usable again by the control means, the control of the operating state such as remote diagnosis and repair from the control device can be done efficiently.
Also according to the invention, the control means, when receiving a cancel signal from the control device, stores the information showing that the cancel signal has been received. As a result, the operator can easily recognize, for example by printing out by printing means, a series of actions in the facsimile apparatus once inactivated and then activated again.
Thus, in the invention, even in the state not detected by the operation detecting means, the information concerning the operating state can be transmitted to the control device. Hence, if a trouble out of the scope of the maintenance control service should occur in the facsimile, the information concerning the trouble can be transmitted to the control device, thereby eliminating the bothering task of reporting to the maintenance service station through telephone or the like by the operator as required in the prior art.
Besides, after the occurrence of such trouble, that is, after transmission of the information concerning the operating state, means other than the communication means of the facsimile apparatus can be inactivated. As a result, the problem of increasing the troubles by manipulation of the defective facsimile apparatus by the operator can be avoided. At the same time, consecutive transmission of the information to the control device due to mistake or abuse may be eliminated, too.
According to the invention, the inactivated function in the facsimile apparatus can be canceled or activated by the control device. Hence, for example, after the occurrence of such trouble, it is reported from the facsimile apparatus causing the trouble to the maintenance service station by telephone or the like, and at the same time the processing from the control device such as remote diagnosis can be done easily and efficiently. Thus, the control device can instantly judge the type of the information transmitted from the facsimile apparatus, so that wrong information or transmission by abuse can be easily judged.
In the invention, moreover, the cancel signal or other information received from the control device is read out, for example, by an arbitrary key operation by the operator, and is easily displayed to the operator. As a result, a series of process after outbreak of the trouble in the facsimile apparatus can be printed out as a result table or the like, so that it can be easily recognized later.
The invention moreover presents a facsimile apparatus comprising:
facsimile communication means for transmitting and receiving image data through a public circuit network,
a telephone set for transmitting and recording voice signals through a public circuit network,
changeover means for connecting the public circuit network either to the facsimile communication means or to the telephone set,
means for recording the image data in recording paper,
means for reading the original optically and converting to image data,
operating state detecting means for detecting the operating state of at least the facsimile communication means, recording means, and reading means, and
operating state transmitting means for transmitting the information about the detected operating state through the public circuit network to a control device for controlling the operating state, thereby transmitting the information about the operating state to the control device automatically when the operating state is detected, wherein the apparatus further comprises
information input means for receiving the information to be transmitted to the control device,
input information transmission means for transmitting the information received by the information input means to the control device, and
control means for changing over the changeover means by force to connect the public circuit network to the telephone set, responding to the changeover signal from the control device, after transmission of information to the control device by the input information transmission means.
According to the invention, when the information to be transmitted is entered by the information input means, it is transmitted to the control device by the information transmission means. That is, to the control device, even the information not detected by the operating state detecting means or the information not transmitted automatically can be transmitted. Besides, after transmission of information to the control device, when a changeover signal is received from the control device, the changeover means is changed over by force by the control means, and the public circuit network is connected to the telephone set. Therefore, for example, if the information about the trouble occurring in the facsimile apparatus is entered by the information input means, when making a so-called answer call as telephone report from the control device side to the facsimile apparatus side for confirming about the trouble, the public circuit network is connected to the telephone set by force after transmission of information to the control device, and hence if the public circuit network is connected, for example, to the facsimile communication means by the changeover means, the answer call is made normally.
Thus, according to the invention, even the operating state that is not detected by the operating state detecting means, the information about the operating state can be transmitted to the control device. Hence, even in the facsimile apparatus, for example, the information about trouble can be transmitted to the control device, and the bothering operation of reporting to the maintenance service station by telephone or the like by the operator as required in the prior art may be eliminated. Incidentally, if the public circuit network is connected to the facsimile communication means, that is, if the facsimile apparatus is set in the image data reception mode, the answer call which is a telephone report from the control device can be normally done. Therefore, if a trouble should occur in the facsimile apparatus, for example, the trouble may be always predicted or confirmed adequately by the answer call from the control device.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects, features, and advantages of the invention will be more explicit from the following detailed description taken with reference to the drawings wherein:
FIG. 1 is a block diagram showing a basic composition of a facsimile apparatus 1 in an embodiment of the invention.
FIG. 2 is a plan view of an operating part 15.
FIG. 3 is a sectional view showing the constitution of the facsimile apparatus 1.
FIG. 4 is a flow chart for explaining the operation in transmission of information of the facsimile apparatus 1.
FIG. 5 is a flow chart for explaining the operation after transmission of information of the facsimile apparatus 1.
FIG. 6 is a flow chart for explaining the operation of a control device 3.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to the drawing, preferred embodiments of the invention are described below.
FIG. 1 is a block diagram showing a basic composition of a facsimile apparatus 1 in an embodiment of the invention. The facsimile apparatus 1 is connected to a telephone circuit network 2, and image data is transmitted and received with other facsimile apparatus, and various information can be transmitted and received with a control device 3 which is described later through the telephone circuit network 2. The facsimile apparatus 1 executes an electrostatic copying process of forming a charged image and recording (transferring) on recording paper.
The facsimile apparatus 1 comprises a controller 11 realized by a microcomputer or the like, and the controller 11 is connected with a communication controller 12, a reading part 13, a recording part 14, and operating part 15, a display part 16, a detector 17, and a memory 18. The communication controller 12 comprises an incoming detecting circuit, a modem and other standard features. The communication controller demodulates the received image data, applies the demodulated image data to the controller 11. In addition, the communications controller modulates image data to be transmitted and delivers to the telephone circuit network 2. The reading part 13 comprise a CCD (charge coupled device) mentioned below, lens, exposure device and other features. The reading part optically reads a document to be transmitted, and converts into electric signals (image data) and applies the data to the controller 11. When copying a document, the document is exposed, and the document image is focused on a photoreceptor surface of the recording part 14.
The recording part 14 comprises photoreceptor, developing device, charger, fixing device and other features. The recording part transfers the image onto the recording paper in the electrostatic copy process.
The operating part 15 comprises numeric keys and various function setting key as mentioned below. The display part 16 is realized by a liquid crystal display device or the like. The display part displays the input data from the operating part 15 and the operating state of the facsimile apparatus 1, such as the error information and the information showing a shortage of consumable parts.
The detector 17 detects the operating state of the facsimile apparatus 1, or more specifically an abnormal operating state, and applies the detected operating state to the controller 11. The controller 11 comprises trouble phenomenon judging means, trouble type judging means, and communication information converting means which are not shown, and these means operate according to the control from the detector 17.
The trouble phenomenon judging means judges the nature of the trouble on the basis of the information detected by the detector 17. The trouble type judging means judges if the trouble indeed by the trouble phenomenon judging means is of the type requiring the so-called serviceman call or not. In the case of the trouble of the type not requiring the serviceman call, it means a trouble that can be relatively easily handled by the user, such as paper jamming and shortage of recording paper. The trouble of the type requiring the serviceman call is, for example, the end of life of the photoreceptor in the recording part 14 that cannot be handled by the user.
The memory 18 comprises ROM (read-only memory) and RAM (random access memory), among others, and the ROM stores the programs for controlling the actions of the facsimile apparatus 1, and the RAM incorporates a registration region of opening information transmitted from the control device 3, and a work region used in processing action by the controller 11, among others. In the memory 18, the Information to be transmitted to the control device 3 by the operating part 15 is also stored.
The telephone circuit 19 comprises a handset 20, and is connected to the communication controller 12, and is a circuit for realizing communication with the control device 3 and other telephone set or the like.
The control device 3 is a device basically composed of a so-called personal computer, and it transmits and receives data with the facsimile apparatus 1 or other terminal device through the telephone circuit network 2. The control device 3 comprises a controller 31 composed of CPU (central processing unit) and others, and the controller 31 is connected with a modem 32, a recording part 32, a display part 34, and an operating part 35.
The modem 32 demodulates the received data and applies the received data to the controller 31, and modulates the transmit data to be transmitted given from the controller 31, and delivers the transmit data to the telephone circuit network 2. The recording part 33 is realized by a thermal printer or the like, and records the image data received through the telephone circuit network 2, various received information, or the information entered through the operating part 35 in recording paper such as thermal recording paper. The display part 34 is realized by the liquid crystal display, cathode-ray tube (CRT), or the like, and displays the information received through the telephone circuit network 2 and the information entered through the operating part 35. The operating part 35 comprises plural key switches such as numeric keys and various function setting keys for specifying the operating state of the control device 3.
Fig, 2 is a plane view of the operating part 15. The operating part 15 comprises numeric keys 15a for entering the destination telephone number of the like at the time of calling, a start/copy key 15b for starting transmission of image data or printing the communication result table or the like by the recording part 14, a stop key 15c for stopping transmission of image data, and a mode selector key 15d for selecting various functions such as the mode for receiving the image data (hereinafter called tax mode) and the mode for receiving voice signal (hereinafter called telephone mode). In this embodiment, of various information transmitted to the control device 3, the information other than the data relating to the operating state detected by the detector 17, that is, the information about troubles out of the maintenance service scope on the basis of the preset opening information can be arbitrarily transmitted by the operator by pressing, for example, the "*" key of the mode selector key 15d and numeric keys 15a.
FIG. 3 is a sectional view showing the construction of the facsimile apparatus 1. The facsimile apparatus 1 is roughly divided into the reading part 13, recording part 14, and document conveying part 19. When the document 41 is inserted into a document inlet 42, setting of the document 41 is detected by a document detecting sensor 43 realized by a microswitch or the like. Later, when the copy key which is not shown or the start/copy key 15b for starting the transmission of the image data is manipulated by the operator, the conveying action of the document 41 is started.
When transmitting the document, the document 41 is pressed and conveyed by a roller 44 and a pressing member 45, and is further conveyed into an exposure region in which a transparent glass 47 is instaled by a pair of conveying rollers 46. In the exposure region, irradiation light from a light source 48 is emitted to the original plane of the document 41, and its reflected light enters the CCD 51 through mirror 49 and lens 50. By the CCD 51, the incident light is converted into an electrical signal (image data), and is given to the controller 11. The document 41 after exposure is conveyed by a pair of discharge rollers 52, and is discharged onto a document tray 53.
At the downward side of the mirror 49 in FIG. 3, an exposure head 54 is disposed, and when copying the document 41, an electrostatic copy process is executed along with the document conveying action. The document image exposed by the exposure head 54 is focused on a photosensitive drum 58 through lens 55 and mirrors 56, 57.
The photosensitive drum 58 is rotated in the direction of arrow 59. The surface of the photosensitive drum 58 is uniformly charged by a corona charger 60. Next, the other parts than the document image are illuminated with light by the exposure head 54, and the electric charge of the illuminated area is removed, and the charge is left over in the document image area, thereby forming an electrostatic latent image. In a developing part 61, a toner composed of coloring particles charged in the reverse polarity of the electrostatic latent image is supplied from a toner cartridge 52, and it is deposited on the electrostatic latent image to form a toner image. Consequently, the recording paper is laid over this toner image, and the electric charge in the reverse polarity of the charge polarity of the toner is applied on the recording paper by a transfer device 63 from the opposite side of the photosensitive drum 58 of the recording paper, and the toner image is transferred on the recording paper by the electrostatic force.
The recording paper is stored in a recording paper cassette 64, and is conveyed in a conveying route by paper feed roller or the like not shown herein, and is supplied into a transfer region in which the transfer device 63 is installed by the paper feed roller 65.
The toner image transferred on the recording paper is fixed on the recording paper by applying heat or pressure by a fixing device 66. On the other hand, the latent image charge on the photosensitive drum 58 after transfer is destaticized by a destaticizer 70. Besides, the residual toner left over on the photosensitive drum 58 without being transferred is removed by a cleaner which is not shown. By repeating this series of process from charging to cleaning, the document image is continuously copied on the recording paper.
The recording paper on which the toner image is fixed is conveyed by a discharge roller 67, and is discharged onto a discharge tray 68.
Near the exposure head 54, a cooling fan 69 is installed in order to cool off the heat of the exposure head 54.
FIG. 4 is a flow chart explaining the operation of the facsimile apparatus 1 in the mode of information transmission. At step a1, when the operating state (abnormal state) is detected by the detector 17, it is judged by the controller 11, at step a2, whether it is necessary or not to automatically transmit the detected abnormal state. At step a2, if the detected abnormal state is not included in the maintenance service on the basis of the preset opening information, it is judged at step a3 whether the key input for the information transmission of the operating part 15 has been done or not. If the key input for information transmission has been done, the control device 3 is called at step a4, and the information of the signal showing the trouble or the like is transmitted at step a5. At step a3, if the key input operation has not been done, the operation is terminated.
At step a2, on the other hand, if the detected abnormal state is included in the maintenance service on the basis of the preset opening information, for example, a trouble such as end of life of the photosensitive drum 58, the control device 3 is called at step a8, and the detected abnormal state, that is, the information telling it necessary to replace the photosensitive drum 58 is transmitted at step a9, and the operation is terminated.
At step a6, it is judged whether the recording part 14 is usable or not. If usable, at step a7, the information transmitted at step a5 is printed on the recording paper to terminate the operation, and if unusable, for example, if the abnormal state detected at step a1 is related with the recording part 14, the information transmitted at step a10 is stored in the memory 18. At step a11, the stored information is delivered and displayed in the display part 16, and the operation is terminated.
Thus, according to the embodiment, even in the case of the information other than the information about the abnormal state of the facsimile apparatus 1 detected by the detector 17, that is, the information out of the scope of the maintenance service on the basis of the preset opening information, it is possible to transmit to the control device 3 by the key input operation by the operator. Hence, even if a trouble out of the scope of maintenance control of the facsimile apparatus should occur, the information about the trouble can be transmitted to the control device 3.
In addition, the transmitted information is printed out by the recording part 14, or stored in the memory 18, and delivered and displayed in the display part 16. Accordingly, the operator can visually recognize the transmitted information, so that the convenience and utility of the facsimile apparatus 1 may be enhanced.
FIG. 5 is a flow chart explaining the operation after the information transmission mentioned above. The Information to be transmitted to the control device 3 is, meanwhile, not limited to the information transmitted by the key input operation alone, but includes the information about the operating state detected by the detector 17.
When transmission of information from the facsimile apparatus 1 to the control device 3 is over at step b1, the other functions than the controller 11 and communication controller 12 out of various functions of the facsimile apparatus 1, that is, the facsimile functions are stopped by the controller 11 at step b2. As a result, the key input operation from the operating part 15 by the operator, for example, is disabled. Even after stopping the functions, however, the image data signals from the telephone circuit network 2, the voice signals from other telephone set not shown herein, control signals such as cancel signal from the control device 3 described below are received by the communication controller 12, and the other signals than the image data signals out of them are operated according to the received signals.
When a signal is received at step b3, it is judged at step b4 whether the signal is a signal transmitted from the control device 3 or not. If judged to be a signal transmitted from the control device 3, it is further judged at step b5 whether it is a voice signal for requesting the call or not. If not a voice signal, at step b6, the controller 11 judges the received signal to be a cancel signal as a control signal for canceling the function stop, and cancels the function stop at step b2. At sled b7, the information showing that the cancel signal is received is stored as data in the memory 18, and is printed out by the recording part 14 as the so-called cancel result data on the basis of the stored data at step b8.
At step b4, if the incoming signal is not from the control device 3, advancing to step b9, it is judged to be a voice signal or not. If not a voice signal, returning to step b2, or at step b10 in the case of a voice signal, it is judged whether the telephone function is valid or not. In this embodiment, the functions stopped at step b2 are related to the facsimile function, but the functions to be stopped can be selected by the mode selector 15d, and it is judged whether the telephone function is valid or not at step b2.
At step b10, if the telephone function is valid, a ringing tone is cent out at step b11, and the call is made at step b12, and the operation returns to step b2 after the call service.
At step b10, if the telephone function is stopped, the circuit is cut off at step b13, and the operation returns to step b2. At step b5, if not a voice signal, it is judged at step b14 whether the telephone function is valid or not. When the telephone function is valid, advancing to step b15, or if the telephone function is stopped, the telephone function is restored at step b17 by receiving a changeover signal for recovering the telephone function from the control device 3 as described below, and a ringing tone is sent out at step b15, and the call is made. In this way, if the incoming signal is a voice signal from the control device 3, whether the telephone function is valid or invalid, it is sat in the call service state by force by the control signal from the control device 3.
FIG. 6 is a flow chart for explaining the operation of the control device 3. Incidentally, FIG. 6 shows the action conducted by the control device 3 in order to recover the telephone function at step b17 in FIG. 5.
At step c1, when reception of the information from the facsimile apparatus 1 is over, the facsimile apparatus 1 is called for reply (answer call) at step c2. At step c3, it is judged whether the facsimile apparatus 1 is set in the fax mode by the mode selector 15d or not. In the case of the fax mode, at step c4, a mode changeover signal is sent out, and the telephone mode is selected by force by the controller 11, so as to exchange talk with the facsimile apparatus 1. At step c3, if not of the fax mode, that is, in the case of the telephone mode, the talk is made without the processing at step c4.
Thus, according to the embodiment, for example, if the reading parts 13 is defective and this trouble is not the operating state to be detected by the detector 17, the information about this trouble can be transmitted to the control device 3 by the key input operation through the operating part 15. At this time, after transmission of the information, since the facsimile functions are stopped by the controller 11, occurrence of new troubles is prevented. If the facsimile apparatus 1 is disabled due to this trouble, the apparatus is recovered in the usable state by the cancel signal received from the control device 3. Therefore, the maintenance control such as so-called remote diagnosis and repair from the control device 3 may be done efficiently.
Besides, the controller 11 stores the information showing the reception of the cancel signal from the control device 3 in the memory 18, and therefore by printing out the information by the recording part 14, for example, the process may be easily recognized.
According to the embodiment, when the control signal for changing over the circuit from the control device 3 is received in the communication controller 12, the controller 11 connects the telephone circuit network 2 to the telephone circuit 19 by force, and hence if the fax mode is preliminarily selected by the mode selector 15d, the answer call may be always made adequately.
The invention may be embodied in other specific forms without departing form the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and the range of equivalency of the claims are therefore intended to be embraced therein. | A facsimile apparatus is disclosed capable of manually transmitting information about its operating state to the control device. If trouble not detectable by an internal detector occurs, or trouble not transmitted automatically arises, information about the trouble can be transmitted to a remote control device by a key input operation in the operating part of the facsimile apparatus. At this time, the facsimile functions, except for the controller and communication controller in the facsimile apparatus, so that occurrence of new troubles due to manipulations made before a stop cancel signal from the control device is received may be prevented. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a rare earth magnetic powder having high magnetic anisotropy, and to a method for manufacturing a rare earth magnet using the rare earth magnetic powder.
2. Description of the Background
A method for manufacturing a rare earth magnetic powder is known as described in, for example, Japanese Patent Laid-Open No. 2-04901, in which an alloy material (hereinafter referred to as an R--T--M alloy material) containing at least one rare earth metal including Y (hereinafter referred to as R), Fe or an Fe component, which is partly replaced by Co or Ni (hereinafter referred to as T), and B or a B component, which is partly replaced by C (hereinafter referred to as M) as primary components, and an alloy material (hereinafter referred to as an R--T--M--A alloy material) comprising the R--T--M alloy material and 0.001-5 atomic percent of at least one element selected from the group consisting of Si, Ga, Zr, Nb, Mo, Hf, Ta, W, Al, Ti and V (hereinafter referred to as A) is homogenized, if necessary, in an Ar gas atmosphere at a temperature of 600-1,200° C. The alloy material is heated 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas and held at the specific temperature for a hydrogenation treatment. The alloy is dehydrogenated at a temperature of 500-1,000° C. in a vacuum, cooled and then pulverized.
In recent years, the demand for rare earth magnetic powders having higher magnetic anisotropy than conventional powders has increased in order to achieve further miniaturization and higher performance of magnetic parts in the electric and electronic fields. No rare earth magnetic powder having sufficiently high magnetic anisotropy for these purposes has yet been obtained.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a method of manufacturing a rare earth magnetic powder having higher magnetic anisotropy than conventional powders.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by a method of producing a rare earth magnetic powder in which:
(a) A rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having a higher magnetic anisotropy can be produced by heating the R--T--M or R--T--M--A alloy material from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and holding it at the specific temperature, performing a hydrogenation treatment by holding the R--T--M or R--T--M--A alloy material at a specific temperature in a range of 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas to promote phase transformation by hydrogenation, performing medial annealing by holding the R--T--M or R--T--M--A alloy material after the hydrogenation treatment at a specific temperature in a range of 500-1,000° C. in an inert gas atmosphere, and performing dehydrogenation by holding the R--T--M or R--T--M--A alloy material at a specific temperature in a range of 500-1,000° C. in a vacuum at a final pressure of less than 1 Torr to promote phase transformation by forcibly causing the release of hydrogen from the R--T--M alloy material.
(b) It is preferred that the R--T--M or R--T--M--A alloy material be homogenized by holding it at a temperature of 600-1,200° C. in a vacuum or under an Ar gas atmosphere.
(c) It is preferred that the medial annealing at a given temperature in a range of 500-1,000° C. of the R--T--M or R--T--M--A alloy material after the hydrogenation treatment be performed in an inert gas atmosphere with a pressure in a range of 0.5-11 atm.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing, wherein:
FIG. 1 is a schematic illustration of a heat treatment pattern of a method of manufacturing a rare earth magnetic powder of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention has been completed based on these findings. Accordingly, one(1) embodiment of the invention is a method for manufacturing a rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy, comprising:
heating an R--T--M alloy material from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and optionally holding the alloy at this temperature;
performing a hydrogenation treatment on the R--T--M alloy material by holding the R--T--M alloy material at a specific temperature in the range of 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas to promote phase transformation of the R--T--M alloy material by hydrogenation;
performing medial annealing by holding the R--T--M alloy material after the hydrogenation treatment at a specific temperature in the range of 500-1,000° C. in an inert gas atmosphere; and
performing dehydrogenation by holding the R--T--M alloy material at a specific temperature in the range of 500-1,000° C. in a vacuum of a final pressure of less than 1 Torr to promote phase transformation in the R--T--M alloy material by forcibly releasing hydrogen from the R--T--M alloy material, followed by cooling and pulverizing.
In a second embodiment(2) of the invention a rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy is manufactured, by:
heating an R--T--M alloy material, which is homogenized at a temperature of 600-1,200° C. in a vacuum or Ar gas atmosphere, from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and optionally holding the alloy at this temperature;
performing hydrogenation of the R--T--M alloy material by holding the R--T--M alloy material at a specific temperature in a range of 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas to promote phase transformation of the R--T--M alloy material by hydrogenation;
performing medial annealing by holding the R--T--M alloy material after the hydrogenation treatment at a specific temperature in the range of 500-1,000° C. in an inert gas atmosphere; and
performing dehydrogenation by holding the R--T--M alloy material at a specific temperature in the range of 500-1,000° C. in a vacuum of a final pressure of less than 1 Torr to promote phase transformation in the R--T--M alloy material by forcibly releasing hydrogen from the R--T--M alloy material, followed by cooling and pulverizing.
In a third embodiment(3) of the invention a rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy is manufactured by:
heating an R--T--M--A alloy material from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and optionally holding the alloy at this temperature;
performing hydrogenation of the R--T--M--A alloy material by holding the R--T--M--A alloy material at a specific temperature in the range of 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas to promote phase transformation of the R--T--M--A alloy material by hydrogenation;
performing medial annealing by holding the R--T--M--A alloy material after the hydrogenation treatment at a specific temperature in the range of 500-1,000° C. in an inert gas atmosphere; and
performing dehydrogenation by holding the R--T--M--A alloy material at a specific temperature in the range of 500-1,000° C. in a vacuum of a final pressure of less than 1 Torr to promote phase transformation in the R--T--M--A alloy material by forcibly releasing hydrogen from the R--T--M--A alloy material, followed by cooling and pulverizing;
In a fourth embodiment (4) of the invention a rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy is manufactured by;
heating the R--T--M--A alloy material, which is homogenized at a temperature of 600-1,200° C. in a vacuum or Ar gas atmosphere, from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and optionally holding the alloy at this temperature;
performing hydrogenation of the R--T--M--A alloy material by holding the R--T--M--A alloy material at a specific temperature in the range of 500-1,000° C. in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas to promote phase transformation of the R--T--M--A alloy material by hydrogenation;
performing medial annealing by holding the R--T--M--A alloy material after the hydrogenation treatment at a specific temperature in the range of 500-1,000° C. in an inert gas atmosphere; and
performing dehydrogenation by holding the R--T--M--A alloy material at a specific temperature in the range of 500-1,000° C. in a vacuum of a final pressure of less than 1 Torr to promote phase transformation in the R--T--M--A alloy material by forcibly releasing hydrogen from the R--T--M--A alloy material, followed by cooling and pulverizing.
In a fifth embodiment (5) of the invention a rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy described in embodiments (1)-(4) is subjected to medial annealing in an inert gas atmosphere an atmosphere having a pressure in a range of 0.5-11 atm.
In one embodiment of manufacturing a rare earth magnet, a rare earth magnetic powder, which is produced by one of the method embodiments (1)-(5) of the present invention and has a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and high magnetic anisotropy, is combined with an organic binder or a metallic binder, or by hot-pressing or hot-isostatic pressing the powder at a temperature of 600-900° C.
In another embodiment of manufacture of a rare earth magnet, a green compact of an embodiment of a rare earth magnetic powder (1)-(5) above is prepared, and then the green compact is hot-pressed or hot-isostatic pressed at a temperature of 600-900° C.
The method for manufacturing the rare earth magnetic powder of the present invention has, as a significant aspect, a medial annealing step in which the alloy material is held at a specific temperature in the range of 500-1,000° C. in an inert gas atmosphere having a pressure of 0.5-11 atm between the hydrogenation step and the dehydrogenation step.
The medial annealing step after the hydrogenation treatment causes a change in the texture in the alloy in which the phases are decomposed by occlusion of hydrogen in the hydrogenation treatment, and the following dehydrogenation treatment forms a rare earth magnetic powder having fine recrystallization textures in which the c axis in the R 2 T 14 M intermetallic compound phase is further oriented in one direction. Thus, the rare earth magnetic powder has a higher magnetic anisotropy and coercive force than rare earth magnetic powders which are produced by conventional methods.
The method for making the rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy in accordance with the present invention is now described with reference to the drawing.
FIG. 1 shows a heat treatment pattern in the method for manufacturing the rare earth magnetic powder having a recrystallization texture of fine R 2 T 14 M intermetallic compound phases and having high magnetic anisotropy of the present invention. That is, the relationship between the temperature, the time and the atmosphere in the heating step, the hydrogenation step, the medial annealing step, and the dehydrogenation step, and the cooling step is shown. In FIG. 1, numerals 1, 2, 3, 4 and 5 represent the heating step, the hydrogenation step, the medial annealing step, and the dehydrogenation step, and the cooling step, respectively.
In the heating step 1, the R--T--M or R--T--M--A alloy material is heated to a temperature from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere (for example, a hydrogen gas atmosphere, a vacuum, or an inert gas atmosphere), or is heated and held at a specific temperature x (for example, 100° C.) of less than 500° C. and then reheated.
In the hydrogenation step 2, the R--T--M or R--TM--A alloy material is held in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas at 500-1,000° C. to promote phase transformation in the alloy material by hydrogenation.
In the medial annealing step 3, the R--T--M or R--T--M--A alloy material after the hydrogenation treatment is held in an inert gas atmosphere, preferably, at a pressure of 0.5-11 atm, and more preferably 0.5-2 atm, at a specific temperature in a range of 500-1,000° C., preferably, 650-950° C., and more preferably 750-900° C., for a specified time. The medial annealing step 3 is most preferably performed in an Ar gas atmosphere with a pressure of 0.5-2 atm at a temperature of 750-900° C. for 1-30 minutes. The introduction of the inert gas in the medial annealing step 3 is preferred as a substitute for the hydrogen gas atmosphere or the mixed gas atmospheres of hydrogen and an inert gas in the hydrogenation step 2. The medial annealing step 3 is the most characteristic step in the present invention. When the medial annealing step 3 is performed after the hydrogenation step, the texture of the alloy in which the phase is decomposed by hydrogenation changes. Upon the subsequent dehydrogenation treatment, a rare earth magnetic powder having a fine recrystallization texture, in which the c axis of the R 2 Tm 14 M intermetallic compound is further oriented in one direction, is obtained. Thus, the magnetic powder has higher magnetic anisotropy and coercive force than the rare earth magnetic powders produced by conventional processes.
In the dehydrogenation step 4, the R--T--M or R--T--M--A alloy is held at a temperature in the range of 500-1,000° C. in a vacuum with a final pressure of less than 1 Torr to forcibly release hydrogen which is not released in the medial annealing step 3. After the dehydrogenation step 4, the alloy material is cooled to room temperature in the cooling step 5 using inert gas (Ar gas).
Having now generally described the invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purpose of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
Melts were prepared in a high frequency vacuum-melting furnace and cast to produce ingots a to j of R--T--M or R--T--M--A alloy materials having the compositions shown in Table 1. Each of the ingots of the resulting R--T--M or R--T--M--A alloy materials was shaped into a block with a side of 10 mm or less. Ingot blocks were heated from room temperature to specific temperatures or heated and held at the specific temperatures shown in Tables 2-5. The blocks were subjected to hydrogenation treatment, to medial annealing, and to dehydrogenation under the conditions shown in Tables 2-5, forcibly cooled to room temperature with Ar gas and then pulverized to produce a rare earth magnetic powder having a particle size of 300 μm or less. Invention Methods 1-28 of the present invention, Comparative Methods 1-2 for comparison, and Conventional Methods 1-10 were conducted in such a manner.
To the rare earth magnetic powder of each of Invention Methods 1-28, Comparative Methods 1-2 and Conventional Methods 1-10, 3 percent by weight of epoxy resin was added. The materials were kneaded and compressed in a magnetic field of 20 kOe to form green compacts. The green compacts were thermoset in an oven at 150° C. for 2 hours to form bonded magnets with a density of 6.0-6.1 g /cm 3 . The magnetic characteristics of the resulting bonded magnets are shown in Tables 6-9.
Anisotropic green compacts were prepared in a magnetic field from the rare earth magnetic powders of Invention Methods 1-28, Comparative Methods 1-2 and Conventional Methods 1-10, placed into a hot press, and hot-pressed at a temperature of 750° C. and a pressure 0.6 Ton/cm 2 for 1 minute in Ar gas so that the green compacts were compressed in the direction in which the magnetic field is applied. Hot press magnets with densities of 7.5-7.7 g/cm 3 were prepared by quenching the compressed compacts. The magnetic characteristics of the resulting hot press magnets are shown in Tables 6-9.
TABLE 1______________________________________Type Composition (atomic %) (the balance is Fe)______________________________________Ingot a Nd:12.0%, Co:16.5%, B:6.2%, Zr:0.2%, Al:0.5% b Nd:11.0%, Dy:1.2%, Pr:0.2%, Co:5.7%, B:6.0%, Zr:0.1%, Ti:0.3% c Nd:12.0%, Pr:0.3%, Co:20.0%, B:6.5%, C:0.05%, Zr:0.2%, Ga:0.5% d Nd:12.0%, Dy:0.6%, B:7.0%, Hf:0.1%, Nb:0.2%, Si:0.1% e Nb:6.5%, Pr:6.0%. Co:18.7%. B:5.8%, Hf:0.1%, Ta:0.2%, Ga:0.5% f Nd:11.5%, Dy:0.6%, Pr:0.3%, Co:9.0%, B:6.0%, Zr:0.1%, Ga:0.3% g Nd:12.3%, Ce:0.1%, Pr:0.2%, Co:16.5%, B:6.2%, Zr:0.5%, Ga:0.5% h Nd:14.1%, La:0.1%, Pr:0.2%; Co:20.1%, B:6.5%, Nb:0.5%, Ga:1.0% i Nd:12.1%, Pr:0.5%, Co:18.0%, B:6.0%, C:0.1% j Nd:11.2%, Dy:0.3%, Pr:0.3%, Co:11.7%, Ni:1.0%, B:5.5%, C:0.2%, Zr:0.05%, Mo:0.2%, Al:0.7%______________________________________
TABLE 2__________________________________________________________________________ Heating Hydrogen occulusion Medial annealing Dehydrogenation Atmosphere from H.sub.2 Holding Holding Ar Holding Holding Final Holding Holding room temp. to less press temp. time press temp. time press temp. time Type Ingot than 500° C. (atm) (° C.) (min.) (atm) (° C.) (min.) (Torr) (° C.) (hr.)__________________________________________________________________________Invention's Method 1 a Vacuum from room 1 850 20 1 850 10 0.98 830 40 2 b temp. to 100° C., and 5 850 20 1 850 10 0.98 830 40 H.sub.2 of 1 atm. from 100° C. to 500° C. 3 c Vacuum from room 1 830 60 1.2 840 5 0.05 820 50 4 d temp. to 200° C., and 1 830 60 1.2 840 5 0.05 820 50 5 e H.sub.2 1 atm. from 1 830 60 1.2 840 5 0.5 820 50 200° C. to 500° C. 6 f Vacuum from room 2 850 120 1 850 10 0.05 850 60 7 g temp. to 100° C., and 1 850 120 2 850 10 0.2 850 60 8 h H.sub.2 of 1 atm. from 1 850 120 2 850 10 0.02 850 60 9 i 100° C. to 500° C. 1 850 120 1 850 10 0.2 850 60 10 j 1.5 850 120 1 850 10 0.001 850__________________________________________________________________________ 60
TABLE 3__________________________________________________________________________ Heating Hydrogen occulusion Medial annealing Dehydrogenation Atmosphere from H.sub.2 Holding Holding Ar Holding Holding Final Holding Holding room temp. to less press temp. time press temp. time press temp. time Type Ingot than 500° C. (atm) (° C.) (min.) (atm) (° C.) (min.) (Torr) (° C.) (hr.)__________________________________________________________________________Invention's Method 11 a Vacuum from room 1 820 30 1 820 10 0.05 820 40 12 b temp. to 100° C., 3 880 60 1 850 10 0.01 850 30 13 c hydrogen of 1 atm at 0.8 860 10 2 860 5 0.02 840 50 14 d 100° C. for 30 min., 2 800 30 2 820 20 0.02 830 60 15 e and heating in H.sub.2 of 1 920 120 1 850 10 0.01 800 60 1 atm to less than 500° C. 16 f Heating in Ar from 2 800 30 2 820 20 0.005 770 60 17 g room temp. to 0.5 890 60 3 770 60 0.01 800 50 18 h 200° C., Ar at 1 840 60 1 840 20 0.002 770 60 19 i 200° C. for 60 min., 0.7 780 10 0.5 850 10 0.50 850 30 20 j and heating in Ar to 1 800 120 0.8 800 40 0.1 800 50 less than 500° C.__________________________________________________________________________
TABLE 4__________________________________________________________________________ Heating Hydrogen occulusion Medial annealing Dehydrogenation Atmosphere from H.sub.2 Holding Holding Ar Holding Holding Final Holding Holding room temp. to less press temp. time press temp. time press temp. time Type Ingot than 500° C. (atm) (° C.) (min.) (atm) (° C.) (min.) (Torr) (° C.) (hr.)__________________________________________________________________________Invention's Method 21 a Vacuum from room 1 830 60 0.3 840 5 0.05 820 50 22 b temp. to 200° C., 1 830 60 0.5 840 5 0.05 820 50 23 c H.sub.2 of 1 atm. 1 830 60 5.0 840 5 0.05 820 50 24 d at 200° C. for 1 830 60 11.0 840 5 0.05 820 50 25 e 30 min., and 1 830 60 1.2 840 300 0.05 820 50 26 f H.sub.2 of 1 atm. 1 830 60 1.2 840 30 0.05 820 50 27 g from 200° C. 1 830 60 1.2 840 5 0.05 820 50 28 h to 500° C. 1 830 60 1.2 840 0.5 0.05 820 50 Comparative Method 1 i 1 830 60 13.0* 840 5 0.05 820 50 2 j 1 830 60 1.2 1050* 0.5 0.05 820 50__________________________________________________________________________
TABLE 5__________________________________________________________________________ Heating Hydrogen occulusion Medial annealing Dehydrogenation Atmosphere from H.sub.2 Holding Holding Ar Holding Holding Final Holding Holding room temp. to less press temp. time press temp. time press temp. time Type Ingot than 500° C. (atm) (° C.) (min.) (atm) (° C.) (min.) (Torr) (° C.) (hr.)__________________________________________________________________________Conventional Method 1 a Vacuum from room 1 850 20 -- -- -- 0.98 830 40 2 b temp. to 100° C., and 5 850 20 -- -- -- 0.98 830 40 H.sub.2 of 1 atm. from 10° C. to 500° C. 3 c Vacuum from room 1 830 60 -- -- -- 0.05 820 50 4 d temp. to 200° C., and 1 830 60 -- -- -- 0.05 820 50 5 e H.sub.2 of 1 atm. from 1 830 60 -- -- -- 0.5 820 50 200° C. to 500° C. 6 f Vacuum from room 2 850 120 -- -- -- 0.05 850 60 7 g temp. to 100° C., and 1 850 120 -- -- -- 0.2 850 60 8 h H.sub.2 of 1 atm. from 1 850 120 -- -- -- 0.02 850 60 9 i 100° C. to 500° C. 1 850 120 -- -- -- 0.2 850 60 10 j 1.5 850 120 -- -- -- 0.001 850 60__________________________________________________________________________
TABLE 6______________________________________Bonded Magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 1 10.1 11.0 22.1 12.6 10.7 36.1 2 8.9 25.4 18.3 11.1 25.1 28.6 3 10.2 11.7 23.0 12.8 11.4 37.6 4 9.1 20.3 18.6 11.4 18.7 30.2 5 9.8 10.7 20.7 12.3 10.3 33.8 6 9.4 21.6 20.3 11.8 20.3 33.0 7 10.1 11.6 22.5 12.6 11.7 35.1 8 9.7 13.1 20.2 12.1 12.8 33.5 9 9.8 7.2 19.4 12.2 7.0 32.0 10 9.4 16.3 19.8 11.8 15.6 32.7______________________________________
TABLE 7______________________________________Bonded Magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 11 10.0 11.4 21.8 12.5 11.3 34.3 12 9.1 24.6 19.2 11.4 24.1 30.0 13 10.0 11.8 22.0 12.5 11.7 34.7 14 9.2 19.8 19.7 11.5 19.0 29.7 15 9.6 10.7 20.1 12.0 10.8 32.8 16 9.6 21.6 21.2 12.0 20.5 34.0 17 9.7 12.7 20.6 12.2 12.5 33.8 18 9.7 13.5 20.7 12.1 13.2 33.6 19 9.7 7.0 18.8 12.1 7.1 32.1 20 9.2 17.5 18.7 11.5 17.0 30.2______________________________________
TABLE 8______________________________________Bonded magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 21 9.7 11.4 20.4 12.1 11.0 32.2 22 10.1 12.0 22.1 12.7 11.6 35.5 23 10.0 12.1 21.6 12.5 11.9 34.6 24 9.9 12.3 20.8 12.4 12.1 35.1 25 9.6 5.9 18.6 12.0 5.5 27.1 26 9.9 8.7 20.8 12.3 8.6 32.2 27 10.2 12.0 23.1 12.8 11.4 36.2 28 9.8 12.4 20.6 12.3 12.1 33.7 Comparative Method 1 8.8 8.3 13.7 10.8 7.7 17.6 2 3.6 1.4 <3 5.3 0.8 <3______________________________________
TABLE 9______________________________________Bonded magnet Hot pressed Magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Conventional Method 1 9.6 11.1 18.8 12.0 10.7 30.4 2 7.6 24.3 13.2 9.5 23.5 20.2 3 9.3 11.9 18.5 11.5 12.2 29.7 4 7.2 20.1 11.8 9.0 19.3 18.0 5 9.4 10.1 18.0 11.7 10.2 29.5 6 6.5 22.3 9.2 8.1 21.8 13.3 7 9.5 11.8 19.7 11.8 11.3 30.0 8 9.2 12.6 18.1 11.4 12.4 28.6 9 8.7 8.4 15.5 11.0 8.3 25.4 10 7.0 17.0 10.8 8.7 17.1 16.7______________________________________
The results presented in Tables 1-9 demonstrate that the magnetic characteristics of the bonded magnets prepared from the rare earth magnetic powders of Invention Methods 1-28, the processing including a medial annealing step, are superior to those of the bonded magnets prepared from the rare earth magnetic powders of Conventional Methods 1-10 not including medial annealing. In contrast, the bonded magnets prepared from the rare earth magnetic powders of Comparative Methods 1 and 2, which are out of the range of the present invention, have low magnetic characteristics.
The results also demonstrate that the magnetic characteristics of the hot pressed magnets prepared from the rare earth magnetic powders of Invention Methods 1-28, whose processing included medial annealing, are superior to those of the hot pressed magnets prepared from the rare earth magnetic powders of Conventional Methods 1-10 not including medial annealing. In contrast, the hot pressed magnets prepared from the rare earth magnetic powders of Comparative Methods 1 and 2, which are out of the range of the present invention, have low magnetic characteristics.
EXAMPLE 2
The ingots a to j, which were prepared in Example 1, of the R--T--M or R--T--M--A alloy materials having the compositions shown in Table 1 were subjected to homogenization under the conditions shown in Table 10, and the resulting homogenized ingots A-J were pulverized blocks or powders having the sizes shown in Table 10. These blocks and powders were subjected to heating, hydrogenation, medial annealing, dehydrogenation, and cooling as in Invention Methods 1-28, Comparative Methods 1-2, and Conventional Methods 1-10 in Example 1, and pulverized powders of a particle size of 300 μm or less. The rare earth magnetic powders of Invention Methods 29-56, Comparative Methods 3-4, and Conventional Methods 11-20 were prepared in such a manner. Bonded magnets and hot pressed magnets were prepared from the resulting rare earth magnetic powders as described in Example 1. The magnetic characteristics of the resulting bonded magnets and hot pressed magnets are shown in Tables 11-14.
TABLE 10______________________________________ Conditions of homogenization Size of Used Holding Holding block or Type ingot temp. (° C.) time (hr.) Atmosphere powder______________________________________Homoge- nized ingot A a 1,140 20 1-atm. Ar <15 mm B b 1,120 30 Vacuum <5 mm C c 1,130 15 1-atm. Ar <8 mm D d 1,110 40 Vacuum <500 μm E e 1,120 30 2-atm. Ar <500 μm F f 1,140 20 1-atm. Ar <10 μm G g 1,150 5 Vacuum <20 mm H h 1,100 20 1-atm. Ar <400 μm I i 1,140 15 1-atm. Ar <30 mm J j 1,130 30 1.5-atm. Ar <15 mm______________________________________
TABLE 11______________________________________ Homoge- nized Hydrogen Medial Dehydro- Type ingot Heating Occlusion annealing genation______________________________________ Inven- tion's Method29 A The same as Invention's Method 1 in Example 1 30 B The same as Invention's Method 2 in Example 1 31 C The same as Invention's Method 3 in Example 1 32 D The same as Invention's Method 4 in Example 1 33 E The same as Invention's Method 5 in Example 1 34 F The same as Invention's Method 6 in Example 1 35 G The same as Invention's Method 7 in Example 1 36 H The same as Invention's Method 8 in Example 1 37 I The same as Invention's Method 9 in Example 1 38 J The same as Invention's Method 10 in Example 1______________________________________
TABLE 12______________________________________ Homoge- nized Hydrogen Medial Dehydro- Type ingot Heating Occlusion annealing genation______________________________________ Inven- tion's Method39 A The same as Invention's Method 11 in Example 1 40 B The same as Invention's Method 12 in Example 1 41 C The same as Invention's Method 13 in Example 1 42 D The same as Invention's Method 14 in Example 1 43 E The same as Invention's Method 15 in Example 1 44 F The same as Invention's Method 16 in Example 1 45 G The same as Invention's Method 17 in Example 1 46 H The same as Invention's Method 18 in Example 1 47 I The same as Invention's Method 19 in Example 1 48 J The same as Invention's Method 20 in Example 1______________________________________
TABLE 13______________________________________ Homoge- nized Hydrogen Medial Dehydro- Type ingot Heating Occlusion annealing genation______________________________________ Inven- tion's Method49 C The same as Invention's Method 21 in Example 1 50 C The same as Invention's Method 22 in Example 1 51 C The same as Invention's Method 23 in Example 1 52 C The same as Invention's Method 24 in Example 1 53 C The same as Invention's Method 25 in Example 1 54 C The same as Invention's Method 26 in Example 1 55 C The same as Invention's Method 27 in Example 1 56 C The same as Invention's Method 28 in Example 1 Com- para- tive Method 3 C The same as Comparative Method 1 in Example 1 4 C The same as Comparative Method 2 in Example 1______________________________________
TABLE 14__________________________________________________________________________ Homogenized Hydrogen Medial Type ingot Heating Occlusion annealing dehydroenation__________________________________________________________________________Conventional 11 A The same as Conventional Method 1 in Example 1 Method 12 B The same as Conventional Method 2 in Example 1 13 C The same as Conventional Method 3 in Example 1 14 D The same as Conventional Method 4 in Example 1 15 E The same as Conventional Method 5 in Example 1 16 F The same as Conventional Method 6 in Example 1 17 G The same as Conventional Method 7 in Example 1 18 H The same as Conventional Method 8 in Example 1 19 I The same as Conventional Method 9 in Example 1 20 J The same as Conventional method 10 in Example 1__________________________________________________________________________
TABLE 15______________________________________Bonded magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 29 10.4 11.4 23.1 13.1 11.1 38.8 30 9.3 31.6 19.8 11.7 30.5 31.5 31 10.4 12.6 24.0 13.2 12.6 40.1 32 9.5 24.3 20.6 12.0 23.7 33.6 33 10.1 10.6 22.7 12.7 10.2 35.4 34 9.6 21.5 19.5 12.1 21.6 34.2 35 10.3 12.3 23.7 12.9 11.8 36.5 36 9.9 12.8 21.6 12.4 12.5 34.3 37 10.0 8.7 20.7 12.6 8.3 34.7 38 9.7 18.5 20.1 12.1 17.8 33.0______________________________________
TABLE 16______________________________________Bonded magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 39 10.2 12.3 23.3 12.8 12.4 36.1 40 9.4 27.5 20.2 11.8 26.4 32.5 41 10.3 12.3 23.6 13.0 12.1 37.6 42 9.5 22.1 20.5 11.9 21.6 32.5 43 9.8 10.8 20.7 12.3 10.4 34.0 44 9.9 23.7 22.0 12.5 22.8 35.4 45 10.0 13.3 22.7 12.6 13.4 35.0 46 9.9 13.1 21.6 12.4 13.0 34.7 47 9.9 8.4 20.4 12.3 8.2 32.2 48 9.4 17.3 19.1 11.8 17.1 31.1______________________________________
TABLE 17______________________________________Bonded magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 49 9.9 12.0 21.6 12.4 11.8 34.5 50 10.5 12.2 24.7 13.2 12.1 39.8 51 10.3 12.5 23.1 12.9 12.5 37.6 52 10.2 12.5 22.8 12.8 12.3 37.0 53 9.8 7.6 20.6 12.3 7.5 32.0 54 10.1 10.4 23.0 12.6 9.6 35.1 55 10.4 12.7 24.5 13.0 11.8 37.2 56 9.9 12.5 20.7 12.4 12.1 33.4 Comparative Method 3 8.7 7.8 14.2 9.8 6.7 16.7 4 4.1 2.0 <3 5.4 0.5 <3______________________________________
TABLE 17______________________________________ Bonded magnet Hot pressed magnet Br iHc BHmax Br iHc BHmax Type (kG) (kOe) (MGOe) (kG) (kOe) (MGOe)______________________________________Invention's Method 49 9.9 12.0 21.6 12.4 11.8 34.5 50 10.5 12.2 24.7 13.2 12.1 39.8 51 10.3 12.5 23.1 12.9 12.5 37.6 52 10.2 12.5 22.8 12.8 12.3 37.0 53 9.8 7.6 20.6 12.3 7.5 32.0 54 10.1 10.4 23.0 12.6 9.6 35.1 55 10.4 12.7 24.5 13.0 11.8 37.2 56 9.9 12.5 20.7 12.4 12.1 33.4 Comparative Method 3 8.7 7.8 14.2 9.8 6.7 16.7 4 4.1 2.0 <3 5.4 0.5 <3______________________________________
The results shown in Tables 10-18 demonstrate that the magnetic characteristics of the bonded magnets prepared from the rare earth magnetic powders of Invention Methods 29-56, in which these rare earth magnetic powders were obtained by annealing, hydrogenation, medial annealing, dehydrogenation, cooling and pulverizing of the homogenized ingots A-J as in Example 1 and had sizes of 300 μm or less, are superior to those of the bonded magnets prepared from the rare earth magnetic powders of Conventional Methods 11-20 not including medial annealing. In contrast, the bonded magnets prepared from the rare earth magnetic powders of Comparative Methods 3-4, which are out of the range of the present invention, have slightly low magnetic characteristics.
These results also demonstrate that the magnetic characteristics of the hot pressed magnets prepared from the rare earth magnetic powders of Invention Methods 29-56 including medial annealing are superior to those of the hot pressed magnets prepared from the rare earth magnetic powders of Conventional Methods 11-20 not including medial annealing. In contrast, the hot pressed magnets prepared from the rare earth magnetic powders of Comparative Methods 3-4, which are out of the range of the present invention, have slightly low magnetic characteristics.
Advantages
It is clear from the description above that the method of the present invention for manufacturing rare earth magnetic powders, in which a medial annealing treatment is employed between a hydrogenation treatment and a dehydrogenation treatment, produces a rare earth magnetic powder having improved magnetic characteristics over rare earth magnetic powders prepared by conventional methods. Thus the present invention provides a significant industrial advantage in the technology of rare earth metal magnetic powders.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | An R--T--M alloy material, wherein R is at least one rare earth metal including Y, T is Fe or an Fe component partially replaced by Co or Ni, M is B or a B component partially replaced by C as primary components is prepared by heating the alloy at a temperature from room temperature to a specific temperature of less than 500° C. in a non-oxidizing atmosphere and holding it at the given temperature, if necessary; performing hydrogenation by holding the alloy in a hydrogen atmosphere or a mixed gas atmosphere of hydrogen and an inert gas at a specific temperature in the range of 500-1,000° C.; medial annealing the alloy by holding the R--T--M alloy after the hydrogenation step in an inert gas atmosphere at a specific temperature in the range of 500-1,000° C.; and dehydrogenating the alloy by holding the alloy in a vacuum of less than 1 Torr for dehydrogenation, and then cooling the alloy. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a fused deposition model cold slurry printer for printing cold slurrys such as soft serve ice cream into selected three-dimensional shapes.
Additive manufacturing has taken off over the last few decades and created a revolution in the manufacturing industry. More specifically, 3D printing has changed the way in which companies are able to prototype with almost any material, including plastic, metal, ceramic, and wood. Within the last decade, 3D printing has continued to push the boundaries of what was thought to be possible in industry prototyping and customization, hut just as importantly, it has entered mainstream culture. Fused deposition model (FDM) printing, which is the process of depositing layers of filament into a pattern while changing the z-plane has become a novelty and household name referred to generally as 3D printing. Stores are now available that sell desktop FDM printers or offering to make custom parts such as bracelets, scale buildings, busts, as a customer waits for the product to be printed.
In recent years, the innovations in FDM have skyrocketed and moved into materials ranging from concrete to chocolate. Most of the materials being used today rely on heating up of the material and printing into a warmed environment.
An object of the invention is a system for printing a cold material printed in a cold environment.
SUMMARY OF THE INVENTION
The fused deposition model printer system for printing cold slurry substances according to the invention includes a source of a cold slurry substance such as soft serve ice cream. A print platform is provided and is supported for at least three axes of motion under computer control. An extruder head system including a nozzle for extruding a stream of the cold slurry substance from the source onto the print platform is provided. The extruder head includes a heater. A cryogen line including a perforated section surrounding the stream of the cold slurry substance is provided to spray a cryogen such as liquid nitrogen on the cold slurry substance to cool it upon extrusion. A chilled compartment or freezer is provided in which the print platform, extruder head system and cryogen line are contained to maintain these components at a selected temperature wherein the cold slurry substance is printed to form a desired three dimensional shape.
In a preferred embodiment of the invention, the source of the cold slurry substance is a hopper that may also be a churn. It is preferred that the cryogen be contained within a Dewar in the chilled compartment. A compressor and storage tank communicates with the Dewar to force the cryogen through the cryogen line.
Extrusion pressure is supplied by the churn. The cold slurry substance is preferably a soft serve ice cream, but can be any cold slurry, such as sorbet or sherbet. A suitable cryogen is liquid nitrogen.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic illustration of an embodiment of the fused deposition model cold slurry printer disclosed herein.
FIG. 2 is a perspective view of the ice cream churner that includes a screw portion to push the cold slurry substance.
FIG. 3 is a cross-sectional view of an embodiment of the hopper and churn system disclosed herein.
FIG. 4 is a perspective view of a valve used to start and stop the ice cream flow during the printing process.
FIG. 5 is a perspective view of an extruder fixture attached to a pre-made consumer 3D printer such as a Solidoodle printer for holding the extruder stationary during the printing process.
FIG. 6 is a cross-sectional view of an embodiment of the extruder system disclosed herein.
FIG. 7 is a schematic illustration of an embodiment of the cryogen system disclosed herein.
FIG. 8 is a bottom view of the cryogen spraying system that wraps around the extruder nozzle and sprays the extruded ice cream in all directions through small holes in the tubing.
FIG. 9 is a cross-sectional view of another embodiment of the printing system disclosed herein.
FIG. 10 is a schematic view showing the attachment of plastic pieces to position the Solidoodle extruder head.
FIG. 11 is a perspective view showing details of the translating motion for system operation.
FIG. 12 is a flow chart illustrating the steps in the process for printing a cold slurry material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The primary design for the Fused Deposition Model Soft Serve Ice Cream Printer (FDM Ice Cream Printer) involves a bowl that churns soft serve ice cream, a cryogen system, used to freeze the ice cream upon extrusion, and a pre-made consumer 3D printer such as an altered Solidoodle 3D printer available from the Solidoodle company of Brooklyn, N.Y. The FDM Ice Cream Printer could also be used to print other “cold slurry” substances such as frozen yogurt, sherbet, or sorbet into three dimensional shapes. The printer takes 3D file inputs and outputs printed 3D shapes in soft serve ice cream or any other cold slurry substance, for example a star or heart (For the rest of this document the cold slurry printing substance will be referred to as “ice cream” but the same principles apply to any cold slurry being printed with the FDM Ice Cream Printer). A general schematic of the components and the assembly thereof in the FDM Ice Cream Printer can be seen in detail in FIG. 1 . With reference now to FIG. 1 , an embodiment 10 of the fused deposition model cold slurry printer includes a hopper 12 that supports a churner 14 supported for rotation by a motor 16 . The churner 14 includes a cold slurry substance 18 such as soft serve ice cream. The churner 14 includes a screw section 20 for extruding the cold slurry 18 through a nozzle 22 . The cold slurry 18 is deposited on a print platform 24 . Upon extrusion of the cold slurry 18 through the nozzle 22 , the cold slurry is encircled by a perforated section 26 of a cryogen line 28 . The cryogen line 28 delivers liquid nitrogen to the perforated portion 26 from a liquid nitrogen Dewar 30 . A compressor 32 pressurizes a pressure tank 34 to force the liquid nitrogen in the Dewar 30 through the cryogen line 28 .
To ensure that the nozzle 22 does not freeze up in the presence of the liquid nitrogen emanating from the portion 26 , a heating portion 36 under the control of an autotransformer 38 maintains a free flow of the cold slurry 18 through the nozzle 22 .
The print platform 24 is supported by brass rods 40 in this embodiment so that the print platform 24 is able to move in three dimensions with respect to the nozzle 22 . The brass rods 40 may be supported on ball casters 42 .
Because the cold slurry 18 printed on the print platform 24 must retain its shape, the extruder nozzle 22 , print platform, and the retraining portions of a 3D printer 44 along with the Dewar 30 are enclosed within a chilled compartment or freezer 46 .
The ice cream hopper 12 contains a chilled hopper and rotating churner 14 . The rotating churner 14 also acts as a screw 20 to push the ice cream 18 down to the extender nozzle 22 once the soft serve ice cream 18 is ready to print 3D shapes. The hopper 12 walls are made of metal and are filled with coolant. The coolant freezes, after being in a freezer (or at least 24 hours, and keeps the ice cream around 10° F. for two hours. An alternative method for the hopper could be made with electrically (e.g., pettier) or electromechanically (e.g., refrigerant loop) cooled elements similar to a freezer to avoid the long wait time for the coolant to freeze.
The churner 14 is made of plastic and is dimensioned no that the outer diameter of a scraper 48 turning radius is 0.25″ smaller than the inner diameter of the hopper to allow for clearance when spinning as shown in FIG. 2 . They both have the same tapered curve at the bottom to aid in pushing the ice cream down the extruder and avoid ice cream getting stuck in the corners. This allows the churner to scrape off any accumulated ingredients off the sides of the hopper to fully and consistently mix the soft serve materials in the bowl and ensure that none of the ingredients get frozen to the sides of the bowl. On the bottom of the hopper there is a hole that fits the screw component 20 of the churner. This section of the churner is essentially one middle rod through the edge scrapers, slipped like a screw at the bottom to push the ice cream down into the extruder. The churner is attached to the motor 16 which spins the scrapers 48 at a constant speed throughout the process. The motor 16 is attached to the churner 14 at the very top nob 50 through a lid that locks the churner into a vertical position. When the motor is turned on, the two pieces of the churner spin in opposite directions through a gear train 52 . Alternatively, the churner 14 could be held stationary with the hopper motorized to get the same screw effect. The hopper could also be pressurized to force the ice cream down instead of using a motor and churner. The motor 16 , hopper 12 , and churner 14 are encased in plastic but this encasement could be made of metal or wood.
Attached to a hole in the hopper 12 is a Delrin valve piece 54 leading to a ¼″ plastic (such us PVC) robe 56 for extrusion of the ice cream as shown in FIG. 3 . The hopper 12 includes a space 57 filled with a coolant. The piece of Delrin 54 has a hole drilled through for the ice cream to pass from the hopper to the extruder tube. There is another hole 58 drilled through, of larger diameter than the ice cream flow hole, for a cylindrical stopper 60 to press in and act as a valve to stop ice cream flow as shown in FIG. 4 . The valve plug or stopper 60 is made from a piece of aluminum but could be made of any type of metal or plastic with cold temperature resistance. The aluminum valve plug 60 is pulled straight out of the Delrin piece 54 to allow ice cream to flow along the path 62 once everything is ready for printing. Another option for the operation of the valve 54 could be through turning, similar to turning on or off a faucet rattier than a linear motion. Alternatively the valve 54 could be placed down at the extruder head rather than directly below the hopper. This whole configuration is attached with adhesive to the top of the freezer 46 with a hole for the extruder tube to fit through, however this, configuration could have been placed inside the freezer 46 as well. The valve 54 may be computer controlled in order to stop or start the How of ice cream mid-print.
With reference to FIG. 5 the tube 64 connecting the hopper system to the extruder head 66 is made of a ¼″ plastic tube. The tube 64 could also be constructed of other plastics of varying diameters depending on speed of pruning and tin of the extruder head 66 . The tube 64 is fed into the extruder and connected to the extruder head 66 . The extruder is an aluminum fixture with a brass extruder nozzle of ⅛″ diameter. Toe brass extruder nozzle may be coated with a food-safe plastic coating if necessary. The extruder is made of two pieces of aluminum connected at a right angle with screws. One piece 68 is connected to the back of the 3D printer frame 44 while the other piece 70 extends over the top off the printer 44 . Contrary to typical 3D printer designs, the extruder for the FDM Ice Cream Printer is stationary. The piece 70 that extends over the top has a hole drilled all the way through to hold the extruder head 66 and tube 64 . A second hole is drilled directly next to the first to hold a heating element used to keep the extruder head temperature at 18° F. The extruder head 66 is a hollowed out cylindrical piece of brass starting from the diameter of the incoming tube and then tapering so the desired ⅛″ diameter for extrusion of the ice cream. The bottom of the extruder head is located 8 mm above the printing platform when it is at its z-zero position. As shown in FIG. 6 , this fixturing system can be made of different types of metals or plastics to achieve the same stationary hold of the extruder head. Alternatively the whole fixture can be connected directly to the freezer 46 wall lather than the 3D printer 44 . Other materials that held their shape under extreme temperatures can be used to construct the extruder head. The extruder head can end in a different final diameter depending on the desired size and speed of printing the ice cream.
There is a heating system to moderate the temperature of the extruder head while being sprayed try liquid nitrogen. The heating system, shown in FIG. 6 , is comprised of a variable autotransformer 38 ( FIG. 1 ) supplying 35V of AC voltage to a 58 Ω resistor 72 . The variable autotransformer 38 automatically regulates the voltage going us the resistor 72 to keep the extruder temperature between 18° F. and 20° F. A thermocouple is inserted into the aluminum fixture piece 70 next to the extruder nozzle 22 . This is then connected with wires 74 to the variable autotransformer 38 which travels through the freezer, out the top to the variable autotransformer which is adhered to the top of the freezer. The resistor size and variable autotransformer supply can be altered depending on the temperature of the freezer, rate of liquid nitrogen flow, and material properties of the extruder. The variable autotransformer could also have been connected to the side of the freezer.
As shown in FIG. 7 , the cryogen system is comprised of a Dewar 30 , a compressor 52 and pressure tank 34 , and cryogen line 28 . The Dewar 30 is 1 L in volume and built with a double-walled flask made of aluminum with a vacuum between the walls. This is used to hold the liquid nitrogen in its liquid state before spraying onto the extruded ice cream. The top of the Dewar 30 is a 1″ thick piece of Delrin with two ¼″ holes. One hole holds the cryogen line and other holds a ¼″ plastic tube which connects up to the pressure tank. The cryogen line is made of ¼″ topper tubing and is formed into a circle to surround the extruder head as shown in FIG. 8 . The end of the copper tube is crimped to avoid any liquid nitrogen from exiting the tube at the end, instead small holes 76 are drilled at 45° into the copper rube to allow the liquid nitrogen to be sprayed in ail directions on the ice cream as it is extruded as indicated by the arrows 78 . The cryogen line could have been made from a larger size copper lubing to increase liquid nitrogen flow. Additionally the cryogen line did not have to surround the extruder head 66 , the liquid nitrogen could have been sprayed out of the lube directly onto the extruded ice cream.
The compressor 32 is charged to 5 Psi to regulate the flow rate of liquid nitrogen during the printing process. The compressor 32 fills the pressure tank 34 which is connected to the Dewar 30 with a ¼″ plastic tube. The 5 Psi pressure forces the liquid nitrogen nut of the Dewar to spray continually during the printing process. The Dewar 30 is located inside the freezer, but it could have also been located outside with the copper tubing going through the side of the freezer. The compressor 32 and pressure tank 34 are located on the top of the freezer 46 with the variable autotransformer 38 and ice cream hopper 14 but could also be fixed inside of the freezer.
The printing platform is inside the freezer so ensure the printed ice cream 3D shape stays frozen at a constant temperature of 10° F. The size of the freezer is 2′×2′×4′. The 3D printer fits into the bottom of the freezer. By elevating the print platform the dimensions of the build volume of the FDM Ice Cream Printer matches that of the 3D printer. The 3D printer print platform was removed and replaced with a piece of plastic spanning the full inner dimensions of the printer and called the traverse platform.
With reference to FIG. 9 , the print platform is built with a baseline elevation, z-zero, located 7″ above the top of the Solidoodle printer. The print platform 24 is supported by three continuous brass rods 40 which are held in place at the bottom and top by press fit plastic sleeves 80 . The brass rods 40 are guided by plastic guiding sleeves 80 which are connected so the Solidoodle at the position where the old extruder was located. The rods 40 extend ail the way to a traverse platform 82 where they are connected to three ball casters 42 which allow the printing platform assembly to move freely in ail three x, y, and z directions.
The three brass rods 40 are attached to the print platform 24 with another plastic fitting that also has three cylindrical support sleeves to press fit the rod into. This fitting is glued to the bottom of the 6″×6″ plastic prim platform. For the FDM Ice Cream Printer the original extruder was taken off the Solidoodle and replaced with the plastic guiding sleeves. As shown in FIG. 10 , this plastic fitting is connected to the Solidoodle printer with screws 84 located at the original Solidoodle extruder attachment location. The plastic guiding sleeve 80 is made of one piece of plastic with three holes with cylindrical supports sleeves allowing the three ⅛″ diameter and 12″ long brass rods to pass through freely. At the bottom the rods are press fit into to a third plastic fitting 86 with the same cylindrical support sleeves. This bottom fitting connects to three ball caster wheels ¾″ in diameter as shown in FIG. 11 . The casters 42 rest on the traverse platform 82 substituting the original Solidoodle print platform. Alternatively, the original Solidoodle system with x and y movement of the extruder head and z movement of the print platform could have been used instead of having a stationary print head and fully mobile print platform as in the design of the FDM Ice Cream Printer. All the fittings along with the print platform and traverse platform could have been made out of metal instead of plastic. Instead of hail caster wheels, the rods could be connected to regular caster wheels or Omni wheels.
To start the 3D printing process, the ice cream hopper bowl is placed in a freezer upside down and left for at least 24 hours. Once the bowl is fully frozen, it is placed back into the FDM Ice Cream Printer and the ingredients for making the ice cream (cream, milk, flavor, and sugar mixture) are placed into the bowl and the churning process begins. After about 20 minutes of churning, the ice cream achieves the desired consistency for printing into 3D shapes. While the ice cream is churning, the exemplary Solidoodle printer is hooked up to a computer and a Standard Tessellation Language (stl) file is loaded into the Solidoodle software Repetier Host to generate the print pattern. The Solidoodle can also be reprogrammed to use other open source software and take different file formats such as Drawing Interchange Format (dxf) or Polygon File Format (ply). Within the Repetire set-up parameters the first layer height is set at 8 mm, subsequent layer height at 3 mm, retract distance at 0 mm, and the print speed is set at 16 mm/sec. The final parameters and printing pattern is uploaded into the Solidoodle printer controls. The FDM Ice Cream Printer will then go through a series of checking motions to make sure nothing is blocking its fell motion and puts the extruder head at x, y, and z zero.
Next, the Dewar 30 is completely filled with liquid nitrogen is installed into the FDM Ice Cream Printer. The compressor 32 is mined on and liquid nitrogen begins flowing to precool the cryogen line 28 . Once the ice cream has reached the proper consistency, the valve is opened for the ice cream to start flowing. As soon as the ice cream begins having consistent flow from the extruder head onto the printer bed, the printer program can be started. The extruder, located 8 mm from the print platform at the beginning of the process, starts to emit ice cream in 3 mm layer height increments. The print platform moves at a speed of 16 mm/sec without any retraction movements. The FDM Ice Cream Printer runs through the preset printing program until the complete 3D ice cream treat is printed (See FIG. 12 for process flow chart). The speed and layer size of the printing process can be varied depending on the extrusion speed, extrusion diameter, and liquid nitrogen spray speed. The build volume of the FDM Ice Cream Printer is 6″×6″×6″ and can support any 3D shape with minimal slope overhangs and voids resulting therefrom.
It is recognized that modifications and variations of the present invention will be apparent to those of ordinary skill in the an and it is intended that all such modifications and variations be included within the scope of the appended claims. | Fused deposition model printer system. The system prints cold slurry substances and includes a source of a cold slurry substance with a print platform supported for at least three axes of motion under computer control. An extruder head system including a nozzle extrudes a stream of the cold slurry substance from the source onto the print platform, the extruder head including a heater. A cryogen line is provided having a perforated section for surrounding the continuous stream of the cold slurry substance to spray a cryogen onto the cold slurry substance to cool it upon extrusion. A chilled compartment or freezer is provided in which the print platform, extruder head system, and cryogen line are contained to maintain those components at a selected temperature whereby the cold slurry substance is printed to form a desired three dimensional shape. | 0 |
This application is a file-wrapper continuation, of application Ser. No. 08/797,423, filed Feb. 10, 1997, which is a continuation of application Ser. No. 08/406,026, filed Mar. 17. 1995.
This application is a file-wrapper continuation, of application Ser. No. 08/406,026, filed Mar. 17, 1995, now abandoned.
FIELD OF THE INVENTION
The present invention relates in general to communication devices and, in particular, to communication devices that may be worn by a user.
BACKGROUND OF THE INVENTION
Large scale public gatherings, such as sporting events, automobile races, political conventions and rallies, ticker tape parades, and other mass meetings provide opportunities for large numbers of people having an emotional or intellectual attachment to an ideal, organization, team, celebrity athlete, or other focus of attention to meet en masse in a public forum. Most attendees of these gatherings are supporters, boosters or fans of a participant or group of participants in the public event and have a high level of enthusiasm. Sporting events and political conventions are two of the best known sorts of gatherings in which members of large crowds permit themselves to display their enthusiasm not merely in public, but often in the presence of television cameras. At these events, banners are waved, cheers erupt, and shouts of encouragement occur. A crowd will sometimes take collective action, performing what has become known as "the wave" around a stadium holding tens of thousands of people. The highly public nature of the setting seems to fuel the fervor of the crowd, and the willingness of crowd members to display their emotion.
This expression of emotion, in addition to being enjoyable, serves important public functions, including the constructive, or at least passive channeling of public energy and the rallying of a community about a common cause. High-spirited public events stimulate the economy, bring a wholesome sense of well being to a community, and become the vehicle for regional or institutional spirit and unity.
In addition, the settings in which gatherings occur provide an opportunity for the promotion of products, services, events and attractions of interest to the attendees. Attendees are generally predisposed during these events to consume freely, taking advantage of the comparatively rare opportunity to indulge themselves in something they enjoy.
Sporting events in particular present promoters of products, services, events and other commercial activities an opportunity to reach a receptive audience, and one whose members are likely to be demographically well-understood. The tastes and preferences of these individuals may therefore be effectively targeted, so that an efficient match can be made between them and purchasing opportunities they are likely to find of interest. Promoters of products and services frequently consider it advantageous to establish a linkage between a popular competitor, such as a race car driver, golfer or other figure and a product or service. Not only does the attention paid to the public figure provide camera exposure for trademarks and logos associated with the product or service being promoted, but an element of celebrity or team sponsorship or endorsement is introduced, so that fans or spectators who admire and trust a particular athlete or other public figure will consider favorably the good or service being endorsed.
In recent years, opportunities for promotion of goods and services at public gatherings have been limited by physical constraints on available space. Scoreboards, billboards, automobile bodies, golf bags and similar objects present a decidedly finite number of opportunities, and this scarcity has driven up their price. In some instances, the fans or spectators themselves can present an opportunity for promotion, through the sale of hats, tee shirts and similar products. Some venues, however, prohibit certain of the more obtrusive means for expressing spirit, such as banners and other larger objects.
Between the need to expand beyond the presently saturated market for opportunities for promotion, and the inherently large and animated promotional vehicle presented by spectators themselves, an unmet need apparently exists for a device capable of harnessing that vehicle by providing a new means for fans and supporters to communicate their spirit and enthusiasm, while at the same time providing a new set of opportunities for promotion of teams, athletes or other public figures, as well as goods and services of interest to spectators.
SUMMARY OF THE INVENTION
The present invention provides a device capable of addressing the unmet need described in the previous section. In particular, the present invention provides a communication and promotional display device that is wearable and directable. The device according to the present invention is unlike garments bearing images or alphanumeric symbols, such as college sweatshirts, ballcaps with team insignia, and the like. With such garments, any display is merely incidental to the basic function of covering the body. The device of the present invention, by contrast, is directed to and oriented around the act of directed display and communication of team spirit, devotion to a sports organization or individual athlete, or affiliation with a common cause, and achieves this purpose and function in a way that garments cannot.
The human hand provides a unique and previously insufficiently recognized platform for visual communication of graphical and/or symbolic messages. The hand is directional. It may be raised above the body. It can be waved around. Hands can be "hi-fived." They may be moved much more rapidly than can the body, shooting skyward upon the scoring of a touchdown, for example. In short, hands enable a human to attract attention and express emotion in a unique and powerful way.
The present invention increases the expressive power of the human hand in the context of the drama of athletic competitions or other events by providing an inexpensive, conveniently stored, instantly donned, and highly visible, positionable and directable platform for the communication of messages of an athletic, political, or commercial nature. The device according to the present invention provides a platform for expression and communication that can be simultaneously bi-directional. Moreover, the device provides this communication platform in a manner that is simple to produce, lightweight, easily stored in a pocket when not in use, and which, when in use, can permit activities like holding a drink or mopping a brow.
To achieve these ends, the device according to the present invention provides a hand-wearable, directable device for permitting a wearer to communicate visually to one or more viewers, having a body portion with a first side and a second side surrounding an interior pocket for receiving a hand, and also having an aperture through one end and through which the hand passes when being received in the interior pocket. The body portion interior pocket is adapted to receive the hand without presenting obstructions between the fingers, including the thumb. In addition, the device includes at least one image coupled to at least one side of the body portion. Using the device having this structure, the wearer can communicate with the one or more viewers by directing the hand that has been received in the device, and thereby the device itself, in the field of view of the one or more viewers so that the image is visible in that field of view.
The device can also include a neck portion having an aperture and coupled to the body portion adjacent the aperture in the body portion, such that the wearer's hand passes through neck portion aperture prior to passing through the body portion aperture when the device is placed on the hand. When included as part of the device, the neck portion thus fits around the wrist of the wearer and assists in maintaining the body portion on the hand of the wearer.
Accordingly, it is an object of the present invention to provide a directable device, for communication and promotion using images, that may be worn on the hand.
It is a further object of the present invention to provide a directable, hand-wearable communication device that permits a wearer to communicate a visual message at a public gathering without excessively obstructing the fields of view of others.
It is another object of the present invention to provide a directable, hand-wearable communication device that may be easily manufactured from conveniently available materials.
It is yet another object of the present invention to provide a directable, hand-wearable communication device that may conveniently stored and transported by a wearer in his or her pocket, for instance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded view of portions of the body of a device according to the present invention
FIG. 2 shows a view of a device according to the present invention in which the body and the neck portion of the device are shown in exploded form.
FIG. 3 shows a device according to the present invention in use, the rear portion and corresponding display surface of the device being visible in this view.
FIG. 4 shows a device according to the present invention in use, the frontal portion and corresponding display surface of the device being visible in this view.
DETAILED DESCRIPTION
FIG. 1 shows in an exploded view portions of the body portion 30 of one embodiment of the directable display and communication device according to the present invention. A frontal portion 10 on one side of the body portion 30 is, without limitation, generally of flexible sheeting material. Frontal portion 10, as shown in the embodiment of the device depicted in FIG. 1, but without limitation, has a generally oval peripheral contour 14, tapering to a narrowed and comparatively straight lower edge 16. The generally oval shape provides an aesthetically pleasing contour, but is only one of a variety of possible shapes for frontal portion 10 (and also for rear portion 20, as discussed below). Whatever the shape, however, it should most preferably be convex in geometry (i.e., having no appreciable peripheral indentations) and thus provide the maximum amount of uninterrupted surface area for displaying images, which will be described at further length below.
A rear portion 20 on a second side of body portion 30, also without limitation, has a generally oval peripheral contour 24, tapering to a narrowed and comparatively straight lower edge 26, the geometry of rear portion 20 being as close to identical to that of frontal portion 10 as reasonably possible (even if frontal portion is a shape other than the generally oval one shown in the Figures).
Frontal portion 10 has an image 12 affixed to its surface. In the illustrated embodiment, but without limitation, the image 12 is one of a football helmet. Rear portion 20, also in this view, has an image 22 disposed on its display surface and thus visible only in phantom. Unlike the image 12 on the display surface of frontal portion 10, image 22 in the illustrated embodiment, but without limitation, is not a graphic image, but rather is an alphanumeric image.
Frontal portion 10 and rear portion 20 are most preferably cut to a shape substantially, although without limitation, as shown in the figures. The dimensions of frontal portion 10 and rear portion 20, and thus of body portion 30, are preferably in excess of the peripheral dimensions of the fully opened hand of the intended wearer. This sizing provides a front and rear display area larger than the wearer's hand, although not large enough to significantly obstruct the fields of view of the wearer's fellow spectators or crowd members. In the extreme, the maximum width of the device for an average adult male user should preferably be at least about 6 inches, and its maximum height preferably at least about 9 inches. For intended users of the device whose hand sizes are smaller, such as women, children or even infants, the dimensions preferably are proportional. Given the above-described dimensions for the front and rear display surfaces of the device provided by frontal portion 10 and rear portion 20, each of the surfaces provides a substantially convex and thus uninterrupted display area of preferably at least about 35 square inches for a device wearable by an average adult male, and proportionally smaller for women, children and infants.
Prior to being joined, frontal and rear portions 10 and 20 are aligned so that their peripheries are collocated and an enclosed space or pocket 28 is created. Pocket 28, as can be seen in FIG. 1, is most preferably a simple, undivided space having no partial walls or septa to separate any one or more of the fingers, including the thumb, from any other.
Frontal and rear portions 10 and 20, respectively, are joined in position using any suitable means, preferably by sewing. The peripheries of portions 10 and 20 are not sewn all the way around, however. Rather, the peripheries of portions 10 and 20 are left unjoined along their respective lower edges 16 and 26 to leave an aperture through which a hand may be inserted in order to occupy pocket 28.
As shown in FIG. 2, the result of the joining of frontal portion 10 with rear portion 20 is body portion 30, having a contoured periphery 34 defined by the contoured peripheries 14 and 24 of frontal and rear portions 10 and 20, respectively. Body portion 30 also has an aperture 32 respectively defined by edges 16 and 26 of portions 10 and 20. In an additional step, also shown in FIG. 2, a neck portion 40, having an aperture 42 defined at its upper extent by edge 44 and at its lower extent by edge 46, is joined to body portion 30 by any suitable means, preferably by sewing. Although neck portion 40 may be of any material or configuration suitable for achieving a snug fit about the wrist of the wearer and thus comfortably securing the device 50 to the hand of the wearer and holding it fast throughout vigorous use, neck portion 40 is preferably a ribbed and/or elasticized fabric or other material of the kind used for cuffs attached to the sleeves of long sleeved sweatshirts or similar garments. Neck portion 40 alternatively could be any structure capable of releasably maintaining a constriction about the wrist, including, without limitation, hook and loop fasteners.
Upper edge 44 of neck portion 40 is aligned with edges 16 and 26 of joined portions 10 and 20 and is fastened to it, preferably, although without limitation, by sewing. To be properly joined, the circumference of neck portion 40, when in a relaxed state, should be as close in size as possible to the circumference of aperture 32. Although the illustrated embodiment is conveniently formed from three major components as described in connection with the illustrated embodiment, other configurations are within the contemplation of the present invention. For example, alternative embodiments of device 50 could be fabricated with a greater or fewer number of components than the three major components of the illustrated embodiment, subject to the constraint that the device be hand-wearable, and have two major sides or display surfaces.
The described embodiment of the device according to the present invention is simple and accordingly easy and inexpensive to fabricate. The frontal and rear portions 10 and 20 can be a simple contour that, unlike a glove or mitten for permitting manual manipulation functions, need not be anthropomorphic. The portions, moveover, and the manner in which the portions are joined, need not be shaped or formed to accommodate the front-to-back asymmetry of the flexure of the human hand. Indeed, the two portions can be cut or otherwise formed so as to have identical and symmetrical geometry side-to-side and front-to-back.
The device may nevertheless have a preferred orientation. In particular, frontal portion 10 is intended to correspond to the palm of the wearer's hand, while rear portion 20 is intended to correspond to the back of the wearer's hand. Since the geometry of the device is preferably symmetric front-to-back as well as side-to-side, the preferred orientation may be expressed through different choices as to materials, colors and images to be used on each side. For instance, the front and back portions can be of different colors or even different fabrics or other materials. As another example, the frontal portion 10 can be of a breathable mesh fabric, while the rear portion 20, which may be exposed to the sun's rays for longer periods of time than the frontal portion 10, can be of higher opacity.
Frontal portion 10 and rear portion 20 of the illustrated embodiment of the device 50 according to the present invention may include more than one layer of material. For example, a lighter, more decorative material may be supported by a stiffer and heavier though less decorative material to enable the device 50 to better hold a particular shape.
The fabric from which frontal portion 10 and rear portion 20 of body 30 are made may, for example and without limitation, be of cotton or a cotton blend, wool, canvas, denim, flannel, nylon, poplin, polyester, polypropylene, rayon, terry cloth, suede, leather, seersucker, satin, silk, velvet, or any other natural or synthetic material suitable for receiving one or more images according to techniques further described below. The weight and the consistency of the material may range from a very sheer material, to a lightweight tee shirt material or a mesh of the type often used in football jerseys, to a heavier fabric of the sort used in sweatshirts. The device 50 could even be of a stiffer consistency, such as a fabric of the type used in the making of ball caps, or even be of suede or leather as listed above.
The material for a given embodiment of the device 50 can be selected to provide any desired properties. For example, embodiments of the devices 50 incorporating terry cloth would be most useful in warmer regions or climates, whereas woolen embodiments would perhaps be most suitable for use in colder regions or climates.
The material used to form frontal and rear portions 10 and 20, respectively, of the embodiment of the device 50 according to the present invention should be capable of receiving a graphic or alphanumeric image or design. As shown in FIG. 1, frontal portion 10 has a graphic design 12 applied to its outer surface, which may be considered a display surface. The image 12 may be applied according to any known method, including, without limitation, silk screening, iron-on or other elastomeric laminate, embroidery, sewn-on patch, fabric painting, Jacquard or other known methods.
FIG. 3 shows an embodiment of the device 50 according to the present invention in use on the hand of a wearer 60, only the arm of which is visible in this view. The entire hand of wearer 60 is received in pocket 28 (not directly visible in this view) and neck portion 40 fits snugly around the wrist, securing device 50 and maintaining it in position during vigorous usage. In FIG. 3, the rear portion 20 of device 50 is visible. When wearer 60 raises a hand on which device 50 has been placed, wearer 60 can communicate the message present in image 22 with others in whose general field of view he or she is able to place his or her hand and device 50. For instance, if wearer 60 is in a stadium or arena attending a sporting event, raising even slightly the hand that has been placed in pocket 28 of device 50 will place rear portion 20 of the device, and thus image 22, in the general field of view of those seated above and behind the wearer 60. In the illustrated example, where the image 22 is a "#1", those in whose general field of view device 50 is positioned by wearer 60 will at one level of awareness or another observe and receive the message carried by image 22, for example that "the home team is the best" or a similar sentiment. Image 22, of course, could be any graphical, symbolic or alphanumeric symbol, including commercial logos and trademarks, in which event the raising of the wearer 60's hand would display the logo or mark to those above and behind wearer 60.
FIG. 4 shows device 50 and the arm of wearer 60 from a vantage point opposite to that shown in FIG. 3. In this view, frontal portion 10, and therefore image 12, are visible. As can be appreciated from FIG. 3 and especially FIG. 4, images 12 and 22 can be as large or nearly as large as the display surfaces provided by front and rear portions 10 and 20, since the convex geometry of the surfaces includes no appreciable indentations or interruptions to accommodate the thumb or fingers. A wearer 60 who is a fan of a given team or athlete, such as a professional or college football team, could display image 12 toward the field as a gesture of spirit and support for the team. Image 12 in the embodiment shown in the figures is a football helmet, but could be any desired image. For instance, image 12 could be a graphic illustration, an alphanumeric symbol, or a logo or trademark. The football helmet of image 12 could bear the coloring and logo of the team supported by wearer 60, so that team members and others, including other fans and even media video cameras, would be potential recipients of wearer 60's communication of spirit, enthusiasm and support for that team.
In the presently described embodiment, the image is collocated with the device to achieve a visual effect in which the hand of the wearer becomes a two-dimensional surrogate for the object of interest. The precise peripheral contour 14 of frontal portion 10 and the matching peripheral contour 24 of rear portion 20 can be preselected to correspond to the geometry of a desired image to be communicated. As in the embodiment of the present invention shown in FIGS. 1, 2, and 4, image 12 is in the form of a football helmet, and the periphery of the football helmet of image 12 is seen to coincide with the peripheral contour 14 of frontal portion 10 and peripheral contour 24 of rear potion 20. The precise peripheral contour 14 of frontal portion 10 and the matching peripheral contour 24 of rear portion 20 could also be preselected to correspond to the geometry of a desired image to be communicated.
When wearer 60 raises his or her hand to display image 12 on the front portion 10 of device 50, he or she simultaneously communicates using image 22 on the rear portion 20 of the device 50. The ability to communicate, using a hand-wearable device, a first message in a first direction and a second message in a second direction, and in particular, one which can be visibly but unobtrusively raised above a crowd, presents a unique opportunity for promoters. A device 50 could be provided with a first image 12 on its frontal portion 10 corresponding to the team, athlete or other attraction of interest to the wearer 60, so that he or she can direct the message embodied by image 12 using his or her hand. Image 12 is shown as a football helmet, but could be any image that expresses the sentiment desired by wearer 60. The same device 50 could also be provided with a second image 22, which, rather than a simple "#1", as shown, could be a logo or trademark of a supplier of goods and services, a corporate sponsor, or other entity interested in maximizing its public visibility and, particularly, doing so in a setting where the viewer demographics are reasonably well understood.
The device 50 of the present invention is an effective but comparatively unobtrusive means for visual communication particularly at public events, and its effectiveness is enhanced by the ease with which it can be transported and used. Device 50 can be easily stored in the pocket or other convenient storage space of wearer 60. Wearer 60 could bring two devices 50 to a sporting or other public event and wear one on each hand simultaneously. Wearers 60 that are true devotees might even bring a larger number of versions of device 50 having differing images or colors that can be changed throughout the course of an athletic contest or event, the compactness of the device 50 enabling them to be easily stored and transported.
The simplicity and inexpensiveness of the devices 50 permit them to be produced and distributed on a large scale in many different versions. Thus, a team, athlete, corporate sponsor or other entity having images they and/or the wearers of the device are interested in displaying would easily be able to accommodate diverse wearer interests either by manufacturing and making available devices at a cost enabling the consumers to buy several of the devices, or even to collect them. Similarly, and particularly when manufactured on a large scale, the devices could be sufficiently inexpensive that they could be handed out on a complimentary basis by a corporate sponsor, similar to computer mousepads, cup coolers, key chains, calendars and other inexpensive and corporate message-bearing promotional gifts.
While the present invention has been described with reference to certain embodiments depicted in the accompanying drawings, one of ordinary skill in the art will recognize that other structures may embody the spirit of the invention as described herein and as set forth in the claims. | A directable, hand-wearable communication device provides a frontal display surface and a rear display surface to which images can be applied for promoting teams, athletes, corporate sponsors, political parties and the like. Frontal and rear display surfaces may be provided by corresponding members that are joined at their perimeters to form a pocket for receiving a human hand and presenting no obstructions between the fingers, including the thumb. The device has an aperture at the lower extremity of the joined perimeter for permitting access by the hand to the pocket. An elastic neck portion is preferably joined along the edge of the aperture to snugly fit around the wrist of the wearer and keep the device securely in his or her possession, particularly during vigorous use. The display surfaces provided by one or both of the front and rear sides of the device are provided with an image, such as a graphic image, an alphanumeric symbol, a team or corporate logo, or any other image a wearer may wish to display and thereby communicate. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. Ser. No. 11/410,813, filed Apr. 25, 2006, entitled COMPOUND BOW WITH IMPROVED RISER, now U.S. Pat. No. 7,383,834, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to a bow and, more particularly, to a compound bow that exhibits improved vibration dampening and generates less noise than conventional bows.
[0003] Bows typically have four main components: a riser or handle; two arms or limbs that mount to the riser; and a bow string or cable that is tensioned between the two arms. In the past, the riser was made from wood, but more recently risers are formed from metals, such as cast aluminum or magnesium. Even more recently, the risers have been formed from extruded metals, such as extruded aluminum. While metal risers have provided increased stiffness and, in some cases, reduced the weight of the bow, they have exhibited increased vibration and, more significantly, generate louder and higher frequency noise when the riser makes contact with an object, such as an arrow, tree, or tree stand, when the riser is bumped into the object or the object bumps into the riser. These risers even tend to produce more noise during a release cycle. Noise is particularly undesirable when a hunter is approaching his or her prey.
[0004] While vibration dampeners have been proposed to reduced noise when the bow string is pulled and then released, heretofore these vibration dampeners have not succeeded in reducing the other noises inherent when handling a bow.
[0005] Accordingly, there is a need for a bow that will exhibit increased vibration dampening and further will minimize noise that is inherent when using or handling the bow.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention provides a bow that produces less noise when used and also when handled.
[0007] In one form of the invention, a compound bow includes a base member, which is formed from a rigid material and has a grip location between the two ends of the base member, which provide mounting locations for mounting limbs to the base member. An elastomeric body is applied over and at least substantially encapsulates the base member over the longitudinal extent of the base member, with the elastomeric body comprising a dampening material and, further, forming a grip member at the grip portion.
[0008] In one aspect, the base member is formed from an extruded material, such as extruded aluminum or magnesium.
[0009] In other aspects, the elastomeric body is formed from two materials with one of the materials forming the grip member and having a different durometer value than the other material.
[0010] In yet another aspect, the bow includes two limbs mounted to the opposed ends of the base member with the dampening material applied over at least a portion of each of the limbs.
[0011] According to another aspect, the dampening material may be applied to at least a portion of at least one of the ends of the base member. For example, at least one of the ends may include at least one recess, with the dampening material extending into the recess.
[0012] In other aspects, the base member includes at least one mounting opening at the grip location for mounting a separate grip member to the base member, with the elastomeric body being applied over the opening but being removable wherein the separate grip member may be mounted to the base member at the mounting opening in place of the grip member formed by the elastomeric body. Optionally, the elastomeric body has an indication around the grip location to provide a cutting guide for a user to cut and remove the dampening material around the grip location.
[0013] In yet further aspects, the elastomeric body terminates at the ends wherein the ends of the base member are free of the elastomeric body.
[0014] Further, the base member may include at least one lightening opening, with the elastomeric body at least partially extended into the lightening opening.
[0015] In another form of the invention, a compound bow includes a base member, which is formed from a rigid material and has a grip location between its ends, which provide mounting locations for mounting limbs to the base member. The grip location has at least one mounting opening for mounting a separate grip member to the base member. In addition, an elastomeric body is applied over and at least substantially encapsulates the base member over its longitudinal extent and covers the mounting opening but is removable at least at the mounting opening. The elastomeric body comprises a dampening material and may have a durometer in a range of 15 to 90 Shore A.
[0016] In one aspect, the base member is formed from an extruded material, such as an extruded metal.
[0017] In other aspects, the elastomeric body is formed from two materials, with one of the materials having a different durometer value or different color or texture than the other material. For example, one material may be applied to one portion of the base member, while the other material is applied to another portion of the base member.
[0018] In accordance with another aspect, the elastomeric body is molded to the base member.
[0019] According to another form of the invention, a compound bow includes a base member with a longitudinal extent and first and second ends. The base member is formed from a rigid material and has a grip location between its first and second ends. The base member further has at least one lightening opening to thereby reduce the weight of the base member. The grip location has at least one mounting opening for mounting a separate grip to the base member. The ends of the base member provide mounting locations for mounting limbs to the base member. An elastomeric body is applied over and at least substantially encapsulates the base member over the base member's longitudinal extent. The elastomeric body terminates around the grip location to thereby expose the grip location and is formed from a dampening material, which extends at least partially into the lightening opening.
[0020] In one aspect, the dampening material is applied to at least a portion of at least one of the ends of the base member. In a further aspect, the dampening material is applied to both ends.
[0021] According to yet another form of the invention, a compound bow riser is made by forming a base member from a rigid material, which has a longitudinal extent and first and second ends. The base member includes a grip location between the first and second ends and a mounting opening at the grip location. A dampening material is molded over the base member at least along the longitudinal extent to form an elastomeric body, which at least surrounds the grip location and provides dampening of the base member.
[0022] In one aspect, the grip location is covered with the elastomeric body, which forms a grip member at the grip location.
[0023] In another aspect, the elastomeric body covers the mounting opening. Optionally, an indication of the perimeter of the grip location may be provided wherein a user may cut along the indication to remove the dampening material from the grip location.
[0024] Accordingly, the bow of the present invention exhibits improved vibration dampening and generates less noise when impacted by an object.
[0025] These and other objects, advantages, purposes, and features of the invention will become more apparent from the study of the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a side view of a compound bow embodying the invention;
[0027] FIG. 2 is an enlarged side view of the riser of FIG. 1 ;
[0028] FIG. 3 is a back view of the riser of FIG. 1 ;
[0029] FIG. 4 is a cross-section taken along line IV-IV of FIG. 2 ;
[0030] FIG. 5 is a side view of another embodiment of the riser of the present invention;
[0031] FIG. 6 is a back view of the riser of FIG. 5 ;
[0032] FIG. 7 is a similar view to FIG. 5 illustrating a grip molded onto the riser; and
[0033] FIG. 8 is a back view of the riser of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring to FIG. 1 , the numeral 10 generally designates a compound bow with a riser 12 of the present invention. As will be more fully described below, riser 12 is configured to dampen and reduce the vibration of bow 10 to thereby reduce the noise generated during a release cycle and, further, to reduce the bow noise when bow 10 is contacted by an object, just as a tree or tree stand or arrow or any other object that may be encountered during hunting.
[0035] As best seen in FIG. 1 , bow 10 includes riser 12 and two limbs 14 and 16 that are mounted to the opposed ends 12 a and 12 b of riser 12 by fasteners. Mounted to the ends of limbs 14 and 16 are pulleys 18 and 20 , which support a bow string or cable 22 . No further details of the pulleys and cable will be provided herein as they are conventional and well known in the art.
[0036] As noted above, bow 10 is adapted to dampen the vibration of the bow during a release cycle and when impacted by an object. For example, when a hunter is using a bow, he or she will sometimes contact the riser with the arrow, which generates noise. Similarly, hunters often climb in trees and, sometimes, sit in a tree stand while waiting for prey. When climbing up or down a tree or when simply moving around a tree, the bow may come in contact with a tree or tree stand. Again, this generates noise, which can scare-off prey.
[0037] Referring to FIGS. 2 and 3 , riser 12 includes a base member 24 and a vibration dampening body 26 , which is applied over base member 24 . In the illustrated embodiment, base member 24 comprises an extruded member that is formed from a metal, such as aluminum or magnesium; however, it should be understood that the base member may be formed from other materials and, further, may be machined. One suitable base member may be configured and formed using the method described in U.S. Pat. Nos. 5,365,650 and 5,335,644, which are incorporated in their entireties herein.
[0038] As best seen in FIG. 2 , base member 24 includes a grip area 28 with at least one optional mounting opening 30 . Described in further detail below, mounting opening 30 provides a mounting opening for mounting a separate optional grip member to riser 12 . In addition to mounting opening 30 , base member 24 may include one or more lightening openings 34 . Lightening openings 34 may be provided to reduce the weight of base member 24 and, hence, bow 10 . Base member 24 also includes a plurality of limb mounting openings 36 at its respective ends 24 a and 24 b and a cable guide mounting opening 37 . Additional openings that may be provided include tool holes 38 and “AMO” holes 40 , which are archery industry standard holes. As would be understood, the number of openings or holes may be varied to suit the particular manufacturer and bow application.
[0039] Referring again to FIGS. 2 and 3 , body 26 is applied over the full length of base member 24 . Body 26 is preferably formed from a dampening material such as an elastomeric material. For example, one suitable material is SANTOPRENE, and may have a durometer in a range of 15 to 90 Shore A. Further, body 26 may be applied to base member 24 using standard over molding techniques. As best seen in FIG. 2 , body 26 is applied over grip area 28 and, further, optionally forms a grip member 42 . Further, body 26 may be formed from two or more materials, with one material forming grip member 42 and the other material for covering the balance of base member 24 . When formed from two or more materials, body 26 may be formed from two shot molding, for example. In this manner, the grip member 42 may be formed from a softer or stiffer material than the material covering the balance of member 24 . Further, the two materials forming body 26 may be formed from materials with different colors or different textures or finishes to provide an aesthetic function as well.
[0040] As would be understood, therefore, when molding elastomeric body 26 onto base member 24 to form grip member 42 , body 26 covers mounting opening 30 . Alternately, when forming riser 12 the material forming body 26 may optionally be terminated around grip area 28 so that grip area 28 of base member 24 may be exposed. In this manner, a separate grip member, such as a wood grip or customized grip, may be mounted to riser 12 .
[0041] Alternately, elastomeric body 26 may be molded over grip area 28 as noted above but formed with a demarcation line or recesses or some sort of indication that provides a guide to allow the elastomeric body to be cut and trimmed to remove that portion of the elastomeric body that forms grip member 42 . In this manner, a single riser may be made that can be used in both a standard configuration and a customized configuration.
[0042] In addition, elastomeric body 26 may be molded over, for example, lightening openings 34 so that the material forming body 26 either completely fills the lightening openings or only partially fills the openings. Alternately, when over molding base member 24 , plugs or spacers may be inserted into the lightening openings so that the elastomeric material partially fills the openings but leaves openings of smaller dimensions than the original lightening openings when the plugs are removed. Alternately, the plugs may fill the entire opening so that the elastomeric material terminates at the edges of the openings. Similarly, cable guide opening 37 may be filled with a plug during molding or the elastomeric material may be trimmed at the opening so that the cable guide may be mounted to riser 12 in a conventional manner.
[0043] Referring again to FIG. 2 , as noted above elastomeric body 26 is applied over the full length of base member 24 . In the illustrated embodiment, elastomeric body 26 terminates at the ends of base member 24 so that ends 24 a and 24 b are exposed. Optionally, as illustrated in reference to end 24 a , elastomeric member 26 may extend over the ends of member 24 . For example, elastomeric body 26 may entirely cover the surfaces of ends 24 a , 24 b or cover portions of the surfaces of ends 24 a , 24 b . For example, ends 24 a and 24 b may include one or more recesses 44 into which the elastomeric material may extend and, further, project to form elastomeric ribs or regions 46 to provide dampening between limbs 14 and 16 and base member 24 .
[0044] In addition to covering base member 24 , the elastomeric material may be applied to portions of or the entire lengths of limbs 14 and 16 .
[0045] In addition to dampening vibration and reducing noise, body 26 also protects the base member from oxidation. Thus, body 26 eliminates the need for painting base member 24 . Further, body 26 may provide a medium for decorating base member 24 . For example, as noted, body 26 may be formed from a colored elastomeric material. In addition, decorative patterns or designs or the like may be molded into body 26 . For example, emblems can be molded into the outer surface of body 26 or may be embedded onto body 26 either during molding or inserted into recesses molded into body 26 .
[0046] In addition to dampening vibration and reducing noise, body 26 also provides a barrier that makes riser 12 warmer to the touch. Further, body 26 allows for riser 12 to be formed with a unique and/or customized shape.
[0047] Referring to FIGS. 5-8 , the numeral 112 designates another embodiment of the riser of the present invention. Similar to riser 12 , riser 112 includes a base member 124 and an elastomeric body 126 . Body 126 preferably is applied, such as by over molding, to base member 124 to dampen the vibration of riser 112 and reduce the noise of riser 112 when impacted by an object similar to riser 12 .
[0048] In the illustrated embodiment, grip member 142 is formed from a different elastomeric material than the balance of body 126 , which covers the remaining portion of base member 124 . Similarly, grip member 142 covers a grip mounting opening 130 formed in base member 124 , which allows for another grip member to be mounted to base member 124 after removal of grip member 142 .
[0049] As shown in FIG. 5 , base member 124 includes a different arrangement and number of lightening openings 132 as well as AMO holes and tool holes. As noted, the number and location of lightening openings, as well as AMO homes and tool holes, can vary.
[0050] Accordingly, the present invention provides a bow that exhibits dampened vibration and, further, generates reduced noise levels when impacted by an object, such as a tree, tree stand, or an arrow. Further, the riser is assembled in a manner that permits further customization of the riser while also providing greater resistance to corrosion.
[0051] While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the invention which is defined by the claims which follow as interpreted under the principles of patent law including the doctrine of equivalents. | A compound bow includes a base member with a longitudinal extent and has first and second ends. The base member is formed from a rigid material and has a grip location between its first and second ends, which provide mounting locations for mounting limbs to the base member. An elastomeric body is applied over, for example by molding, and at least substantially encapsulates the base member over the longitudinal extent. The elastomeric body comprises an elastomeric material, and optionally forms a grip member at the grip portion. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention relates to Provisional Application Serial No. 60/078,625, filed Mar. 19, 1998, by Istvan M Boszormenyi, and entitled “INTEGRATED LASER CLEANING AND INSPECTION SYSTEM”. The contents of this application is incorporated by reference herein.
BACKGROUND OF THE INVENTION
This invention relates to laser cleaning and inspecting of surfaces. In particular the system is for use on disc surfaces which are used for recording data.
In most high technology industries, for instance, semiconductor device, hard disc or flat panel display manufacturing, improved performance is linked to the ability to reduced the feature size. Thus there is the narrower line width, smaller bit cell or pixel size. As a consequence, the size of detrimental contamination, for example, particles, steadily decreases. Hence, there is an increased demand for effective cleaning technologies, tools and processes. To reduce cost these cleaning processes need to be monitored closely.
Laser cleaning has emerged as a potential new dry cleaning technology to remove particles and other contaminants from surfaces. For example the Radiance (U.S. Pat. No. 5,024,968) process utilizes a pulsed intense light source (such as an excimer laser) in the presence of an inert gas flow over the surface to remove contamination.
With the reducing feature size the time to necessary to inspect a surface for cleanliness increases and it becomes impractical to inspect every surface or even the entire surface going through a cleaning process. Usually, samples are taken and a significant portion of these surfaces are analyzed for cleanliness.
Most commonly these inspection tools are based on light scattering. A small beam of light is directed at the surface and photomultiplier tubes detect the scattered light. The smaller the wavelength the smaller particles can be detected.
There is need top provide for an enhanced technique, system and apparatus for cleaning and inspecting surfaces
SUMMARY OF THE INVENTION
According to the invention cleaning and inspecting a surface of the substrate comprises subjecting the surface to the output of a laser source for applying a cleaning energy to the surface and thereby remove contaminants on the surface. The laser source is used for inspecting the surface being cleaned and to measure the effect of the cleaning.
The integrated laser cleaning and inspection system uses the light from laser cleaning light source as the inspection light source. The system allows:
a) in situ 100% surface inspection of every workpiece during laser cleaning
b) controlling the laser cleaning process
c) sorting the substrates based on cleanliness and damage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representation of an integrated laser cleaning and inspection tool.
FIG. 2 is a flow diagram illustrating the laser cleaning process.
FIG. 3 is an example of modifying the laser beam cross-section to achieve uniform energy distribution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description, reference is made to the accompanying drawings which form a part hereof, and which show, by way of illustration, several embodiments of the present invention. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
The invention combines laser cleaning and inspection in one tool. The laser beam used for cleaning is also used as the light source for the inspection. As the surface is being cleaned the level of cleanliness can be monitored at the same time. Since the entire surface of every workpiece needs to be cleaned and not just samples the tool allows 100% inspection which would be cost prohibitive if the inspection was to be carried out off-line.
A drawing of such an integrated system for cleaning and monitoring cleanliness for discs is shown in FIG. 1 with excimer laser 10 as a source for a beam 11 and a hard disc 12 as a substrate for cleaning. An ultraviolet (UV) laser beam 11 is favored in both cleaning and detection processes because it allows the removal and detection of smaller particles. The beam from the source 10 is directed through a beam homogenizer 13 and focusing lenses 14 to the disc 12 .
The intensity of the scattered light from contaminants on the substrate 12 is directed to focusing lenses 15 and collected with one or more photomultiplier tubes (PMT) 16 . The signal from the PMT 16 is used to control the cleaning process and to make decision on the quality of the substrate. A process control protocol is outlined in the flow diagram of FIG. 2 . In this diagram,
I
intensity of scattered light from PMT
n
number of laser pulses
φ
angle
I cleam
background intensity, scattering from a clean surface
n max
maximum n allowed (e.g., n ave + 2σ)
P
laser power
P max
maximum safe laser power.
At the start of the process the excimer laser 10 is activated to start cleaning as indicated by box 17 . The intensity of the scattered light and the angle of the scattered light is determined by the photomultiplier 16 as indicated in box 18 . Depending upon that determination, the cleaning continues as indicated in 19 . In this situation there are further pulses of light which are applied by the excimer laser 10 . The excimer laser 10 can increase in power, as indicated by 20 , if necessary. Where that power is increased greater than the maximum safe laser power as indicated in 21 , the process is stopped as indicated in 22 , since the substrate 12 would have flaws. The increase in power can be caused by either the number of laser pulses exceeding the maximum amount or the time of the pulses being applied increases beyond a maximum amount as indicated in 25 . As indicated in 23 , when the intensity of the scattered light as measured by the photomultiplier 16 increases in a number of pulses and angle beyond the amount necessary, then a substrate cleaning process is stopped as indicated in 24 . In the situation where the intensity of the scattered light relative to the number of laser pulses is greater than a predetermined number as indicated in 27 , then the process stops because of possible damage to the substrate as indicated in 26 .
The location of the laser spot on the disc surface is identified by the radial (r) and angular (α) position on the disc surface. The area to be scanned on the disc surface can be selected by choosing the appropriate radial and angular position limits. Angle θ 1 is the angle at which the detector(s) are placed to collect the scattered light from the disc surface. A number of detectors will be placed at different angles (0-90°) around the disc to ascertain the size of the particle. Angle θ 2 is the angle of incidence of the laser beam on the disc surface. This angle will be chosen, between 0-45°, to obtain maximum cleaning and minimum damage to the substrate. The maximum number of pulse n max will vary from 30-200 Hz for different substrates. This quantity is used to control the amount of laser energy incident on the substrate.
For efficient cleaning of the discs the laser beam shape incident on the disc surface is modified with properly designed shutters and optics. This is done so that uniform energy is made incident throughout the disc surface. FIG. 3 shows a scheme of designing the beam cross-section 30 such that the desired overlap over two subsequent measurements can be obtained.
In this scheme for disc cleaning the scattered light intensity is measured as a function of number of laser pulses used and angular location ∝ on the disc. If the intensity reduces to a level characteristic of a clean surface there is no need for further exposure and the cleaning process is aborted.
There may be a need for a minimum exposure, however, to assure uniform surface properties on the post clean substrate. If the intensity is higher even after a n max number of pulses applied, the laser power can be increased up to a the maximum safe laser power (P max ). If the scatter intensity increases with the number of pulses, surface roughening or other damage to the surface is likely. The discs are taken out of the process flow if there is indication of surface damage, or the maximum safe laser power is reached without reduction of the scatter intensity. The values of I clean , n max , and P max are determined experimentally with calibration discs.
The geometry of the source 10 and detection PMT(s) 16 are optimized to allow discrimination of particles and other non-removable surface features such as pits, bumps and micro scratches.
In one preferred embodiment, laser cleaning and inspection procedures are carried out, for example, on a surface of a recording medium or disc substrate, prior to applying a thin layer of film of magnetic material to the surface. In further embodiments, such laser and inspection procedures may also, or alternatively, be carried out on the layer or film of magnetic material, after the material has been applied (such as sputtered on) to the substrate surface.
Combining laser cleaning with inspection results in savings in tool cost. The yield of downstream processes will increase because discs that cannot be cleaned are not be processed any further.
CONCLUSION
This concludes the description of the preferred embodiment of the invention. The following describes some alternative embodiments for accomplishing the present invention.
For example, any number of different types of surfaces could be used with the present invention. Those skilled in the art will recognize that the present invention could be applied to both magnetic and optical disk drives.
In another example, surfaces having different structures and components from those described herein could benefit from the present invention. Those skilled in the art will recognize that the system, method and apparatus could have a different steps and structures from that disclosed herein without departing from the scope of the present invention. Those skilled in the art will recognize that the present invention could be used with heads that only read, but do not record. Those skilled in the art will also recognize that the present invention could be used to position optical heads rather than magnetic heads.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. `It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | Cleaning and inspecting a surface of the substrate comprises subjecting the surface to the output of a laser source for applying a cleaning energy to the surface and thereby remove contaminants on the surface. The laser source is used for inspecting the surface being cleaned and to measure the effect of the cleaning. | 8 |
TECHNICAL FIELD
[0001] The present invention concerns the production of optic fibre chemical sensors used in particular to measure nitric acidity.
[0002] In the area concerning the treatment of spent nuclear fuel, demands in terms of quality and process control require very swift knowledge, even real-time knowledge, of any variations in physical or chemical parameters, in nitric acidity in particular.
[0003] During the various steps in the treatment of spent fuel, the on-line measurement of free acidity provides important data which largely contributes to control over extraction methods, to a substantial reduction in waste and to a lighter work load for laboratories.
PRIOR ART
[0004] Optic fibre chemical sensors suitable for measuring nitric acidity have been described by M. H. Noiré et al in the following documents:
[0005] Sensors and Actuators B51, 1998, pages 214-219 [1], and
[0006] Journal of Sol-Gel Science and Technology 17, 2000, pages 131-136 [2].
[0007] These sensors measure the absorbency of a coloured indicator sensitive to the protons released by the acid. The coloured indicator, Chromoxane Cyanine R for example, is immobilized on a porous film chemically grafted onto the core of a silica optic fibre. The optic fibre chemical sensor is coupled to a spectrophotometric device for remote, in situ analysis of the acidity. The sensor operates by total mitigated reflection. When this sensor is used, the rays from a light source propagate under multiple reflection in the core of the optic fibre, transiting however along a wave length fraction in the porous film containing the coloured indicator whose colour relates to the acidity of the medium with which it is in contact. The transmitted light, representing the acidity of the medium, is measured by visible UV-spectrophotometry.
[0008] The method used for the manufacture of these sensors uses the sol-gel technique, a soft mode chemical technique for the synthesis of metallic oxides. This technique consists of preparing a sol by acid-catalysed hydrolysis of an alcoxysilane-in-alcohol solution containing the coloured indicator, leaving the sol to mature to initiate gelling, followed by its depositing on the core of an optic fibre whose mechanical and optic sheaths have been removed over a central part, and then drying to form a micro-porous film, containing the coloured indicator, grafted onto the core of the fibre.
[0009] In this method, the organic precursor, tetraethoxysilane, through hydrolysis and condensation leads to the formation of an inorganic network of low porosity in which the molecules of the coloured indicator are trapped.
[0010] To conduct acidity measurement, the optic fibre provided with this porous film is placed in a cell in which the medium to be measured circulates, and which is connected via optic fibres to a multi-channel spectrophotometric system fitted with a CCD detector.
[0011] The advantage of such device is the possible simultaneous follow-up of acidity at different points of an installation via several sensors.
[0012] The absorbency measured by the detector represents the protonated form of the coloured indicator and is directly linked to the nitric acid concentration of the medium being analysed.
[0013] The sensors manufactured to date using this method show analytical performing capacities of interest, but have the disadvantage that they do not have good reproducibility and especially lifetime characteristics owing to desorption of the coloured indicator molecules from the porous film towards the medium to be analysed.
DESCRIPTION OF THE DISCLOSURE
[0014] The subject matter of the present invention is precisely a method for manufacturing an optic fibre chemical sensor using the sol-gel technique, which has very high stability, that is to say the capacity to withhold practically the entirety of the coloured indicator in the porous film over very long periods, while allowing the protons released by the acid to diffuse inside this film.
[0015] According to the invention, the method of producing a silica-based optic fibre chemical sensor, which can be used to analyse a chemical species present in a liquid or gas, consists of chemically grafting onto the core of the optic fibre a porous film containing a coloured indicator sensitive to the chemical species to be analysed, by conducting the following steps:
[0016] a) Preparing a sol by acid-catalysed hydrolysis of a solution of an alcoxysilane in an alcohol, containing the coloured indicator,
[0017] b) sol maturing
[0018] c) depositing the sol on the core of the optic fibre, and
[0019] d) drying
[0020] and is characterized in that, in step a), the quantity of acid used is such that the pH of the aqueous phase of the sol is 0.44 to 0.72.
[0021] In the sol-gel technique, the choice of parameters used is of great importance since these parameters have a direct influence on the final structure of the porous film which is to withhold the coloured indicator.
[0022] According to the invention, optimum conditions are chosen to obtain porosity providing total withholding of the coloured indicator while allowing the species to be analysed, for example the protons released by the acid, to diffuse inside the film.
[0023] It was therefore found that the pH of the aqueous phase of the sol is a determinant parameter for obtaining the desired microporous characteristics of the grafted film containing the coloured indicator.
[0024] The choice of this parameter has an important influence on the gelling time of the sol and on the pore sizes of the dried product subsequently obtained. Hence, with pH values for the aqueous solution of less than 0.72, pores in the microporous region are obtained whereas pH values of more than 0.72 lead to the macroporous domain.
[0025] Obtaining a macroporous film is not desirable, since it allows the coloured indicator molecules to diffuse in the solution to be analysed and is detrimental to the reproducibility and lifetime of the sensor.
[0026] The pH of the aqueous phase of the sol is generally adjusted to the desired value through the addition of hydrochloric acid. A value of 0.72 relates to a HCl percentage of 2%, 2% meaning 2 moles of HCl per 100 moles of alcoxysilane.
[0027] Another important parameter when adjusting the porosity of the grafted film to the desired values concerns sol maturing step b). Preferably, this maturing is conducted at a temperature of 40 to 70° C., preferably between 50 and 60° C., for a period of no more than 3 days.
[0028] Indeed, it was verified that maturing time has an influence on the pore size of the dried film. Pore diameter increases with maturing time. Therefore, to limit this diameter, it is appropriate to choose a maturing time which does not exceed 3 days and is preferably between 24 and 50 hours.
[0029] A further parameter having a considerable influence on the quality of the porous film is the quantity of water used for hydrolysis during step a) for preparation of the sol. Preferably, a water/alcoxysilane molar ratio of 4 to 6 is used for hydrolysis. By choosing this water/alcoxysilane molar ratio, it is possible to stabilize the density of the film and its porosity characteristics.
[0030] In the method of the invention, to carry out step d), vacuum drying is preferred for a time of 20 to 30 hours, preferably for approximately 24 hours. Drying temperature may be 100° C.
[0031] According to the invention, the sensor is preferably used after being stored for at least 3 weeks away from light and at room temperature.
[0032] This additional storage step also has its importance since it allows for stabilisation of the deposited film. Drying at 100° C., even when conducted on thin films, does not permit total condensation of the alcoxy functions. Therefore the film undergoes change in time through slow condensation of the remaining alcoxy functions. It is therefore most important to use the sensor after this condensation process is completed so as to avoid encountering reproducibility problems for characterization.
[0033] Preferably, storage is made for a period ranging from 3 weeks to 2 months. It is also possible to accelerate this condensation process by means of vacuum drying.
[0034] The other parameters of this sol-gel manufacturing method have lesser influence on the porosity of the deposited film, and may be chosen from among the values chosen for known production methods of chemical sensors using the sol-gel technique.
[0035] Therefore, the alcohol content of the alcoxysilane solution may be such that the alcohol/alcoxysilane molar ratio is approximately 10.
[0036] Generally, the alcoxy groups of the alcoxysilane have from 1 to 4 carbon atoms. Preferably tetraethoxysilane is used.
[0037] The alcohol used may be an alcohol having from 1 to 4 carbon atoms; preferably ethanol is used which is the most suitable for the synthesis of microporous gels.
[0038] In the method of the invention, the coloured indicator is chosen in relation to the chemical species to be analysed by the chemical sensor. If this sensor is intended to measure nitric acidity over the concentration range of 1 to 10 mol/L, the coloured indicator may be Chromoxane Cyanine R or Chromazurol S. Preferably, Chromoxane Cyanine R is used.
[0039] If the sensor is intended to measure nitric acidities over a lower concentration range, for example from 0.1 to 2 mol/L, the coloured indicator may be chosen from among Thymol Blue, Phenol Red and Pyrocatechol Violet.
[0040] The concentrations of the coloured indicator are chosen such that a sufficient quantity of indicator is obtained in the film. They may be such that the coloured indicator/alcoxysilane molar ratio ranges from 1/300 to 1/700. It is preferably 1:335. At higher values, dimers and/or aggregates may occur.
[0041] A further subject of the invention is a fibre optic chemical sensor for measuring nitric acidity, obtained using the above method, whose acidity measurement signal is stable for at least 1000 hours in 8N acid circulated around the porous film.
[0042] Other characteristics and advantages of the invention will become better apparent on reading the following description of examples of embodiment given by way of illustration and evidently non-restrictive, with reference to the appended drawings.
SHORT DESCRIPTION OF THE DRAWINGS
[0043] [0043]FIG. 1 is a schematic illustration of the sol-gel method used for the invention.
[0044] [0044]FIG. 2 is a diagram illustrating a measurement installation comprising a chemical sensor conforming to the invention.
[0045] [0045]FIG. 3 shows the absorption spectra of a sensor conforming to the invention, in a pure nitric medium, for acidity values ranging from 2 to 10 N relative to a 1 N reference.
[0046] [0046]FIG. 4 illustrates changes in the signal transmitted by different sensors in relation to time in hours, curves 1 to 4 relate to sensors conforming to the invention, whereas curves 5 to 8 are given by way of comparison and represent sensors which do not conform to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0047] [0047]FIG. 1 shows a sol-gel method for producing a silica-based porous film containing a coloured indicator formed of Chromoxane Cyanine R (CCR).
[0048] As illustrated in this figure, the starting alcoxysilane is tetraethoxysilane Si (OEt) 4 in solution in ethanol EtOH, to which is added water H 2 O and an acid catalyst, hydrochloric acid HCl, and a coloured indicator CCR.
[0049] Hydrolysis leads to Si(OH) 4 which, by condensation, gives a sol in which the CCR molecules are trapped. By sol maturing, a gel is obtained as shown in this figure. Generally, the sol-gel matrix is prepared at room temperature in a clean environment protected from draughts and, if possible, under controlled temperature and hygrometry.
[0050] To implement the method of the invention, an optic fibre such as a silica fibre may be used comprising an optic sheath in hard polymer and an outer sheath in Tefzel, having a total length of 256 mm. The central part of this fibre, or active part, is uncovered, over 100 mm for example, to expose the core of the fibre. It is possible to conduct a first mechanical removing operation to remove the outer Tefzel sheath, and a second removal operation under heat to remove the optic sheath of hard polymer. Sol-gel depositing is then carried out on the active part of this fibre previously cleaned with ethanol for example.
[0051] This depositing may be made by placing the fibre vertically in a tube containing the sol, then by withdrawing it vertically at a slow, constant rate, for example at 1 mm/s. The ends of the mechanical sheath immersed in the sol-gel solution are then cleaned with alcohol. After depositing, the coated fibre is dried, for example at a temperature of 100° C., so that the film adheres to the fibre and porosity is reduced.
[0052] This depositing step is conducted away from any draughts of air to obtain a uniform deposit thickness when the solvent is evaporated It is also possible to conduct several successive deposits by immersing the fibre in the sol to obtain the desired thickness.
[0053] The following examples illustrate the preparation of the sensors using the method of the invention.
EXAMPLE 1
[0054] Sensors 1 and 2 are prepared from two identical sols, obtained by successively adding to a sealed flask in opaque glass: absolute ethanol, 99% pure tetraethoxysilane (TEOS), dilute hydrochloric acid and the coloured indicator CCR having a molecular weight M of 536.4 and 40% purity.
[0055] For this preparation, the quantity of hydrochloric acid used is such that the pH of the aqueous phase of the sol is 0.72, the water/TEOS molar ratio is 6, the ethanol/TEOS molar ratio is 10 and CCR concentration represents 1 mole CCR per 335 moles TEOS.
[0056] The mixture is homogenized for 1 hour at room temperature, and it is then placed in sealed storage in an oven at 55° C. for a maturing time of 50 hours, before the sol is deposited on the fibre using the above-described method.
[0057] After depositing the film, vacuum drying is conducted at 100° C. for 24 hours and the sensor is then stored for 3 weeks in ambient atmosphere.
EXAMPLE 2
[0058] The same operating mode is followed as in example 1 to prepare sensors 3 to 8, using the same parameters for the method except those concerning the pH of the aqueous phase of the sol and temperature.
[0059] Table 1 below illustrates the values chosen for the pH of the aqueous phase and maturing temperature to prepare sensors 1 to 8.
TABLE 1 Sensor pH Temperature (° C.) 1 0.72 55 2 0.72 55 3 0.44 42 4 0.44 68 5 0.99 42 6 1.27 55 7 0.17 55 8 0.99 68
[0060] Sensors 1 to 4 prepared as described above, have the following characteristics:
[0061] The thickness of the film is in the region of 100 nm for a sol layer deposit. This thickness is measured on optic fibre by scanning electronic microscopy (SEM) and on silicon plate by X reflectometry and ellipsometry.
[0062] The density of the film is 1.85 g.cm −3 measured by X reflectometry. The deduced porous volume is 16%.
[0063] The refractive index of the film is 1.44 compared with 1.46 for the index of the optic fibre core in melted silica. This value was obtained by ellipsometry on silicon plate.
[0064] The chemical sensors thus obtained were tested in 8N nitric medium.
[0065] For this purpose, the device shown in FIG. 2 is used.
[0066] This device comprises an xenon lamp 1 which sends a light beam onto sensor 3 in contact with the medium to be measured and onto a reference line 5 measuring possible fluctuations in the lamp signal. The light beams are then directed by optic fibres 7 into a plane field spectrophotometer 9 fitted with mirrors and a Charge Coupled Device detector (CCD) which is a two-dimension matrix detection system, the columns representing wavelengths and the lines representing the position of the 10 fibres (or 10 measurement channels) as seen by the detector.
[0067] The absorption spectra of the sensor in 1N HNO 3 medium are obtained which is the reference, and the spectra corresponding to the sensors in 8N HNO 3 medium, i.e. the measurement. The optic density is determined on these absorption spectra at the wavelength of maximum absorption located at 545 nanometres, compared with the reference which is 1N nitric acid.
[0068] [0068]FIG. 3 shows the absorption spectra obtained for nitric acid concentrations of 2, 5, 8, 10 and 12N.
[0069] The stability of the signal emitted by each of sensors 1 to 8 in a nitric medium is verified by measuring the optic density at time to, which is 0.14 for 8N HNO 3 and which corresponds to 100% of the signal; then the optic signal is determined in relation to time by its expression as a percentage of initial optic density, measured for the concentration HNO 3 =8N.
[0070] The results obtained are shown in FIG. 4 which illustrates the changes in the signals emitted by sensors 1 to 8 in relation to time (in hours).
[0071] In this figure, it can be seen that the best results are obtained with sensors 1 to 4 produced with a pH of 0.72 or less, and that sensors 5 and 7 also correspond to average stability.
[0072] On the other hand, sensors 6 and 8 show no signal stability.
[0073] Therefore, it is verified that the choice of parameters such as pH, temperature and maturing time, according to the invention, play a very important role in results, in particular in respect of sensor stability.
[0074] The response of the sensors of the invention was also measured in the presence of metallic cations such as FE 3+ , Ce 3+ , UO 2 2+ , Pu (IV), U (IV) and it was verified that for contents of these elements lower than 10 g.L −1 , comparable results were obtained.
[0075] Cited References
[0076] [1] M. H. Noiré et al, Sensors and Actuators B51, 1998, pages 214-219.
[0077] [2] M. H. Noiré et al, Journal of Sol-Gel Sciences and Technology 17, 2000 pages 131-136. | The invention concerns the production of a chemical sensor which can be used to measure nitric acidity.
This sensor is produced using a sol-gel method for depositing a porous film, containing a coloured indicator, on the core of an optic fibre. The pH of the initial sol is adjusted as are other conditions for implementing the sol-gel method to obtain stability of the signal (curves 1 to 4 ) emitted by the sensor in an 8N nitric medium for at least 1000 hours. | 8 |
RELATED APPLICATION DATA
[0001] The instant application is a continuation of U.S. Non-Provisional Application No. 12/874,662 filed Sep. 2, 2010, still pending, which is a continuation of U.S. Non-Provisional Application No. 12/555,303 filed Sep. 8, 2009, now abandoned, which is a continuation of U.S. Non-Provisional Application No. 12/221,231 filed Jul. 31, 2008, now abandoned, which is a divisional of U.S. Non-Provisional Application No. 11/704,614 filed Feb. 9, 2007, now issued as U.S. Pat. No. 7,410,327, which is a continuation of U.S. Non-Provisional Application No. 10/820,597 filed Apr. 8, 2004, now abandoned, which claims the benefit of prior Provisional Application No. 60/461,602, filed Apr. 8, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of oil and gas drilling and production. In a specific, non-limiting embodiment, the invention comprises a system and method of drilling oil and gas wells in arctic, inaccessible or environmentally sensitive locations without significantly disturbing an associated ground surface.
DESCRIPTION OF THE PRIOR ART
[0003] The drilling and maintenance of land oil and gas wells requires a designated area on which to dispose a drilling rig and associated support equipment. Drilling locations are accessed by a variety of means, for example, by roadway, waterway or another suitable access route. In particularly remote locations, access to a drilling site is sometimes achieved via airlift, either by helicopter, fixed wing aircraft, or both.
[0004] Some potential drilling and production sites are further constrained by special circumstances that make transportation of drilling equipment to the drilling site especially difficult. For example, oil and gas reserves may be disposed in locales having accumulations of surface and near-surface water, such as swamps, tidal flats, jungles, stranded lakes, tundra, muskegs, and permafrost regions. In the case of swamps, muskegs, and tidal flats, the ground is generally too soft to support trucks and other heavy equipment, and the water is generally too shallow for traditional equipment to be floated in. In the case of tundra and permafrost regions, heavy equipment can be supported only during the winter months.
[0005] Moreover, certain production sites are disposed in environmentally sensitive regions, where surface access by conventional transport vehicles can damage the terrain or affect wildlife breeding areas and migration paths. Such environmental problems are particularly acute in, for example, arctic tundra and permafrost regions. In these areas, road construction is frequently prohibited or limited to only temporary seasonal access.
[0006] For example, substantial oil and gas reserves exist in the far northern reaches of Canada and Alaska. However, drilling in such regions presents substantial engineering and environmental challenges. The current art of drilling onshore in arctic tundra is enabled by the use of special purpose vehicles, such as Rolligons™ and other low impact vehicles that can travel across the arctic tundra, and by ice roads that are built on frozen tundra to accommodate traditional transport vehicles. Ice roads are built by spraying water on a frozen surface at very cold temperatures, and are usually about 35 feet wide and 6 inches thick. At strategic locations, the ice roads are made wider to allow for staging and turn around capabilities.
[0007] Land drilling in arctic regions is currently performed on ice pads, the dimensions of which are about 500 feet on a side; typically, the ice pads comprise 6-inch thick sheets of ice. The rig itself is built on a thicker ice pad, for example, a 6- to 12-inch thick pad. A reserve pit is typically constructed with about a two-foot thickness of ice, plus an ice berm, which provides at least two feet of freeboard space above the pit's contents. These reserve pits, sometimes referred to as ice-bermed drilling waste storage cells, typically have a volume capacity of about 45,000 cubic feet, suitable for accumulating and storing about 15,000 cubic feet of cuttings and effluent. In addition to the ice roads and the drilling pad, an arctic drilling location sometimes includes an airstrip, which is essentially a broad, extended ice road formed as described above.
[0008] Ice roads can run from a few miles to tens of miles or longer, depending upon the proximity or remoteness of the existing infrastructure. The fresh water needed for the ice to construct the roads and pads is usually obtained from lakes and ponds that are generally numerous in such regions. The construction of an ice road typically requires around 1,000,000 gallons of water per linear mile. Over the course of a winter season, another 200,000 gallons or so per mile are required to maintain the ice road. Therefore, for a ten-mile ice road, a total of 2,000,000 gallons of water would have to be picked up from nearby lakes and sprayed on the selected route to maintain the structural integrity of the ice road.
[0009] An airstrip requires about 2,000,000 gallons of water per mile to construct, and a single drill pad requires about 1,700,000 gallons. For drilling operations on a typical 30-day well, an additional 20,000 gallons per day are required, for a total of about 600,000 gallons for the well. A 75-man camp requires another 5,000 gallons per day, or 150,000 gallons per month, to support. Sometimes, there are two to four wells drilled from each pad, frequently with a geological side-track in each well, and thus even more water is required to maintain the site. Thus, for a winter drilling operation involving, for example, 7 wells, 75 miles of road, 7 drilling pads, an airstrip, a 75-man camp, and the drilling of 5 new wells plus re-entry of two wells left incomplete, the fresh water requirements are on the order of tens of millions of gallons.
[0010] Currently, arctic land exploration drilling operations are conducted only during the winter months. Roadwork typically commences in the beginning of January, simultaneous with location building and rig mobilization. Due to the lack of ice roads, initial mobilizations are done with special purpose vehicles that are suitable for use even in remote regions of the arctic tundra.
[0011] Drilling operations typically commence around the beginning of February, and last until the middle of April, at which time all equipment and waste-pit contents must be removed before the ice pads and roads melt. However, in the Alaskan North Slope, the tundra is closed to all traffic from May 15 to July 1 due to nesting birds. If the breakup is late, then drilling prospects can be fully tested before demobilizing the rig. Otherwise, the entire infrastructure has to be removed, and then rebuilt the following season.
[0012] From the foregoing, it is clear there are several drawbacks associated with current arctic drilling and production technology. For example, huge volumes of water are pumped out of ponds and lakes and then allowed to thaw out and become surface run-off again. Also, the ice roads can become contaminated with lubricant oil and grease, antifreeze, and rubber products. In addition to the environmental impact, the economic costs associated with arctic drilling can be prohibitively high. Exploration operations can be conducted only during the coldest times of the year, which typically lasts less than 4 or 5 months. Thus, using ice pads, actual drilling and testing can be conducted in a window of only two to four months or less, and actual production and development can occur during less than half the year. At the beginning of each drilling season, the ice roads and pads must all be rebuilt, and equipment must again be transported to and removed from the site, all at substantial financial and environmental cost. As for the commercial development of hydrocarbons in the arctic tundra, the current state of the art requires the use of a gravel pad for year round operations. When production activities are completed (for example, at the end of the lifecycle of the field), the gravel pads must be removed and the site remediated. Such remediation efforts can be very costly and difficult to accomplish.
SUMMARY OF THE INVENTION
[0013] According to one aspect of the invention, a method of constructing a drilling or production platform is provided, the method including: drilling a post hole into a ground surface; inserting a support post into said post hole, wherein said support post has an adjustable shoulder member; adding a fluid slurry to said post hole to freeze said support post within an interior region of said post hole; disposing a modular platform section on top of said adjustable shoulder member to establish a platform deck surface; and adjusting said adjustable shoulder member so that said platform deck surface is disposed substantially level.
[0014] According to a further aspect of the invention, a method of constructing a drilling or production platform is provided, the method including: drilling or hammering a support post into a ground surface, wherein said support post further comprises an adjustable shoulder member; disposing a modular platform section on top of said adjustable shoulder member to establish a platform deck surface; and adjusting said adjustable shoulder member so that said platform deck surface is disposed substantially level.
[0015] According to a further aspect of the invention, a method of constructing a platform suitable for drilling and producing oil, gas and hydrate reserves is provided, the method including: disposing a platform section atop a plurality of support posts; disposing two substantially parallel support beam sections between two of said support posts; and disposing a deck section atop said two substantially parallel support beams to provide a bridging support means between said two substantially parallel beams.
[0016] According to a further aspect of the invention a method of constructing a drilling or production platform is provided, the method including: providing a first platform section supported by support posts, wherein each of said support posts are disposed proximate to the corners of said first platform section; providing a second platform section, wherein said second platform section further comprises a hooking member that hooks onto a first side of said first platform section; providing a plurality of support posts to support a side of said second platform section disposed opposite said first side of said second platform section;
[0017] and providing a third platform section, wherein said third platform section further comprises a hooking member that hooks said second platform section.
[0018] According to a still further aspect of the invention, a method of assembling a plurality of interlocking modular platform sections useful for supporting drilling equipment to on a deck surface is provided, the method including: disposing a first modular platform section and a second modular platform section atop a plurality of platform support posts; disposing a hook and hook receiving member proximate an interface formed between said first platform section and said second platform section, wherein said hook is disposed along a side portion of said first platform section, and said hook receiving member is disposed on a side portion of said second platform section, and thereby.
[0019] According to a still further aspect of the invention, a method of communicating utilities between a deck section and a platform section of a drilling or production platform is provided, the method including: disposing a deck section atop a platform section; disposing one or more holes in a top surface of said deck section to permit utility communication between an interior region of said deck section and a deck surface disposed atop said deck section; and disposing one or more holes between a lower surface of said deck section and an upper surface of said platform section.
[0020] According to a still further aspect of the invention, a method of heating a drilling or production platform support post is provided, the method including: disposing a fluid conduit through a body portion of said support post; disposing a hollow fluid transfer member around or near an outer surface of said support post, wherein said fluid conduit disposed in a body portion of said support post is in fluid communication with said hollow fluid transfer member; and drawing a cooling or warm fluid into said fluid conduit and passing said fluid through said hollow fluid transfer member.
[0021] According to a further aspect of the invention, a method of removing a drilling or production platform support post is provided, the method including: disposing a fluid conduit through a body portion of said support post; disposing a hollow fluid transfer member around or near an outer surface of said support post, wherein said fluid conduit is disposed in fluid communication with said hollow fluid transfer member; drawing a warm fluid into said fluid conduit and passing said fluid through said hollow fluid transfer member to heat the surrounding ground; and applying a pulling force to said support post to pull said support post from the ground.
[0022] According to a still further aspect of the invention, a method of removing a drilling or production platform support post is provided, the method including: disposing a fluid conduit through a body portion of said support post; disposing a hollow fluid transfer member around or near an outer surface of said support post, wherein said fluid conduit is in fluid communication with said hollow fluid transfer member; disposing a vent between said fluid conduit and a surrounding ground surface using jets or ports; drawing a fluid or gas into said fluid conduit and passing said fluid through said hollow fluid transfer member, through said vent and out to the surrounding ground surface; and applying a pulling force to said support post to pull said support post from the ground.
[0023] According to a still further aspect of the invention, a method of adjusting the height of a modular drilling or production platform section is provided, the method including: disposing a modular platform section atop an adjustable shoulder nut disposed on a support post, wherein a top portion of said support post further comprises a lift receiving means; disposing a lifting means proximate to said lift receiving means, and then mutually engaging said lifting means and said lift receiving means; lifting said modular platform section off of said adjustable shoulder nut and then supporting said modular platform section using a support means; raising said adjustable shoulder nut; and replacing said modular platform section atop said adjustable shoulder nut using said support means.
[0024] According to a still further aspect of the invention, a method of sealing an intersection formed between a plurality of interlocked platform modules, the method including: disposing four interlocked platform modules so that a four-way intersection is formed therebetween; disposing a sealing member over said four-way intersection, wherein said sealing member comprises a body member and a plurality of leg members; and augmenting the seal using a deformable sealing material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a modular drilling or production platform according to the invention.
[0026] FIG. 2 is a section of a well bore included in the drilling or production platform shown in FIG. 1 , taken at a right angle along a length of the platform.
[0027] FIG. 3 is a section of a well bore included in the drilling or production platform shown in FIG. 1 , taken along a centerline of the platform.
[0028] FIG. 4 is a sectional view of a surface tundra region in which a plurality of post holes has been drilled.
[0029] FIG. 5 is the sectional view of FIG. 4 , further comprising a plurality of support posts disposed in the post holes.
[0030] FIG. 6 is the sectional view of FIG. 5 , further comprising a plurality of support posts having adjustable shoulders.
[0031] FIG. 7 is the sectional view of FIG. 6 , further comprising a group of interconnected modular platform sections disposed on top of the platform support posts.
[0032] FIG. 8 is the sectional view of FIG. 7 , further comprising a full level of interconnected modular platform sections disposed on top of the platform support posts.
[0033] FIG. 9 is the sectional view of FIG. 8 , further comprising a plurality of deck sections installed atop the modular platform sections.
[0034] FIG. 10 is the topmost portion of a support post, further comprising an adjustable nut disposed at the bottom of the adjustment stroke.
[0035] FIG. 11 is the topmost portion of a support post, further comprising an adjustable nut disposed at a position higher than the bottom of the adjustment stroke.
[0036] FIG. 12 is a group of interconnected modular platform sections, installed atop a plurality of platform support posts.
[0037] FIG. 13 is a cross-sectional view of the installed platform sections shown in FIG. 12 .
[0038] FIG. 14 is a top view of assembled modular platform sections according to the invention.
[0039] FIG. 15 is a cross-sectional view of the assembled platform sections of FIG. 14 .
[0040] FIG. 16 is a partial view of the assembled platform sections shown in FIG. 14 .
[0041] FIG. 17 is a top view of a group of interconnected modular platform sections.
[0042] FIG. 18 is a top view of a group of interconnected modular platform sections.
[0043] FIG. 19 is a cross-sectional view of the interconnected modular platform sections shown in FIG. 18 .
[0044] FIG. 20 depicts a connecting means useful for interconnecting a plurality of modular platform sections.
[0045] FIG. 21 is a top view of a group of modular platform sections that are interconnected using a connecting means according to the invention.
[0046] FIG. 22 is a depiction of an intersection established between four interconnected modular platform sections.
[0047] FIG. 23 is a view of the intersection of four interconnected modular platform sections shown in FIG. 22 , wherein the intersection is substantially sealed by a sealing means.
[0048] FIG. 24 a is a top view of an x-shaped sealing member useful for substantially sealing a gap formed at the intersection of a plurality of interconnected modular platform sections.
[0049] FIG. 24 b is a side view of the x-shaped sealing member shown in FIG. 24 a.
[0050] FIG. 25 is a sectional view of a fluid waste retention member disposed on an outer perimeter portion of a modular platform section.
[0051] FIGS. 26 a and 26 b are plan views of a fence sealing member that has been clipped onto a portion of a fluid retention fence using a clip tab.
[0052] FIGS. 27 a and 27 b are plan views of a retaining fence gap sealing member equipped with a seal extension member.
[0053] FIGS. 28 a and 28 b are plan views of a fence corner seal, in which the corner seal is bridging a gap foimed between corner sections of a fluid retention fence.
[0054] FIG. 29 is a top view of a group of assembled modular deck sections following installation atop a plurality of associated platform sections.
[0055] FIG. 30 is a cross-sectional view of the platform shown in FIG. 29 .
[0056] FIG. 31 is a cross-sectional view of the platform shown in FIG. 29 .
[0057] FIG. 32 is a cross-sectional view of a support post disposed in a post hole.
[0058] FIG. 33 is a cross-sectional view of an upper end of the support post shown in
[0059] FIG. 32 .
[0060] FIG. 34 is a detailed view of a lower end of the support post shown in FIG. 32 .
[0061] FIG. 35 is a platform and deck assembly supported by a support leg, wherein a jacking assembly is disposed above a lift socket located on a topmost portion of the support leg.
[0062] FIG. 36 is the platform and deck assembly shown in FIG. 35 , wherein a hydraulic cylinder is extended down from the jacking assembly until contact with the support post is established.
[0063] FIG. 37 is the platform and deck assembly shown in FIG. 35 , wherein a jacking assembly has lifted the platform and deck assembly off an adjustable nut disposed on the support post.
[0064] FIG. 38 is the platform and deck assembly of FIG. 35 , wherein the adjustable nut has been raised to again support the weight of the lifted platform and deck assembly.
[0065] FIG. 39 is the platform and deck assembly of FIG. 35 , shown after the jacking assembly has been removed and adjustment of the platform height has been completed.
[0066] FIG. 40 is a jacking assembly installed beneath a platform and deck assembly so that the platform can be lifted from the bottom.
[0067] FIG. 41 is a cross-sectional view of a support post, wherein a wedge section is disposed on a tapered shoulder portion of an adjustable nut.
[0068] FIG. 42 is a top view of the support post head shown in FIG. 41 .
[0069] FIG. 43 is a partial rotational view of the support post head shown in FIG. 41 .
[0070] FIG. 44 is a platform floor plan according to an example embodiment of the invention.
[0071] FIG. 45 is a platform building isolated from the example floor plan of FIG. 44 .
[0072] FIG. 46 is a platform section having a bladder tank disposed within.
[0073] FIG. 47 is a cross-sectional view of the platform section and bladder tank assembly shown in FIG. 46 .
[0074] FIG. 48 is a wellhead cellar suitable for use in an arctic platform system.
[0075] FIG. 49 is an alternative wellhead cellar suitable for use in an arctic platform system.
[0076] FIG. 50 is a cross-sectional view of the seals used to secure an inner and an outer skin of a wellhead cellar.
[0077] FIG. 51 is a post hole in which a platform support post is disposed.
[0078] FIG. 52 is an adaptor useful for adding an extension onto the bottom of a support post.
[0079] FIG. 53 is the adaptor of FIG. 52 , with an additional pipe section welded thereon.
[0080] FIG. 54 is a partial section of a bottom portion of the support post shown in FIG. 51 .
[0081] FIG. 55 is a partial section of a support post on which an extension has been added.
[0082] FIG. 56 is a post hole in which a platform support post is disposed.
[0083] FIG. 57 is the post hole of FIG. 56 after the support post has been removed.
DETAILED DESCRIPTION
[0084] Referring now to a specific, though non-limiting, embodiment of the invention shown in FIG. 1 , a tundra region 1 is shown in which a number of support posts 2 are disposed in a number of post holes drilled into the tundra. The support posts 2 support a substantially level drilling or production platform 4 comprised of numerous interconnected modular platform sections. In certain embodiments, a cylindrical (or other shape) winterizer 6 encloses and winterizes a drilling rig (not shown), and a number of easily transportable modular platform sections 8 are installed around the drilling rig. In some embodiments, for example, where drilling is carried out at very cold temperatures (e.g., in arctic tundra regions), the rig area is heated during drilling operations. In a particular embodiment in which the platform is used for hydrate production, the rig area is only heated to an intermediate temperature of about +10 degrees F., so that recovered hydrates will not thaw and can be preserved for analysis. In other embodiments, however, the rig area is cooled to permit more comfortable drilling conditions during wanner summer seasons.
[0085] According to an alternative embodiment, a crane 10 is positioned on a deck portion of platform 4 , and is sufficiently mobile to move around on the deck area so that the crane can be used to carry out a number of different lifting and support functions. For example, in one example embodiment, crane 10 is used to assist in the initial outfitting of the platform, and thereafter to move spools of drilling string and other drilling supplies around the platform during drilling and production operations. One or more cranes can also be fixed mounted at key points.
[0086] In other embodiments, a group of interconnected housing modules are assembled to provide living quarters for personnel working on the rig. In some embodiments, the housing platform employs a support post and platform module construction method similar to the platform described above, except that housing modules are disposed on the top of the platform deck instead of drilling modules.
[0087] Referring now to an example embodiment shown in FIG. 2 , an arctic platform is provided wherein a plurality of support posts 2 are inserted into a plurality of corresponding post holes 20 that have been drilled into the tundra. In one embodiment, support posts 2 are fixed in the post holes 20 by a process known as ad freeze, which comprises pouring a fluid slurry (for example, a slurry of water, sand and gravel) into the post holes 20 in order to fix the support posts 2 in place after the slurry freezes and hardens. In other embodiments, the support posts are drilled or hammered directly into the ground surface. In a further embodiment, a plurality of modular, interconnectible platform sections 4 are installed atop and supported by the support posts 2 after the support posts have been frozen in place; in still further embodiments, a plurality of drilling container sections 8 are then stacked on top of the platform sections 4 to permit convenient local storage of drilling bits and other equipment related to the drilling operation.
[0088] In the particular embodiment depicted in FIG. 2 , the well being drilled 22 is disposed beneath a wellhead cellar 24 that supports a wellhead 26 and blowout prevention stack 28 . In the depicted embodiment, a substructure housing member 30 is disposed above the blowout prevention stack 28 during drilling operations so that the wellhead and blowout stack are safely housed beneath the housing structure 30 . In certain other embodiments, however, drilling rig 32 is disposed above the substructure housing 30 so that drilling rig 32 is instead contained within a winterizer 6 .
[0089] Similar to the embodiment shown in FIG. 1 , drilling platform 4 is comprised of a plurality of interconnectible, modular platform sections 34 and associated deck sections 36 . In a presently preferred embodiment, drilling or production platform 4 comprises 8 platform sections in width, and is supported by 9 rows of evenly spaced support posts 2 frozen into corresponding post holes 20 drilled in the tundra.
[0090] Referring now to the example embodiment of FIG. 3 , a drilling platform 4 is shown in cross section through a centerline of the well bore, drawn along a length of drilling rig 32 . In some embodiments, wellhead cellar 24 is disposed in operative communication with a pair of long wellhead platform sections 40 and 42 . In the particular embodiment depicted in FIG. 3 , drilling platform 4 further comprises three rows of support posts 2 .
[0091] According to a presently preferred embodiment, arctic drilling platform 4 further comprises about sixteen individual, interconnected platform modules, each of which are about 12.5 feet wide and about 50 feet long; the resulting drilling platform 4 is therefore substantially square, and measures about a 100 feet on each side. In the aforementioned embodiment, there are about twenty-seven support posts 2 , each of which supports the weight and alignment of various platform sections. In further embodiments, one or more additional support posts 2 are strategically installed to lend additional stability and load capacity to the system.
[0092] In other embodiments, additional wells 44 are drilled to serve as backup wellbores in the event the primary wellbore encounters technical problems such as a broken drill bit or a jammed drilling string. According to a further embodiment, additional wells 44 are used to drill an underground pipeline routed to a remote location so that production removed from the primary well can be pipelined to a remote location in coordination with the ongoing drilling operation. The ability to drill an underground pipeline is particularly useful in environmentally sensitive sites in that removal and transportation of oil, gas and/or hydrates reserves can all be carried out deep beneath the ground surface, thereby reducing disturbance of the surrounding tundra region. The additional wells 44 can also be used to establish a field size.
[0093] According to a method of practicing the invention shown in FIGS. 4-9 , a plurality of holes 50 are first drilled into a ground surface or frozen tundra region 1 . In some embodiments, post holes 50 are evenly spaced apart; however, in other embodiments, additional support posts are strategically installed to lend greater stability and structural rigidity to the platform system. In other embodiments, only a few post holes (or even a single hole) are drilled to receive the support posts of a smaller, stand-alone work module, for example, a nearby secondary well drilled to relieve or apply fluid pressure to the drilling operation.
[0094] According to the embodiment shown in FIG. 5 , a plurality of support posts 2 are then inserted into each of the post holes 50 , with lower portions of the posts being supported by a plurality of post hole ground surfaces 60 , and intermediate portions of the posts being supported by one or more support brackets 64 and 66 attached to provide a temporary surface fitting at the surface level 62 of tundra region 1 while the support posts are being frozen in place within the post holes. According to a further embodiment, once the support posts 2 have been fixed in drilled post holes 50 , a slurry comprised of water, sand and gravel mixture is poured into the hole and allowed to freeze. According to still further embodiments, adjustable support brackets 64 and 66 are inserted near the top of the hole during the slurry freezing process, so that the tops of the support posts 2 stay accurately aligned during the slurry freezing process. In the example embodiment of FIG. 5 , a plurality of adjustable shoulder nuts 70 , 72 and 74 are disposed near the tops of each of the support posts 2 ; in the depicted embodiment, the adjustable nuts are disposed at different elevations (as indicated by lines 76 , 78 and 80 ) due to localized inaccuracies in the depths of the post holes.
[0095] As seen in the example embodiment shown in FIG. 6 , adjustable shoulder nut 72 is then raised (for example, by threading the nut up the shaft of a complementary threading foiined on a portion of the support post) up to the same elevation level as the other adjustable nuts 70 and 74 (as indicated by lines 80 , 82 and 84 ). In this manner, a level plane is formed to support the later installation of a drilling platform, although in other embodiments, portions of the drilling platform are assembled prior to the drilling of the post holes, and whole sections of previously assembled platform modules are installed on the legs, and then leveled using the adjustable nuts.
[0096] Those of ordinary skill in the art will appreciate that when various platform sections are of a common cross-sectional thickness, it is convenient to set each of the adjusting nuts at about the same height. However, in other embodiments it is beneficial to set the adjustable nuts at different predetermined heights rather than a common height, depending upon the actual structural requirements imposed by various operational environments, for example, to build up the pitch of a side of the platform disposed on a downward slope.
[0097] FIG. 7 shows the cross-sectional platform view of FIG. 6 , further comprising a pair of interconnected modular platform sections 92 and 94 installed over a plurality of adjustable shoulder nuts. In one example embodiment, four interconnected modular platform sections are installed over the shoulder nuts of four support posts, for example, the two platform sections 92 and 94 depicted herein and two additional modular sections (not shown) disposed directly behind sections 92 and 94 . When the installation of deck sections is complete, workers are provided with a level and secure platform surface from which to drill, and effluent and metal cuttings can be contained in the box-like lower body portions of the deck sections. In still further embodiments, a canvas tarp or the like is disposed beneath and around an outer perimeter of the deck sections, and serves as a skirt or trap to ensure that as much waste as possible is captured and recovered from the drilling site.
[0098] Referring now to the example embodiment of FIG. 8 , a full level of interconnected modular platform sections 100 - 105 is then installed over each of the adjustable shoulder nuts. According to one aspect of the invention, minor adjustments to the heights of the shoulder nuts are then effected in order to correct the level of the platform on an as-needed basis. According to various other embodiments, the leveling corrections can be effected when the individual deck sections are being installed, or after all or some of the sections have already been assembled and interlocked.
[0099] In the example embodiment of FIG. 9 , a plurality of modular storage sections 106 - 109 is then installed above at least a portion of the platform deck. In some embodiments, the various storage sections 106 - 109 are strategically arranged so as to conveniently contain the equipment and supplies required to drill and maintain a well, for example, drill string and associated casings, lubricants, power generators, etc.
[0100] According to the example embodiment shown in FIG. 10 , the upper portion 120 of a support post 2 further comprises an adjustable shoulder nut 124 disposed at the bottom of the adjustment stroke. In some embodiments, upper post portion 120 has a reduced cross section 122 , and an adjustable shoulder nut 124 . In further embodiments, adjustable shoulder nut 124 further comprises an internal threaded region 126 , and a tapered, upwardly facing shoulder member 128 .
[0101] According to one aspect of the invention, support posts 2 are installed with each of the adjustable shoulder nuts 124 set at the bottom of the adjustment stroke; in other embodiments, however, the adjustable shoulder nuts 124 are set at predetermined positions other than at the bottom of the stroke, or even in random positions, depending upon the particular operational requirements of the drilling environment. In other embodiments, a tapered section 134 is provided at the top of adjustable nut 124 to allow wedges or shims to be dropped inside a space formed when a module is placed onto a post, thereby lending lateral support to the post as well as vertical support. In still other embodiments, one or more fluid receiving fittings 130 are provided at the top of the support post for receiving and circulating a heating or cooling fluid within a body portion of the post, and a threaded receiving member 132 is provided for attachment of a lifting means. In alternative embodiments, receiving member 132 is not threaded, and instead comprises a slip-toothed fastening assembly; in still further embodiments, receiving member 132 comprises an inverted nut and bolt receiving assembly for receiving a lifting means that has been lowered from the deck surface disposed above.
[0102] According to further examples of the invention, FIG. 11 shows an adjustable nut that was initially set at a position higher than the bottom of the adjustment stroke, for example, near the middle of the adjustment stroke in order to build up a platform section disposed on a downward slope. In FIG. 11 , adjustable shoulder nut 124 has been threaded up the support post to a higher position as a method of setting an upper shoulder 126 of the adjustable nut at the same elevation as the shoulders on neighboring posts.
[0103] According to the example embodiment of FIG. 12 , a plurality of interconnected modular platform sections 50 is provided, each of which is installed atop a plurality of support posts. According to a further embodiment, the lengths of the platform sections are elongated relative to their widths; in a presently preferred embodiment, the lengths of the platform modules are elongated relative to their widths by a ratio of about 4:1. For example, in one particular embodiment, each platform section is about 12.5 feet wide and about 50 feet long. In the depicted embodiment, sixteen such platform sections are combined to provide a substantially square deck surface that is about 100 feet in both length and width.
[0104] According to a detailed embodiment, platform 52 is supported by twenty seven different support posts 54 , each of which engage various platform sections from beneath the platform. Along the left side of platform section 60 is a beam member 62 , which provides bridging support between support posts 64 and 66 . Along the right side of platform section 60 is another beam member 70 , which provides bridging support between support posts 72 and 74 . In one embodiment, the underside of platform section 80 is a flat plate and includes a plurality of stiffening members 82 ; in some embodiments, stiffening members 82 are not intended to be structural or load bearing members, and are instead designed to support an accumulation of liquids and effluent that usually develops on a drilling platform.
[0105] According to one example embodiment, an interlocking method of securing the platform modules to one another permits disposition of but a single support post at each platform intersection, and adjacent platform modules are all supported by that single post. Although the interior corners of each platform section are near to and supported by a single support post, the support post is not necessarily attached to each of the surrounding platform sections. In one embodiment, for example, platform sections are attached to the support posts in such a fashion as to provide greater support in the direction of a line between support post 64 and support post 66 ; in this embodiment, greater support would also be provided between support post 72 and support post 74 . In this configuration, however, only minimal support is provided in the direction from support post 64 to support post 72 , and from support post 66 to support post 74 , said minimal support deriving from the rigidity produced when adjoining portion of platform sections are interlocked rather than by attachment of the platform section to a support post.
[0106] According to an example embodiment depicted in FIG. 13 , a load placed anywhere on the individual deck sections will be supported initially by the deck surface 120 , which in turn transfers the weight load in the direction indicated by arrow 130 (see FIG. 12 ) toward beam sections 82 and 96 disposed beneath the deck. The weight of the load is then transmitted down the side beams in the direction of arrow 132 (see FIG. 12 ) toward the support posts, which in turn directs the weight into the surface of the tundra. According to a further embodiment, rectangular beam 82 is established by assembly of a plurality of interlocked platform modules disposed on a side 94 portion of platform section 80 ; likewise, opposed rectangular beam 96 is established by assembly of a plurality of interlocked platform modules disposed on another side 104 of platform section 80 .
[0107] On top areas 110 and 111 of beam sections 82 and 96 , a deck section 120 is installed and then locked into place. In one example embodiment, deck section 120 provides direct support for the various equipment and supply packages loaded on top of the deck. According to another embodiment, beam sections 82 and 96 provide support in the direction of the support posts 64 and 72 shown in FIG. 12 .
[0108] In a further embodiment, deck section 120 comprises a composite structure having a top plate 122 and a bottom plate 124 , separated by a foam mixture 126 disposed in an interior region established within the platform modules. In one particular embodiment, foam mixture 126 is a polyurethane foam mixture that not only stabilizes and supports the structural integrity of the top and bottom plates, but also provides a compressive strength sufficient to support heavy equipment loads placed on top of the deck surface 120 . According to a further embodiment, the polyurethane foam mixture 126 also dampens the loud noises and structural vibrations typically created during drilling operations.
[0109] Turning now to methods and means of interlocking the platform modules, FIGS. 14 and 15 show a plurality of assembled modular platform sections similar to the embodiments described in FIGS. 12 and 13 .
[0110] For example, the platform is supported by twenty-seven support posts 54 , which engage the various platform sections from underneath. Along the one side of platform section 60 is a beam member 62 that provides bridging support between support posts 64 and 66 . Along the other side of platform section 60 is another beam member 70 , which provides bridging support between support posts 72 and 74 . The bottom of platform section 80 is a flat plate and includes a plurality of stiffening members 82 , which are not intended to be structural or load bearing in nature other than having sufficient capacity to support an accumulation of fluids that build up during drilling operations.
[0111] A single support post is disposed at each platform intersection, and the adjacent platform modules are all supported by that single post. While each platform section corner is near to and supported by a support post, the support post is not necessarily disposed in that platform section; the corners of some of the platform sections are supported by only the interlocking connection members disposed therebetween.
[0112] According to the example interlocking platform connection system shown in FIG. 16 , a first platform section 60 is disposed adjacent to a second platform section 140 ; a first deck section 142 is installed over platform section 60 , and a second deck section 144 is installed over platform section 140 . According to certain embodiments, a fence member 152 projects upwardly from an upper surface 150 of platform section 60 . According to a further embodiment, upper surface 160 of platform section 140 has a hook 162 disposed over the fence member 152 . According to the example embodiment of FIG. 16 , hook 162 is formed structurally integral with platform section 160 , and provides support for the side of platform section 160 ; in other embodiments, however, hook 162 is not formed structurally integral with platform section 160 , and is instead mechanically affixed to the system to provide support for the side of platform section 160 .
[0113] According to the example embodiment of FIG. 17 , a first platform section 60 is logically supported by at least four different support posts 64 , 66 , 72 and 74 . According to a further embodiment, however, a second platform section 160 is supported by only two additional support posts 162 and 164 , while support on the opposite side is achieved by means of a hooking member 163 engaged over a portion of fence member 152 shown in FIG. 16 . According to a still further embodiment, platform section 170 is supported by only two additional support posts 172 and 174 , though platform section 170 also gains support from support posts 162 and 164 on the opposite side by means of the mentioned hook and fence member combination. According to a still further embodiment, additional platform sections 180 , 182 , 184 , 186 and 188 are successively installed, in each instance installation requiring only two additional support posts and an opposed, complementary hook and fence member combination to ensure a secure and reliable connection.
[0114] Similarly, platform section 190 employs two additional support posts 192 and 194 at the end of the platform section disposed furthest away from platform section 170 . However, platform section 190 gains additional support from attachment to support posts 164 and 174 , and also from a hook and fence member combination disposed at the end most proximate to platform section 170 . Consequently, platform section 200 requires only a single additional support post 202 , provided said support post is employed in combination with a hook and fence member support means at each of intersections 204 and 206 . Additional platform sections 210 , 212 , 214 , 216 , 218 and 220 will also require only a single additional support post each, again provided the configuration includes an appropriate hook and fence member combination on two of the sides disposed opposite the support post.
[0115] Turning now to other example methods and means for connecting platform sections together, FIGS. 18-21 again show a drilling platform comprised of a group 52 of platform sections that have been interconnected for support of equipment storage modules that will later be installed on top of various portions of the platform. As shown, the platform sections are supported by twenty-seven support posts 54 , which engage various platform sections from locations disposed beneath the platform. Those of ordinary skill in the art, however, will appreciate that any number of platform and deck sections can be assembled into a single unitary whole (or even several discrete modular platform units), and any number of support posts can be employed to support the structure, depending on the various field requirements imposed by actual operating environments. Those of ordinary skill in the art will also appreciate that by employing the example platform assembly methods described above, weight loads can be directed and distributed in virtually any direction along the platform, and additional interconnections between platform sections can be established to either support weight loads disposed on deck sections, or to otherwise lend stability and structural rigidity to the resulting platform system.
[0116] Referring now to the example embodiment of FIG. 22 , a support post 2 is shown disposed near an intersection 230 of four interconnected platform modules 232 , 234 , 236 and 238 . Moving out radially from intersection 230 , a plurality of connecting hooks 240 , 242 , 246 and 248 are disposed over complementary fence members 250 , 252 , 254 and 256 , so that the several associated platform sections are securely interconnected. The hook and fence member assemblies also serve to effectively seal the intersection 240 where the platform sections are joined, at least insofar as accumulated water and the like will easily pass from one platform section to another across body portions of the hook and fence locking assemblies.
[0117] Intersection 230 , however, is more problematic. For example, virtually any liquid can pass through the space formed at the center of the four-corner intersection, and then pass between platform sections and down onto the ground surface disposed below. According to one aspect of the invention, therefore, a sealing member is provided to close the space formed at intersection 230 , the seal generally being disposed on the top side portion of the intersection, although installation of the seal from the bottom side of the intersection 230 is also contemplated. The sealing member, which in this case is referred to as an x-seal because of its shape, extends in each of four directions at least as far as a series of sealing grooves 260 that have been cut into body portions of each of the associated fence members 250 , 252 , 254 and 256 .
[0118] For example, as seen in FIG. 23 , a platform in sealing member 270 is dropped over a four-corner intersection where four assembled platform modules have been interconnected. The body of the seal is substantially in direct contact with body portions of the fence members 250 , 252 , 254 and 256 (see FIG. 22 ), and therefore also directs water or other accumulated fluids across away from the intersection 230 of the interconnected platform modules. Since there is still a potential for dirty water or other fluids to land on top of a fence member and then seep underneath an end portion of one of the x-seals, a plurality of small grooves disposed in the fence members cut crossways across the fence members so that any fluid that would otherwise tend to run along the bottom of the x-seal will instead be diverted in another direction by means of fluid contact with any one of the series of small cut grooves 260 depicted in FIG. 22 .
[0119] According to an example of the invention shown in FIGS. 24 a and 24 b , an appropriate x-shaped seal member 270 is shown, which in some embodiments comprises a thin metal plate 274 equipped with a plurality of leg members 272 , which depend from and around various portion of thin plate 274 . In some embodiments, leg members 272 are formed structurally integral with thin plate 274 , though in other embodiments leg members 272 comprise a plurality of separate pieces (e.g., a number of small metal rectangles) affixed to thin plate 274 using a known connection method, for example, welding the metal rectangles to the thin plate.
[0120] As seen in FIG. 25 , a further embodiment is provided wherein an outer perimeter of assembled platform modules is fitted with a safety fence 282 so that liquids that splash off the surface of the drilling platform will not pass over the sides of the platform and down onto the ground surface below. According to some embodiments, safety fence 280 comprises or retention plate 282 , which is either welded on or mechanically affixed to a body portion 284 of safety fence 280 . In other embodiments, retention plate 282 includes a portion having a double bend 284 that slips into and engages a top portion of platform section 288 at a predetermined location so as to establish the desired fluid retention fence 280 . According to still further embodiments, the presence of safety fence 280 causes splashing liquids to be diverted back toward the interior surfaces of the interconnected platform sections, though in one particular embodiment, re-directed fluid flow is allowed to drain into a container portion of a platform section by means of one or more drain holes 290 . In other embodiments, cable races are attached to the retention plates or, in further embodiments, to the platform perimeter.
[0121] Referring now to the example embodiments of FIGS. 26 a and 26 b , it will be understood that individual fluid waste retention fence members are necessarily going to be fabricated in advance at finite, predetermined lengths. According to one particular embodiment, for example, the fluid waste retention fence member measures about twelve and one-half feet long.
[0122] According to an example method of practicing the invention, as successive fluid retention safety members are installed next to other pieces of the fence, cracks that form between the kick plates are sealed using one or more fence seals 300 . In certain embodiments, fence seal sections 300 are fastened to a waste retention member using known fastening means such as a screw or a nut and bolt assembly. In one particular embodiment, the fence seal 300 is clipped onto those portions of the fence disposed nearest the gaps formed between fence sections using one or more clip tabs 302 and 304 . In a further embodiment, fence seal 300 is clipped onto the safety fence by hooking each of clip tabs 302 and 304 over a top lip portion of the kick plate. According to a particular example embodiment, a vertical fence seal portion 300 is fabricated so that it is about the same height as the terminal vertical portion of the kick plate, so that water or other fluids are directed back toward the interconnected platform sections.
[0123] Referring now to the example embodiments of FIGS. 27 a and 27 b , a retaining fence gap sealing member 312 is provided, in which the sealing member further comprises an extension member disposed thereon that is similar in both nature and function to the previously discussed four-way seal, so that excess water that seeps along an interior surface of the fence seal will again be redirected to a region contained within the perimeter of the fence. According to a specific example embodiment, platform sections on which the fence members are affixed have a plurality of cut grooves disposed beneath the sealing member that further prevents seeping fluids from migrating down the sides of the platform sections.
[0124] In the further embodiments of FIGS. 28 a and 28 b , a fence corner seal 320 is disposed so that the gap that forms between two sections of fence installed at corners of the platform is bridged. In practice, the corner seal functions similar to the other fence seals discussed above, except that the corner seal also engages multiple sections of the fence. In a presently preferred embodiment, each of the fence sections upon which the corner seal is installed is disposed at about a ninety-degree angle relative to the other.
[0125] According to the example embodiment of FIG. 29 , a number of assembled modular platform sections 50 are depicted following the installation of a plurality of deck sections atop upper portions of the platform sections. According to one embodiment, one or more manholes 54 is disposed at each end of the deck sections, except for platform section 56 , which has a shortened deck (and thus a manhole 54 disposed at only one end) due to the location of the platform's wellhead cellar 61 .
[0126] According to further embodiments, within a body portion of each of the deck sections is a utilities communication pipe 60 , which, in certain embodiments, is configured to run along an entire length (or width) of the platform section. According to one embodiment, utility pipe 60 has a predetermined number of regularly spaced junctions, permitting convenient access points for installation and maintenance of utilities related equipment (e.g., fiber optics bundles, electrical wiring, etc.). In other embodiments, utilities communication pipe 60 comprises a plurality of junctions disposed at irregularly spaced locations disposed along a length of the pipe. According to a specific example embodiment, after the disclosed arctic drilling platform has been fully assembled, communication pipes 60 (and the various junctions and utility access points disposed thereupon), serves as the framework for distribution of power and other utilities around the surface of the platform during drilling operations.
[0127] According to a further embodiment, each of the deck sections are slightly greater in length than the utilities communication pipes contained within, so that sufficient room remains within the interior of the deck module to install one or more power boxes, water junctions, or utility cross-connections, near the terminal ends of the communication pipes. In various embodiments of the invention, one or more utilities communication pipes 60 are used to accommodate installation of electrical power lines, telephone lines, fiber optic connections, gas hoses, fuel lines, etc.
[0128] As seen in the example embodiment of FIG. 30 , a crawl space is disposed between the ends of deck sections 70 and 72 . As depicted, deck sections 70 and 72 are disposed atop platform sections 74 and 76 , though those of ordinary skill in the art will appreciate that the deck sections can also be assembled in combination with other types of platform modules. According to a still further embodiment, deck sections are constructed by stacking one or more layers, wherein each layer further comprises one or more communication pipes.
[0129] According to a presently preferred embodiment, there is a space or gap of about 12 inches disposed between innermost portions 78 and 80 of deck sections 70 and 72 ; the space or gap is disposed above the topmost portions of platform sections 74 and 76 , and below a manhole cover 82 laid on a top lip established by the end points of deck sections 70 and 72 . In further embodiments, pipes 84 and 86 extend into the deck in order to facilitate utilities communication. Deck section 70 has an upper plate 88 and a lower plate 90 , each of which are usually formed from a metal or composite material of some type. For example, according to one embodiment, upper plate 88 and/or lower plate 90 are formed from an aluminum plate, though in other embodiments an aluminum alloy or other combination of materials is preferred. According to still further embodiments, an insulation material is installed in the space or gap established between the utilities communication pipes. For example, in one embodiment, polyurethane foam is placed into the space between the communications pipes to lend compressive resistance to the deck plate disposed above the crawl space.
[0130] According to the example embodiment of FIG. 31 , a utility junction 100 is disposed in proximity to utilities communication pipes 102 and 104 . The horizontal utility pipes intersect a vertical junction pipe 106 that has been cut to reflect the actual height of the space established between upper plate 88 and lower plate 90 . A drain hole 106 is opened in the lower plate 90 , so that utility lines and the like can be fed into and through the platform sections disposed below. On the top side of the deck section, a vertical pipe having a threaded engagement means 110 is prepared, so that utility lines can also be drawn out of the engagement means 110 and up into other modules affixed on top of the deck. According to a further embodiment, a plug is threaded into the threaded engagement means 110 when the portal is not in use, thereby providing a smooth deck surface that is substantially uninterrupted by open manholes.
[0131] FIG. 32 is a detailed view of a support post 50 according to the invention. In some embodiments, support post 50 is inserted into a post hole 52 that has been drilled into a ground surface. In other embodiments, support post 50 has an interior space 54 established for receiving a slurry 56 of water, sand and gravel. In still other embodiments, an external surface of the support post is smooth or flat. When the platform is assembled in a very cold environment, for example, a frozen tundra, slurry 56 will also freeze and lend additional stability and rigidity to support post 50 . According to further embodiments, a lower portion 60 of support post 50 has a spiral support fin 62 , and an upper post end 64 is configured to fit into a receiving socket 66 disposed in the bottom of platform section 68 .
[0132] FIG. 33 is a detailed view of an upper end 64 of the support post 50 shown in FIG. 32 , further comprising a process fitting 70 that allows fluids to be pumped down into a conduit or pipe 80 disposed in a body portion of the support post 50 . According to one example embodiment, fluids pumped into pipe 80 travel to the bottom of support post 50 , and a return flow is established by directing accumulated fluid pressure toward a process fitting disposed in flanged member 72 . In other embodiments, support post 50 further comprises a plurality of threaded ports 74 , so that support post 50 can be installed using an attached padeye or other fitting device (not shown).
[0133] According to the example embodiment of FIG. 34 , a terminus portion of fluid transport pipe 80 extends downwardly from a body portion of support post 50 , and then exits through a reducer port 83 and spiral fin member 82 . According to a specific embodiment, spiral fin 82 is fabricated from two metal plates, viz., a lower, rolling spiral plate 84 that extends substantially perpendicularly from an outer diameter 86 of lower pipe section 88 , and an upper, conical spiral plate 90 that extends downwardly at an angle of about thirty to forty five degrees. Rolling spiral plate 84 and conical spiral plate 90 are joined together by, for example, a known welding or sintering process, so as to establish a hollow fluid transport space 92 disposed within spiral fin 82 . In other embodiments, the exterior surface of the support post is substantially smooth and the fluid transport space is located within an interior region of the support post.
[0134] According to one example embodiment, a fluid solution is pumped downward through pipe 80 and into spiral fin 82 . The fluid circulates around the spiral fin 82 down to the bottom of the post 100 , and then vents into an internal bore 106 of support post 50 through transport hole 104 . The fluid solution then circulates back up the body of internal bore 106 . In this configuration, a liquid or gaseous medium can be pumped down the pipe 80 and around spiral fin 82 , and then back up the internal bore 106 of support post 50 to either cool or heat the ground surface area surrounding support post 50 . According to other embodiments, a very cold fluid or gas is pumped through pipe 80 into the body of the post, so as to ensure that the surrounding ground surface will remain firmly frozen. According to a further embodiment, however, a warm fluid or gas is instead pumped through pipe 80 in order to melt the ground surface around the support post, so that the support post can then be removed from its moorings and more easily retrieved when drilling operations are complete. According to a still further embodiment, the fluid transportation means is vented to a surrounding ground surface using jetting ports or the like in order to make removal of the support posts easier.
[0135] According to one particular embodiment, a fluid such as a food-grade glycol, which has a freezing temperature well below the lowest anticipated temperature of the surrounding tundra, is employed to facilitate the aforementioned freezing steps. In case of an accidental spill, food-grade glycol is also bio-degradable, and thus will have only a limited impact on the surrounding ground surface. Those of ordinary skill in the art, however, will appreciate that many other fluid solutions, for example, chilled air, heated air or hot steam, can be pumped through the support post 50 in order to carry out the aforementioned freezing and heating.
[0136] On heavily weighted platforms, individual support posts often bear a heavy load. Since in some embodiments the support posts are frozen into the surrounding ground surface using a slurry, there can be a tendency for the underlying ice to either shift or compact, thereby causing one or more of the posts to sink more deeply into the ground and destabilize the rest of the platform. In most cases, the sinking of a post is in proportion to the load it bears, and will vary from post to post. While it is anticipated that the incremental sinking of any individual post will usually have a negligible impact on the stability of the platform, those of ordinary skill in the art will appreciate that a mechanical adjustment will sometimes be required to bolster the structural support capacity of some sinking posts. According to the invention, there are at least two different effective methods of improving the support capacity of sinking posts.
[0137] According to the embodiment shown in FIG. 35 , for example, a platform and deck assembly 350 is supported by a support post 360 , wherein a jacking assembly 370 is disposed above a lift socket 365 located on a topmost portion of the support post 360 . As seen in the embodiment of FIG. 36 , a hydraulic cylinder 375 is then extended down from the jacking assembly 370 until contact with the support post lifting socket 365 is established. According to some embodiments, the engagement means provided to ensure a reliable mechanical interface between cylinder head portion 380 and lifting socket 365 is a slip-toothed sprocket assembly. In other embodiments, the engagement means comprises a known fastener assembly, for example, a nut and bolt assembly. Those of ordinary skill in the art, however, will recognize that virtually any type of engagement means could be used to hold the cylinder head 380 in place against the support post receiving socket 365 , so long as the engagement means is sufficient to reliably facilitate the secure attachment of cylinder head 380 to the top of the support post.
[0138] In further embodiments, hydraulic cylinder 375 is shaped like a piston, and exerts a downward force against the head of the support post so as to engage the two members via the fastening means. According to still further embodiments, however, the hydraulic cylinder member 375 is a telescoping cylinder, so that successive, concentric portions of the cylinder are revealed as the cylinder is extended to engage with the support post lifting socket 365 , and the platform and deck assembly 350 are then lifted.
[0139] As seen in the example embodiment of FIG. 37 , once the platform and deck assembly 350 have been lifted off of the shoulder of adjustable nut 368 by means of attached jacking assembly 370 , adjustable nut 368 is relieved of its weight load and can then be height-adjusted without further disturbing the level or stability of the surrounding platform. As seen in the example embodiment shown in FIG. 38 , after adjustable nut 368 has been re-adjusted to a desired setting, platform and deck assembly 350 is set back down onto a flanged receiving portion 369 of adjustable nut 368 by means of hydraulic cylinder 375 , and cylinder head 380 is unfastened or otherwise withdrawn from support post lifting socket 365 . As shown in the example embodiment of FIG. 39 , after the desired platform height adjustment is completed, jacking assembly 370 can then be removed from the vicinity of support post 360 and used elsewhere on the platform if desired.
[0140] As shown in the example embodiment of FIG. 40 , platform and deck assembly 350 need not necessarily be lifted from above in order to relieve the weight load disposed on the support post 360 . For example, jacking assembly 390 can also be installed underneath the platform and deck assembly 350 , and then used to lift the platform off of the support post 360 by pushing a top surface of the cylinder against a bottom surface of the platform and deck assembly 350 and then driving the cylinder upward using the cylinder's hydraulic system.
[0141] In instances where the hydraulic cylinder is piston shaped, the stroke distance of the hydraulic cylinder effectively determines the extent of support post height adjustment that can be effected. However, in other embodiments, one or more cylinder retaining pins can also be disposed in-between the jacking assembly's telescopic cylinder members in order to provide a standardized range of support post height adjustments. According to a particular embodiment, for example, a plurality of retaining pins is inserted through regularly spaced receiving holes formed in body portions of the inner, middle and outer telescopic cylinder members. As the cylinder progresses through a stroke cycle and retaining pins are inserted into the receiving holes, a basic height for the jack assembly is established at one of several predetermined elevations.
[0142] According to a detailed example embodiment, a bottom jack assembly is positioned adjacent to a side portion of a platform in such a fashion that the jack's hydraulic cylinder traverses a first portion of its stroke distance. A chain or other lifting means is then wrapped around the raised cylinder head, and the pins are removed from the cylinder's telescopic body sections. When the cylinder is retracted, the telescopic sections are pulled back in and the pins are reinserted. The cylinder is again extended, and slack in the restraining chain is withdrawn, so that the height of the cylinder head is raised; at that point, the cylinder head is held in place by only the shortened restraining chain. The pins are then pulled out of the receiving holes again, and the cylinder is retracted. As before, the telescopic cylinder members are raised to a higher position and then re-pinned, this process being repeated until the cylinder head has been raised to its desired height using only the hydraulic lift strength of the jack assembly. After the height of hydraulic cylinder head is basically adjusted, the jack assembly is slid into place under a desired portion of the platform, and the cylinder head is again extended to permit final adjustment of the height of the support posts.
[0143] According to the further embodiment of FIG. 41 , an installed support post 54 comprises a tube-like member 50 disposed through a body portion of a platform section 52 , wherein the support post 54 is inserted from below into a cylindrical interior space formed in post tube 50 . An adjustable nut 56 is disposed on a body portion of support post 54 so as to engage a bottom surface 58 of platform section 52 . According to some embodiments, engagement between adjustable nut 56 and platform bottom surface 58 further comprises an insulating member 60 . When the insulating member 60 is formed from a poorly conductive material such as, for example, Delrin or UHMW polyethelene, the insulating member serves to establish an electrical ground between the steel adjusting nut 56 and the aluminum platform section 52 .
[0144] According to other aspects of the invention, a tapered receiving member 62 disposed on an upper portion of adjustable nut 56 resides within tube member 50 after the support post is installed. A first chocking assembly 70 is then lowered down into the space formed between the tube member 50 and support post 54 so as to engage both the tapered receiving member 62 and an inner wall surface 78 of tube member 50 . In the particular embodiment depicted in FIG. 41 , a lower wedge member 72 is disposed to engage the adjustable nut 56 at a lower location, and to support an additional tapered receiving section 74 disposed on a topmost portion of chocking assembly 70 . Likewise, an upper wedge 76 is disposed to engage the topmost portion of tapered receiving section 74 and inner wall surface 78 of tube member 50 .
[0145] FIG. 42 is a top view of the support post head shown in FIG. 41 . According to one example embodiment, several chocking assemblies 70 are disposed around a perimeter region of support post head 80 in order to hold the support post 54 securely in place and lend additional stability and structural rigidity to the system after installation is complete.
[0146] For example, disposition of multiple chocking members 70 and 74 provides a fixed side distance between the support post and an interior surface of the platform section tube member, so that side loads (e.g., forces being delivered to the sides of the platform, such as strong winds) will be uniformly absorbed across an entire cross-section of the support post portion installed within the tube member. Since both top and bottom portions of the support post are engaged with interior surfaces of the tube member, the support post and tube member assembly is substantially fixed, and lends additional structural rigidity to the platform system. If, on the other hand, the support post is fixed at only the bottom of the tube member, a pivot-like connection between the support post and platform section results, and a high inertial moment established near the ground surface reduces stability of the assembled platform system. FIG. 43 is a perspective view of the support post head shown in FIG. 41 , wherein several of the design features described above with respect to FIG. 42 are emphasized.
[0147] Turning now to other aspects of the invention, FIG. 44 is a proposed platform floor plan in which the general arrangements of storage buildings and other necessary structures are depicted. Care must be given to the layout and grouping of platform structures so that related equipment is strategically stored, safe and comfortable housing is available for platform personnel, and to ensure that the rig is in compliance with strict fire and safety codes.
[0148] For example, according to specifications promulgated by the American Petroleum Institute (e.g., the API 500 specifications), a five-foot radius around the bell of any drilling rig is considered a Division One explosion environment, and all electrical equipment used in the area must be configured to accommodate the requirements associated with a Class One Division One area. Most enclosed structures that have a door opening out to a Division One environment are considered Class One Division Two explosive environments, environments that, under the API regulations, are regulated nearly as restrictively as Class One Division One areas. In practice, virtually all electrical equipment used on the rig, including computers and telephones, must be reviewed for electrical explosion potential in order to comply with the mentioned industry regulations.
[0149] In the example embodiment of FIG. 44 , a driller's doghouse 50 is disposed on one side of the drilling rig 52 , and a company man house 54 is disposed on an opposite side of the rig 52 . Both the driller's doghouse and the company man house have a picture window 56 and 58 , so that personnel can look onto the drilling floor 60 .
[0150] It would also be desirable for both the driller's doghouse and the company man house to have a doorway that permits personnel stationed in these offices to walk out onto the rig floor to perform work or conduct discussions regarding rig activities; however, the presence of a doorway between the rig floor and either the driller's doghouse or the company man house would cause these areas to be classified as Division Two areas, and since both the drillers and the company men often have need for telephones and portable computers and the like, most of which are not explosion-proofed, it has in the past been the case that convenient doors between the rig floor and the personnel stations are not present.
[0151] As seen in the example embodiment of FIG. 45 , in which a building structure from the floor plan of FIG. 44 is isolated in greater detail, rig floor access difficulties are overcome by constructing a company man house 54 that is actually a combination of a company man room 70 and a computer and communications room 72 . In a substantially central portion of the company man house 54 , a door 80 opens into a small hallway 82 , rather than directly into the company man room 70 . According to one embodiment, the small hallway 82 passes straight through the company man house 54 and is fully opened to the environment on a side 84 opposite the door 80 . Since door 80 opens into a hallway 82 that is open to the environment, hallway 82 becomes a non-classified area, and company men can use the telephones and computers provided in computer room 72 without conflicting with the industry regulations.
[0152] Turning now to various storage structures that are useful in a platform environment, for example, liquid storage platform sections, an embodiment of the invention depicted in FIGS. 46 and 47 comprises a platform section 50 that has a deck section 52 installed on top of the platform. In some embodiments, support foam 54 disposed within deck section 52 provides a layer of insulation at the top of the deck portion; in a presently preferred embodiment, the layer of insulation is about six inches thick. A plurality of six-inch insulation members 56 have also been added to the ends, bottom, and both sides of the platform and deck sections, effectively making the storage module a large thermal container.
[0153] In some embodiments, the floor of thermal container 52 further comprises an electric heating element 60 ; lying on top of the heating element is a balloon type tank or collapsible pillow tank 62 . In some embodiments, the balloon tank stores fresh water that can later be processed into either potable water or water suitable for use in showers and sinks. According to other embodiments, balloon tank 62 is used to store other liquids, for example, diesel fuel or well operation fluids. In further embodiments, a pump 70 is used to draw fluid out of the bladder tank prior to transfer of the fluid into other parts of the platform structure. In still further embodiments, pump 70 is used to draw liquids from other platform sections, and to pump the drawn fluids into the bladder tank through appropriate process connections 72 , for example, a metal pipe or durable plastic conduit connection.
[0154] Those of ordinary skill in the art will appreciate that there are usually a great many platform areas that are stacked high with relatively heavy platform modules and drilling equipment. However, there are also many other areas, for example, the deck sections beneath the crane, which are lightly loaded. By using one of the liquid storage bladder configurations, fluid loads can be maintained in platform sections that functionally serve as open deck spaces. The liquid storage bladders are also lighter than the steel tank storage modules that are presently known, and thus the total weight required to be supported is reduced according to the invention.
[0155] Most liquids suitable for storage in the disclosed bladder will tend to freeze at very low temperatures, for example, the very low temperatures that would be expected in arctic drilling environments. In the example embodiment of FIGS. 46 and 47 , problems associated with freezing fluids are overcome using one or more electric heaters disposed along the bottom of the bladder tank. According to further embodiments, however, one or more additional heating strips is applied directly to the bottom of the tank, or is instead applied to the bottom of an aluminum plate laid on the bottom of the platform section so that the bladder tank is disposed on top of the aluminum plate. The aluminum heating plates provide superior temperature distribution, and generally will not cause hot spots that can overheat a particular area of the bladder like other known methods of tank heating. According to further embodiments, hot air is circulated within the storage section to prevent the stored fluid from freezing; in still other embodiments, electric heaters are disposed within the fluid so that warm water is continuously circulated through the storage tank.
[0156] FIG. 48 is a cross-sectional view of a wellhead cellar according to one aspect of the invention, in which an outer portion of the wellhead cellar is comprised of multiple layers, for example, an inner skin and an outer skin, with two-part polyurethane foam insulation disposed between the inner and outer skins. In the bottom of the wellhead cellar, there are at least two levels of seals provided to ensure the unit is as environmentally secure as possible and that the ground surface is protected from inadvertent spills. The disclosed wellhead cellar also permits the entire drilling operation to be carried out without disturbing any of the ground surface except for the production hole.
[0157] As seen in the example embodiment of FIG. 49 , the wellhead center cellar further comprises additional sets of casing and the like suitable for use in additional wellbores. According to further embodiments of the invention, the backup casings are also sealed within the wellhead cellar to prevent leakage, and to maintain the environmental integrity of the drilling operation. In a further embodiment, a ladder or stairs provide access to personnel required to move into and out of the wellhead cellar.
[0158] As seen in the example embodiment of FIG. 50 , a wellhead cellar sealing assembly engages an outermost stream of production casing. The seals comprise an inner and outer skin, with polyurethane foam disposed in-between. According to some embodiments, each of the seals are energized using bolts attached by known fasteners in order to provide a secure and reliable sealing assembly for the protection of wellhead. Other means for energizing the seals include introduction of low pressure air feeds, for example, an air feed having about 2 PSI, so that the seals are held fast after attachment by means of compressive pressure or the use of a sealant such as foam.
[0159] FIG. 51 is a post hole in which a platform support post 50 is disposed according to further aspects of the invention. The support post 50 has an adjustable nut 56 for making fine adjustments to the level of the platform 52 disposed thereon, and a fluid transfer means 58 that permits fluid to be pumped from the platform down inside the body of the support post 52 for heating or cooling operations. A lower end 60 of support post 50 is contoured to permit pumped fluids to flow toward the bottom of the support post for full, uniform heating of the support post. At the lower end of the support post 50 , a smaller diameter section 62 is for engagement with an extension member.
[0160] As seen in the example embodiment of FIG. 52 , an adaptor 70 useful for adding an extension onto the bottom of a support post is provided. According to some embodiments, adaptor 70 has an internal bore 72 sized to engage a smaller diameter section 62 of the bottom of support post 50 . According to certain embodiments, one or more fastening bolts 74 are also provided; in a particular example embodiment, the fastening bolts 74 are disposed at 90 degree intervals around the circumference of the device, and engage and lock onto the bottom of the support post 50 . Disposed on a bottom portion of the adapter 70 is an extension receiving member 76 , sized to engage a piece of extension pipe that is added to the bottom of the adapter 70 . FIG. 53 shows the adaptor 70 of FIG. 52 , with the mentioned extension pipe section 80 attached thereto. According to one aspect of the invention, the extension member 80 is welded onto a bottom portion of the extension receiving member 76 , though in other embodiments any known fastening means will suffice so long as the connection between the extension member 80 and the extension receiving member 76 is secure and dependable. For example, certain embodiments use shear pins or the like to secure the extension member and the extension receiving member so that the connection will break apart when a predefined amount of force is applied.
[0161] As seen in the embodiment of FIG. 54 , a bottom portion of support post 50 has a lower end 60 sized so as to engage within an interior surface of extension receiving member 72 (see FIG. 52 ). In the embodiment of FIG. 55 , the support post has an extension member added, with the outer surface of lower end 60 being attached to the extension receiving member 72 using a plurality of fastening bolts 74 .
[0162] According to the further embodiment of FIG. 56 , a post hole 100 is depicted in which a platform support post is disposed. Extension member 84 has already been friction-locked to a bottom end of the support post. After the support post is inserted into the post hole, a slurry of water, sand and gravel is added to freeze the support post in place. At this point, the support post is ready for supporting the raised load for which it was designed.
[0163] Referring now to the example embodiment of FIG. 57 , the post hole shown in FIG. 56 is depicted after removal of the support post from the post hole. According to some embodiments, the support post is heated using circulated warm fluid so as to unfreeze the post from the surrounding ground formation. The plurality of bolts used to fasten the extension member to the extension receiving member are then removed or sheared, so that the support post can in turn be removed from the adapter and extension member. According to one embodiment, the adapter and extension member remain in the ground afterward, buried well beneath the surface of the surrounding ground formation. In some embodiments, the adapter and extension member are left in the ground about fifteen to twenty feet beneath the ground surface. In some embodiments, the adapter and extension are forever abandoned, and the post hole is filled in or covered over so that only minimal signs of the drilling operation are imprinted on the surrounding ground surface. However, in other embodiments, the adapter and extension member assembly are re-used whenever production from the site is again desired, and thus the post hole is not filled in or covered over. According to still further embodiments, the adapter and extension member assembly are abandoned, and the upper portion of the post hole is refilled with a slurry of sand and ice. In still other embodiments, the post hole is re-filled with a mixture of tundra and ice, and thus the former drilling site cannot easily be discerned from the surrounding tundra after operations have been completed and the platform has been removed.
[0164] The foregoing specification is provided for illustrative purposes only, and is not intended to describe all possible aspects of the present invention. Moreover, while the invention has been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from either the spirit or scope thereof. | The instant disclosure relates to a system and method of constructing drilling and production platforms that are particularly useful in remote, inaccessible and/or environmentally sensitive operating environments. According to one aspect of the invention, an arctic drilling platform is provided wherein various methods and means of interlocking neighboring platform modules are provided. Methods and means for sealing the intersections formed between a plurality of interlocked platform modules are also disclosed. According to further aspects of the invention, improved platform floor plans are provided, and various wellhead cellar layouts and sealing means are also described. Methods and means of enhancing the usefulness of modular storage platforms are disclosed, and a number of support post installation and removal techniques are also provided. Also taught are a variety of methods of adjusting the height and level of an assembled drilling platform, and methods and means of adding extension members useful for extending the length of a support post are also described. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 09/702,277, filed on Oct. 30, 2000, which is a continuation-in-part of U.S. application Ser. No. 09/122,616, filed on Jul. 24, 1998, now U.S. Pat. No. 6,209,665 B1, issued on Apr. 2, 2001, which is a continuation-in-part of U.S. application Ser. No. 08/790,066, filed on Jan. 28, 1997, now U.S. Pat. No. 5,975,222, issued on Nov. 2, 1999, which is a continuation-in-part of U.S. application Ser. No. 08/674,123, filed on Jul. 1, 1996, now U.S. Pat. No. 5,787,999, issued on Aug. 4, 1998. The priority of these prior applications is expressly claimed and their disclosures are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention is related to earth drilling equipment, and particularly to down hole, pneumatic, percussive hammer drilling systems. As noted in my related co-pending application Ser. No. 08/674,123, filed Jul. 1, 1996, and Ser. No. 08/790,066, filed Aug. 27, 1997, to which the present application is a continuation-in-part, underreamers are used for the formation of radially enlarged areas extending about a pilot bit for insertion of a casing.
[0003] Eccentrically mounted underreamers are known which include an arm which travels in an orbit for underreaming operation, and which are retractable toward the hole axis for tool removal purposes. However, eccentrically mounted underreamers can be diverted off-axis if the underreamer encounters rock fragments, buried metal objects, etc. Any diversion of a large drill bit is unacceptable in most drilling operations, and particularly where a series of closely spaced holes are being formed. The installation of casing in a drilled ground hole is also greatly hindered by any such diversion.
[0004] Other known underreaming equipment utilizes three bit mounted plates which are outwardly displaceable, but which incorporate a total working surface which is substantially less than the perimeter of the bore. Such undersized plates are subject to excessive wear and result in slow drilling operation.
[0005] Underreaming can also be achieved by use of a crown or ring bit, but components of those bits must be left in the underreamed area when drilling is complete, which is costly and otherwise unacceptable in some drilling operations.
[0006] Each of these problems is addressed by my co-pending U.S. application Ser. No. 08/674,123, and by the additional related underreamer embodiments disclosed and claimed below.
[0007] In addition to the foregoing problems associated with known underreamers, quick and efficient removal of drilling debris from the hole and drilling bits remains a problem. In my U.S. Pat. No. 5,511,628, which is hereby expressly incorporated by reference into this application, I disclosed a pneumatic down-hole drill with a central evacuation outlet. The apparatus of U.S. '628 permits continuous evacuation of large debris fragments through a central axial bore formed in the bit and through a central evacuation tube attached thereto. Compressed air is directed downwardly through peripheral channels, under the drill bit, and into a central evacuation tube. The flow of compressed air through the central evacuation tube provides continuous and efficient removal of earthen fragments from the bore, including rapid removal of fragments that would be too large for removal through peripheral pathways along the casing.
[0008] However, a need remains for a reverse circulation pneumatic drill which provides for underreaming of the bore, continuous evacuation of drilling debris fragments from the drilling face in the bore, and for ready removal of the drill bit through the casing during or after completion of the drilling operation.
SUMMARY OF THE INVENTION
[0009] The present invention is embodied in a reverse circulation system that addresses the shortcomings of the prior art.
[0010] It is therefore an object of the invention to provide an underreamer that includes a pilot bit on which are mounted underreamer arms which can be extended and retracted by relative rotation between the pilot bit and the underreamer arms. Each underreamer arm includes a strengthening boss. The strengthening boss includes axial bearing surfaces that engage corresponding axial surfaces of the pilot bit. The bearing surfaces of the arm bosses and the bits include surfaces shaped to extend the arms as the pilot bit is rotated relative to the pilot bit. Surfaces are also provided for locking the arm in its extended underreaming position. As the bit is rotated in the opposite direction, the locking surfaces disengage and the arm can be retracted without vertical movement of the driver.
[0011] In another aspect of the invention, provision is made to continually flush the bit with compressed air which is exhausted from the down hole hammer. The flow of exhaust air is routed through porting in the bit assembly into the central evacuation tube. A second flow of compressed air may also be provided to continually flush the perimeter region of the bit. In one embodiment, the perimeter flushing air is received from compressed air introduced at the well-head to pressurize the casing.
[0012] These and other aspects of the invention will be described in further detail with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a partial cross-sectional view of a drilling assembly according to the present invention.
[0014] [0014]FIG. 2 is an expanded partial cross-sectional view of the assembly shown in FIG. 1, showing the power head assembly, compressed air inlet collar, and the upper terminus of the dual wall pipe assembly.
[0015] [0015]FIG. 3 is an expanded cross-sectional view of the assembly shown in FIG. 1, showing the casing driver in greater detail.
[0016] [0016]FIG. 4 is an expanded cross-sectional view of assembly shown in FIG. 1, showing the dual wall pipe assembly and the box and back head assembly connecting the lower terminus of the dual wall pipe assembly to the down-hole pneumatic hammer.
[0017] [0017]FIG. 5 is a cross-sectional view of the down-hole pneumatic hammer assembly, including the bit assembly.
[0018] [0018]FIG. 5A is a perspective view of an alternative design for the hammer barrel of the down-hole pneumatic hammer assembly.
[0019] [0019]FIG. 6A is an exploded perspective view of a first embodiment of a bit assembly according to the present invention.
[0020] [0020]FIG. 6B is an exploded perspective view of a second embodiment of a bit assembly according to the present invention.
[0021] [0021]FIG. 7A is a perspective view of the pilot bit on the embodiment of FIG. 6A.
[0022] [0022]FIG. 7B is a bottom view of the pilot bit shown in FIG. 7A.
[0023] [0023]FIG. 8 is a perspective view of an underreamer arm used in the embodiment shown in FIG. 6A.
[0024] [0024]FIG. 9A is an end view of the underreamer arm shown in FIG. 8.
[0025] [0025]FIG. 9B is an outer side view of the underreamer arm shown in FIG. 8.
[0026] [0026]FIG. 10 is a bottom view of the bit driver of the embodiment shown in FIG. 6A, showing the axial surfaces which define the recesses which receive the underreamer arms, and the axial surfaces which bear against the underreamer arms for extension and retraction.
[0027] [0027]FIG. 11 is a bottom view of the bit driver in a second embodiment of the invention.
[0028] [0028]FIG. 12 is a bottom view of an underreamer arm of the embodiment referred to in FIG. 11.
[0029] [0029]FIG. 13 is a bottom view of the arms depicted in FIG. 12 mounted in their retracted position on the bit driver shown in FIG. 11.
[0030] [0030]FIG. 14 is a top view of a pilot bit for use with the bit driver and underreamer arms depicted in FIG. 13.
[0031] [0031]FIG. 15 is a bottom view of the pilot bit depicted in FIG. 14.
[0032] [0032]FIG. 16 is the bit driver and underreamer arms shown in FIG. 13 with the underreamer arms in their extended positions.
[0033] [0033]FIG. 17 is an enlarged partial view of the bit driver and underreamer arm shown in FIG. 13.
[0034] [0034]FIG. 18 is a partial cutaway bottom view of the bit assembly depicted in FIGS. 11 - 17 showing the compressed air flow path.
DETAILED DESCRIPTION
[0035] Referring now to FIG. 1, a reverse circulation drilling system, shown generally at 10 , includes a head assembly 11 , a dual wall pipe assembly 12 , and a down hole pneumatic hammer 13 within a bore casing 14 . Turning to FIGS. 2 and 3, head assembly 11 includes a casing driver 15 for driving the bore casing 14 downwardly as the bit advances, and a power head assembly 16 of standard design for rotating the bore casing 14 it is driven downwardly. Casing driver 15 includes an annular hammer 17 which reciprocates vertically as compressed air is alternatively admitted to chambers above and below hammer 17 . Hammer 17 impacts on anvil 18 , which in turn impacts on casing cap 19 . Casing cap 19 is sealed against the inner surface of bore casing 14 to permit pressurization, through port 20 , of bore casing 14 between casing cap 19 and down hole hammer assembly 13 . Pressurization of the casing provides a downward flow of air between the casing and the down hole hammer, preventing upward migration of debris between the down hole hammer and casing, which can hinder the removal of the hammer.
[0036] In locations where there is a concern about the stability of the formation being drilled, use of a pressurizing fluid other than air is preferred. The alternative pressurizing fluid in such instances can be water, drilling mud, a polymeric liquid, or another substantially noncompressible fluid. When a noncompressible fluid is used to pressurize the casing, a portion of the fluid is discharged into the lower portion of the bore, and supports the surrounding formation, reducing the likelihood of the bore collapsing.
[0037] Power head assembly 16 is connected to anvil 18 through linkage assembly 21 to impart rotation to the dual pipe assembly and the down hole hammer. Power head assembly 16 is of a design generally known in the field, other than its central member 22 , that is threaded onto the upper end of dual wall pipe assembly 14 , includes a central bore in communication with the dual wall pipe assembly to extend the debris discharge path through the power head to the elbow 29 . The joint of central member 22 and the dual wall pipe 14 includes a port 23 for admitting air to the annulus 24 between the inner wall 25 and the outer wall 26 of the dual wall pipe assembly. Collar 27 is mounted around the joint, and includes air inlet 28 , through which compressed air is admitted into the dual wall pipe assembly for driving the down hole hammer as further described below. An elbow 29 is rotatably mounted and sealed to the upper end of central member 22 . Elbow 29 , central member 22 and the inner wall 25 of dual wall pipe assembly 14 together form a central drilling debris discharge tube for continuously discharging drilling debris from the down hole hammer as will also be described more fully below.
[0038] Turning also to FIG. 4, dual wall pipe assembly 12 is assembled from individual segments, each of which includes an inner pipe 31 and an outer pipe 33 . Each segment includes a threaded male connector 33 and a threaded female connector 35 at opposite ends. Male connector 14 and female connector 15 each includes air ports 36 and 37 respectively which are in communication with outer annulus 24 of dual wall pipe assembly 11 . At its upper end, dual wall pipe assembly is threaded in to central member 22 of power head 16 . At its lower end, dual wall pipe assembly 11 is connected to the box 38 , which in turn is threaded into back head 40 of down-hole hammer 13 . Ports 42 an 44 communicate with annulus 24 of the dual wall pipe assembly to route compressed air therefrom into the down hole hammer.
[0039] Turning now to FIG. 5., down-hole hammer 13 includes box 38 threaded onto back head 40 . A sleeve 41 and a hammer barrel 42 are threaded into back head 40 . A centrally located discharge tube 43 is pressed into sleeve 41 . A wear sleeve 44 is fitted around hammer barrel 40 , and press fitted over ring 45 and onto shoulder 46 of back head 40 . Sleeve 41 and barrel 42 define an annular upper air chamber 48 . Central evacuation tube 43 and barrel 42 define an annular lower air chamber 50 . The lower end of barrel 42 abuts bit driver 52 , and also includes a perimetrical lip 54 which engages wear sleeve 44 to center barrel 42 in the wear sleeve. Hammer 53 is slidingly fitted into barrel 42 for reciprocation. Bit driver 52 is slidably fitted into barrel 42 below hammer 53 , and over the lower end of central evacuation tube 43 . Bit driver 52 is retained in barrel 42 by a plurality of keys 56 , each of which is fitted into a keyway 58 and annular recess 60 of bit driver 52 . (See also applicant's U.S. Pat. No. 5,511,628, incorporated by reference above, for detail of an alternate barrel assembly incorporating a like key and keyway assembly for mounting the bit driver in the hammer barrel.) The key-keyway assembly permits the bit assembly to advance ahead of the dual wall pipe assembly during drilling.
[0040] A bit assembly according to the present invention is shown in FIG. 6. Turning to FIG. 6, a bit assembly includes bit driver 52 , pilot bit 82 , and arms 88 a - c. Pilot bit 82 includes an upper shank 83 having a recessed chamfer 84 , camming surfaces 85 a and 85 b , and a lower portion 86 . Lower portion 86 includes three peripheral recesses 87 a - c. Hardened drilling buttons, preferably made of a carbide material, are mounted on the peripheral and bottom surfaces of the pilot bit (FIG. 7). Arms 88 a - c are nested atop pilot bit 82 , and slide thereon in an prescribed arcuate path as will be described. Each of the arms includes a raised boss 89 which is received into corresponding recess 90 of bit driver 52 (FIG. 10). Raised boss 89 serves several functions. First, impact forces from the hammer are transmitted downwardly to the pilot bit 82 through bit driver 52 , boss 89 , and arm 88 . Second, boss 89 is received and retained in recess 90 , where it rotates through a limited arc to extend and retract arm 88 . With arm 88 in its retracted position, surface 91 is adjacent camming surface 85 a . in this configuration, the overall diameter of the bit assembly is less than the inner diameter of the bore casing, permitting the bit assembly to be withdrawn from the bore. As arm 88 is rotated clockwise about pilot bit 82 by clockwise rotation of bit driver 52 , angled surfaces 85 a engage surface 92 and urge arm 88 outwardly. The rotation and extension of arm 88 continues until surface 92 a abuts surface 85 b and surface 92 b abuts surface 85 a , locking arm 88 in its extended position. To unlock and retract arm 88 , bit driver 52 is rotated in the opposite direction. In its fully retracted position, the overall diameter of the underreamer assembly is less than the inside diameter of the casing, permitting withdrawal of the entire underreamer bit assembly through the casing if necessary. This feature represents a significant advance over known underreamers, which cannot be retracted and withdrawn through the casing if necessary.
[0041] In operation, compressed air is delivered into annular chamber 59 through port 37 , radial ports 60 , annulus 62 and axial ports 64 . In FIG. 5, hammer 53 is shown during its downward stroke. Lip 66 is engaged with lip 68 , sealing off chamber 48 . Lip 72 is engaged with lip 74 , sealing off chamber 50 . Port 78 is closed. As piston 53 continues downwardly, port 76 is uncovered, exhausting chamber 48 . At about the same time, lip 74 disengages from lip 72 , admitting a fresh charge of compressed air into chamber 50 to raise piston 53 to its upper position after it has struck bit driver 52 . As piston 53 rises, port 78 is uncovered, exhausting chamber 50 . Lip 74 engages lip 72 , sealing chamber 50 . Port 76 is sealed by piston 53 , and lip 66 disengages from lip 68 , admitting a fresh charge of compressed air into chamber 48 . The fresh charge of compressed air in chamber 48 drives piston 53 downwardly to begin another stroke. The compressed air exhausted into ports 76 and 78 is collected in port 80 (FIG. 5A), and discharged through the bit assembly into central evacuation tube 43 , carrying with it drilling debris and earthen fragments dislodged by the bit. As an added precaution against drilling debris becoming lodged between arms 88 a - c and the pilot bit, in the bit assembly embodiment shown in FIG. 6B, port 91 is provided through which compressed air can be discharged to clear debris. The flow of compressed air through the bit assembly is essentially continuous, and provides a continuous evacuation of drilling debris from the drilling face of the bore. Moreover, the essentially constant diameter of the evacuation tube and inner wall of the dual wall pipe assembly provides a constant air velocity, which further aids debris removal. The continuous removal of debris through the central evacuation tube promotes continuous drilling. It is seldom, if ever necessary to stop drilling and raise the bit to clear debris from the bore. Significant improvements in drilling rates directly result. In addition, since debris is quickly removed as it is dislodged, it is possible to obtain a relatively accurate “core” sample from the bore. This aspect of the invention is useful in both exploratory and environmental applications.
[0042] In another aspect of the invention, pilot bit 104 advances into the ground with the underreamer arms locked in a deployed position below and radially beyond the advancing end of the casing at C. Casing movement is facilitated by the relatively large underreamed area, and if required, by the casing driver 15 . In one embodiment shown in FIGS. 1 and 3, if the drill bit assembly advances more than a predetermined distance ahead of the casing, linkage 21 operates a valve to provide compressed air to the pneumatic hammer 17 and associated porting casing driver 15 .
[0043] An alternative embodiment of the invention will now be described with reference to FIGS. 11 - 19 . In this embodiment, the bit assembly also includes a bit driver 100 , arms 102 a - c, and pilot bit 104 , which are fitted together as described in the previous embodiment shown in FIG. 6. In this embodiment, however, compressed exhaust air from port 80 is routed through internal ports in the bit driver, arms and pilot bit. Referring to FIG. 1, hammer exhaust air from port 80 flows into and through bit driver 100 via ports 106 a - c . The hammer exhaust air then flows through ports 108 a - c formed in arms 102 a - c respectively (FIG. 12). In FIG. 13, the arms are shown mounted on the bit driver in their closed and retracted positions. Exhaust air from ports 108 a - c flows into ports 110 a - c in pilot bit 104 (FIGS. 14, 15), through channels 112 a - c, ports 114 a - c, and into central evacuation tube 43 (FIG. 5). Ports 106 a - c, 108 a - c and 110 a - c respectively are located so that they are all aligned when arms 102 a - c are extended; i.e., holes 106 a , 108 a , and 110 a are aligned, holes 106 b, 108 b , and 110 b are aligned, and holes 106 c , 108 c and 110 c are aligned. Referring to FIGS. 16 and 17, when driver 100 is rotated relative to pilot bit 104 to position arms 102 a - c in their closed, retracted positions, ports 108 a - c (through arms 102 a - c respectively) are partially offset from ports 106 a - c, respectively; ports 110 a - c (through the pilot bit) are offset from ports 108 a - c (through the pilot bit) are entirely offset. To provide for a continuous flow of air through ports 106 a - c, 108 a - c , and 110 a - c when the arms are retracted, channels 112 a - c are provided in the underside of arms 102 a - c. Turning again to FIG. 15, pilot bit 104 also includes axial recesses 114 a - c, and transverse channels 116 a - c. Recesses 114 a - c and channels 116 a - c provide a path for the discharge of compressed air from outside the bore casing to also be discharged through central evacuation tube 43 .
[0044] The foregoing description of the invention is intended to be illustrative rather than exhaustive. Those skilled in the art will appreciate that numerous changes in detail are possible without departing from the scope of the following claims. | A underreamer drill bit assembly including a pilot bit and extendable underreaming arms operatively connected to the pilot bit. The underreaming arms have an extended position for underreaming, and a retracted position in which the overall diameter of the underreamer drill bit assembly is less than the inside diameter of the well casing, permitting the entire bit assembly to be withdrawn through the well casing. In another aspect of the invention, the bit assembly is operatively connected to a dual wall pipe assembly. A supply of compressed air is conducted through the annulus of the dual wall pipe assembly to a down hole pneumatic hammer. Exhaust air from the down hole hammer is directed to the bit assembly for continuous removal of drilling debris through a central evacuation tube of the dual wall pipe assembly. In another aspect of the invention, a pressurized, incompressible fluid is injected into the annulus between the well casing and the downhole pneumatic hammer. | 4 |
RELATED APPLICATIONS
[0001] This application claims a benefit of priority under 35 U.S.C. §119 to GB Patent Application No. 0523543.7 by Richard Mishra, Markus Buchner, Johnston Glendinning, Manfred Geyer and Adan Pope entitled “Network Planning” filed on Nov. 18, 2005, the entire contents of which are hereby expressly incorporated by reference for all purposes.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to management and/or modeling of telecommunications services, and in particular, to methods and apparatus for processing service information relating to a plurality of user services available in a telecommunications system. More particularly, the present invention relates to network management and planning. Even more particularly, particular aspects relate to a method of performing network modification in a telecommunications network, a method of managing a telecommunications network and a method of generating planning data defining changes to a telecommunications network.
BACKGROUND OF THE INVENTION
[0003] The management and planning of a telecommunications network is often supported by a data model which models the telecommunications network, and is also often referred to as an inventory. However, the data in the data model is often inaccurate and does not provide a clear view of the actual installed network. This can affect the quality of planning decisions, and lead to the construction of inefficient networks. Without an accurate model automation of service provisioning can also be more difficult.
[0004] Planning decisions are also often based on the analysis of high-level service requirements, from which optimized network configurations are derived. However, it is often difficult to adapt existing network structures to conform to these optimized configurations without simply replacing the existing network structures, which is typically not feasible. Physical movement of equipment is also expensive and can cause damage to the equipment. Many telecommunications operators hence prefer to avoid physical restructuring of existing network resources.
[0005] The present invention seeks to alleviate some of these problems.
SUMMARY OF THE INVENTION
[0006] Accordingly, in a first aspect of the invention, there is provided a method of performing network modification in a telecommunications network, comprising: storing a database comprising a master inventory defining network resources available in the network; and performing a network modification by a process comprising: modifying the database storing the master inventory; and modifying the network in dependence on the modified database.
[0007] In this way, a system can be provided in which changes in the actual network are made in response to changes to the inventory (preferably always or at least in normal circumstances, possibly not including emergency repairs or modifications). An inventory can thus be provided which reflects the state of the actual network more accurately, and which can allow for more reliable planning decisions and changes to the network. The inventory can also enable service provisioning processes to be automated more effectively.
[0008] The term ‘telecommunications network’ preferably refers to a network of interconnected devices (and possibly associated software) which provides telecommunications services. Optionally, other types of services may additionally be provided by or using the telecommunications network, for example data processing, storage, and retrieval services. Examples of such services include a mailbox, web space, an interactive travel booking system, a multimedia content delivery system or an online game. Such additional services are particular relevant in “next-generation” networks. Instead of a telecommunications network, the invention may also be applied to any suitable type of communications system or information processing system in which communication functionality or services are provided using distributed interconnected devices, for example in a local area network (LAN).
[0009] The master inventory may define network resources which exist in the network and are available for use, and may additionally define planned network resources which do not yet physically exist in the network or are not connected or configured for use.
[0010] Preferably, performing the network modification further comprises: outputting a change record describing the modification made to the database; and modifying the network using the change record. This can provide a reliable mechanism for controlling changes to the network.
[0011] The method may comprise collating a plurality of change records describing modifications to the database to generate a network modification plan, the network modification plan defining multiple network changes, and modifying the network using the modification plan. This can enable more efficient network modification by grouping multiple changes. The changes may be grouped based on a number of factors, including the type of equipment to which a change relates and/or the network location at which the change is to be performed. Using the latter criterion, network modifications can be grouped based on location, so that, for example, the modifications can be performed in a single visit to the location.
[0012] The network modification preferably comprises addition and/or deletion of one or more network resources to and/or from the network. The database preferably stores elements representing network resources; and modifying the database preferably comprises adding, deleting or modifying one or more database elements in the database.
[0013] The method may further comprise: storing a service inventory, the service inventory being derived from the master inventory and containing information used for the provisioning of services in the network; and provisioning services in the network using the service inventory. This can allow service provisioning (typically a more frequent activity) to be performed separately of network design and planning, which can lead to improved reliability. Preferably, the service inventory includes only such information as is required to perform service-provisioning and related tasks.
[0014] Provisioning a service preferably comprises: modifying the service inventory in dependence on the service being provisioned; and configuring the network to provide the service in dependence on the modified service inventory. This can ensure that the service inventory reflects provisioned services more accurately and can allow for more sophisticated provisioning processes. Provisioning the service preferably comprises generating configuration information in dependence on the service inventory modification, and transmitting the configuration information to one or more network resources in the network to configure the network resources to provide the service.
[0015] The method preferably comprises updating the service inventory in response to changes in the master inventory. In this way, the service inventory can be kept up-to-date.
[0016] In a further aspect of the invention, there is provided a method of managing a telecommunications network comprising: storing a database comprising a master inventory defining network resources available in the network; storing a database comprising a service inventory, the service inventory being derived from the master inventory and containing information used for the provisioning of services in the network; and modifying the service inventory in response to modification of the master inventory. This can allow network design/planning and service provisioning to be performed independently, whilst ensuring that both use an accurate data model.
[0017] The method preferably comprises modifying the network by a process including: modifying the master inventory; generating change information in response to modification of the master inventory; and modifying the network in dependence on the change information. The method preferably comprises provisioning a service in the network by a process including: modifying the service inventory; generating configuration information in response to the modification of the service inventory; and transmitting the configuration information to the network. The method may comprise receiving a service order relating to a service, and provisioning the service using the service inventory in response to the order.
[0018] Preferably, the method comprises analysing utilisation of network resources in the network, and planning changes to the network in dependence on the outcome of the analysis. Analysing and planning preferably comprises: measuring the utilisation of one or more network resources in the network over time; analysing the measured utilisation over time of the one or more network resources to determine a utilisation trend; predicting future utilisation of the one or more network resources using the determined utilisation trend; and planning changes to the network in dependence on the predicted future utilisation.
[0019] This feature is also provided independently. Accordingly, in a further aspect of the invention, there is provided a method of generating planning data defining changes to a telecommunications network, comprising: measuring the utilisation of one or more network resources in the network over time; analysing the measured utilisation over time to determine a utilisation trend; calculating a predicted future utilisation of the one or more network resources using the determined utilisation trend; and generating planning data defining changes to the network in dependence on the predicted future utilisation of the one or more network resources. This can enable higher-quality planning data to be generated, which is derived using information on the actual network and the utilisation of actual network resources. A planning process can thus be provided which is driven by the actual (existing) network, rather than high-level, abstract service requirements. This can lead to the planning of network changes which can be more easily implemented in the existing network.
[0020] The one or more resources are preferably associated with a given network location; the planning data defining changes to the network at the network location. Alternatively or additionally, the one or more resources may be associated with connection resources between network locations; the planning data defining changes to the connection resources.
[0021] The term ‘network location’ preferably refers to a location or area where a specified portion of the network is located, for example a geographical area such as a town or city, or a location where network equipment and connections are provided, such as a building or building complex, or a floor or room in a building. For example, an exchange may be a network location. A network location may also be a logical grouping of network resources. A network typically includes a plurality of such network locations, interconnected in some way.
[0022] The method preferably comprises calculating a measure of the predicted demand for a type of network resource in dependence on the predicted utilisation; and generating the planning data in dependence on the predicted demand. The measure of the predicted demand for a type of resource is preferably calculated in dependence on the predicted utilisation of the one or more resources and in dependence on one or more adjustment parameters. This can provide greater flexibility.
[0023] The one or more adjustment parameters may comprise one or more of: a global adjustment factor, a local adjustment factor, and a service trend adjustment factor. The method preferably comprises analysing service data relating to services provided using the one or more network resources or the network location over time to determine a service trend; and determining the service trend adjustment factor in dependence on the service trend. In this way, higher-level service requirements can still be taken into account in a network driven planning process.
[0024] The global adjustment factor may relate to external conditions relevant to the network, for example general economic conditions. The local adjustment factor may relate to conditions local to a geographical area or population of an area and/or local to a portion of the network including the one or more network resources and/or the network location. The planning data may define one or more modifications, additions and/or removals of network resources in the network.
[0025] The invention also provides a method of performing network modification in a telecommunications network comprising generating planning data defining changes to the network using a method as described above, and performing network modification in dependence on the planning data. The network modification may be performed using a method as described above. The above methods (as well as those set out below) may be combined in any other suitable way.
[0026] In a further aspect of the invention, there is provided a method of managing a telecommunications network, comprising: maintaining a master inventory defining network resources available in the network; and implementing changes to the network by: implementing the changes in the master inventory; and translating the inventory changes into changes to the network.
[0027] In a further aspect of the invention, there is provided a method of managing a telecommunications network comprising: maintaining a master inventory describing network resources available in the network; maintaining a service inventory, the service inventory being derived from the master inventory and containing information used for the provisioning of services in the network; and updating the service inventory in response to changes in the master inventory.
[0028] In a further aspect of the invention, there is provided a method of planning changes to a telecommunications network, comprising: measuring the utilisation of one or more network resources in the network over time; analysing the measured utilisation over time to determine a utilisation trend; predicting future utilisation of the one or more network resources using the determined utilisation trend; and planning changes to the network in dependence on the predicted future utilisation of the one or more network resources.
[0029] In a further aspect of the invention, there is provided a method of generating planning data defining planned changes to a telecommunications network, comprising: representing the network in an abstract representation as a plurality of capability objects, each capability object representing a network capability; and generating planning data specifying changes to network capabilities, the changes being expressed in the planning data at a level of abstraction corresponding to that of the abstract representation.
[0030] This can enable more effective planning of network changes which does not rely on a detailed network model. Planning decisions can be expressed in more abstract terms, allowing their implementation to be determined separately by a resource planner.
[0031] Network capabilities may, for example, include groupings of network resources and/or network functions, technical or functional characteristics of parts of a network, and/or services and functions providable by a network or by part of a network. Network capabilities are preferably represented independently of the network resources which provide the capabilities.
[0032] The changes may be expressed in the planning data in terms of or in terms corresponding to the abstract representation. Thus, the changes are preferably expressed in terms of the capabilities represented (or representable) in the abstract representation. For example, the planning data may specify the addition, modification and/or removal of network capabilities. The terms “change” and “modification” (and related terms) are herein meant to encompass the addition of new capabilities or resources as well as the modification or deletion of existing capabilities or resources (or of representations thereof in a model or database), unless the context otherwise requires.
[0033] The abstract representation is preferably in the form of an abstract network model (also referred to herein as a planning model or capability plan), preferably stored in a database. The term “object” is used here in a general sense to refer to a representational unit or entity. Capability objects may be represented using database entities such as database tables (in a relational database) or database objects (in an object database), depending on the type of database used.
[0034] The method preferably comprises modifying the abstract representation in dependence on the planning data. This may involve adding, modifying or changing capability objects so as to reflect the planned changes. Preferably, the method comprises translating the planning data specifying changes to network capabilities at the abstract level into detailed planning data specifying network changes for implementing the capability changes. The detailed planning data may specify addition or removal of or changes to network resources (for example network equipment) in the network (or in a network model).
[0035] The method preferably further comprises storing a model of the network, the model defining network resources of the network; and modifying the network model in dependence on the planning data. The model is preferably more detailed than the abstract representation (i.e. at a lower level of abstraction), and preferably represents network resources of the network, for example network equipment and connections between equipment.
[0036] The method may further comprise storing a plurality of templates each defining changes to the network model, selecting a template in dependence on the planning data, and modifying the network model using the template. The use of templates can allow for more efficient and controlled implementation of planning requirements in the network model. A given template may be associated with one or more parameters, in which case values for the parameters are preferably derived from the planning data. Parameterisable templates can provide greater flexibility.
[0037] The method preferably comprises implementing the network changes in the network in dependence on the modifications made to the network model. This can ensure that correspondence is maintained between the network model and the actual installed network.
[0038] Capability objects may represent one or more of: partitions of network resources of the network, for example network domains, network areas, network locations, or equipment sites; physical characteristics of locations or sites; and technological capabilities or logical capabilities available at locations or sites or connecting locations or sites. Technological and logical capabilities may also be viewed as representing partitions of network resources (i.e. technological/logical rather than geographic partitions).
[0039] Preferably, the abstract representation comprises a hierarchy of capability objects representing a hierarchical partitioning of network resources of the network (for example, a network location comprising one or more equipment sites each comprising one or more technological capabilities). This can simplify planning and enable more efficient implementation of planned changes. The abstract representation preferably does not directly represent low-level network resources such as pieces of network equipment or specific connections. More generally, the abstract representation preferably comprises only such information as is needed for performing planning tasks (i.e. data is held only at a level of detail needed to support network planning).
[0040] The term “network resource” preferably refers to tangible/physical or low-level logical/technological entities (rather than high-level conceptual entities) from which a network is constructed, including, for example, pieces of equipment, devices, components for devices (e.g. cards), facilities of devices or subdivisions thereof (e.g. ports), groups or associations of equipment or devices, connections (e.g. cables), support structures (e.g. ducts), software executing on devices, or low-level logical entities (e.g. timeslots, files or other storage space assignments).
[0041] The invention also provides a planning system for generating planning data defining planned changes to a telecommunications network, comprising: a database storing a planning model representing the network using a plurality of capability objects, each capability object representing a network capability; and a planning module adapted to generate planning data specifying changes to network capabilities in dependence on the planning model.
[0042] Also provided are a network management system or network planning system adapted to perform a method as described herein, apparatus comprising means for performing a method as described herein and a computer program or computer program product comprising software code adapted, when executed on a data processing apparatus, to perform a method as described herein.
[0043] More generally, the invention also provides a computer program and a computer program product for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, and a computer readable medium having stored thereon a program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
[0044] The invention also provides a signal embodying a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein, a method of transmitting such a signal, and a computer product having an operating system which supports a computer program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.
[0045] The invention extends to methods and/or apparatus substantially as herein described with reference to the accompanying drawings.
[0046] Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa.
[0047] Furthermore, features implemented in hardware may generally be implemented in software, and vice versa. Any reference to software and hardware features herein should be construed accordingly.
[0048] These, and other, aspects of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. The following description, while indicating various embodiments of the invention and numerous specific details thereof, is given by way of illustration and not of limitation. Many substitutions, modifications, additions or rearrangements may be made within the scope of the invention, and the invention includes all such substitutions, modifications, additions or rearrangements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer impression of the invention, and of the components and operation of systems provided with the invention, will become more readily apparent by referring to the exemplary, and therefore nonlimiting, embodiments illustrated in the drawings, wherein identical reference numerals designate the same components. Note that the features illustrated in the drawings are not necessarily drawn to scale. Preferred features of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which:
[0050] FIG. 1 illustrates a network management system in overview, including network engineering and order fulfillment processes;
[0051] FIG. 2 illustrates the network engineering process in greater detail;
[0052] FIG. 3 illustrates a network planning method;
[0053] FIG. 4 illustrates a Tier 1 Systems Architecture
[0054] FIG. 5 illustrates a high-level planning process;
[0055] FIG. 6 illustrates an example of a typical planning process (high-level);
[0056] FIG. 7 illustrates solution components of an example implementation of a network planning module;
[0057] FIG. 8 illustrates an example of a Network Capability Plan;
[0058] FIG. 9 illustrates partitioning a network into domains and classifying nodes; and
[0059] FIG. 10 illustrates the planning/inventory interface.
DETAILED DESCRIPTION
[0060] The invention and the various features and advantageous details thereof are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well known starting materials, processing techniques, components and equipment are omitted so as not to unnecessarily obscure the invention in detail. Skilled artisans should understand, however, that the detailed description and the specific examples, while disclosing preferred embodiments of the invention, are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions or rearrangements within the scope of the underlying inventive concept(s) will become apparent to those skilled in the art after reading this disclosure. Reference is now made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts (elements).
[0061] FIG. 1 shows in overview a network management system for managing a telecommunications network 26 .
[0062] The network management system provides facilities for carrying out two distinct management processes: a network engineering process and a service order fulfillment process. The network engineering process includes the planning, design, and physical construction of the network. The order fulfillment process includes the provisioning of services to users of the network in response to service orders.
[0063] Underlying these processes is a master inventory 14 . The master inventory 14 provides a representation or model of the network which supports the various processes outlined above. Specifically, the inventory stores information defining the network resources available in network 26 , including network devices, connections between network devices, and features and characteristics of devices and connections. The inventory may also store information defining planned resources, i.e. resources which do not yet physically exist in the network or are not connected or configured for use, but which are intended to be added to the network. In preferred embodiments, the master inventory (also referred to as the resource inventory) stores sufficient detail, but no more detail than required, to carry out its two primary tasks: firstly to allow the specification of changes to the network that will be implemented by physical planning and construction processes (either internally, by device vendors, or by other suppliers); secondly, to populate the service inventory 22 (described below) with network data, so that the service inventory is able to build service specific inventory data on top of the network data and so enable service provisioning in the inventory.
[0064] The inventory is managed by a resource planner 12 . Resource planner 12 controls changes to the inventory, for example the addition or removal of network resources.
[0065] A network planning module 10 interacts with the resource planner 12 and provides functions for supporting the planning of the network, principally by analysing information held in the inventory and identifying changes to the network needed to enable the network to meet future demand. The network planning module 10 interacts with the resource planner 12 to implement the changes.
[0066] Any changes made to the master inventory 14 are translated into changes to the actual network 26 . These changes are typically physical changes, such as the installation of new equipment or connections. The planning and construction functions together form the network engineering process represented by arrow 30 in FIG. 1 .
[0067] The order fulfillment process is represented by arrow 32 .
[0068] To support the order fulfillment process, an order entry module 16 , an order management module 18 , a provisioning subsystem 20 and an activation module 24 are provided.
[0069] Service orders are received by the order entry module 16 , which may, for example comprise an interactive order entry application. Service orders are then processed by order management module 18 , which identifies the specific services that need to be provisioned in response to a given order, and carries out other associated functions (such as billing), in some cases by interaction with external systems. Once the relevant services have been identified, the order management system instructs the provisioning system 20 to provision those services in the network.
[0070] The service provisioning system 20 is responsible for provisioning services to users of the network 26 . The provisioning system 20 maintains a service inventory 22 used for provisioning services in the network. The service inventory 22 is derived from the master inventory 14 , but typically contains only the information from the master inventory 14 that is needed to enable the provisioning of services and the management of provisioned services. The service inventory 22 typically also contains additional information not present in the master inventory to support the provisioning processes.
[0071] To provision a service, the provisioning system 20 identifies network resources in the service inventory 22 which can be used to provide the service, generates network configuration information for configuring the identified network resources to provide the service, and updates the service inventory 22 to reflect the new service. The configuration information is passed to activation module 24 which generates device-specific configuration instructions and transmits these to the network to set up the new service.
[0072] The network engineering process 30 is illustrated in more detail in FIG. 2 .
[0073] Information about the network is obtained and analysed in step 40 . This information typically includes information obtained from the master inventory 14 , but may also include other information, such as service data and external data. In some embodiments the information is provided by a separate, abstract, planning model (described in more detail below). The analysis results in the identification of requirements for the network.
[0074] In step 42 , changes to the network are determined to support the identified requirements. These changes are implemented in the inventory 14 in step 44 .
[0075] In response to changes in the inventory 14 , change records are generated in step 46 . These change records define the changes which need to be made to the network to ensure that the network corresponds to the network model of the inventory 14 . The change records are used to implement the changes in the network in step 48 .
[0076] The changes typically include the addition of new network resources (e.g. network devices or physical connections between devices) to the network 26 as well as (less frequently) the removal of existing network resources from the network 26 . This process of maintaining and changing the physical network is referred to herein as network construction.
[0077] In normal circumstances, the physical network is thus modified only in response to modification of the inventory 14 . In this way, it can be ensured that the master inventory 14 maintains an accurate model of the network and can thus serve to reliably support other operational processes. The inventory 14 is, in effect, master of the network in the present system, unlike many prior art systems where a network model is generated from the physical network, for example by information extraction/discovery. In the present system, the inventory 14 controls the physical shape and configuration of the network, not vice versa.
[0078] The master inventory stores the information required to support any operational processes, in particular those under the control of the network management system, but also external processes not discussed here, such as reporting functions.
[0079] Changes may also be made to the inventory 14 without the network planning process of steps 40 and 42 (which are supported by the network planning module 10 of FIG. 1 ). To enable such changes, the resource planner 12 typically includes an interactive application by way of which a network designer can add, modify or delete network resources in the inventory directly, for example to increase capacity or introduce new technologies.
[0080] A variety of planning methods may be used in the network planning process summarised above in steps 40 and 42 . One example of a planning method is illustrated in more detail in FIG. 3 .
[0081] This planning method uses utilisation information relating to specific resources to determine future demands and determine network upgrades needed to support those demands.
[0082] The utilisation of a resource or group of resources is measured in step 102 . This information is obtained from the service inventory and measured over time. In some embodiments, utilisation data may also be directly obtained from the network.
[0083] The utilisation data typically specifies the assignment of resources to services (e.g. the assignment of ports or timeslots). For example, the utilisation data may specify that, at a given network location, n out of m available access ports are assigned to services, and that m-n access ports are hence available for provisioning of future services. In some embodiments, as an alternative or in addition to the above view of resource utilisation based on service assignment, utilisation data relating to data flow through given network resources may also be used (such data would typically be obtained from the network).
[0084] The utilisation data is analysed in step 104 , and a utilisation trend is determined. The utilisation trend specifies whether utilisation of the resource or resources is increasing or decreasing and the rate of that increase/decrease, or whether utilisation is essentially static. The utilisation over a given future period is then predicted at step 106 based on the identified utilisation trend. Known curve-fitting/extrapolation techniques may be used to identify trends and calculate predicted utilisation.
[0085] The predicted utilisation of the resource or resources may be used to determine a predicted demand 116 for a given type of resource. Typically, the type of resource directly corresponds to the resource or resources under consideration. Alternatively, the resource or resources under consideration may be of a different type, but the information on their utilisation may nevertheless be useful in (indirectly) predicting demand for a certain type of resource.
[0086] This predicted demand 116 can be directly derived from the predicted utilisation calculated in step 106 . Alternatively, the predicted demand may be arrived at by combining the predicted utilisation with one or more adjustment parameters in step 108 . By way of example, three types of adjustment parameter are described here: a global adjustment parameter 110 , a local adjustment parameter 112 , and a service trend adjustment parameter 114 .
[0087] A global adjustment parameter 110 may be used to reflect conditions relevant to future demand which are generally applicable to the network as a whole, for example prevailing economic conditions or economic predictions, marketing campaigns or sales initiatives, or changes in service pricing. As a specific example, economic conditions may suggest that a period of increased growth is expected, and the global adjustment parameter may then specify that the predicted demand should accordingly be increased by a specified percentage.
[0088] A local adjustment parameter 112 may be used to reflect conditions which may affect a portion of the network, for example a specific network location, such as a network exchange. For example, knowledge of a major residential building programme in a given area may indicate a likelihood of greater-than-average growth in resource utilisation at a certain exchange, and a local adjustment parameter may therefore specify that the predicted demand for that exchange should be increased by a specified percentage. Alternatively, a local adjustment parameter may relate to conditions local to a given geographical area or population of an area (typically an area associated with the network resources under consideration).
[0089] A service trend adjustment parameter 114 may be used to reflect trends in the use of certain services (typically services relevant to the network resources under consideration or a network location including those resources). The service trend adjustment parameter may be determined by analysing service information held in the service inventory to determine service trends. For example, a given network location may be associated with a greater-than-average increase in the uptake of broadband internet services. A service trend adjustment parameter may reflect this service trend by specifying that the predicted demand for a given type of network resources should be increased by a specified percentage. The service trend adjustment parameter may itself be varied in dependence on the magnitude of the service trend. Instead of services provided at a specific location, end-to-end service trends may also be analysed (e.g. by analysing services provided between given locations). Such service trends may affect future demand at the relevant locations or at some other location (e.g. an intermediate location which may be involved in the provision of the services), and may thus be used as the basis for service trend adjustment parameters.
[0090] The above adjustment parameters may be used in any suitable combination, and multiple adjustment parameters of any given type may be used. Typically, a local adjustment parameter will relate to a specific location or portion of the network, and will accordingly only be used in the calculation of resource demand for that location.
[0091] The adjustment parameters may be stored by the network planning module, or in the inventory 14 itself, and may be set by a network planner or obtained automatically from a suitable source. Service trends may be calculated off-line and stored (typically associated with network locations), or may be calculated on-the-fly during planning.
[0092] Once the predicted demand for a type of network resource at the given location (or, in the case of connection resources, between locations) has been determined, the network planning module 10 derives planning requirements by comparing the predicted demand for resources to the resources which are actually in place in the network and which are available for providing services (this information is available in the master inventory model 14 and/or the service inventory 22 ). The difference between the resource demand and the existing resources determines what resources need to be added to the network in order to meet the predicted future demand. These requirements are then used to instruct the resource planner 12 to create new resources of the relevant type in the network (e.g. at the specified location). The network planning module 10 may also instruct the resource planner to create additional resources needed to support the resources being added. For example, the addition of a certain type of device to the network may require other supporting devices to be added, and connections between devices may also need to be created. In some cases, certain network functionality required for operation of the new resources may be implemented by way of internal services (i.e. services which are not directly associated with end users), in which case the resource planner 12 interacts with the provisioning system 20 to initiate provisioning of those internal services.
[0093] Resource planner 12 , which is preferably an automated process (but may include a human planner), receives the information specifying the new resources from network planning module 10 and creates the new resources in the master inventory 14 .
[0094] As discussed above, in response to the changes in the inventory, change records are generated documenting the changes. These change records are then used to physically implement the changes in the network, e.g. by adding network devices and/or connections at the relevant location.
[0095] The system preferably collates multiple related change records to produce a network modification plan. Such plans typically represent groups of network changes, grouped for organisational purposes. Network construction activities are then driven by network modification plans. Changes may be grouped into plans based on appropriate criteria, such as the equipment type involved, the class of engineering personnel required to carry out the changes, and/or the network location at which the physical changes are to be implemented. Grouping network modifications in this way (especially by the latter criterion) can improve the efficiency of the network construction process.
[0096] In a preferred embodiment, the network planner 10 outputs planning data describing planned changes at a more abstract or less detailed level than is needed for implementation of the changes in the network. The resource planner 12 then determines the detailed, low-level implementation of the changes.
[0097] More specifically, in this embodiment the network planner maintains a higher-level, more abstract representation of the network, referred to as the planning model or capability plan. The capability plan models the network in terms of network capabilities (typically associated with network locations or connections between network locations), without representing the detailed network structure that provides those capabilities. In preferred embodiments, the capability plan preferably holds only such information as is needed for the planning functions.
[0098] The network planner 10 analyses resource utilisation to determine future resource demands, and identifies network capabilities needed to meet those demands based on the existing capabilities modeled in the capability plan. It then outputs a planning request specifying the capabilities needed to the resource planner 12 . The resource planner 12 then determines the changes to or additions of network structure and resources needed to provide the new capabilities, and implements the changes in the master inventory 14 . The changes to the master inventory 14 are then translated into physical network changes as has been described above.
[0099] One preferred method of converting the high-level planning requirements output by the network planning module 10 into specific changes in the master inventory 14 uses templates, referred to herein as Standard Builds. A template or Standard Build represents a set of specific configurations, preferably expressed in the same way as data items in the master inventory and used to specify controlled changes to the master inventory.
[0100] Standard Build templates specify standard types of growth, shrinkage or change of network facilities (typically those change types which occur reasonably frequently in day-to-day operations). They can also act to constrain the planning module 10 (and/or human planners) to a given set of possible change types, which can lead to a more controlled and structured network.
[0101] Thus, a Standard Build template may specify the addition, modification or removal of resources in the master inventory. The system preferably stores a library of Standard Build templates, each associated with given planning requirements. The resource planner 12 selects a Standard Build template associated with a given planning requirement, and instantiates the template with any required parameters (for example specifying a relevant network location), to produce detailed implementation information for implementing the requirement in the master inventory.
[0102] Standard Build templates may, for example, correspond to types of capability object used in the capability plan. The addition of a given capability object to the capability plan by the planning module 10 can then be implemented by the resource planner 12 in the master inventory by using the appropriate Standard Build template corresponding to the capability object added.
[0103] As an example, a Standard Build template called ‘Mid-Size SDH Customer Access’ could specify an SDH Add Drop Multiplexer, at a specified location, with two connections of STM-4 bandwidth from its East and West ports to separate, unspecified core SDH Cross Connects that exist at the specified location, and presenting 400 tributary ports at 2 Mbit/s bandwidth. Such a Standard Build would be invoked if the planning module 10 determined a requirement for, say, 325 additional SDH customer access ports at a location.
[0104] To enable the resource utilisation and service trends to be determined, the service inventory preferably records information allowing changes to the network over time to be analysed. This can be achieved through data warehousing techniques such as maintaining time-stamped records corresponding to previous states of the network alongside the current network state.
[0105] In some embodiments, the master inventory 12 may store some service-related data for the purposes of determining utilisation trends. This data is received from the service inventory 22 when new services are provisioned by provisioning system 20 or by way of a periodic update procedure. In this way, the network planning module 10 can determine utilisation trends without needing to access both the master inventory 14 and the service inventory 22 , which can lead to improved efficiency. In some further embodiments, the master inventory and service inventory may be provided as a single inventory accessed separately by resource planner 12 and provisioning system 20 , thus removing the need for updating one inventory in response to changes in the other.
[0106] Example: An example implementation of the network planning module 10 will now be described in more detail with reference to FIGS. 4 to 10 . In this embodiment, the planning module is referred to as the Planning Engine.
[0107] Overview: One purpose of the Planning Engine as described in this example is to drive network evolution in accordance with operational strategy. The following describes the solution architecture of this capability.
[0108] Many carriers have begun the process of migrating their traditional networks into so-called next-generation networks. Due to the major investment required to achieve such a fundamental shift in the network, it is desirable for key strategic decisions to be captured and applied in a planning process that is informed by both future demand and existing infrastructure.
[0109] It is believed that such a planning function can be best achieved as an extension to a universal inventory. This can provide a credible platform for addressing the long-term challenge of both planning rollout and ongoing strategic operation of the network. The aim is to construct an automated planning process coupling a Planning Engine with the more detailed resource planning beneath.
[0110] The Planning Engine can provide improvements in the management of network evolution, in particular with regard to the changes taking place for rollout and operation of next-generation networks. The approach described aims to achieve this through integration with the inventory, enablement of a repeatable process rather than once-only designs, the modeling of service with respect to capability as well as capacity, and an understanding of the full cross-domain problem space.
[0111] The Planning Engine forms the uppermost module in the network engineering stack, and follows the principles of a business driven network, where decisions are made in each system on data that are only as detailed as is necessary. The Planning Engine module is the master of high-level network change, and passes planning requests to the resource planning inventory for detail design and realization. The Planning Engine is enabled by the underlying network inventory data for initial abstraction load and ongoing utilization data. Tools are provided to visualize and manage the data, and to undertake high-value network analysis functions.
[0112] The following abbreviations are used in the description of the Planning Engine.
Abbreviation Description API Application Programmable Interface ATM Asynchronous Transfer Mode CoS Class of Service COTS Commercial off-the-shelf DSLAM Digital Subscriber Line Access Multiplexer EJB Enterprise Java Bean ERP Enterprise Resource Planning FR Frame Relay GEthernet Gigabit Ethernet IP Internet Protocol MPLS Multi-Protocol Label Switching MTNM Multi-technology Network Management MTOSI MTNM Operating System Interface NMS Network Management System PWE Pseudo-Wire Encapsulation QoS Quality of Service SDH Synchronous Digital Hierarchy SONET Synchronous Optical Networks VoIP Voice over Internet Protocol VPLS Virtual Private LAN Service VPN Virtual Private Network XML Extensible Mark-up Language
[0113] Network Evolution Planning: Traditionally, network planning assumed stable relationships between network domains and their associated technologies. Network planning was conducted in a domain-by-domain fashion, each such domain normally a technology-specific exercise. New networking technologies were introduced as an overlay to a current technology domain.
[0114] The current network planning processes, however, typically need to cover a host of new networking technologies (e.g. VOIP, VPLS, PWE). An important issue now is how to make the transition into a next-generation network, and ongoing operation of that network. Reducing capital expenditure for telecommunication networks by using new technologies means combining the need to simplify the network (i.e. replace or at least converge legacy services such as FR and ATM by new data VPNs) and the drive to increase the range of service types. Understanding and considering the coexistence of old and new can be important. Network planning guides incremental planning to a strategic vision, allowing migration to and ongoing maintenance of a changed network structure.
[0115] The (End-to-end) Service Perspective: While telecom markets have become much more mature in terms of competition and customer focus, the services contained in each telecommunications product map less rigidly into a dedicated, associated network technology. A telecommunications product can comprise many different components. Each end-to-end service might make use of different underlying network technologies, e.g. Internet-Connectivity through IP-DSLAM vs. ATM-DSLAM in different access regions of the network, though both connected to the public Internet through an MPLS core.
[0116] Furthermore, competition is forcing convergence; various telecommunications services are being migrated onto a shared technology infrastructure. Network planning now usually needs to maintain end-to-end metrics (in particular on service quality), which are calculated across network domains and technologies.
[0117] Planning for Network Capacity and Capability: Through ‘bandwidth’ increasingly being considered a cheap commodity, the importance of ‘capacity’ as the major measure for network cost has been complemented by networking ‘capabilities’. A key decision in network planning is where to put (or co-locate) different network capabilities and how to ensure connectivity with appropriate redundancy levels between them. Modern telecommunications products and their associated services each require access to a number of capabilities. The capability placement decisions, together with the capability requirements for each service, determine the traffic flows in the network. The capability placement decisions, and their associated resilience requirements, strongly impact network cost, both by themselves and through their impact on capacity demand.
[0118] The advent of next-generation networks has taken the requirements for network planning solutions far beyond their roots. The focus has shifted away from sophisticated mathematical optimization algorithms derived from graph theory, towards cross-domain network modeling and built-in support for adoptable and repeatable planning processes.
[0119] Architecture: The OSS architecture for a Tier 1 operator in the Resource Engineering and Service Fulfillment stacks can be represented as in FIG. 4 .
[0120] The resource engineering planning stack comprises three components that are relevant to planning network evolution:
[0121] Planning Engine (corresponding to the network planner 10 of FIG. 1 )
[0122] Resource Planning (corresponding to the resource planner 12 of FIG. 1 ). The resource planning component is responsible for low-level planning and implementation of changes in the inventory (and more generally, management of the inventory).
[0123] Physical Planning
[0124] The Planning Engine is responsible for planning decisions for both major changes and ongoing incremental refinement, based on long-term trends, demands, strategic policy and abstracted network data from Resource Planning. The Planning Engine outputs planning requests to Resource Planning, and generally acts to automate higher level functions required by Resource Planning.
[0125] Resource Planning is responsible for converting planning requests into detailed plans. A detailed plan in Resource Planning is actualized by passing physical planning requests to Physical Planning and logical requests to the fulfillment stack. Resource Planning is synchronized with Physical Planning and the fulfillment domain managers and inter-domain manager. Resource Planning will update network planning changes in these domain managers. The Planning Engine extracts and abstracts Resource Planning data to support its function.
[0126] Physical Planning is responsible for the physical layout and cabling of the network infrastructure, including power, cooling and space requirements for both outside plant and within buildings.
[0127] The present example is concerned primarily with the Planning Engine, within the context set out in FIG. 4 . The Planning Engine is designed to facilitate ongoing network evolution and refinement by directing day-to-day growth, in accordance with a strategic intent, using inventory data as a key enabler. This is based on market forecasts and an understanding of the planned network structure and topology and its utilization trends.
[0128] General capability: The Planning Engine is cross-domain and multi-technology. A network may be conceptually split into domains, such as access, backhaul and core. The Planning Engine can enable this split to be defined and adhered to. The network will also typically comprise a multiplicity of layered and intersecting technology topologies. The Planning Engine capability can enable the management of the evolution of these network layers.
[0129] Planned extensions to the network are made in the Planning Engine and passed down as planning requests to the Resource Planning platform for detailed design. The network can then be proactively managed according to operational policies. Network utilization data is fed back to planning to complete a closed loop of network evolution.
[0130] It is this access to inventory data and coupled process that empowers the Planning Engine process. The Planning Engine can also interact with marketing systems to receive market forecasting data and feedback actual utilization, and with ERP to set budgetary requirements and enable decisions on expenditure.
[0131] The Planning Engine can manage networks on a green-field or brown-field basis, and the ongoing evolution of those networks.
[0132] Planning Engine Process: Objects are planned in the Planning Engine at abstract level, for example introduction of locations, or circuits between locations. These abstract objects are managed according to the map stored in the Capability Plan. The Planning Engine is master of these abstract objects for capacity/capability affecting changes, and their introduction to/removal from the network. The utilization of these objects is synchronized with an underlying inventory and held on each object.
[0133] The planning cycle is illustrated in simple terms in FIG. 5 .
[0134] Initially, utilization data is populated in the Planning Engine from Resource Planning ( 1 ). The utilization data on an object records utilization over time. The utilization information is updated by marketing forecasts ( 3 ), and is used to drive network demand inputs. Marketing forecasts are improved by feeding back service utilization trending data ( 2 ).
[0135] The service demands are then mapped onto underlying domains using a map of location-based capability—the Capability Plan ( 4 ).
[0136] The network evolution is then planned ( 5 ), for each domain and its capacity requirements. The planning system can be validated against the underlying inventory data, and exceptions raised to the user.
[0137] The deltas (i.e. differences) to the abstract network are captured as planning requests. A manual checkpoint and dialogue to ERP systems ( 6 ) for budgetary level validation may follow, before the request is passed down to the Resource Planning system for detailed design ( 7 ).
[0138] The loop with Resource Planning is closed when the utilization data is passed back to Planning Engine ( 8 ). A synchronization capability is provided between Planning Engine and underlying Resource Planning to flag any exceptions to this process (V).
[0139] Initial dataload of the Planning Engine is possible from the Resource Planning system over the same interface, or manually within the Planning Engine.
[0140] Use of the Planning Engine: The Planning Engine can facilitate the planning of the future evolution of the network taking input from current network utilization and capacity usage, the projected future network demand and the operator's forward looking technology strategy. The key objective is to facilitate ongoing network capacity and capability management, e.g. adjusting the network to make sure that enough capacity will be available to accommodate the forecasted demand and expected network load.
[0141] Typical use cases include:
Network extension Network capacity and capability expansion in response to projected future traffic growth, evaluation of alternative network structure and architecture evolution options. Network consolidation Consolidation of the network based on re-routing optimization aimed at optimizing network utilization, consolidating fragmented service routing and improving network performance. Network migration Support for the introduction of new technologies
[0148] The Planning Engine applies across all network domains with the objective of determining required changes to the current structure and what additional capacity and capability within the individual domains will be needed in order to support the projected demands. In general, the main use case is the non-greenfield situation, since an existing network (with already installed and partially used network resources) typically needs to be taken into account.
[0149] The usage of the Planning Engine is characterized by the following fundamental guidelines:
[0150] Network planning is performed against an abstract network model: Network evolution planning is typically carried out on an abstracted view of the network represented in the logical network inventory (e.g. master inventory 14 ). Abstraction is mainly driven by data aggregation (e.g. bulk object model, collapse) and simplifications. The level of abstraction may vary and depends on the type of use case and application scenario (for example: bulk capacity estimation vs. fine-grained capacity adjustment).
[0151] Network planning is organized according to planning domains: In general, the planning process is organized in a step-by-step fashion and performed against distinct planning domains. These planning domains represent an appropriate partitioning of the overall network, which reflects the different network segments involved in delivering a certain type of service. Each planning domain is characterized by a certain technology (for example ATM, GEthernet, MPLS).
[0152] A typical planning domain topology is characterized by a partitioning of the network into a converged packet core and geographically separated backhaul aggregation domains with gateway and service enabling functions at metro nodes.
[0153] FIG. 6 illustrates a typical network planning scenario focused on network capacity extension and indicates potential design steps. In this example the backhaul aggregation segment might be based on ATM technology facilitated by an underlying SDH/SONET transport infrastructure while the packet core network is based on IP/MPLS.
[0154] An architectural principle of the solution is to provide a flexible, configurable framework for the Planning Engine. This framework is preferably extensible and comprehensive.
[0155] The example is based on a number of assumptions:
For the sake of cross-domain coverage, the Planning Engine operates on a more abstract representation of the network than the inventory does (e.g. by aggregation of circuits into bundles and neglecting time slot assignment) Planning requirements cover both abstract capabilities for automation and strategic decision-making, and for detailed network design. Planning results in terms of new equipment build are expressed in terms of (frequently used) building blocks for network elements (so-called standard builds). Detailed configuration choices should preferably be made in detailed resource planning, but could also be incorporated into the Planning Engine. The traditional focus of network planning is strategic. It was undertaken occasionally, with target network design driven by mathematical optimization (primarily operating on a minimum cost metric). The approach proposed herein considers network planning as a continuous process. It frees the user from the majority of repeated planning tasks. It improves the significance of the results by starting from a more recent view of the network (from the inventory).
[0160] Differentiators: This section describes aspects where the present approach for planning is different from existing approaches.
[0161] Planning Integrated with Inventory: Traditionally, network planning is performed offline. The gap in functionality and data between the NMS and the planning applications is too wide for simple upload interfaces. Mediation to the various NMSs and an additional consolidation function are too expensive.
[0162] Additionally, driving an offline planning system from out of date snapshots of the network increases the risk of failure.
[0163] The present solution for planning uses the inventory functions (in particular the master inventory 14 as shown in FIG. 1 ), to keep the data accurate and enabling an effective network engineering process.
[0164] From Once-only Design to Repeatable Processes: Traditionally, network planning is performed on a network-snapshot, with optimization determining near-simultaneous, one-off, local optimizations in order to achieve an approximate global cost minimum for the network captured in the snapshot. The lifecycle of planning consisted of a sequence of usually un-correlated snapshots.
[0165] The present solution can support a repeatable planning process, both in a periodic and perpetual manner. In particular, planning decisions can be stored, re-used in repetition runs and can be open for re-evaluation.
[0166] Each planning proposal typically requires many atomic decisions, each of which is usually a selection of a very limited number of options (e.g. should there be a direct link on layer x between location A and B?). The present solution builds an audit trail of decisions, and allows rollback of these decisions and capture of processes as templates.
[0167] In that respect, the Planning Engine preferably also stores a repository of planning decisions, whose re-use is enabled via process templates.
[0168] Capability in Complement to Capacity: Traditionally, network planning focuses on network capacity, i.e. the objective is to determine the necessary capacity within and between locations, on a per domain basis. The objective of planning was to determine a (cost-) minimized network i.e. an appropriate network topology and associated capacities (on a per layer basis). ‘Cost of capacity’ was the driving force.
[0169] The present solution for planning preferably combines network ‘capabilities’ (such as voice call features in the call servers) with network capacity and QoS-related network metrics. This implies a cost model which can contain cost items that are not capacity-related at all.
[0170] From Domain-specific to Cross-domain Optimization: Traditionally, network planning follows a sequential process, optimizing the overall network in a sequential layer-by-layer process.
[0171] From a pure capacity perspective, this de-composition approach can work. However, as a single end-to-end service now travels across various stacks of network technology, the present approach preferably supports:
a cross-domain cost model allowing comparison of different solutions end-to-end and cross-domain resilience analysis function
[0174] Optimizing networks in a cross-domain sense can be a complex task. A two-step approach can help:
a cross-domain metric (in terms of both end-to-end cost and end-to-end QoS/resilience quantifiers) can be used; such a metric can allow for comparing different options and provide a framework for ‘simple’, rule-based planning procedures on top of the cross-domain metric, ‘true’ cross-domain optimization procedures could be built, which attempt to propose the appropriate distribution of network capabilities and capacities across network domains
[0177] Many COTS products for planning are dedicated to a subset of network types e.g. mobile wireless or fixed wireline. Consolidation of historically grown networks onto converged platforms will typically result in a mix-and-match of network technology stacks.
[0178] The present solution for planning is preferably configurable in terms of the network technology stack it can support.
[0179] Solution Architecture: The proposed Planning Engine solution comprises a set of interacting solution components. Each of these components accesses data in a common repository and provides a consistent interface through APIs, the Process Engine and through the GUI. The solution components are illustrated in FIG. 7 .
[0180] The solution architecture is conceptually split into three tiers as shown in FIG. 7 . There is a data tier, an application tier and an interfacing tier. Within these tiers, there are a number of major blocks and sub-components. These are listed below:
[0181] Demand Forecast Analysis—this comprises demand forecasts due to Network utilization and Market forecasting, and the amalgamation of these demands into a common framework of service demand matrices in Network service forecast.
[0182] Domain Demand Mapping—this maps the service demand onto each domain.
[0183] Network Domain Planning—Equipment Mapping resolves the demand on a domain onto the supporting network resources, without the need for the detailed equipment models found in Resource Planning. Management of the topology of the network is undertaken in Structure planning. Comparison with current utilization data in the data repository leads to delta capacity plans, managed in Capacity planning.
[0184] Network Data Repository—comprises the data supporting planning. The Data Store comprises the network data on which planning takes place at the level of abstraction required for planning purposes. The Capability Plan describes the strategic intent in terms of location and technology capability and domains. It provides a simple yet comprehensive way of modelling, at a summary level, a large-scale telecommunications network. This allows the strategic network planners to decide the strategic intent of the network and its exploitation policy at the outset of network design. It then directs the ongoing plan of the network to be constructed in accordance with these rules. These rules are derived from a common network strategy, which also determines how the network is utilized. They are captured as data and are applied either as network is constructed automatically or manually.
[0185] Historically, it has not been possible to adopt a bottom-up approach to summarizing network models based upon ITU-T G.805 and TMF 513/608/814. This bottom-up approach has struggled because of a lack of abstraction, so attempts have tended to focus on solutions that preserve the greatest amount of information.
[0186] The Capability Plan uses a top-down approach, taking into account the operational (or business) and technical requirements, which are validated as supporting the needs of the network resource operator and Service Provisioning architecture. The absence of detail in the model means that it does not need to be permanently synchronized with the Resource Planning system, providing a level of decoupling that benefits the overall architecture.
[0187] Network Construction kit—this describes the rules by which the data in the store is constructed, and is composed of three sub-component libraries: Domain library, Equipment library and Capability Model.
[0188] Process Support—comprises Scenario Management which describes the rules by which planned scenarios are managed within a time-line, Collaborative framework which manages user access and responsibility, Planning Records and Rollback which captures changes and enables rollback, and Process Engine which can be used to capture processes with automatic and manual intervention.
[0189] Network Analysis—comprises Network Validation which provides the capability to analyze network designs with respect to their compliance to the intended planning rules, Failure Simulation which provides the capability to analyze and verify the current network or a proposed network design for the extent of network failures, Demand Sensitivity which provides a sensitivity analysis of network forecasts based on variations in service forecasts from marketing or network utilization, and Network Cost Model which provides a framework for describing a network and its sub-items in terms of ‘cost’. The network cost model allows for assigning cost to both capacity and capability related network items. It supports cost items of both capital and operational expenditure. It thus can deliver expenditure data for profit/loss related calculations as well as for cash flow/investment related calculations.
[0190] The cost model delivers both
cost figures, i.e. a list of all cost items associated with a single network object and aggregate cost figures, i.e. it sums up cost of certain categories (‘all capital expenditure for equipment of type Edge, Metro and Core’)
[0193] In addition, it works as a server to fill cost attribute values for all sorts of algorithms (routing, topology optimisation).
[0194] Cost information is generally owned across systems, at differing levels of granularity and for differing purposes. The cost model used internally for making planning decisions is based on real world costs assigned to equipment and capacity. Asset management systems or ERP systems can manage such costs, which implies that the Planning Engine can preferably liaise with these systems to build and maintain its cost model. Cost information maintenance may be manual.
[0195] Interfaces—comprises GUI which defines a user interface to facilitate user interaction, API which defines a comprehensive application programmable interface for undertaking all planning activities, a Marketing interface that supports reports on actual service utilization trends to aid marketing forecasts, an ERP interface that supports the publishing of proposed plans for budgetary approval, a Business Object Universe for extra reporting requirements, an Export Adapter to allow scheduled, scoped export of data to external systems and Inventory Interface which defines an interface to enable the utilisation of inventory data and a coupled process between planning and inventory. This two-way interface comprises extraction from the inventory for data population and validation, and a publish plan capability to the inventory.
[0196] The above sets out the structure of the Planning Engine in overview in terms of constituent components and their functions. Some aspects of the Capability Plan component and interface components will now be described in more detail.
[0197] Capability Plan: The removal of capacity management responsibility from the Capability Plan can help to create a summary model of the network. Without capacity to consider, detailed logical and physical information can be omitted.
[0198] The Network Capability Plan can be modeled using six basic objects:
Network Domains Area Locations Physical Capabilities Site Locations Technology Capabilities Logical Capabilities
[0205] Each object type can be sub-typed so that a particular Capability Plan can be adapted to address specific technologies or provide an appropriate level of granularity. This is achieved in the Capability Model. For example, specialist Technology Capabilities (and Logical Capabilities) are normally created for MPLS, Ethernet, and so on. However, it is possible to go further and create network roles, such as backbone and access within the Technology Capabilities if required.
[0206] FIG. 8 shows schematically how they might be related in a particular implementation of a Capability Plan. The following sections define the function of each element in the Capability Plan.
[0207] Network Domain: Planning Domains group together locations of like purpose. These represent a flexible method of splitting the network into functional blocks. For example, Access domain, backhaul domain and core domain are useful splits of a next-generation network (an example of this is illustrated in FIG. 9 ).
[0208] The domain is then used as a method of dynamically classifying locations.
[0209] Area Location: This represents an administrative arrangement of other Area Locations and Site Locations. An important concept associated with an Area Location is that all Logical Capabilities (see below) that exist at Site Locations within Area Locations can be connected without recourse to outside agencies. This delegation of responsibility to local field engineering enables the Capability Plan to summarize its model further because local physical connectivity between technical domains can be omitted from the model.
[0210] Therefore, an Area Location has a single operational owner from a physical planning perspective. Area Locations may be hierarchical so that complex physical and organizational structures can be represented.
[0211] Site Location: A Site Location is a place where equipment can be located. However, as no actual equipment is referenced in the Capability Plan, this concept has some flexibility. It may be a central (CO), a point of presence (POP) or a customer location. A site location usually represents an equipment room, not necessarily a site.
[0212] Interconnections within a location can be assumed or can be explicitly captured between abstract devices. Non-connectable connectable floors can be captured by explicitly excluding such interconnections.
[0213] A Site Location may contain a number of Technology Capabilities.
[0214] Physical Capabilities: This represents the high level or strategic view of the location. It includes the routes between Area Locations, which is a technology independent indication of the potential physical connectability of Area Locations. It is similar in concept to strategic cables or ducts.
[0215] It also includes an aggregated record of the space, power and cooling that is present at the location and is available for use by new network facilities. This gives the planner a good indication of what capability can be deployed at a location and the extent it can be used for strategic growth.
[0216] Technology Capability: This is an abstracted view of technology that is present or that is strategically available at a Site Location, and represents the capability of the network.
[0217] Note: The presence of a Technology Capability does not imply the presence of equipment or capacity. It implies that the location can be used to site equipment with a particular capability.
[0218] Logical Capability: Technology Capabilities are connected by Logical Capabilities. They are logical pathways in the network. They represent the aggregate of all connections that join things together and record the total capacity provided by the aggregated Technology Capabilities and the capacity available for new service.
[0219] In overview, the Capability Plan can provide the following functions & capabilities:
Provide an abstract framework for the global optimization of network planning decisions.
Identifying placement of node/locations and their role within the network architecture Identify capabilities available at each node/location (‘capability map’) Identify the high-level network architecture and structure in terms of partitioning the network into geographic areas (domains, sub-networks), for example Access area, Backhaul aggregation area and IP/MPLS backbone area
Apply the network exploitation policy decided upon during strategic network design when planning network evolution. Enable existing network configurations to influence future network build decisions in order to minimize operational and capital expenditure. Minimize the data and processing overhead required to maintain the model.
[0227] Capability Model: The Capability Model comprises the rules by which the Capability Plan is constructed.
[0228] These rules are captured as metadata and are applied as the Capability Plan is constructed automatically or manually. For example, location types can be defined in metadata, with the associated allowed capability types. The Capability Plan will then construct data instances of locations of a given type, with capabilities as permitted.
[0229] The effect of these metadata restrictions may be configurable. For example, certain rules may be mandatory, others are recommendations with warning levels. This will allow the user to knowingly build local instances that do not follow the intent of the capability plan. The Network Validation component provides functionality to report on deviations from the capability model.
[0230] The rules can be grouped into the following types, which define the policy decisions to be captured:
Domain classifications—Define the available domain types, such as Access, Backhaul, Core. Site classifications—Define functional classes for locations such as Access Node, Metro, Core, Service Technology classifications—Functional classes for devices and circuits based on the supported technology. Data restrictions based on data type, domain, site and technology classification—For example, device types, standard builds, circuit types can then be associated with these classifications. e.g. a MarconiSmallMetro location type is a Metro class site. MPLS circuits can only terminate on MPLS devices (technology classification) at Core or Metro sites (site classification). Connection cardinality between sites—based on the site classes and connection types (e.g. Metro sites are dual-homed to Core sites). Connection ordinality of sites—determining the containment hierarchy, e.g. Metro Node site also implies an Access Node capability. Service type/Domain mapping—allowed service types for a domain
[0238] Some details of the interface components are set out below.
[0239] GUI: The Planning function preferably provides a complete GUI implementation to facilitate user interaction. Users can preferably browse data, manage planning objects, report on plans and planned network and manage the planning cycle. Low and high level planning functions are supported in a controlled manner via wizards.
[0240] Each solution component is preferably delivered by using a coherent set of one or more GUI Tools, e.g. wizards to create data items and interactive, navigable reports on the data. The specific types of tools will vary for each solution component.
[0241] The following functions and capabilities are preferably provided by the Planning Engine GUI.
Look and Feel should preferably be suitable for use by planning operatives who are not necessarily computer experts. Architecture
The architecture allows flexible creation and manipulation of the user interface A full Web client is preferably provided, compatible with Microsoft Internet Explorer (TM) or other available web browsers
Integration
Flexible full web access is preferably available to all applications
[0248] Export Adapter: A packaged capability may be provided to allow export of data from the Planning Engine.
[0249] The scope of data is preferably configurable, and the export preferably has a scheduler for initiation.
[0250] API: A comprehensive API is preferably provided for undertaking all planning activities. The wizards within the Planning application also make use of these APIs. These APIs exist at each logical layer of the application, providing flexibility in terms of automation (lower level API calls) and integration (coarse-grain service-based interfaces).
[0251] The API preferably includes the following functions and capabilities:
Low level API for writing to data tables. Higher level EJBs for methods on the data Web Services for external interfaces XML-based coarse grain interfaces Maintains a log of API calls Maintains a log of exceptions
[0258] Inventory Interface: One feature of the proposed Planning Engine is the ability to utilize inventory data and provide a coupled process between planning and inventory.
[0259] The interface between planning and inventory is a two-way interface with three modes of interaction:
Data population: Planning retrieves data from the inventory to populate its data repository with initial data and thenceforth with ongoing utilization data Data validation: Planning retrieves data from the inventory to validate the state of its repository (especially before issuing a planning request) Publish Planning Request: Planning initiates requests, updates and cancellations of planned network alteration
[0263] These three modes may be further classified as an Import/Validate Strand, and a Planning Request Strand.
[0264] This is shown in FIG. 10 , which illustrates the planning/inventory interface.
[0265] The Export/Validate strand is initiated in the Planning Engine to retrieve data from the inventory. This may be either for an initial (or new) load of data, or for a targeted validation of a portion of network on which a scenario has been constructed. This data extraction is preferably MTOSI compliant.
[0266] The data is abstracted using transformation and aggregation. This abstraction is as specified below:
[0000] Sites/devices:
[0000]
Port data is aggregated by type
Device structure is not passed at all
Circuits:
Circuit timeslots and timeslot mappings are not held
Circuits may be aggregated into n×bandwidth connections between locations, or individual connections between locations.
No customer circuits are passed over the interface, just utilization.
[0272] Planning may require common terms of reference for the data passed over the interface. This is achieved by a mapping between the systems that is not necessarily 1-to-1 due to the data abstraction.
[0273] The Plan strand is to initiate new build requests, updates and cancellations from Planning, and accept Plan status updates from Design. These requests take the form of requests for:
Site capacity (number of terminations by type, standard build) Link capacity A to Z (technology, CoS, protection), with underlying node-to-node routing Topology structures (device/circuit mesh)
[0277] Some functions and capabilities of the Inventory Interface component are set out below (these may be provided independently or in any combination):
[0278] Import/Validate Strand
Data retrieval The inventory provides an export capability of data to Planning, on demand. The exports will be either a complete record of the relevant data objects, or the ‘deltas’ since a defined time. The delta export is a record of those objects to have changed since a specified date. Create deltas and Update deltas are defined as those objects to have changed since the specified time (i.e. not a record of the change, but a record of the object following the change). Delete deltas are a set of deletion actions (or state changes to ‘pending delete’), with associated object ID. Exports are scoped according to:
Object type (sites, circuits, topologies). Modified flag (for delta exports) Object status (e.g. do not include ‘Planned’ objects, do include ‘Pending’ or ‘In Service’).
The data export is preferably configurable and flexible. The data export preferably accepts scoped requests for data. The data request is initiated from Planning, and may be scoped down to a subset of data (to support the validation for a specific scenario). The data export preferably adheres to the MTOSI standard. The data from the inventory source is aggregated into abstracted forms for planning, i.e. aggregation transforms are applied. The import into planning populates the data repository with a new data version. Errors during load are captured and displayed The load process supports an abort, should the errors be considered too serious Planning supports validation checks of the new data, once the load data is successfully stored in the data repository. Validation includes referential integrity checks, attribute checks and simple network connectivity checks. The existing plan scenarios may be migrated onto the new data view The Planning system supports the deletion of the old data version, once obsolete.
[0295] Plan Strand
[0296] Planning Request
The Planning Engine supports the construction and passing of a Planning Request to the inventory/Resource Planner, manually initiated or via API. A Planning request supports the following types:
Build Site: a description of a site requirement (standard build type, number of ports of type) Build Capacity: a description of a (circuit) capacity requirement, CoS, Protection, and the underlying abstract routing through the network Build topology
Resource Planning handles Planning Requests. On receipt of the build plan message, the underlying Resource Planning will generate an Order object corresponding to the plan. In addition to the order object, a project will be created per top level element (n×Location, or n×Circuit). A default project type is preferably supplied for each of these:
Build Plan—Location Build Plan—Capacity Build Plan—Topology Reroute:—circuit ids
Planning Request Update
The Planning Engine supports the construction and passing of a Planning Request update to the inventory, manually initiated or via API. A Planning request update supports the same types as a Planning Request A textual ‘Reason’ may be sent with the update Cancel and submitting a new Plan may be used for any substantive update
Planning Request Cancellation
The Planning Engine supports the cancellation of a Planning Request (manually initiated or via API), and sending a cancellation to the inventory. A textual ‘Reason’ may be sent with the cancellation
Plan Status Update Event
The Inventory may be configured to support a status update message of ‘Abandoned’ or ‘Completed’ The Planning system supports the receipt of the Status Update Event and logs it on the Plan.
The above functions may use the following data items:
Site: a description of a site requirement (standard build type, number of ports of type) Circuit: a description of a (circuit) capacity requirement, COS, Protection, and the underlying abstract routing through the network Topology
[0318] ERP Interface: Plans for network enhancements or changes can have significant impact on Network Engineering budgets within a telecommunications service provider/network operator. Planning decisions are therefore preferably visible to ERP systems. Furthermore, many network operators have a checkpoint in ERP with a go/no-go decision point for any major plans.
[0319] The level of detail held in the Planning Engine is typically insufficient to supply a full bill of materials to ERP. For this level of detail, Resource Planning may be a better source of data. The Planning Engine preferably does hold high level costing data, and can approximate the timing and cost of adding new capability at a location. This can typically be useful for setting budgets for the year ahead etc., rather than for proceeding with a specific equipment order.
[0320] To support these business functions, the Planning Engine preferably supplies plan data for new build, and at least supplies a holding state for plans in the Planning engine, awaiting a go/no-go decision. Optionally, this interface can be automated.
[0321] The following data items may be used by this component:
Approximate equipment costings based on location/node/port costs. Pending state for Plans
[0324] Marketing Interface: An external Marketing function may supply market demographic data, or product and network service forecast data into the Planning Engine's Demand Forecast Analysis components.
[0325] As marketing forecasts are often distrusted within the telecommunications community, the Planning Engine can also supply data on Service Utilization trending back to Marketing. This information can provide an effective feedback mechanism which can enable forecasting to be improved.
[0326] The interface for Marketing data import into the Planning Engine is via file import. The file format is XML, according to a predefined schema.
[0327] The interface from the Planning Engine to Marketing may be a report of Service Utilization trending, made available to the external system.
[0328] Some functions and capabilities of this component are set out below:
The Planning Engine supports the publishing of Service Utilization Trending data to marketing
The data is preferably formatted and human readable, as a report
The Planning Engine preferably supports at least file-based import of market demographic data or product and network service forecast data
The data format may be XML
[0333] The above describes features of an example implementation of the network planning module 10 . However, the network planning module can be implemented in a variety of different ways.
[0334] More generally, it will be understood that the present invention has been described above purely by way of example, and modification of detail can be made within the scope of the invention.
[0335] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims. | A method of performing network modification in a telecommunications network is disclosed. The method comprises storing a database comprising a master inventory defining network resources available in the network. A network modification is performed by a process comprising modifying the database storing the master inventory; and modifying the network in dependence on the modified database. The method can be used in the management of telecommunications systems. A network planning method is also disclosed. | 7 |
RELATED APPLICATION
This application claims priority to U.S. provisional patent application serial number 60/132,783 entitled GAITER-SOCK COMBINATION, and filed on May 6, 1999.
BACKGROUND
1. The Field of the Invention
This invention relates to socks and gaiters and, more particularly, to socks and gaiters that are used as barriers for protection of the lower extremities, boots (shoes), socks, or any combination of these.
2. The Background Art
Sandals, socks, and pants were invented to warm and protect humans' lower extremities. When these proved inadequate at times, others invented and improved the shoe and boot. But anyone who walks very far off paved roads soon discovers these protectors still have their shortcomings. Thorns and thistles penetrate or lodge in the socks and the boot (shoe) linings. Rocks and other debris slip in between the boot (shoe) and sock to discomfort. Insects and arachnids such as spiders and ticks crawl up the sock to bite the exposed skin and perhaps infect. Plant toxins like poison ivy can still afflict the legs of the wearer of socks and boots (shoes). Snow and water soak socks and the inside of boots (shoes), even when the boot (shoe) exteriors are waterproofed.
Attempts to overcome the deficiencies of pants, socks, and boots (shoes) as barrier protectors led to the development of a class of inventions commonly called gaiters. A dictionary describes gaiters in part as “cloth or leather leg coverings reaching from the instep to above the ankle.” Another dictionary describes a gaiter in part as “an outer covering of the leg below the knee or for the ankle, made usually of cloth or leather, for outdoor use.” A functional gaiter, as opposed to a decorative gaiter, serves in some way beyond the boot (shoe) or sock or pant legs as additional barrier protection for the lower extremity. Gaiters help prevent inconveniences and discomforts like thistles, burrs or the like in the sock, or stones in the shoe or boot. More importantly, good gaiter designs can protect the lower extremities from trauma, bug bites, infections, plant toxins, cold, snow, and water.
A review of the U.S. patents issued, hiking and walking gear offered for sale in the USA, and the long memories of a number of older, experienced hikers demonstrate that previous gaiters have a few common elements. Typically, gaiter attachments have been cumbersome and time consuming to use. The more effective barrier protection gaiter inventions have been large, heavy, hot, expensive, and therefore used sparingly. Prior simple gaiter inventions are difficult to attach adequately, stay in place poorly, and commonly break down as effective barrier protection.
“The extendible boot” disclosed in U.S. Pat. No. 4,586,271 to Maleyko, et al, issued May 6, 1986, requires the purchaser to choose that model only for protection and hence cannot be used universally with other boots. Brown's “Shoe with integral storable gaiter,” U.S. Pat. No. 5,642,573, issued Jul. 1, 1997 also has the limitation of not being usable as a gaiter with any other boot. Chen discloses a “fastening means to secure a gaiter to a shoe” (U.S. Pat. No. 5,491,911, issued Feb. 20, 1996). It will only fit shoes “having a pair of studs integrally formed at the rear” of the shoe. Again, this is a complex and non-universal (any shoe) design. A “Shoe covering and gaiter,” U.S. Pat. No. 3,477,147, issued to Bauer on Nov. 11, 1969, discloses a very complex, apparently heavy gaiter that attaches to the shoe. Datson's “Shoe and gaiter,” U.S. Pat. No. 4,856,207, issued Aug. 15, 1989, requires the gaiter to be “permanently affixed” to the boot. Fugere, et al, has several similar patents (U.S. Pat. No. 4,001,953, issued Jan. 11, 1997 and 4,035,860, issued Jul. 19, 1997), in which each includes “an energy-absorbing pad.” The description suggests substantial weight for protection from substantial trauma. Both inventions require the gaiter to be worn over the instep.
Johnson discloses an “insulated boot and gaiter combination” (U.S. Pat. No. 4,896,437, issued Jan. 30, 1990). This requires a special “gaiter” which attaches to a special “boot”. With at least two layers on the gaiter, three snaps, one zipper, one drawstring, one clip, one elastic strap, one other strap, and hook-and-loop fasteners, it is hardly simple or convenient
Other devices such as Winer's (U.S. Pat. No. 4,665,562, issued May 19, 1987) describe fairly typical gaiters with various ways of fastening the gaiter around the lower extremity. Again these designs in general are elaborate, heavy, and warm.
Calabrese discloses an “ankle gaiter with boot stirrup” (U.S. Pat. No. 4,393,522, issued Jul. 19, 1983). This has a “band” around the ankle and a “stirrup” over the instep. It holds “the bottom trousers or pant legs in place to allow for ease of insertion in a sock.” It obviously would have difficulty containing any but very long pant legs. The “stirrup” proves a nuisance and debris can still get into the boot.
In U.S. Pat. No. 3,633,290, issued Jan. 11, 1985, Rubeling discloses his “Snow blocks.” Like other extant designs, it is simply a “tube” or cuff that wraps around the junction of a boot top and a “trouser”. These unattached designs do not stay in place well.
The “double sock construction” of Guigley (U.S. Pat. No. 4,373,215, issued Jul. 15, 1983) has nothing to do with gaiter protection, and merely makes the inner sock shorter to prevent “bunching of the toe of the double sock.” Pacanowsky discloses a “waterproof breathable sock” (U.S. Pat. No. 4,809,447, issued Mar. 7, 1989), taking waterproof breathable material technology and applying it to socks. His design can keep the foot dry, but not the inner lining of the boot. Also, debris can still get into the boot, and bugs can enter the pant leg. Willard did a spinoff on the foregoing sock. He created a “waterproof oversock” (U.S. Pat. No. 5,325,541, issued Jul. 5, 1994) to be worn over the wearer's choice of under socks. It has the same inherent limitations of the previous sock invention.
Holder discloses a “boot sock with stay-up cuff and method” (U.S. Pat. No. 4,034,580, issued Jul. 12, 1977), described as an “integrally knit” design to allow one portion to extend upward around the leg. The patent states that the sock only “covers the upper edge of the boot”. But since boot heights vary greatly, the inventor acknowledged having to make socks with the cuffs at different levels in order to be useful at all. This design does not extend down and cover the sides of the boot. Between the design specifications of “knit” material and not covering the side of the boot, this design doesn't protect against bugs, snow, water, or thistles, and the sock could easily dislodge enough for debris to enter between the sock and boot.
Baptista et al (U.S. Pat. No. 4,542,597, issued Sep. 24, 1985) for a “snow shield foot and leg insulator” discloses an “inner cloth tube for engagement with a foot and leg and an outer cloth tube.” He specifies that the “said inner cloth tube is made of 100% nylon shell having a core of 100% polyester filler”, a bulky wrapping indeed, for the confines of a foot within the body of a boot. Since he claims the “inner cloth tube is for engagement with a foot and a leg”, there is an inferior opening on the tube, which inferiorly exposes the end of the foot, or the foot per se, to the boot itself, unless a sock is worn under the “tube”. The tube can potentially creep up the ankle, as there is no cap or closed end to prevent such upward migration. Further, this invention as its name implies (“snow shield foot and leg insulator”) is limited to cold and/or snow conditions, and would be most uncomfortable with its four layers (sock, insulated inner tube, boot and outer tube) in hotter climates. The inventors consistently refer to the portion which covers the foot and leg as a “tube” and the illustration shows only a “tube”.
Judging by the continued application for patents, and patents issued for gaiters, there has been a perceived need for improvements. The ideal invention would be simple, effective, easy to use, lightweight, versatile, inexpensive, and dependable as a barrier protection. Such an invention should conceivably encourage far more gaiter use and hence, more and better protection for the lower extremities of humans.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to provide an improved gaiter integrated or readily integrable with a sock for several advantageous results.
Principal objects and advantages of the gaiter sock invention include being simple, stable, quick and easy to use, small, lightweight, and relatively inexpensive, effective barrier protection. In some embodiments, other objects and advantages include being cooler and more breathable than other presently available inventions, while still allowing other embodiments for warmth. In its various embodiments, the common objects and advantages of the gaiter sock invention are barrier protection against a wide variety of harmful or annoying agents. These include snow, water, rocks, sand, dirt, thistles, plant toxins, insecta, arachnida, and infectious agents, etc. Further objects and advantages of the gaiter sock invention will become apparent from a consideration of the drawings and ensuing description, attention being called to the fact that the drawings are illustrative only, and that changes may be made in the specific constructions illustrated.
Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, an apparatus and method are disclosed, in suitable detail to enable one of ordinary skill in the art to make and use the invention. In certain embodiments an apparatus and method in accordance with the present invention may include a sock, a gaiter secured thereto, and constrictions for.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1A is a perspective view one embodiment of the gaiter-sock combination;
FIG. 1B is a perspective view of the apparatus of FIG. 1A as it appears when worn appropriately with a boot, in one embodiment;
FIG. 1C is a perspective view of the apparatus of FIG. 1A as it appears when worn appropriately with a boot, in an alternative embodiment;
FIG. 1D is a cross-sectional view of the apparatus of FIG. 1B where the gaiter member and the sock member of the invention are primarily attached together;
FIG. 1E is a cross-sectional view of the apparatus of FIG. 1C where the gaiter member and the sock member are primarily attached together;
FIG. 2A is a perspective view of another embodiment of an apparatus in accordance with the invention;
FIG. 2B is a perspective view of the apparatus of FIG. 2A as it appears when worn appropriately with a boot;
FIG. 2C is a cross-sectional view of the apparatus of FIG. 2B, where the gaiter member and the sock member are primarily attached together;
FIG. 3A is a perspective view of another embodiment of an apparatus in accordance with the invention;
FIG. 3B is a perspective view of the apparatus of FIG. 3A as it appears when worn appropriately with a boot;
FIG. 3C is a cross-section view of the apparatus of FIG. 3B, where the gaiter member and the sock member of the invention are primarily attached together;
FIG. 4A is a perspective view of another embodiment of an apparatus in accordance with the invention;
FIG. 4B is a perspective view of the apparatus of FIG. 4A as it appears when worn appropriately with a boot;
FIG. 4C is a cross-sectional view of the apparatus of FIG. 4B, where the gaiter member and the sock member are primarily attached together;
FIG. 5A is a perspective view of an alternative embodiment of a gaiter sock combination;
FIG. 5B is a perspective view of the apparatus of FIG. 5A as it appears when worn appropriately with a boot;
FIG. 5C is a cross-sectional view of the embodiment of FIG. 5B where the gaiter member and the sock member of the invention are primarily attached together;
FIG. 6A is a perspective view of another alternative embodiment of an apparatus in accordance with the invention;
FIG. 6B is a perspective view of the apparatus of FIG. 6A as it appears when worn appropriately with a boot; and
FIG. 6C is a cross-sectional view of the apparatus of FIG. 6B where the gaiter member and the sock member of the invention are primarily attached together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in FIGS. 1A through 5C, is not intended to limit the scope of the invention. The scope of the invention is as broad as claimed herein. The illustrations are merely representative of certain, presently preferred embodiments of the invention. Those presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
Those of ordinary skill in the art will, of course, appreciate that various modifications to the details of the Figures may easily be made without departing from the essential characteristics of the invention. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain presently preferred embodiments consistent with the invention as claimed.
A gaiter sock synthesizes sock design with gaiter design to create a new form of barrier protection for a lower body extremity, boot (shoe), sock, or combination of these.
In FIG. 1A, a sock member 22 may be made of any available sock material such as wool, acrylic, or polyester. A gaiter member 24 can likewise be made of any natural or synthetic clothing material such as nylon or polyester. Gaiter material can be treated to render it waterproof and/or breathable. The gaiter 24 covers and encloses the upper end of the sock 22 . The sock and gaiter members are joined or fastened together at a primary attachment 26 .
There also can be a variable attachment 28 of the gaiter member to the sock member. The method of attachment(s) may be by any method now known or discovered in the future, such as sewing, snaps, hook and loop fasteners, drawstrings, buttons, adhesives, elastics, etc. In order to enclose the boot top, or the leg, or the pant leg bottom, the top and bottom circumferences, or edges, of the gaiters 24 in FIGS. 1A-1E can be designed in various ways. One may use elasticized nylon, hook and loop fasteners, drawstrings, and any other suitable material or method.
FIG. 1B shows an embodiment of a gaiter sock as worn with a boot (shoe) 32 on a lower extremity or leg 30 . The bottom (or inferior) portion of the gaiter 24 covers the upper portion of the boot (shoe) 32 . FIG. 1C shows how, in a variation of this main embodiment, the gaiter 24 not only covers the boot 32 and sock 22 , but can, in its upper portion, also enclose, hold, and cover a lower pant leg 34 . Thus the upper portion of the gaiter 24 can be worn inside or outside the pant leg 34 .
FIG. 1D shows a cross-section of the device of FIG. 1B while FIG. 1E shows a cross-section of the device of FIG. 1 C. Both cross-sections are taken at approximately the level of the top of the boot 32 and the primary attachment 26 of the gaiter and sock members. In FIG. 1D the gaiter 24 top is worn inside the pant leg (not shown). In FIG. 1E, the gaiter 24 top covers and encloses the pant leg 34 . In both cross-sectional views (FIG. 1 D and FIG. 1 E), the lower portion of the gaiter 24 covers the boots 32 .
FIG. 1B illustrates the gaiter sock invention as worn on the foot like a conventional sock. The boot 32 is worn over the lower sock 22 portion, but underneath the lower or inferior gaiter 24 portion. The pant leg (not shown) may be worn over the leg 30 and gaiter 24 . The gaiter member 24 of the invention may be held primarily in place by the attachment 26 of the gaiter to the sock member 22 , but also at the variable attachment 28 . The sock member 22 , in turn, is held in place by the boot 32 . Also, the attachment 26 of the gaiter member 24 to the sock member 22 keeps the sock from creeping down into the boot 32 as they together bridge the boot 32 top and are thus essentially held in place. Cross-sections in FIGS. 1D and 1E illustrate the bridge over the boot 32 top.
FIG. 1C illustrates an embodiment wherein the upper portion of the gaiter 24 is open at the top and hence able to enclose or hold the pant leg 34 . There is only the primary attachment 26 of the sock member 22 to the gaiter member 24 . In other respects, the features illustrated in FIG. 1B and 1C are similar. The embodiment of FIG. 1C completely encloses the lower pant leg, sock and upper boot, giving additional barrier protection against such things as bugs crawling up the leg. No skin of the lower extremity is exposed.
For hotter climates, light and breathable materials may be chosen, like stretch nylon for heat and moisture dissipation. For snowy or wet climates, waterproof breathable coated fabrics for protection from snow and water may be selected. For cold climates, heavier materials may be used. When thistle, burr, or thorn protection is needed, the fabric choice may be one with a dense weave. As clearly demonstrated in the foregoing description, many suitable materials and closure methods may be used in any of the illustrated embodiments to make the gaiter sock most reliable and easy to use. Furthermore, any of the above description and operation applies in general to the remaining descriptions and operations, as listed following.
FIGS. 2A-2C illustrate a second embodiment of the gaiter sock. This embodiment differs from the embodiment shown in FIGS. 1A-1E by the sock member 22 ending some distance below the top of the gaiter member 24 . This embodiment allows a single layer of material to cover the leg 30 above the top of the boot or shoe 32 . In operation, this can provide barrier protection with minimal heat and moisture retention. An example is the use of a very breathable, thin gaiter 24 portion for hot climate use.
FIGS. 3A-3C illustrate a third embodiment of the gaiter sock. This embodiment differs from the embodiment shown in FIGS. 1A-1E by the gaiter member 24 ending just above the boot 32 , while the sock 22 member continues up the leg 30 . In operation, like the second embodiment, this allows a single material layer to cover the leg. So this third embodiment also provides barrier protection with minimal heat and moisture retention.
FIGS. 4A-4C illustrate yet a fourth embodiment of the gaiter sock. This embodiment differs significantly from the main embodiment illustrated in FIGS. 1A-1E. FIG. 4A shows the basic design of a sock 22 within a second sock 22 . The two “socks” are primarily attached together 26 , at a level that will be above the top of the boot or shoe 32 (not shown). When worn with a boot (see FIG. 4 B), the top portion of the outer sock is folded down over the boot, thus forming a “gaiter” 24 .
In operation this embodiment allows the wearer to wear the top of the outer sock as a gaiter (FIG. 4B) in the field, or up on the leg (not shown) as in FIG. 4A, when not needed as barrier protection, thus hiding the gaiter function or appearance. It should be noted here that veteran hikers often wear two socks, an inner liner to wick moisture away from the boot, and to reduce friction, and an outer sock for warmth or ventilation, and/or for cushioning. This embodiment of the gaiter sock allows double layering while adding the advantages of an effective lightweight, simple gaiter.
FIGS. 5A-5C illustrates a fifth embodiment of the gaiter sock invention. This embodiment differs significantly from the embodiment illustrated in FIGS. 1A-1F. FIG. 5A shows a sock 22 appearing like any typical sock on the outside. At a level above the intended boot or shoe height, there is an inner tube or cylinder of material 42 attached to the outer sock 22 at the primary attachment 26 . When worn on the boot (FIG. 5 B), the outer top portion of the gaiter sock is folded down over the boot, thus functioning as a “gaiter” 40 . The inner upper material functions as a sock 42 and a gaiter around the leg 30 . In operation this embodiment, like the second, third, and fourth embodiments, covers the leg 30 with only one layer of the gaiter sock. Again, this allows for good heat and moisture dissipation. Like the fourth embodiment, the “gaiter” 40 portion can be worn up off the shoe and onto the leg for the self conscious wearer, when not in the field, thus hiding its “gaiter” portion.
FIGS. 6A-6C illustrate a sixth embodiment of the gaiter sock invention. This embodiment differs from the main embodiment shown in FIGS. 1A-1E by not having a gaiter portion that covers the boot 32 . Instead, a gaiter member 24 covers only the leg 30 and encloses, holds and covers the pant leg 34 . In operation this embodiment may not prevent debris, etc. from entering the boot but does prevent bugs such as ticks from crawling up the sock onto the leg. It also leave; no portion of thee foot or leg exposed,
From the above discussion, it will be appreciated that the present invention provides a sock member 22 , gaiter member 24 , with a primary attachment 26 of sock 22 and gaiter members 24 . The apparatus may provide variable attachment(s) 28 of sock 22 and gaiter 24 members with respect to a leg 30 , boot or shoe 32 , or pant leg 34 . The primary attachment 26 may or may not coincide with the top 36 of a sock member 22 , or an outer sock 38 . In certain embodiments, upper and outer material 40 functioning as a “gaiter” may be a contiguous and/or continuous portion with upper inner material 42 functioning as a “sock.”
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A combination of a gaiter member ( 24 ) attached ( 26 ) to a sock member ( 22 ) in various embodiments creates a gaiter-sock combination, which simply and efficiently provides barrier protection to a lower body extremity. The gaiter portion ( 24 ) may protect a sock portion ( 22 ), or the inside of a boot or shoe ( 32 ), or various combinations of them, from debris, insects, arachnids, thorns, burrs, and the like. | 0 |
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