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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Patent Application No. PCT/CN2006/000327 with an international filing date of Mar. 6, 2006, designating the United States, now pending, and further claims priority benefits to Chinese Patent Application No. 200520041709.2, filed on May 20, 2005. The contents of the aforementioned specifications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fishing reels, and more particularly to drag brake devices for use in fishing reels.
2. Description of the Related Art
A spool device is a part of a fishing reel. The main purpose of the spool is to store and release the fishing line. While the line winding device turns and winds the fishing line onto the spool neck, the spool device remains still. When the line is released, for example, being pulled by fish, the line winding device keeps still. While the fishing line is let out, the spool is turned by the line and continuously releases the line out. However, the line should not be released without tension. Specifically, it is beneficial to let fish feel certain resistance in order to prevent unhooking. The drag force will also exhaust the fish. However, the resistance cannot be too large; otherwise the line may fail. Accordingly, the spool has to provide an adjustable drag force.
A conventional fishing reel spool device is shown in FIG. 1 . The spool device consists of a brake device 2 , a turning support device, a drag adjust knob 1 , and a main shaft 5 which passes through the spool. The spool device also consists of lid 31 , core 32 and skirt 33 . A concave section of core 32 serves to store the line.
Through central bore, the spool 3 is mounted at the front of the main shaft 5 . The spool is freely rotatable on main shaft 5 . The brake device 2 consists of a drag stack, a drag washer, a keyed washer, an eared washer all of which form multiple brake friction pairs in a cavity located at the front of the core 32 . The drag adjust knob 1 is screwed on the main shaft 5 to form drag adjustable mechanism.
Referring to FIG. 1 , when drag adjust knob 1 is turned clockwise, it is screwed into the main shaft. The more the knob is screwed in, the bigger the force applied through the coil spring to the drag stack will be. The force is converted into a brake torque acting on the drag stack. The brake torque is resisting the spool's 3 turning. While the above parts are utilized, the main shaft 5 remains still. When the knob 1 is screwed out of the main shaft, the spring becomes uncompressed, the drag force becomes zero, and so does the brake torque. The spool 3 is dragged out by fish without difficulty and the line is let out easily. The magnitude of the braking force depends mainly on the rigidity of the spring, the compress displacement of the spring, the material of the drag stacks, the friction coefficient, and the number of brake pairs.
However, a conventional fishing reel spool described above has the following disadvantages:
1) Due to the fact that spool 3 is made in one-piece, the fishing reel spool 3 can usually have only a relatively simple structure. Hence, the material consumption is large and the material cost high.
2) A single spring action limits the magnitude of brake resistance to the spool. The drag adjustable range is also limited.
3) The turning support mechanism, as shown in FIG. 2 , has a cantilever support configuration since it needs to accommodate a cavity for installing a drag stack device. Therefore, the support length L 1 becomes relatively short, and this affects its supporting performance.
4) The spool does not easily accommodate an outlet for water brought in with a wet line; water drains uncontrollably adversely affecting the fishing experience.
SUMMARY OF THE INVENTION
The modularized fishing reel spool of the invention is constructed with the goal of overcoming the above-described problems, i.e., to reduce the material cost, to enlarge the drag adjustable range, to improve the turning support mechanism, and to improve the draining function of fishing reels.
In certain embodiments of the invention, provided is a modularized fishing reel spool comprising a drag adjust knob, a brake device, a spool, a turning support device, and a main shaft.
In a class of this embodiment, the spool is formed by the front lid, the core having a cavity and skirt, which elements are connected to each other by a connecting element or a thread.
In a class of this embodiment, the main shaft has pin, and the front part of the main shaft is threaded. This main shaft is set in the bore on core shaft. The pin is embedded in the key slot on the flange of the core shaft.
In a class of this embodiment, the brake device is disposed in the middle of the cavity of the core and on the core shaft. From the back to the front, there are disposed a big spring, drag stacks, a small spring and a front lip.
In a class of this embodiment, the rigidity of the big spring is larger than the rigidity of the small spring.
In a class of this embodiment, the turning support device 4 comprises the second ball bearing between the skirt and the core shaft, the first ball bearing between the front lid and the front actuator. The turning support device keeps the spool constantly supported as a freely-supported beam.
In a class of this embodiment, the main shaft passes through the core shaft, the brake device and the turning support device; the central thread of the brake adjustable knob screws onto or into the thread of the main shaft; and the adjustable knob presses upon the front actuator.
In a class of this embodiment, the connecting element is a screw.
In a class of this embodiment, the core has more than one elongated water drainer for draining water.
In a class of this embodiment, at the end of the skirt disposed is one or more water drainers and/or through holes.
In a class of this embodiment, spline slots are disposed axially at the concave inside of the core.
In a class of this embodiment, the core shaft comprises a round hole; the shape of the core shaft is a regular polygon, and the back part of the core shaft expands to flanges. A pair of symmetrical flutes is disposed at the connecting area between the back side of the flange and the round hole.
In a class of this embodiment, the drag washer stack is assembled in the following order: (1) the keyed washer; (2) the drag washer, (3) the eared washer, (4) the drag washer, (5) the keyed washer, and so on.
In a class of this embodiment, the central hole of the keyed washer is a spline connected with the core shaft to form a non-rotating link.
In a class of this embodiment, the centre holes of the eared washer and the drag washer are round and the diameters of the holes are larger than the maximum diameter of polygonal section of the core shaft.
In a class of this embodiment, the ears of the eared washer are embedded into the spline slots inside of the core.
In a class of this embodiment, there is shim between the flange and the skirt.
In a class of this embodiment, the back part of the flange comprises a sound ratchet.
In certain embodiments, the reel spool of the invention comprises individually manufactured components such as front lid, core, and skirt. The core can be made from a drawn pipe, and little further machining is required. The skirt and the front lid can be punch pressed or drawn to form their shape with little machining required, therefore the cost is relatively low.
In certain embodiments, the reel spool of the invention comprises a two bearing turning support system. The support system allows for a wider bearing support span compared to conventional solutions. The working condition of the turning support is greatly improved, and it can achieve a higher line releasing speed.
In certain embodiments, the brake mechanism of this invention has a double action spring. It delivers wider and better defined drag adjusting range, and a larger, and smoother braking force than conventional solutions.
In certain embodiments, the reel spool of the invention comprises a water drainage structure on the core and the skirt of the spool. This structure allows for water brought back by wet fishing line to drain out.
In certain embodiments, the reel spool of the invention comprises a core shaft allowing for a simple construction. The core shaft be easily machined and remains in better mechanical condition throughout the lifetime of the reel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of a fishing reel spool of prior art.
FIG. 2 shows a cross-sectional view of a turning support structure for a fishing reel spool of prior art.
FIG. 3 shows a perspective view of a modularized fishing reel spool according to the best mode of the invention.
FIG. 4 shows a cross-sectional view of a modularized fishing reel spool according to the best mode of the invention.
FIG. 5 shows an exploded view of a modularized fishing reel spool according to the best mode of the invention.
FIG. 6 shows a perspective view of the core and skirt according to one embodiment of the invention.
FIG. 7 shows a modularized fishing reel spool according to another embodiment of the invention.
FIG. 8 shows a perspective view of the core shaft of the modularized fishing reel spool according to one embodiment of the invention.
FIG. 9 shows a schematic view of a turning support structure of the spool according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinbelow is a further description of the embodiments of the invention with reference to drawings. The description is meant to be illustrative and not limiting.
FIGS. 4 and 5 illustrate a cross-sectional and an exploded view of a modularized fishing reel spool. The modularized fishing reel spool comprises a drag adjust knob 1 , a brake device 2 , a spool 3 , a turning support device 4 , and a main shaft 5 .
The spool 3 comprises a front lid 31 , a core 32 with a cavity 323 , and a skirt 33 . These parts are interconnected by means of several connecting elements 34 .
A pin 51 is disposed on the main shaft. The front part of the main shaft comprises a thread 55 . The main shaft 5 is fitted in the bore 521 of the core shaft 52 . The pin 51 is embedded in the key slot 525 located at the flange 524 of the core shaft 52 .
The brake device 2 is disposed between the cavity 323 of core 32 and core shaft 52 . It is formed by the following parts, counting from back to front: a large spring 21 , drag washer stacks 22 , a small spring 23 , and a front actuator 24 . The rigidity of the large spring 21 is larger than that of the small spring 23 .
The turning support device comprises a second bearing 42 which sits between the skirt 33 and the flange 523 of core shaft 52 , and a first bearing 41 which sits between the front lid 31 and the front actuator 24 . This structure keeps the spool in constant support as a freely supported beam.
The main shaft 5 passes through the core shaft 52 , the brake device 2 , and the turning support device 4 . Through the central thread of main shaft 5 , the drag adjust knob 1 screws on the thread 55 of the main shaft 5 . The drag adjust knob 1 presses upon the front actuator 24 .
As shown in FIG. 6 , at the outside surface of core 32 , disposed is more than one elongated water drainer 322 . At the end of the skirt 33 , disposed are several water drainers 331 for draining off water. Referring to FIG. 7 , at the end of the skirt, there can be several holes 332 instead of water drainers 331 . There are spline slots 324 on the internal wall of the cavity 323 inside the core 32 .
As shown in FIG. 8 , the core shaft 52 has a bore 521 . The shape of the core shaft 52 is a symmetrical polygon 522 , such as a square or a rectangle. The back part of the core shaft 52 comprises a flange 523 and a flange 524 . There is a pair of symmetrical key slots 525 located at the junction area between the back side of the flange 524 and the bore 521 .
The drag washer stacks 22 comprise a repeating arrangement of a keyed washer 221 , a drag washer 222 , an eared washer 223 , a drag washer 222 , a keyed washer 221 , and so on. The central hole of the keyed washer 221 sits on the symmetrical polygon 522 without rotating with respect to the core shaft 52 . The central holes of the drag washer 222 and the eared washer 223 are round in shape and their diameters are larger than the maximum diameter of the outside section of the core shaft. The ears of the eared washer are embedded into the key slots disposed at the inside diameter of the core 32 .
A shim 54 is disposed between the flange 524 of core shaft 52 and the skirt 33 .
The back part of the flange 524 comprises a sound ratchet 53 .
Compared to conventional fishing reel spools, this invention features the following advantages.
The turning support device keeps the spool constantly supported as a freely supported beam. As shown in FIG. 9 , the width of the bearing support structure is the distance L 2 , which is much larger than the width of the conventional reel bearing support structure L 1 . The two bearing structure minimize the resistance during line release. This means that the reel of the invention can achieve maximum releasing efficiency.
The brake mechanism of this invention employs two springs. The rigidity of the small spring 23 is smaller than the rigidity of the large spring 21 . The brake force of the reel according to the invention is controlled by turning the drag adjust knob 1 with thread 55 on the main shaft 5 .
Before the drag adjust knob 1 compresses the small spring 23 and large spring 21 , the spool 3 including the core 32 , and the skirt 33 can rotate freely relative to main shaft 5 ; the drag resistance is nearly zero. When the drag adjust knob 1 is continuously screwed in, it will, through front actuator 24 , compress the small spring 23 . Due to the fact that the rigidity of the small spring 23 is smaller than that of the large spring 21 , only the small spring is compressed initially. The brake force mainly acts small spring 23 . Further turning of the drag adjust knob 1 causes the front actuator 24 to touch the adjacent keyed washer 221 . The front actuator 24 is then unable to compress the small spring 23 any further. As a result, through the drag washer stacks 22 , the force of drag adjust knob 1 starts to compress the large spring 21 . The brake force in this period is determined by a combined property of the small spring 23 and large spring 21 . The conclusion is the adjustable range of this invention is much wider than in conventional reels and the brake force can be controlled in separated stages.
The spool 3 comprises a front lid 31 , a core 32 , and a skirt 33 . These parts are connected by mans of connecting element 34 and/or thread. The core 32 can be manufactured from a drawn pipe. The skirt 33 and front lid 31 can be punch pressed or drawn to form their shape with little machining required; therefore the manufacturing and material costs are relatively low.
The spool 3 , the skirt 33 , and the core 32 of the reel according to this invention comprise water drainer slots and/or water drainer holes, which effectively improve the function of the fishing reel and make it more convenient to use.
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A modularized fishing reel spool comprises a drag adjust knob, a brake device having two springs and washer stacks, a front lid, a core and a skirt. A turning support system of the spool comprises a two bearing system, a main shaft and a core shaft. Compared to conventional fishing reel spools, this invention provides a spool having advantages such as better structural design, wider adjustable brake range, superior line-loading force application, well-functioned water drainer system, low manufacturing cost and lower material usage.
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This application is a continuation of application Ser. No. 374,610, filed July 5, 1989, now abandoned, which is a continuation of Ser. No. 172,952, filed Mar. 25, 1988, now abandoned, which is a continuation of Ser. No. 820,747, filed Jan. 22, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sheet conveying device used in an image recording apparatus such as a printer, an ink jet printer, an electronic typewriter, a facsimile apparatus or an electrophotographic copying apparatus to reliably convey, for example, a recording sheet or the like on which an image is recorded.
2. Description of the Prior Art
A sheet conveying device is known which conveys a recording sheet to a recording station in which a recording head or the like is provided by the cooperation between a rotational member rotatable in the direction of sheet conveyance and a keep plate urged against the rotational member in order to effect image recording on the recording sheet. However, in the above-described sheet conveying device of the known structure, if an attempt is made to convey, for example, a transparent plastic sheet for an overhead projector (hereinafter referred to as the OHP sheet) under high temperature and high humidity conditions, the OHP sheet comes into intimate contact with the keep plate due to the humidity, and this had led to an undesirable possibility that normal conveyance cannot be accomplished.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a sheet conveying device which can more reliably accomplish the conveyance of sheets.
It is another object of the present invention to provide a sheet conveying device which can reliably accomplish the conveyance of sheets without causing jamming thereof even under high temperature and high humidity conditions.
It is still another object of the present invention to provide a sheet conveying device which can also reliably convey, for example, other sheets than OHP sheets.
It is yet still another object of the present invention to provide a recording apparatus provided with a sheet conveying device which achieves the above objects.
The sheet conveying device of the present invention has a rotational member rotatable in the direction of sheet conveyance, a contact member provided in contact with the peripheral surface of said rotational member to cooperate with said rotational member to convey a sheet, and a plurality of protruded portions provided on said contact member projecting toward said rotational member.
Further, the sheet conveying device of the present invention has a sheet feeding roller rotatively driven to convey a sheet, a pinch roller disposed in contact with said sheet feeding roller and following the rotation of said sheet feeding roller, a platen roller provided downstream of said rollers and rotatively driven to convey the sheet, a keep plate provided in pressure contact with the peripheral surface of said platen roller to feed the sheet while nipping the sheet between it and said platen roller, and a plurality of projections provided on said keep plate projecting toward the side opposed to said platen roller, said keep plate and said projections each having a frictional load reducing coating on the surface thereof opposed to the sheet.
An ink jet printer provided with the sheet conveying means of the present invention has a rotational member rotatable in the direction of sheet conveyance, a contact member provided in contact with the peripheral surface of said rotational member to cooperate with said rotational member to convey a sheet, a plurality of protruded portions provided on said contact member projectedly toward said rotational member, and recording means provided downstream of the position of contact between said rotational member and said contact member with respect to the direction of sheet conveyance to inject ink in response of image information and form an image on the sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sheet conveying device to which an embodiment of the present invention is applied.
FIG. 2a is a left side view showing the essential portions of the device of FIG. 1.
FIG. 2b is a partial cross-sectional view of a keep plate.
FIG. 3a is a plan view of the keep plate.
FIG. 3b is a side view of the keep plate.
FIG. 4a is a plan view of another embodiment of the keep plate.
FIG. 4b is a side view of said another embodiment.
FIG. 5 is a perspective view of an ink jet printer provided with the sheet conveying device shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will hereinafter be described in greater detail with respect to some embodiments thereof.
FIG. 1 is a perspective view of a sheet conveying device F to which an embodiment of the present invention is applied, FIG. 2a is a left side view showing the essential portions thereof, FIG. 2b is a partial cross-sectional view of a keep plate thereof, FIG. 3a is a plan view of the keep plate, FIG. 3b is a side view thereof, FIG. 4a is a plan view of another embodiment of the keep plate, FIG. 4b is a side view thereof, and FIG. 5 is a perspective view of an ink jet printer IP provided with the sheet conveying device F shown in FIG. 1.
The sheet conveying device F to which an embodiment of the present invention is applied will first be described with reference to FIGS. 1 2a and 2b.
In FIGS. 1, 2a and 2b, reference numeral 1 designates a drive paper feeding roller which cooperates with a pinch roller 4 (which will later be described in detail) to convey a recording sheet 7 toward a driving platen 2 while guiding the recording sheet 7 along the peripheral surface 1a thereof. The platen 2 comprises rubber rollers 2 1 , 2 2 and 2 3 secured to a shaft 2a at predetermined intervals. The platen 2 may be a full width roller provided over the full width of a recording sheet conveying path P or may be a fixed member or the like.
A paper keep plate 5 is installed on the peripheral surface of the platen 2 over the full length thereof along the recording sheet conveying path P. This paper keep plate 5 is formed of a resilient metallic or plastic plate, and has its lower end secured to the frame member 10 of the device by screws 11 so as to press against the platen 2 with predetermined pressure (FIG. 2b). The left and right ends of the keep plate 5 extend upwardly, and these upwardly extending portions 5c are along the bent portions 12a of the frame member 12 of the device. In the present embodiment, a plurality of projections 6 are provided on that side 5b of the paper keep plate 5 which is opposed to the platen roller 2 and slightly below the portion of contact 13 between the roller 2 and the keep plate 5 (or upstream with respect to the direction of recording sheet conveyance). These projections 6 project circularly toward the platen 2 and are arranged on the keep plate 5 in a row at predetermined intervals over the full width of the recording sheet conveying path P. Accordingly, the area of contact between the paper keep plate 5 and the conveyed recording sheet 7 decreases remarkably as compared with the paper keep plate of conventional structure, and the friction force which the recording sheet 7 receives from the paper keep plate also decreases remarkably.
A paper guide 3 (formed of a rigid material such as a metal or plastic) for guiding the recording sheet is disposed behind the platen 2 and the fore end portion thereof is along the peripheral surface of the paper feeding roller 1.
A plurality of cut-away portions 5a are formed in the lower portion of the paper keep plate 5, and the pinch roller 4 rotatably supported on a shaft 4a parallel to the platen 2 fits in these cut-away portions 5a. The pinch roller 4 is biased by a spring S so as to contact the paper feeding roller 1 with predetermined pressure and follows the rotation of the platen 2.
Driving of the platen rollers 21, 22 and 23 and the paper feeding roller 1 will now be described.
In the present embodiment, the recording sheet can also be manually fed by turning a platen knob 2c provided on one end of the shaft 2a of the platen 2. Alternatively, the recording sheet can be automatically fed by the use of a motor M or the like. Where automatic feeding is to be effected, a drive starting signal produced by a button (not shown) being depressed is received by the motor M, whereupon the motor M starts driving. The rotational force of this motor M is transmitted to gears G1, G2 and G3 through a motor shaft (not shown), and the platen rollers 2 1 , 2 2 and 2 3 start rotating. At the same time, the rotational force of the motor M is transmitted from the gear G1 to a gear G4 through a gear, not shown, whereby the paper feeding roller 1 starts rotating.
Description will now be made of the conveyance of the recording sheet by the sheet conveying device F of the above-described construction.
Description will first be made of a case where the recording sheet is long fan-fold paper. However, of course, even a cut sheet can be conveyed in the present device.
The recording sheet 7 advanced along the peripheral surface 1a of the paper feeding roller 1 is nipped and conveyed between and by the paper feeding roller 1 and the pinch roller 4 and travels toward the platen rollers 2 1 , 2 2 and 2 3 disposed above the rollers 1 and 4. Hereupon, the advanced recording sheet 7 bears against the projections 6 and comes to the portion of pressure contact 13 between the platen rollers 2 1 , 2 2 , 2 3 and the keep plate 5 in a state in which it is not in intimate contact with the planar portion of the keep plate 5, and receives the conveying force with the aid of the platen rollers 2 1 , 2 2 , 2 3 and travels toward the guide 3. The recording sheet 7 having arrived at the guide 3 receives the conveying force by the openings at the opposite ends thereof being engaged with drive pins 14 secured to drive belts (not shown) provided on the opposite ends of the guide 3, and is discharged thereby.
Another embodiment of the projections provided on the keep plate 5 will now be described with reference to FIGS. 3a and 3b and FIGS. 4a and 4b.
FIGS. 3a and 3b illustrate a second embodiment of the present invention. In the present embodiment, circular projections 15 are formed at two upper and lower stages on the paper keep plate 5. If the area of protrusion of the circular projections 15 is made smaller than the area of protrusion in the above-described first embodiment, the area of contact between the projections 15 and the recording sheet will not increase. Moreover, the projections 15 are provided at two stages and therefore, the recording sheet can be caused to feed up more reliably from the keep plate 5.
FIGS. 4a and 4b illustrate a third embodiment of the present invention. In the present embodiment, elliptical projections 16 having their major axis in the direction of paper feeding are formed on the paper keep plate 5.
If such a structure is adopted, an effect similar to that of the previously described embodiment is obtained and in addition, irregularity of feeding in a direction perpendicular to the direction of paper feeding can be prevented because the projections 16 are elongated with respect to the direction of paper feeding.
Now, in the above-described first, second and third embodiments, projections are merely formed on the paper keep plate, but with the formation of the projections, that side of the paper keep plate which contacts the recording sheet may be coated with a material of small friction force. In this manner, the friction force between the recording sheet and the paper keep plate can be decreased and smooth paper feeding can be accomplished.
An ink jet printer IP to which the paper feeding device F according to the first embodiment is applied will now be described with reference to FIG. 5.
In FIG. 5, reference numeral 21 designates a printing head having a plurality of nozzles (not shown) for ejecting ink therethrough in response to image information. This printing head 21 is mounted on a carriage 22 which is reciprocally moved along the recording sheet 7 by a motor 23 through a belt 24. Reference numerals 25 and 26 denote guide bars for guiding the reciprocally movable carriage 22.
Accordingly, in this ink jet printer IP, the ink image is recorded on the recording sheet 7 positively conveyed by the first embodiment, by the printing head 21, after the recording sheet has passed the portion of contact 13 between the platen rollers 2 1 , 2 2 , 2 3 and the keep plate 5. At this time, the carriage 22 is moved to the right from its home position (shown in FIG. 5) to thereby effect image recording, whereafter it is returned to its home position to thereby effect the recording of the image of the next line. Reference numeral 27 designates a transmission path for transmitting an image information signal to the recording head 21. The recording sheet 7 on which image recording has been effected is discharged by the aforedescribed paper feeding device F.
Here, the result of an OHP sheet (a cut sheet of size A4) having been conveyed by the use of the ink jet printer shown in FIG. 5 is shown. The OHP sheet used in this experiment is coated with a special chemical agent to ensure the fixation of ink and quicken the drying of ink.
Now, in the present device, the thickness of the keep plate 5 is about 0.15 mm, the height of each projection 6 is about 0.15 mm and twenty projections 6 are arranged in a row at intervals of about 11 mm. The surfaces of the keep plate 5 and the projections 6 which contact the OHP sheet are coated with a solid coating lubricant called fluorine resin Drilube (manufactured under the trade name of S-1215 by Toyo Drilube Co., Ltd.). When the OHP sheet was conveyed by this device, the OHP sheet could be reliably conveyed without jamming while image recording was effected even if the room temperature was about 33° C. and the humidity was about 80%.
As described above, the present invention can provide a sheet conveying device in which oblique movement and irregularity of feeding of the recording sheet do not occur even under high temperature and high humidity conditions.
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This specification discloses a sheet conveying device for conveying a sheet which is applied to an image recording apparatus. More particularly, the specification discloses a sheet conveying device for conveying a sheet by the cooperation between a rotational member rotatable in the direction of sheet conveyance and a contact member which is in contact with the rotational member. According to the present invention, there is provided a sheet conveying device which can convey a sheet without causing oblique movement and irregularity of feeding of the sheet, for example, even under high temperature and high humidity conditions.
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BACKGROUND OF INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a process for securing data and in particular to a process for securing data in insecure mass memory storage.
[0003] 2. Related Prior Art
[0004] Currently available systems do not provide a simple and complete secure file/record storage solution for an insecure mass memory, where the following fundamental quality can be seen: For example: U.S. Pat. Nos. 6,986,043 Encrypting File Systems and Method by Candieu, et al., 6,981,138 Encrypted Key Cashe by Douceiu, et al, and 6,249,866 Encryption File System And Method by Brundrell, et al. and Patent Publication Nos.: 20006130154 Method and System For Protecting And Verifying Stored Data by Wai Lam, et al., 20040175000 Method And Apparatus For Transaction-Based Secure Storage System by Garonni
[0005] These systems do not efficiently combine user authentication and encryption: in particular:
[0000] 1. File/record is not provided with 100% protection from user and unauthorized modification to file data is not detected 100% of the time.
2. The existing systems do not provide good cryptographic file/record access control to support three file/record access modes; no-access, read only, and read-write.
3. They do not provide access control enforcement on a per file/record basis or for a group of similar files.
4. Most of the current insecure mass memory storage does not provide strong key management.
5. In existing systems and methods, user can not use existing key distribution and revocation due to its complexity.
6. Existing file/record protection mechanisms add extra burden on the file system.
[0006] Therefore it is a primary object of the invention to a process/method for file/record protection in insecure mass memory storage.
[0007] It is another object of the invention to provide for file/record protection in insecure mass memory storage wherein user authentication and encryption are provided.
[0008] It is another object of the invention to provide a process for file/record protection in insecure mass memory storage confidentiality, integrity, and non-repudiation quality for file/record data.
[0009] It is a further object of the invention to provide a process for file/record protection in insecure mass memory storage that supports for three file/record access modes; no-access, read only, and read-write.
[0010] It is a still further object of the invention to provide a process for file/record protection in insecure mass memory storage that eliminates the need for a user or group of users to keep any file keys for file/record system access.
[0011] It is a still further object of the invention to provide a process for file/record protection in insecure mass memory storage wherein a file key can be compatible with simultaneous use in other applications.
[0012] It is another object of the invention to provide a process for file/record protection in an insecure mass memory storage wherein the user does not have to have any knowledge of the file(s) encryption key(s).
[0013] It is another object of the invention to provide a process for file/record protection in insecure mass memory storage where in the user access revocation mechanism for the file system is simple and effective.
SUMMARY OF INVENTION
[0014] The present invention provides a process for data protection in insecure mass memory storage (sometimes called data at rest). The process combines user authentication and encryption properly for user authentication. Confidentiality, integrity, and non-repudiation quality for file data are provided. The process supports three file/record access modes; no access, read only and read-write. Access control is supported on a per file/record basis or for a group of similar files. A user or a group of users will not be required to keep any keys for file system access. The key is compatible with simultaneous use in other applications. The user does not have to have any knowledge of the encryption key(s). The user access revocation mechanism for the file system is simple and effective. When read or write access to a file is revoked, the revoked user will immediately lose access to that file/record. Furthermore, the performance of the system is not hampered by providing these advantages.
[0015] In detail, the invention is a process/method for securing data in a storage unit using public and private key encryption and symmetrical encryption techniques by a owner of the data for use by multiple users, the process including the steps of: 1) encrypting the data; 2) attaching encrypted meta data to the encrypted data providing access at a selected level to the data by each of the multiple users, the access level to each of the multiple users being the ability to read and add/modify the data, or the ability to only read the data, or no access to the data; 3) storing the encrypted data and meta data in the storage unit; and 4) providing each of the multiple users with de-encryption means such that the encrypted data can be de-encrypted at the selected level granted to each of the multiple users at his/her level. A user can be a program process also.
[0016] The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description in connection with the accompanying drawings in which the presently preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for purposes of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a representation of a fully redundant mass memory physical architecture with a cryptographic TOKEN plugged into a trusted control processor via a smartcard in a PCMCIA slot.
[0018] FIG. 2A is a representation of a data block structure.
[0019] FIG. 2B , is a representation of a file data structure.
[0020] FIG. 2C is a representation of a blocked hashed and signed file structure.
[0021] FIG. 3 , is a representation of an access control of Meta data showing a logical structure for access control of a file.
[0022] FIG. 4 is a representation of file groups and user groups showing the grouping which provides efficiency for faster access.
[0023] FIG. 5 , is a representation of key hierarchy showing the key encryption key and data encryption keys structure.
[0024] FIG. 6 , is a representation of a reference monitor as part of the trusted control processor and which provides access control based on security label to provide read, or read/write access.
[0025] FIG. 7 is a flow chart of the control data generator used by the data owner.
[0026] FIGS. 8A and 8B is a flow chart of the data access process used by data users.
[0027] FIG. 9 is a flow chart of the reference monitor operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] It is first necessary to define the following:
[0000] A) Symmetric keying uses one key to encrypt and to decrypt a block of text.
B) Public Key Infrastructure (PKI) uses two keys—mathematically related—one for encryption and another different key for decryption. One of key pair is called the public key and is made public, i.e., published, so all can obtain. The other of key pair is called the private key and is protected from loss or disclosure. When a datum is encrypted using the user's public key, only the user can access the plain text datum by decrypting the cipher text with his/her private key. That certifies for the public that only the designated user can read the datum. If the user encrypts the datum using his/her private key, anyone can read the datum by decrypting the cipher text with the user's public key that all can obtain. It certifies for the public that only the given user wrote the datum.
C) A Hash is a mathematical computation on a datum that produces a unique “hash” value. When the computation is repeated on the same datum the same hash results. For data transmitted over a communication line with the hash attached, the receiver can repeat the computation on the datum and obtain its hash. That computed hash is compared to the sent hash and the two hashes compared. They should be equal if the datum received is the same as the datum sent; no modification in transit. This same theory is being applied here for the data at rest.
D) A Signature attached to a datum provides a way to authenticate the datum. The Signature uses a user's name or ID encrypted in the sender's private key. The receiver checks the signature by decrypting it with the sender's public key. If it checks, it confirms the sender as the only one with the user's private key. If the sender hashes a datum and then signs the hash, the receiver can rehash the datum and decrypt the sent hash with the sender's public key. The two hashes will be equal if and only if the datum came from the sender and has not been modified in route. This same theory is being applied here for the data at rest.
E) The block cipher used is advanced encryption standard (AES) in Counter mode, the hash function is secure hash secure hash algorithm (SHA) and the signature scheme is elliptic curve digital signature algorithm (ECDSA). But other similar cryptography protocol/algorithms can be applied.
[0029] Referring initially to FIG. 1 , which illustrates an example of the security boundary for the system generally indicated by numeral 10 . Various components security boundaries are isolated by the separation kernel. A separation kernel is a type of security kernel used to simulate a distributed environment. The task of a separation kernel is to create an environment which is indistinguishable from that provided by a physically distributed system. It must appear as if each regime is a separate, isolated machine and that information can only flow from one machine to another along known external communication lines. Thus there are no channels for information flow between regimes other than those explicitly provided. Only one control processor will be sending messages to one mass memory unit (MMU) 14 at one time and vice-versa.
[0030] The MMU 14 could be RAM or RAID directly attached to control processor. A tamper proof token/smartcard 16 which stores the users' master key hosted in a PCMCIA slot 18 of the trusted control processor. The card will provide necessary crypto functions. The trusted control processor 16 handles all the key management, encryption, and all data file and Meta data construction via MMU native commands. In this manner all communication between the control processor 16 and the MMU 14 is cryptographically protected. Optional networks 20 A and 20 B may exist between the user and control processors 12 and between the control process 12 and MMU 14 . The other control processor 16 A, also having a token/smartcard 16 A in PCMCIA slot 18 A, coupled to a second MMU 14 A could be incorporated for redundant backup purposes.
[0031] FIGS. 2A , 2 B and 2 C, illustrate typical file data contents and the file/record data format required for block 24 processing of a file. File data 26 is encrypted using the digital encryption key (DEK s ) contained in the corresponding Meta data (Mata data other than file data, which will be subsequently discussed). A hash of the file data is computed and signed using the digital signature key (DK sig ) also contained in the Meta data. This signature 28 is appended to the end of the file.
[0032] A typical file consisting of data blocks one 24 (typically, 512 bytes per block) through data block N 24 A matching the typical disc sectors containing the entire data file. Each block one 24 through N 24 A are encrypted by the AES algorithm using Counter mode encryption. Counter mode permits encrypting a block separate from any other block. Next, a hash 30 through 30 A is computed on each encrypted block one 24 through block N 24 A. Finally, a hash 32 of all the block hashes is computed, and the hash-hash is signed with the private key of the user. Owner identification block 22 is added. With this information each subsequent user is permitted to use of the file/record using the public key of the file creator to check the hash-hash for the integrity of the file.
[0033] A data block, for example block one 24 within the file data is updated as follow. The Meta data has been verified and we have the DEK (DK s ) (TODO) and DSK (DK sign ). SHA is used to Hash encrypted block one 24 and replace the hash 30 for block one 24 in the final hash block 32 . SHA is reapplied to the concatenation of all block hashes to obtain a new file hash, i.e., hash of hashes, and sign that with the DSK (DK sign ).
[0034] For verification of a single file block, both the file block one 24 and the final hash block 32 are retrieved. File block 24 is rehashed and the file hash is re-computed using the hashes of all the other blocks. The actual file data blocks need not be retrieved. The signature from the hash block is re-verified i.e. corresponds to the computed file hash.
[0035] FIG. 3 , the Meta data 40 contains access control information and its format is depicted. The meta data 40 includes the file name 42 , security level 44 , the data block, for example data block 24 , owner encrypted key block 46 , escrow encrypted key block 48 and encrypted key block for user one 50 to encrypted key block N 50 A for user N. Each encrypted key block for user one 50 to user N 50 A corresponds to a user (or a group of users) with some access rights to the corresponding file data. Also included in the Meta data 40 are the file signature key 52 , time stamp 54 and owner's signature 56 . Encrypted key blocks for user one 50 through user N 50 A contain the file data encryption key (DEK) of each user with read access 60 , which includes user ID 60 A, security level (SL) 60 B data encryption key 60 C and data signature key 60 D. Note that DK s , stands for symmetric key encrypted under the user public encryption key and Uk pub , stands for user public key for encryption. If a user also has write access indicated by numeral 62 , then the data signature key (DSK or DK sign which stands for digital signature key) is included in the user's encrypted key block. If no read or right access is granted then access 63 is limited to user ID 60 A and security level 60 B. The Meta data also contains the public portion of the DSK (DK verify , stands for sign verification key) i.e., FSK, un-encrypted so that readers can verify the integrity of the file data. The timestamp 54 is updated by the owner when the Meta data portion of the file is modified.
[0036] Of particular interest in this field is the Security Label (SL) 44 of the data file. The label is classification of file/record such as public, private, etc. SL 44 is used by the Reference Monitor (to be subsequently discussed) to permit cleared users security access to the data file/record. The Meta data part is signed by the file owners OSK (OK sign , stands for signature key of the file owner) and hence can be updated only by the owner. Note that only the file owner has access to OK verify , which stands for verification key of the file owner and can change the file SL. The first encrypted key block is always encrypted under the file owner's OEK (OK pub , stands for public key of the owner). Furthermore, an escrow agency (A third party who wants to have access to the encrypted information, such as police, FBI, CIA, etc.) will have read access as the second block shows the encrypted key block for an escrow party.
[0037] The file owner generates an ECDSA Data Signing Key (DK sign ) and an AES Data Encryption Key (DK s ). Owner's encrypted key block is formed by encrypting the (DK sign ) and (DK s ) using owners OK pub and tag the cipher text with the owner's user name. Apply SHA to the owner's encrypted key block, public key of the DK verify , a timestamp, filename, and first block number. Sign the hash with ECDSA using the owner's Ok sign . Create the Meta data by concatenating the owner's encrypted key block, public key of the DK verify , the timestamp, the filename, the SL, and the signature OK sign . Encrypt the file data with AES using the DK s . Apply SHA to the encrypted file data and sign the hash with ECDSA using the private key of the DK sign . The cipher text is concentrated with the signature to create the file data.
[0038] Owner obtains the Meta data and verifies the signature with his/her OSK verify . (Note that the owner has the public key of users, since she or he created all user keys.) If the user is only granted read access, owner encrypts only the DK s using user's public key UK pub . For user's write access, owner encrypts both the DK s and DK sign . The cipher text, together with user's user name is the encrypted key block to be added to the Meta data. Owner adds a user's encrypted key block to the Meta data and updates the timestamp to the current time. S/he applies SHA to the modified Meta data and signs the hash using ECDSA with his/her Ok sign . One replaces the signature on the Meta data. Owner replaces the old Meta data with the new version. Note, the data file SL is set once by the owner at the time of the Meta data and file creation. All users must have clearances that dominate the file SL or access is denied by the Reference Monitor.
[0039] User obtains the Meta data and identifies the file owner by extracting the user name tag from the first encrypted key block. User obtains the owner's OK verify from user smartcard (via cert) or the system already has that in a PKI such as LDAP and verifies the signature on the Meta data part of the file. Then user locates the encrypted key block with his/her user name in the Meta data and decrypts the key block to obtain the DK s and/or DK sign . The user obtains the file data, and verifies the signature using the public key of the DK sign ; encrypts the file data with the DK s . Add user identity to the file data, i.e., “Joe” at the last block. Hash of the encrypted file data (current block+last block) and signs the hash with the DK sign . The signature is appended to the newly generated cipher text to create the new file data.
[0040] User obtains the Meta data information and identifies the file owner by extracting the user name tag from the first encrypted key block. Obtains the owner's OK pub from user smartcard or it is already in the trusted system and verifies the signature on the Meta data. User locates the encrypted key block with the reader's user name in the Meta data, and decrypts the key block to obtain the DK s obtains the file data and verifies the signature using the public key of the DK verify ; decrypts the encrypted file data with the DK s to obtain the file contents.
[0041] The owner generates a new DK s for read access revocation. Using this key, the file data is updated by encrypting the file data with the new key and then signs using the old DK s . The revoked user's encrypted key block is removed from the Meta data and all the remaining key blocks are updated with the new DK s . Finally, the Meta data is signed with the owner's OK sign .
[0042] Write access revocation is the same as read access revocation except that a new DK sign is also generated. The encrypted key blocks are updated with this new DK sign and the file data is signed with this new key. Revoking write access also involves creating a new DK s and re-encrypting the file data because write access implicitly provides read access.
[0043] All users maintain one “master” key, their PKI private key, for asymmetric decryption—KEK, (UK prv , stands for user private key). Each block of file data is encrypted using a block cipher (i.e. AES) in Counter mode and each block is also hashed i.e., SHA-384 (SHA-384 produces 384 bits hash) for integrity. A hash tree construction will be used to relate block integrity to file integrity. As mentioned earlier, the Meta data part contains the access control information, while the file data part contains the encrypted and signed contents. The file data is encrypted with a symmetric cipher using a unique key—data encryption key DK s for each file or a group of similar files. The file data is also signed using a signature scheme with a unique key—data signature key DK sign for that file or a group of similar files.
[0044] The DK s and DK sign are used to differentiate between read and write access. Possession of only the DK s gives read only access to the file while possession of both the DK s and DK sign allows read and write access. For example, a user with only the DK s cannot create a valid file because s/he cannot produce a valid file signature.
[0045] FIG. 4 , shows how files/records and users can be grouped. Similar types of files can be grouped 70 together and the same symmetric key 72 can be used to encrypt and decrypt that set of files. This helps to reduce the number of keys needs to be managed. Further, files groups, symmetric keys, and file names 42 can be cached in a volatile memory for faster and efficient access.
[0046] User groups 73 can support producers-subscribers access models, where users can be grouped together based on role, coalition, and/or security label. This helps faster and efficient access control, since access is based on group, instead of individual. In this invention, we have said that the information is in the mass memory storage, but the information such as user groups, users, and access control can be cached in other types of memory such as volatile memory for faster and efficient processing.
[0047] FIG. 5 , shows an example of a hybrid key architecture. Private and public keys may be deployed within a fixed hybrid key hierarchy, for instance with the following keys:
[0000] 1. Master key 76 is stored inside TRSM (Tamper Resistance Security Module), typically a symmetric key.
2. Key-encrypting key 78 (KEK)—optional. Typically, a symmetric key—encrypted by the master key.
3. Private keys 80 A and 80 B are encrypted with corresponding public keys 82 A and 82 B. The private keys are encrypted by the master key or a key-encrypting key when outside the TRSM.
4. Public keys 82 A and 82 B corresponding to the private keys 80 A and 80 B —authenticity may be protected with a certificate created by a Certification Authority signature.
5. Data Encryption Key 83 A and 83 B; user data is encrypted by Data Encryption Key and the “Data Encryption Key” is further encrypted by “User Public Key”
[0048] The Key Hierarchy for each user of all users of the file system is a protected data structure in the trusted Control Processor of the system. It is contained in the TOKEN in this description. However, it may be stored and managed as part of the Trusted Computing Base (TCB) of the Control Processor. PIN-protected, tamper-resistant hardware (i.e., smartcard in PCMCIA slot) provides high level of security to master keys (i.e. private keys). Storing master keys encrypted with password also provides additional protection. Binding the authentication session between the user and token also prevents an attacker from profitably stealing a token, and then later a mass memory device. Binding between the token and the Control Processor further enhances security of the system.
[0049] Still referring to FIGS. 1-5 and additionally to FIG. 6 , the reference monitor (RM) 90 is the heart of the secure access control in the trusted Control Computer. A user makes a file access request to read or write a file. The RM 90 retrieves the SL 44 from the Meta data of the corresponding file and compares it to the SL 44 of the user found in the RM trusted user group private information. If the user SL 44 dominates the file SL 44 , access is permitted. Dominance means the SL 44 of the user is greater than or equals that of the file SL 44 , and the file compartments are a subset of the user compartments. After satisfying the security access the user is allowed to Read or Read/Write the file to the extent of his/her permission in the Meta data.
[0050] The RM 90 input actions are user file references and output decisions are Booleans, i.e., yes or no access permitted. Actions are basically file commands supported by the MMU 14 A and 14 B component ( FIG. 1 ). When a user or a process wants to execute a command, the Reference Monitor based on polices 91 decides whether the command should be executed or not. The decisions are based on the policies, which can be set by the administrator(s), and the credentials of the user or process who/which execute the command, i.e., the SL 44 Dominance relation. The RM audits its actions in the Log Files 92 .
[0051] Referring to the flow chart of FIG. 7 , the overall process is as follows:
[0000] Step 101 —Owner generates DEK and DSK encryption codes.
Step 102 Owner generates encryption key block.
Step 103 Owner creates, adds to or modifies escrow and users key block
Step 104 Owner applies hash to data block, DSK. timestamp, filename, SL, and first file block.
Step 105 Owner signs hash with OSK
Step 106 Owner creates Mata data
Step 107 Owner creates the user data
[0052] Referring to the flow chart of FIGS. 8A and 8B the flow chart of the data user is as follows:
[0000] Step 110 Data access Granted
Step 111 User verifies Meta data
Step 112 User obtains DEK and DEK/OSK
Step 113 Determine if user has both read and write access
If Yes, then:
Step 114 Obtains user data
Step 115 Verify user data signature
Step 116 Decrypts data
Step 118 Write user data block(s)
Step 119 Encrypt user data
Step 120 Hash encrypted user data
Step 121 Sign hash
Step 122 Append signature
Step 123 Update user data
[0053] If No, then
[0000] Step 124 Obtain data file
Step 125 Verify user data signature
Step 126 Decrypt user data
Step 127 Read user data
[0054] Referring to FIG. 9 , the reference monitor flow chart is as follows
[0000] Step 130 Start reference monitor
Step 132 User makes a user access request
Step 133 Reference Monitor retrieves the user data SL for the Meta data and Compares to user SL
Step 134 Determine if SL is user data SL
If yes, then
Step 135 User data access is granted
Step 136 Update audit log
If no, then
Step 137 user access denied
Step 136 Update audit log
[0055] Thus it can be seen that the present invention provides a process for file/record protection of data in an insecure mass memory storage. User authentication and encryption properly for user authentication is provided. Confidentiality, integrity, and non-repudiation quality for file data are provided. Three access modes are provided: no access, read only and read-write. Access control is supported on a per file basis or for a group of similar files. A user or a group of users will not be required to keep any keys for file system access. The key is compatible with simultaneous use in other applications. The user does not have to have any knowledge of the encryption key(s). The user access revocation mechanism for the file system is simple and effective. When read or write access to a file is revoked, the revoked user will immediately lose access to that file. Furthermore, the performance of the system is not hampered by providing these advantages
[0056] While the invention has been described with reference to a particular embodiment, it should be understood that the embodiment is merely illustrative as there are numerous variations and modifications which may be made by those skilled in the art. Thus, the invention is to be construed as being limited only by the spirit and scope of the appended claims.
INDUSTRIAL APPLICABILITY
[0057] The invention has applicability to the computer software industry, in particular to those involved in information security.
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The invention is a process for securing data in a storage unit using public and private key encryption and symmetrical encryption techniques by a owner of the data for use by multiple users. The process including the steps of: 1) encrypting the data; 2) attaching encrypted meta data to the encrypted data providing access at a selected level to the data by each of the multiple users, the access level to each of the multiple users being the ability to read and change the data, or the ability to only read the data, or no access to the data; 3) storing the encrypted data and meta data in the storage unit; and 4) providing each of the multiple users with de-encryption means such that the encrypted data can be de-encrypted at the selected level granted to each of the multiple users.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Korean Patent Application No. 10-2014-0016722 filed on Feb. 13, 2014, No. 10-2014-0016724 filed on Feb. 13, 2014 and No. 10-2014-0100471 filed on Aug. 5, 2014, and all the benefits accruing, therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND
1. Field
The present disclosure relates to a resonator for a vehicle, and more particularly, to a resonator for a vehicle, in which a plurality of resonance chambers are formed between an outer pipe configuring an outward appearance and an inner pipe disposed inside the outer pipe to improve noise reduction performance of the resonator.
2. Description of the Related Art
Generally, an intake system of a vehicle includes an air cleaner, a turbo-charger, an inter-cooler, an air duct and an engine manifold, and an external air introduced into an internal combustion engine by the intake system is repeatedly expanded and shrunken to cause intake pulsation. The intake pulsation causes noise due to the change of air pressure, and particularly, greater noise is caused due to air resonance of a vehicle body or an indoor space of the vehicle.
In order to restrain the intake noise, a resonator for tuning the intake system into a specific frequency is installed at an intake hose which connects the air cleaner to the intake manifold.
As an example of existing resonators, Korean Patent Publication No 2006-0116275 discloses a resonator, which includes an outer pipe configuring an outward appearance and an inner pipe installed in the outer pipe to give an air passage. A resonance chamber for tuning air frequency to reduce noise is formed in a space between the outer pipe and the inner pipe, and a slit for guiding air to the resonance chamber is formed at the inner pipe. In other words, the air flowing into the inner pipe moves to the resonance chamber through the slit, and the air moving to the resonance chamber may experience frequency tuning, thereby performing noise reduction of the air.
However, this resonator has a limit in the number of resonance chambers, and thus the frequency tuning work for external air cannot be performed over a broad band. In other words, since the resonator has a limited number of resonance chambers, the degree of frequency tuning freedom is low, and thus the noise reduction for external air is not performed agreeably.
Korean Patent Publication No. 2009-0047083 discloses a resonator in which a first duct and a second duct with different sectional areas are disposed therein, and a length of a region where two ducts overlap with each other is adjusted to reduce noise of a specific frequency. However, in spite of this technique, the number of resonance chambers for noise reduction is still limited, and thus it is not easy to reduce noise of a broad band. In particular, a turning work at a high frequency band is not easy, and thus noise reduction efficiency for external air is low.
SUMMARY
The present disclosure is directed to providing a resonator for a vehicle, which may enhance the degree of frequency tuning freedom for air introduced into a resonance chamber by forming a plurality of resonance chambers between an outer pipe and an inner pipe of the resonator.
In one aspect, there is provided a resonator for a vehicle, which reduces intake noise by using a resonance chamber for frequency tuning, the resonator including: an outer pipe having a first outer pipe with an inlet for introducing external air and a second outer pipe with an outlet for discharging the air introduced into the inlet to outside; an inner pipe disposed inside the outer pipe and having a plurality of slits for giving a passage of air; and an expansion pipe inserted between the outer pipe and the inner pipe to partition a space between the outer pipe and the inner pipe into a plurality of spaces and thus partition the resonance chamber into a plurality of regions.
According to the present disclosure, since an expansion pipe is inserted between an outer pipe and an inner pipe, the number of resonance chambers formed between the outer pipe and the inner pipe may increase, and thus the degree of frequency tuning freedom may also be enhanced.
In addition, since it is possible to increase the number of resonance chambers by inserting a plurality of expansion pipes between the outer pipe and the inner pipe as necessary, noise of various frequencies may be reduced.
Moreover, since the resonator is coupled in an assembling way, the number of resonance chambers may be easily increased or decreased.
In addition, since the outer pipe, the inner pipe and the expansion pipe are hermetically coupled by means of welding, leakage of external air may be prevented, and thus intake noise reduction efficiency may be maximized.
Moreover, since it is possible to increase the number of resonance chambers by inserting an intermediate pipe and a barrier between the outer pipe and the inner pipe as necessary, noise of various frequencies may be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a resonator according to the first embodiment of the present disclosure.
FIGS. 2A and 2B are exploded views showing an inner configuration of the resonator according to the first embodiment of the present disclosure.
FIG. 3 is a cross-sectional view, taken along the line I-I′ of FIG. 1 .
FIG. 4 is a cross-sectional view, taken along the line II-II′ of FIG. 1 .
FIG. 5 is a diagram showing a flow of air passing through the resonator according to the first embodiment of the present disclosure.
FIG. 6 is a diagram for illustrating a size of a plurality of pipes of a first resonance chamber and a size of an interval for guiding air to the first resonance chamber.
FIG. 7 is a graph showing a noise reduction amount according to a frequency of air moving to the first resonance chamber.
FIG. 8 is a cross-sectional view showing an inner configuration of a resonator according to the second embodiment of the present disclosure, observed from one side.
FIG. 9 is a cross-sectional view showing an inner configuration of the resonator according to the second embodiment of the present disclosure, observed from another side.
FIG. 10 is an enlarged view showing the portion E of FIG. 9 , in which a flow of air passing through the resonator according to the second embodiment of the present disclosure is depicted.
FIG. 11 is a cross-sectional view showing an inner configuration of a resonator according to the third embodiment of the present disclosure, observed from one side.
FIG. 12 is a cross-sectional view showing an inner configuration of the resonator according to the third embodiment of the present disclosure, observed from another side.
FIG. 13 is an enlarged view showing the portion F of FIG. 12 , in which a flow of air passing through the resonator according to the third embodiment of the present disclosure is depicted.
DETAILED DESCRIPTION
Hereinafter embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Even though the present disclosure is described based on the embodiments depicted in, the drawings, the technical spirit, essential features or operations of the present disclosure are not limited thereto.
FIG. 1 is a perspective view showing a resonator according to the first embodiment of the present disclosure, FIG. 2 a is an exploded view showing a detailed configuration of the resonator, FIG. 2 b is a perspective view showing an expansion pipe which is a component of the resonator, FIG. 3 is a cross-sectional view, taken along the line I-I′ of FIG. 1 , and FIG. 4 is a cross-sectional view, taken along the line II-II′ of FIG. 1 .
A resonator 1 according to the present disclosure includes a first outer pipe 10 configuring a part of an outward appearance and a second outer pipe 20 configuring another part of the outward appearance. An end diameter A of the first outer pipe 10 and an end diameter B of the second outer pipe 20 may be different from each other. For example, the end diameter A of the first outer pipe may be greater than the end diameter B of the second outer pipe. In addition, an end of the first outer pipe 10 may be an inlet 15 serving as an inflow passage of air, and an end of the second outer pipe 20 may be an outlet 45 serving as a discharge passage of air.
An inner pipe 40 may be inserted into an inner space of the first outer pipe 10 and the second outer pipe 20 . At this time, if the end diameter A of the first outer pipe is 1.4 to 1.5 times of the end diameter B of the second outer pipe, the one end of the inner pipe 40 may not be easily coupled to any one of the outer pipes 10 , 20 .
Therefore, in this embodiment, an expansion pipe 30 may be inserted between the outer pipes 10 , 20 and the inner pipe 40 . In detail, the expansion pipe 30 may be inserted into the inner space of the outer pipes 10 , 20 , and the inner pipe 40 may be inserted into the inner space of the expansion pipe 30 .
The expansion pipe 30 includes a first bent portion 31 having a hollow 31 a for allowing air to pass, an internal coupling unit 32 coupled to the inner pipe 40 , and a chamber forming unit 33 coupled to the outer pipes 10 , 20 . One end of the first bent portion 31 may be connected to the internal coupling unit 32 , and the other end of the first bent portion 31 may be bent.
The first bent portion 31 , the internal coupling unit 32 and the chamber forming unit 33 may be fabricated in an integrally coupled state. In other words, the expansion pipe 30 may be prepared by expanding through a mold during a part production stage.
The other end of the first bent portion 31 may be bent to a direction parallel to an extension direction of the first outer pipe 10 . Therefore, the first bent portion 31 may be spaced apart from the first outer pipe 10 by a predetermined distance. In other words, the first bent portion 31 is disposed to be spaced apart from the first outer pipe 10 with an interval L serving as an air passage. In other words, the interval L giving an air passage is formed between the first bent portion 31 and the first outer pipe 10 , and the air flowing into a resonance chamber 100 through the interval L may have reduced noise by means of frequency tuning.
The chamber forming unit 33 includes a second bent portion 331 bent to a direction perpendicular to the internal coupling unit 32 based on, the moving direction of air, an external coupling unit 333 connected to the second bent portion 331 in a perpendicular direction and coupled to the outer pipes 10 , 20 , and a third bent portion 332 bent to a direction perpendicular to the external coupling unit 333 . A terminal of the third bent portion 332 may be bent for convenient fabrication so as to be easily coupled to the inner pipe 40 .
Heights M of the second bent portion 331 and the third bent portion 332 may be relatively greater than a height N of the first bent portion 31 . Therefore, the interval L serving as an air passage may be formed between the first bent portion 31 and the first outer pipe 10 .
In an existing technique, if the inlet and the outlet have different diameters, an inclined portion should be formed to allow the inner pipe to be directly coupled to the outer pipe. However, in this embodiment, since the inner pipe 40 may be coupled to the outer pipes 10 , 20 even though the expansion pipe 30 has no inclined portion, the resonator 1 may be easily fabricated. In addition, in an existing technique, a slit serving as an air passage should be formed in the inclined portion of the inner pipe, but this is a difficult work since the space for forming the slit is not sufficient.
However, in this embodiment, the interval L may be formed between the outer pipes 10 , 20 and the expansion pipe 30 instead of the slit to give an air passage, and thus the resonator 1 may use its internal space more efficiently.
A plurality of slits 41 giving the same function as the interval L may be formed at the inner pipe 40 . In detail, the plurality of slits 41 includes a first slit 411 disposed adjacent to the inlet based on the moving direction of air, and a second slit 412 disposed spaced apart from the first slit 411 by a predetermined distance.
In addition, the resonance chamber 100 for adjusting a frequency of external air is provided between the outer pipes 10 , 20 and the inner pipe 40 . The resonance chamber 100 is divided into a plurality of regions by the expansion pipe 30 inserted between the outer pipes 10 , 20 and the inner pipe 40 . In detail, the resonance chamber 100 includes a first resonance chamber 110 formed between the first bent portion 31 and the second bent portion 331 , a second resonance chamber 120 formed between the second bent portion 331 and the third bent portion 332 , and a third resonance chamber 130 formed among the third bent portion 332 , the second outer pipe 20 and the inner pipe 40 , based on the moving direction of air.
The first resonance chamber 110 communicates with the interval L, and the second resonance chamber 120 communicates with the first slit 411 . In addition, the third resonance chamber 130 communicates with the second slit 412 for frequency tuning of air.
Hereinafter, a moving passage of external air passing through the resonator 1 and a method for coupling a plurality of pipes of the resonator 1 will be described.
FIG. 5 is a diagram showing a flow of air passing through the resonator according to the first embodiment of the present disclosure.
As shown in FIG. 5 , the resonator 1 of this embodiment includes a plurality of pipes which are coupled to each other by welding. In detail, coupling (a) among the expansion pipe 30 , the first outer pipe 10 and the second outer pipe 20 , coupling (b) between the expansion pipe 30 and the inner pipe 40 and coupling (c) between the second outer pipe 20 and the inner pipe 40 are all performed by welding along a circumferential direction. Since the plurality of pipes are hermetically sealed by welding, it is possible to prevent a leakage of external air and thus maximize the efficiency of intake noise reduction.
Even though it has been illustrated in this embodiment that the plurality of pipes are coupled by welding, the present disclosure is not limited thereto, and another coupling method than welding may also be used as long as the plurality of pipes are hermetically coupled. If the plurality of pipes are hermetically coupled as described above, the resonator I for noise reduction is completely made as an assembly.
Meanwhile, an existing resonator has a limit in the number of resonance chambers. However, the resonator of this embodiment may easily tune a frequency, different from the existing structure.
However, in order to allow air having a high frequency to flow into the first resonance chamber 110 , the size the plurality of pipes 10 , 20 , 30 , 40 may be limited to a predetermined ratio.
Referring to FIG. 6 , the first resonance chamber 110 is formed as a space surrounded by a part of the first outer pipe 10 , the first bent portion 31 spaced apart from the first outer pipe 10 by a predetermined distance, a second bent portion 331 extending in a direction parallel to the extending direction of the first bent portion 31 , and the internal coupling unit 32 having one end connected to the first bent portion 31 and the other end connected to the second bent portion 331 .
Design conditions for the first resonance chamber 110 capable of absorbing air with a high frequency are as follows.
First, a diameter D 1 of the first outer pipe 10 is 1.4 to 1.6 times of a diameter D 2 of the internal coupling unit 32 . In addition, a height W of the internal coupling unit 32 is 0.3 times of a diameter D 2 of the internal coupling unit 32 . In addition, a width L of the interval is 0.04 to 0.12 times of the diameter D 2 of the internal coupling unit 32 .
Table 1 below shows the resonator 1 prepared using an exemplary ratio suitable for the above design conditions, and a maximum frequency of air absorbed into the first resonance chamber 110 is shown as an experimental example.
TABLE 1
maximum frequency of air absorbed to the first
W/D2
D1/D2
L/D2
resonance chamber (Hz)
0.3
1.4
0.08
3600
1.5
0.08
4000
1.6
0.08
4300
As shown in Table 1 above, the resonator 1 of this embodiment fabricated according to the above design conditions may absorb air with a high frequency of 3600 Hz to 4300 Hz. If the above design conditions for the first resonance chamber 110 are changed, it is impossible to absorb air with a high frequency. For example, if a ratio of W/D 2 is changed to 0.2 as in Table 2 below, the maximum frequency of air absorbed to the first resonance chamber 110 decreases as follows.
TABLE 2
maximum frequency of air absorbed to the first
W/D2
D1/D2
L/D2
resonance chamber (Hz)
0.2
1.4
0.08
2800
1.5
0.08
3000
1.6
0.08
3200
If values of D 1 /D 2 and L/D 2 increase as in Table 2 above with W/D 2 being 0.2, this accompanies overall structural changes or manufacturing problems of the resonator 1 , and thus the maximum frequency of air absorbed to the first resonance chamber 110 may not have a value of 3600 Hz to 4300 Hz. In other words, the values of W/D 2 , D 1 /D 2 and L/D 2 shown in Table 1 may be regarded as optimal design conditions for absorbing air with a high frequency to the first resonance chamber 110 .
In FIG. 7 , a noise reduction amount according to a frequency of air absorbed to the first resonance chamber 110 under design conditions with W/D 2 of 0.3, D 1 /D 2 of 1.5, and L/D 2 of 0.08, which accord with the above conditions, is depicted with a graph. As shown in FIG. 7 , since the resonance chamber for absorbing air with a maximum frequency of 3600 Hz to 4300 Hz is formed at the resonator 1 of the present disclosure, noise caused by air with the high frequency may be reduced. In addition, by changing the L/D 2 value, frequency tuning for a low frequency region is also available.
Hereinafter, a moving pass of external air passing through the resonator 1 and a method for reducing intake noise will be described.
First, a part of air flowing into the inlet 15 passes through the interval L and moves to the first resonance chamber 110 , and another part of the air flowing into the inlet 15 moves to the inner space of the resonator 1 formed by the inner pipe 40 . The air flowing into the first resonance chamber 110 may be air with a high frequency as described above as an example. In other words, the first resonance chamber 110 may be a resonance chamber for tuning air with a high frequency and thus reducing noise.
Similarly, a part of air moving along the inner pipe 40 may pass the first slit 411 and another part of the air moving along the inner pipe 40 may pass the second slit 412 , and both of them move to the second resonance chamber 120 and the third resonance chamber 130 , respectively. The air flowing into the second resonance chamber 120 may be air with a relatively lower frequency in comparison to the air flowing into the first resonance chamber 110 . In the same principle, the air flowing into the third resonance chamber 130 may be air with a relatively lower frequency in comparison to the air flowing into the second resonance chamber 120 . Therefore, the air flowing into the inlet 15 moves to the first to third resonance chambers 110 , 120 , 130 depending on its frequency, and since the first to third resonance chambers 110 , 120 , 130 perform frequency tuning, the absorbed air discharges out through the outlet 45 with reduced noise. In this embodiment, since the air flowing in through the inlet 15 discharges out through the outlet 45 , it is possible to reduce noise by performing frequency tuning in a direction where an air frequency region decreases, namely from a high frequency region to a low frequency region. As another example, it is also possible to reduce noise by performing frequency tuning in a direction where an air frequency region increases, namely from a low frequency region to a high frequency region, by changing dimensions of the resonator 1 .
In this embodiment, in order to form a plurality of resonance chambers 100 , a single expansion pipe 30 is inserted between the outer pipes 10 , 20 and the inner pipe 40 . Hereinafter, another example for forming the plurality of resonance chambers 100 will be described.
FIG. 8 is a cross-sectional view showing an inner configuration of a resonator according to the second embodiment of the present disclosure, observed from one side and FIG. 9 is a cross-sectional view showing an inner configuration of the resonator according to the second embodiment of the present disclosure, observed from another side.
Referring to FIGS. 8 and 9 , in this embodiment, a plurality of expansion pipes 400 , 600 are inserted between the outer pipes 10 , 20 and the inner pipe 40 , different from the former embodiment. In detail, the expansion pipes of this embodiment include an inflow expansion pipe 400 disposed adjacent to the inlet 15 and a discharge expansion pipe 600 disposed adjacent to the outlet 45 .
One surface of the inflow expansion pipe 400 is coupled in contact with the inner pipe 40 , and the other surface of the inflow expansion pipe 400 is coupled in contact with the first outer pipe 10 . Therefore, an inflow bent portion 410 extending from the inner pipe 40 to the first outer pipe 10 is formed at the inflow expansion pipe 400 . The resonance chamber 100 may be partitioned into a plurality of regions by the inflow bent portion 410 .
A first discharge bent portion 610 extending from the inner pipe 40 to the second outer pipe 20 based on the moving direction of air and a second discharge bent portion 620 extending from the second outer pipe 20 to inner pipe 40 are formed at the discharge expansion pipe 600 . Therefore, the resonance chamber 100 may be partitioned into a plurality of regions by the first discharge bent portion 610 and the second discharge bent portion 620 . The inflow bent portion 410 , the first discharge bent portion 610 and the second discharge bent portion 620 can be named as the first bent portion, the second bent portion and the third bent portion, respectively.
As a result, the resonance chamber 100 is partitioned into a plurality of regions by the inflow expansion pipe 400 and the discharge expansion pipe 600 . In detail, the resonance chamber 100 may be divided into a first resonance chamber 110 , a second resonance chamber 120 , a third resonance chamber 130 and a fourth resonance chamber 140 , respectively, based on the moving direction of air. The first resonance chamber 110 is a space formed between the inflow expansion pipe 400 and the first outer pipe 10 , and the second resonance chamber 120 is a space formed by the first outer pipe 10 , the first discharge bent portion 610 , the inner pipe 40 and the inflow bent portion 410 . In addition, the third resonance chamber 130 is a space formed between the discharge expansion pipe 600 and the inner pipe 40 , and the fourth resonance chamber 140 is a space formed by the second outer pipe 20 , the inner pipe 40 and the second discharge bent portion 620 .
The second to fourth resonance chambers 120 , 130 , 140 communicate with the first to third slits 411 , 412 , 413 formed at the inner pipe 40 . Therefore, the air flowing into the inner pipe 40 through the inlet 15 moves to the second to fourth resonance chambers 120 , 130 , 140 through the first to third slits 411 , 412 , 413 and experiences frequency tuning.
The first outer pipe 10 is formed by integrally coupling an inflow guide unit 210 for guiding a moving path of air flowing into the inlet 15 and a chamber partitioning unit 230 having a relatively greater diameter than the inflow guide unit 210 . The inflow guide unit 210 and the chamber partitioning unit 230 are integrally fabricate by an extension 220 which extends in a radial direction to connect the inflow guide unit 210 and the chamber partitioning unit 230 . In other words, one side of the extension 220 is connected to the inflow guide unit 210 , and the other side of the extension 220 is connected to the chamber partitioning unit 230 .
A gap 250 for giving a moving path of air is formed between the inflow expansion pipe 400 and the extension 220 of the first outer pipe 10 . In other words, a predetermined space allowing movement of external air is formed between one side of the inflow expansion pipe 400 and the first outer pipe 10 . The air flowing into the inlet 15 passes through the gap 250 and moves to the first resonance chamber 110 . Therefore, the gap 250 plays the same role as the plurality of slits 411 , 412 , 413 formed at, the inner pipe 40 .
Hereinafter, a moving path of external air passing through the resonator 2 of this embodiment and welding locations of the plurality of pipes of the resonator 2 will be described.
FIG. 10 is an enlarged view showing the portion E of FIG. 9 , in which a flow of air passing through the resonator according to the second embodiment of the present disclosure is depicted.
As shown in FIG. 10 , in the resonator 2 of this embodiment, the plurality of pipes are coupled to each other by welding. In detail, coupling (a) between the first outer pipe 10 and the second outer pipe 20 , coupling (b) between the inflow expansion pipe 400 and the inner pipe 40 , coupling (c, d) between the discharge expansion pipe 600 and the inner pipe 40 and coupling (e) between the second outer pipe 20 and the inner pipe 40 are all performed by welding. Since the plurality of pipes are hermetically sealed by welding, it is possible to prevent a leakage of external air and thus maximize the efficiency of intake noise reduction.
Even though it has been illustrated in this embodiment that the plurality of pipes are coupled by welding, the present disclosure is not limited thereto, and another coupling method than welding may also be used as long as the plurality of pipes are hermetically coupled.
If the plurality of pipes are hermetically coupled as described above, the resonator 2 for noise reduction is completely made as an assembly. Hereinafter, a moving path of external air passing through the resonator 2 and a method for reducing intake noise will be described.
First, a part of air flowing into the inlet 15 passes through the gap 250 and moves to the first resonance chamber 110 , and another part of the air flowing into the inlet 15 moves to the inner pipe 40 . The air flowing into the first resonance chamber 110 may be air with a high frequency as an example. In other words, the first resonance chamber 110 may be a resonance chamber for tuning air with a high frequency and thus reducing noise.
Similarly, a part of air moving along the inner pipe 40 may pass the first slit 411 , another part of the air moving along the inner pipe 40 may pass the second slit 412 , and still another part of the air moving along the inner pipe 40 may pass the third slit 413 . All of them move to the second resonance chamber 120 , the third resonance chamber 130 , and the fourth resonance chamber 140 , respectively. The air flowing into the second resonance chamber 120 may be air with a relatively lower frequency in comparison to the air flowing into the first resonance chamber 110 . In the same principle, the air flowing into the third resonance chamber 130 may be air with a relatively lower frequency in comparison to the air flowing into the second resonance chamber 120 , and the air flowing into the fourth resonance chamber 140 may be air with a relatively lower frequency in comparison to the air flowing into the third resonance chamber 130 .
Therefore, the air flowing into the inlet 15 moves to the first to fourth resonance chambers 110 , 120 , 130 , 140 depending on its frequency, and since the first to fourth resonance chambers 110 , 120 , 130 , 140 perform frequency tuning, the absorbed air discharges out through the outlet 45 with reduced noise.
Even though it has been illustrated in this embodiment that the frequency of air flowing into the resonance chamber 100 gradually decreases from the first resonance chamber 110 to the fourth resonance chamber 140 , the present disclosure is not limited thereto. For example, the third resonance chamber 130 and the fourth resonance chamber 140 may be resonance chambers for tuning air with a high frequency, and the first resonance chamber 110 and the second resonance chamber 120 may be resonance chambers for tuning air with a low frequency.
In addition, the air flowing into the resonance chamber 100 may have different frequencies depending on various factors such as a thickness of the expansion pipe 400 , 600 , a horizontal length of the expansion pipes 400 , 600 , a volume of each resonance chamber 100 , a width of the gap 250 or the slits 411 , 412 , 413 serving as an air passage, or the like. However, if the number of the resonance chambers 100 increases, air with various frequencies may flow into each resonance chamber, and thus noise of a broad frequency band may be reduced.
FIG. 11 is a cross-sectional view showing an inner configuration of a resonator according to the third embodiment of the present disclosure, observed from one side, and FIG. 12 is a cross-sectional view showing an inner configuration of the resonator according to the third embodiment of the present disclosure, observed from another side.
Referring to FIGS. 11 and 12 , in this embodiment, in order to increase the number of the resonance chambers 100 , barriers 510 , 520 and an intermediate pipe 530 are inserted between the outer pipes 10 , 20 and the inner pipe 40 , different from the former embodiments (the first and second embodiments of the present disclosure). In detail, a resonator 3 of this embodiment includes a first outer pipe 10 having the inlet 15 serving as an inflow passage of external air and a second outer pipe 20 having the outlet 45 serving as a discharge passage of external air. The intermediate pipe 530 extending in a length direction is disposed between the first outer pipe 10 and the second outer pipe 20 . Therefore, the first outer pipe 10 , the second outer pipe 20 and the intermediate pipe 530 form an outward appearance of the resonator 3 of this embodiment.
The first outer pipe 10 may be classified into an inflow guide unit 210 , an extension 220 and a chamber partitioning unit 230 , which may be integrally fabricated, similar to the second embodiment of the present disclosure.
The inner pipe 40 having a plurality of slits 41 is inserted into the inner space of the outer pipes 10 , 20 . As shown in FIG. 11 , the slits formed at the inner pipe 40 may be a first slit 411 , a second slit 412 and a third slit 413 , respectively, based on the moving direction of air.
The first barrier 510 is disposed between the first outer pipe 10 and the intermediate pipe 530 , and the second barrier 520 is disposed between the intermediate pipe 530 and the second outer pipe 20 . In other words, the first barrier 510 is disposed at one side of the intermediate pipe 530 , and the second barrier 520 is disposed at the other side of the intermediate pipe 530 . In this embodiment, the barrier has been illustrated as being classified into the first barrier 510 and the second barrier 520 , but the number of the barriers 510 , 520 is not limited thereto.
The first barrier 510 and the second barrier 520 are arranged side by side in a direction parallel to the extension 220 of the first outer pipe 10 . In other words, the first barrier 510 and the second barrier 520 may extend in a direction perpendicular to the intermediate pipe 530 .
In addition, an outer circumference of the barriers 510 , 520 may be exposed outwards. In detail, an outer surface of the resonator 3 may be configured with the first outer pipe 10 , the first barrier 510 , the intermediate pipe 530 , the second barrier 520 and the second outer pipe 20 , based on the moving direction of air. However, the first outer pipe 10 , the intermediate pipe 530 and the second outer pipe 20 may be integrally fabricated, and the barriers 510 , 520 may be attached to an inner side of the outer surface of the resonator 3 integrally fabricated.
The resonance chamber 100 for adjusting a frequency of external air is formed in the space between the outer pipes 10 , 20 and the inner pipe 40 and the space between the intermediate pipe 530 and the inner pipe 40 . The resonance chamber 100 is divided into a plurality of regions by the barriers 510 , 520 .
In detail, the resonance chamber 100 is divided into a first resonance chamber 110 , a second resonance chamber 120 and a third resonance chamber 130 , respectively, based on the moving direction of air. The first resonance chamber 110 is a space formed among the first outer pipe 10 , the first barrier 510 and the inner pipe 40 , and the second resonance chamber 120 is a space formed by the first barrier 510 , the intermediate pipe 530 , the second barrier 520 and the inner pipe 40 . In addition, the third resonance chamber 130 is a space formed among the second barrier 520 , the second outer pipe 20 and the inner pipe 40 .
In this embodiment, the resonance chamber 100 is divided into three chambers by two barriers 510 , 520 , but the present disclosure is not limited thereto. For example, if three barriers are disposed in the resonance chamber 100 , the resonance chamber 100 may be divided into four chambers.
The first to third resonance chambers 110 , 120 , 130 communicate with the first to third slits 411 , 412 , 413 formed at the inner pipe 40 . Therefore, the air flowing into the inner pipe 40 through the inlet 15 moves to the first to third resonance chambers 110 , 120 , 130 through the first to third slits 411 , 412 , 413 , thereby performing frequency tuning for the absorbed air.
Hereinafter, a moving path of external air passing through the resonator 3 and welding locations of the plurality of 10 , 20 , 40 , 530 and barriers 510 , 520 of the resonator 3 will be described.
FIG. 13 is an enlarged view showing the portion F of FIG. 12 , in which a flow of air passing through the resonator according to the third embodiment of the present disclosure is depicted.
As shown in FIG. 13 , in the resonator 3 of this embodiment, the plurality of pipes 10 , 20 , 40 , 530 and the barriers 510 , 520 are coupled to each other by welding. In detail, coupling (a) between the first outer pipe 10 and the first barrier 510 , coupling (b) between the inner pipe 40 and the first barrier 510 , coupling (c) between the intermediate pipe 530 and the second barrier 520 and coupling (d) between the second barrier 520 and the inner pipe 40 are all performed by welding. Since the plurality of pipes are hermetically sealed by welding, it is possible to prevent a leakage of external air and thus maximize the efficiency of intake noise reduction.
Even though it has been illustrated in this embodiment that the plurality of pipes are coupled by welding, the present disclosure is not limited thereto, and another coupling method than welding may also be used as long as the plurality of pipes are hermetically coupled.
If the plurality of pipes are hermetically coupled as described above, the resonator 3 for noise reduction is completely made as an assembly. Hereinafter, a moving path of external air passing through the resonator 3 and a method for reducing intake noise will be described.
First, a part of air flowing into the inlet 15 passes through the first slit 411 and moves to the first resonance chamber 110 , and another part of the air flowing into the inlet 15 moves to the inner pipe 40 . The air flowing into the first resonance chamber 110 may be air with a high frequency as an example. In other words, the first resonance chamber 110 may be a resonance chamber for tuning air with a high frequency and thus reducing noise.
Similarly, a part of air moving along the inner pipe 40 passes the second slit 412 and moves to the second resonance chamber 120 , and another part of the air moving along the inner pipe 40 passes the third slit 413 and moves to the third resonance chamber 130 . The air flowing into the second resonance chamber 120 may be air with a relatively lower frequency in comparison to the air flowing into the first resonance chamber 110 . In the same principle, the air flowing into the third resonance chamber 130 may be air with a relatively lower frequency in comparison to the air flowing into the second resonance chamber 120 . Therefore, the air flowing into the inlet 15 moves to the first to third resonance chambers 110 , 120 , 130 depending on its frequency, and since the first to third resonance chambers 110 , 120 , 130 perform frequency tuning, the absorbed air discharges out through the outlet 45 with reduced noise.
Even though it has been illustrated in this embodiment that the frequency of air flowing into the resonance chamber 100 gradually decreases from the first resonance chamber 110 to the third resonance chamber 130 , the present disclosure is not limited thereto. For example, the second resonance chamber 120 and the third resonance chamber 130 may be resonance chambers for tuning air with a high frequency, and the first resonance chamber 110 may be resonance chambers for tuning air with a low frequency.
In addition, the air flowing into the resonance chamber 100 may have different frequencies depending on various factors such as a thickness of the barriers 510 , 520 , locations of the barriers 510 , 520 , a volume of each resonance chamber 100 , a width of the slits 411 , 412 , 413 , or the like. However, if the number of the resonance chambers 100 increases, air with various frequencies may flow into each resonance chamber, and thus noise of a broad frequency band may be reduced.
While the exemplary embodiments have been shown and described, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of the present disclosure as defined by the appended claims. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular exemplary embodiments disclosed as the best mode contemplated for carrying out the present disclosure, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
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A resonator for a vehicle, which reduces intake noise by using a resonance chamber for frequency tuning, includes an outer pipe having a first outer pipe with an inlet for introducing external air and a second outer pipe with an outlet for discharging the air introduced into the inlet to outside, an inner pipe disposed inside the outer pipe and having a plurality of slits for giving a passage of air, and an expansion pipe inserted between the outer pipe and the inner pipe to partition a space between the outer pipe and the inner pipe into a plurality of spaces and thus partition the resonance chamber into a plurality of regions.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority from Taiwan patent application TW 103 124 193, filed Jul. 14, 2014, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a pulley for an alternator, and in particular, to a pulley for an automotive alternator.
[0003] An alternator is a type of generator that can produce an alternating current by converting mechanical energy into electrical energy. An automotive alternator converts mechanical energy of an engine into electrical energy to charge a battery, so as to supply electrical power to other electrical appliances on the automobile, and start a motor to rotate the engine.
[0004] An alternator generally has an annular stator and a rotor received in the annular stator. A wire is wound on the stator, and the rotor rotates rapidly in the stator so that the wire moves relative to a magnetic field generated by the rotor, and an induced electromotive force (voltage) is generated in the wire.
[0005] An automotive alternator is usually utilized by an engine driving a belt. The belt is wound on a pulley, and the pulley is connected to a rotor so as to drive the rotor to rotate. However, in conventional alternator design, when an engine starts, or accelerates or decelerates quickly in an instant, a waveform changes significantly at the moment the generator charges a battery, and it cannot be stabilized. In addition, one side of the belt wound on the pulley is tight, and the other side thereof is slack. The tension of the slack-side belt is low, and therefore a tensioner is disposed thereon to adjust the tension of the belt. However, when a rotation speed at which the engine transmits power changes suddenly, because the pulley of the generator is locked by a nut and the belt is made of a flexible material and cannot reflect the rotation speed immediately, a slip is easily caused between the belt and the pulley. Moreover, the fluctuation of the rotation speed causes the belt to bear not only a repeated stress but also a centrifugal force that is applied on the belt when the pulley rotates. The value of the centrifugal force changes with the rotation speed, and therefore the belt is often affected by adverse factors of an internal micro tension, which pulls the belt, and external large-amplitude shaking.
SUMMARY OF THE INVENTION
[0006] In view of the deficiency of the prior art, the inventor proposes a pulley for an alternator which can effectively mitigate the vibration or belt slack or damage of the pulley caused by the speed change, thereby improving the overall operating efficiency and service life of the alternator.
[0007] To achieve the above objective, a pulley for an alternator according to an exemplary embodiment of the present invention includes an outer wheel, provided with an axle hole at the center; a clutch wheel, fixedly disposed in the axle hole of the outer wheel and having a pivot hole; a hollow connecting shaft, having a first end and a second end, where the first end is rotatably disposed in the pivot hole of the clutch wheel, so that the hollow connecting shaft maintains a co-rotational relationship with the outer wheel in a first relative rotation direction by means of the clutch wheel, while in a second relative rotation direction, the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel, and presents an idling state; a hollow core shaft, having a first end and a second end, where the hollow core shaft is rotatably received in the outer wheel, and the second end of the hollow core shaft is rotatably arranged at the second end of the hollow connecting shaft; and an elastic element, disposed between the second end of the hollow connecting shaft and the second end of the hollow core shaft. When an external force drives the outer wheel to rotate, the outer wheel rotates relative to the hollow connecting shaft in the first relative rotation direction, and drives, through the clutch wheel, the hollow connecting shaft to rotate synchronously; the second end of the hollow connecting shaft presses the elastic element, and while being pressed, the elastic element pushes the second end of the hollow core shaft, thereby driving the hollow core shaft to rotate. When the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and stretches the elastic element, and while being stretched, the elastic element pulls the second end of the hollow connecting shaft, thereby driving the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction, so that the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel, and idles in the clutch wheel.
[0008] According to another implementation of the exemplary embodiment, the hollow core shaft passes through the hollow connecting shaft, and the first end of the hollow core shaft protrudes from the first end of the hollow connecting shaft; a tight-fit component is sleeved over an outer circumferential wall surface of the first end of the hollow core shaft in a tight-fit manner, and the tight-fit component is also tightly fit with an end surface of the first end of the hollow connecting shaft; therefore, the hollow connecting shaft and the hollow core shaft are made to corotate coaxially under a friction between the tight-fit component and the hollow connecting shaft and a friction between the tight-fit component and the hollow core shaft, and when the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and drives, through the tight-fit component, the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction, so that the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel and idles in the clutch wheel.
[0009] According to another implementation of the exemplary embodiment, the tight-fit component is a C-shaped retaining ring.
[0010] According to another implementation of the exemplary embodiment, the second end of the hollow connecting shaft is provided with a first protruding portion, and the second end of the hollow core shaft is provided with a corresponding second protruding portion; the number of one of the first protruding portion and the second protruding portion is at least one, and the number of the other of the first protruding portion and the second protruding portion is at least two; and when a rotation angle of the hollow connecting shaft relative to the hollow core shaft exceeds a predetermined value, the first protruding portion of the hollow connecting shaft contacts the second protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, and setting the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship.
[0011] According to another implementation of the exemplary embodiment, a first ball bearing is sleeved over the first end of the hollow core shaft, a second ball bearing is sleeved over the second end of the hollow core shaft, and the first ball bearing and the second ball bearing are disposed between the hollow core shaft and the outer wheel, so that the hollow core shaft is rotatable relative to the outer wheel.
[0012] According to another implementation of the exemplary embodiment, three grooves are provided in a concave manner on an inner circumferential wall surface of the outer wheel, and an anaerobic adhesive is coated in the grooves, so that the clutch wheel, the first ball bearing, and the second ball bearing are separately tightly fit in the grooves, and are fixedly glued in the outer wheel by using the anaerobic adhesive.
[0013] According to another implementation of the exemplary embodiment, a positioning casing is further sleeved over the first ball bearing, and an axial position of the pulley on the alternator is limited by the positioning casing.
[0014] According to another implementation of the exemplary embodiment, an outer circumferential wall surface of the outer wheel is provided with a belt groove, for a belt to be wound on.
[0015] According to another implementation of the exemplary embodiment, the belt is connected to a mechanical energy generating source, and the mechanical energy generating source provides an external force to drive the belt, thereby driving the outer wheel to rotate.
[0016] According to another implementation of the first exemplary embodiment, the mechanical energy generating source is an engine.
[0017] According to another implementation of the exemplary embodiment, an inner circumferential wall surface of the hollow core shaft is provided with a threaded surface, the threaded surface is screwed with a joint lever having corresponding threads, and the joint lever is connected to a rotor, so that the hollow core shaft and the rotor corotate synchronously.
[0018] According to another implementation of the exemplary embodiment, an inner circumferential wall surface of the outer wheel is provided with a step portion, for the clutch wheel to abut against, thereby limiting an axial displacement of the clutch wheel.
[0019] According to implementation of the first exemplary embodiment, one end of the clutch wheel is provided with a positioning member, to limit an axial position of the clutch wheel, and the positioning member is a C-shaped retaining ring.
[0020] According to implementation of the exemplary embodiment, the elastic element is a torque spring, and a wire profile of the torque spring is circular, elliptical, or rectangular.
[0021] According to another implementation of the first exemplary embodiment, when the wire profile of the torque spring is rectangular, two end surfaces of the torque spring are grinded, so as to enhance axial positioning of the torque spring and control a free length of the torque spring more precisely.
[0022] According to another implementation of the exemplary embodiment, two sides of the clutch wheel are each provided with an oil seal element, so as to prevent liquid in the clutch wheel from flowing into the outer wheel.
[0023] According to another implementation of the exemplary embodiment, one side of one of the oil seal elements is provided with a positioning member, and the positioning member is sleeved over an inner side wall surface of the outer wheel in a tight-fit manner, to limit axial positions of the oil seal elements.
[0024] According to another implementation of the exemplary embodiment, the positioning member is a C-shaped retaining ring.
[0025] According to another implementation of the exemplary embodiment, an end, corresponding to the second end of the hollow core shaft, of the outer wheel is arranged with a dust cover, so as to prevent external dust from entering the outer wheel.
[0026] For better understanding of the detailed description of the present invention, the features and technical advantages of the present invention are described generally above. The following describes the additional features and advantages of the present invention. Persons skilled in the art should be aware that the disclosed concept and specific implementation manner can be easily used as a basis for modifying or designing other structures for implementing objectives the same as the present invention. Persons skilled in the art should also be aware that such equivalent structures do not depart from the spirit and scope of the present invention which are claimed in the patent application scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] For a more thorough understanding of the present invention and advantages of the present invention, the following descriptions are provided with reference to the accompanying drawings, where:
[0028] FIG. 1 is a three-dimensional exploded view of a pulley for an alternator according to the present invention;
[0029] FIG. 2 is a sectional assembled view of a pulley for an alternator according to the present invention;
[0030] FIG. 3 is a schematic structural view of a hollow connecting shaft according to the present invention;
[0031] FIG. 4 is a schematic structural view of a hollow core shaft according to the present invention; and
[0032] FIG. 5 is a schematic view of a rotor of an alternator according to the present invention.
MEANING OF REFERENCE NUMERALS
[0000]
10 Pulley
20 Joint lever
30 Rotor
110 Outer wheel
111 Axle hole
112 Belt groove
113 Step portion
120 Clutch wheel
121 Pivot hole
122 Housing
123 Rolling member
124 Elastic member
125 Cap
130 Hollow connecting shaft
131 First end of the hollow connecting shaft
132 Second end of the hollow connecting shaft
133 First protruding portion
134 Stop wall of the hollow connecting shaft
140 Hollow core shaft
141 First end of the hollow core shaft
142 Second end of the hollow core shaft
143 First ball bearing
144 Second ball bearing
145 Protruding ring of the hollow core shaft
146 Second protruding portion
147 Stop wall of the hollow core shaft
148 Threaded surface
150 Elastic element
160 Tight-fit component
161 Positioning gasket
162 C-shaped retaining ring
170 Positioning casing
171 Protruding ring of the positioning casing
181 Oil seal element
182 Oil seal element
183 Positioning member
184 Dust cover
185 Positioning member
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0071] The following describes the present invention in the context of the exemplary embodiment described above. The skilled person will appreciate that the following description is used to describe the present invention and illustrate the advantages thereof, but it does not mean that the present invention is limited to such an embodiment, and in particular, the scope of the present invention includes equivalents thereof.
[0072] FIG. 1 and FIG. 2 are respectively a three-dimensional exploded view and a sectional assembled view of a pulley for an alternator according to the present invention. As shown in FIG. 1 and FIG. 2 , a pulley 10 for an alternator according to the present invention mainly includes an outer wheel 110 , a clutch wheel 120 , a hollow connecting shaft 130 , a hollow core shaft 140 , an elastic element 150 , and a tight-fit component 160 . The outer wheel 110 is a wheel-shaped member provided with an axle hole 111 at the center, and is provided with a belt groove 112 on an outer circumferential wall surface thereof and a step portion 113 on an inner circumferential wall surface thereof. The clutch wheel 120 is annular, provided with a pivot hole 121 at the center, and fixedly disposed in the axle hole 111 of the outer wheel 110 . For example, a groove may be provided in a concave manner on the inner circumferential wall surface of the outer wheel 110 , and an anaerobic adhesive is coated in the groove so that the clutch wheel 120 can be fixedly connected to an inner circumferential wall surface of the axle hole 111 of the outer wheel 110 by means of tight fit and adhesion of the anaerobic adhesive. One end of the clutch wheel 120 abuts against the step portion 113 of the outer wheel 110 to limit an axial position of the clutch wheel 120 and to ensure that an end surface of the clutch wheel 120 is perpendicular to the hollow connecting shaft 130 and the hollow core shaft 140 , prevent axial displacement of the clutch wheel 120 during high-speed rotation, and moreover, provide an axial positioning reference during assembly of components in the outer wheel 110 , which facilitates positioning during the assembly.
[0073] The hollow connecting shaft 130 has a first end 131 and a second end 132 . The first end 131 is rotatably disposed in the clutch wheel 120 so that the hollow connecting shaft 130 can maintain a co-rotational relationship with the outer wheel 110 in a first relative rotation direction by means of the clutch wheel 120 (for example, the hollow connecting shaft 130 rotates anticlockwise relative to the outer wheel 110 ), and it is disassociated from the co-rotational relationship with the outer wheel 110 in a second relative rotation direction to enter an idling state (for example, the hollow connecting shaft 130 rotates clockwise relative to the outer wheel 110 ), and at this time, the hollow connecting shaft 130 rotates independently of the outer wheel 110 . The hollow connecting shaft 130 is provided with a first protruding portion 133 on the second end 132 , as shown in FIG. 3 .
[0074] In a preferred embodiment of the present invention, the clutch wheel 120 has a housing 122 , a plurality of rolling members 123 , a plurality of elastic members 124 , and two caps 125 . The clutch wheel 120 is provided with a positioning member 185 on an end opposite to the end abutting against the step portion 113 to limit the axial position of the clutch wheel 120 and prevent the caps 125 of the clutch wheel 120 from falling off. The positioning member may be a C-shaped retaining ring. For the detailed structure and operating principle of the clutch wheel 120 , reference may be made to Taiwan Patent Application No. 098129945 filed by the applicant on Sep. 4, 2009. However, the clutch wheel of the present invention is not limited thereto, and any speed-difference clutch apparatus capable of implementing the functions of the clutch wheel 120 described in the present invention may be designed as the clutch wheel 120 of the present invention. Moreover, in the present invention, two ends of the clutch wheel 120 are each provided with an oil seal element 181 / 182 so as to prevent a liquid (for example, a lubricating oil) in the clutch wheel 120 from permeating and polluting the interior of the pulley 10 . Furthermore, a positioning member 183 may be sleeved over one side of the oil seal element 182 . The positioning member 183 may be a C-shaped retaining ring, and may be sleeved over an inner side wall surface of the outer wheel 110 in a tight-fit manner, to limit axial positions of the oil seal elements 181 and 182 and the clutch wheel 120 .
[0075] The hollow core shaft 140 is disposed in the outer wheel 110 and has a first end 141 and a second end 142 . A first ball bearing 143 is sleeved over the first end 141 , and a second ball bearing 144 is sleeved over the second end 142 . The first ball bearing 143 and the second ball bearing 144 are both fixedly connected to the inner circumferential wall surface of the outer wheel 110 (for example, the outer wheel 110 may be provided with two grooves on the inner circumferential wall surface in a concave manner, and an anaerobic adhesive is coated in the grooves so that the first ball bearing 143 and the second ball bearing 144 can be fixedly connected to the inner circumferential wall surface of the axle hole 111 of the outer wheel 110 by means of tight fit and adhesion of the anaerobic adhesive) so that the hollow core shaft 140 is rotatable relative to the outer wheel 110 . In addition, the hollow core shaft 140 passes through the hollow connecting shaft 130 , and the first end 141 of the hollow core shaft 140 protrudes from the first end 131 of the hollow connecting shaft 130 . A protruding ring 145 is annularly arranged at the second end 142 of the hollow core shaft 140 . The protruding ring 145 is rotatably arranged on the second end 132 of the hollow connecting shaft 130 . A second protruding portion 146 is provided in a protruding manner in a direction towards the hollow connecting shaft 130 , and the second protruding portion 146 corresponds to the first protruding portion 133 so that after the hollow connecting shaft 130 and the hollow core shaft 140 rotate by a particular degree relative to each other, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 . For example, when the hollow connecting shaft 130 is provided with two first protruding portions 133 at the second end 132 , and when the hollow core shaft 140 is provided with three second protruding portions 146 at the second end 142 , the hollow core shaft 140 can only rotate clockwise or anticlockwise by 120 degrees relative to the hollow connecting shaft 130 after being sleeved over the hollow connecting shaft 130 because relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 is stopped when the first protruding portions 133 contact the second protruding portions 146 .
[0076] The elastic element 150 is disposed between the second end 132 of the hollow connecting shaft 130 and the second end 142 of the hollow core shaft 140 . In a preferred embodiment of the present invention, the elastic element is a torque spring, and a wire profile of the torque spring may be circular, elliptical, or rectangular. When the wire profile of the torque spring is rectangular, two end surfaces of the torque spring may be grinded so as to enhance an axial positioning capability of the torque spring and control a free length of the spring more precisely. The hollow connecting shaft 130 is provided with a stop wall 134 in a concave manner on an inner circumferential wall surface of the second end 132 (as shown in FIG. 3 ) so that one end of the elastic element 150 can abut against the stop wall 134 , and the elastic element 150 may also be fixedly connected to the stop wall 134 . In addition, The hollow core shaft 140 is also provided with a stop wall 147 on an inner side of the protruding ring 145 of the second end 142 (as shown in FIG. 4 ) so that the other end of the elastic element 150 can abut against the stop wall 147 , and the elastic element 150 may also be fixedly connected to the stop wall 147 . When the two ends of the elastic element 150 are fixedly connected to the stop wall 134 of the hollow connecting shaft 130 and the stop wall 147 of the hollow core shaft 140 , relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 presses or stretches the elastic element 150 ; when the two ends of the elastic element 150 merely abut against but are not fixedly connected to the stop wall 134 of the hollow connecting shaft 130 or the stop wall 147 of the hollow core shaft 140 , relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 only presses the elastic element 150 .
[0077] The tight-fit component 160 is a C-shaped retaining ring; the C-shaped retaining ring is sleeved over the outer circumferential wall surface of the first end 141 of the hollow core shaft 140 in a tight-fit manner, and is tightly fit with a tail end surface of the first end 131 of the hollow connecting shaft 130 . Therefore, under a friction between the tight-fit component 160 and the end surface of the first end 131 of the hollow connecting shaft 130 and a friction between the tight-fit component 160 and the outer circumferential wall surface of the first end 141 of the hollow core shaft 140 , the hollow connecting shaft 130 and the hollow core shaft 140 drive each other and corotate coaxially, as shown in FIG. 3 .
[0078] A positioning casing 170 is further sleeved over the first ball bearing 143 , and the positioning casing 170 is a hollow annular pipe provided with a protruding ring 171 at one end; therefore, the protruding ring 171 penetrates the first ball bearing 143 and provides an abutting and cushioning function when the pulley 10 is installed on an alternator, and an axial position of the pulley 10 on the alternator is limited by the positioning casing 170 .
[0079] The hollow core shaft 140 is provided with a threaded surface 148 on an inner circumferential wall surface thereof, the threaded surface 148 may be screwed with a joint lever 20 having corresponding threads, and the joint lever 20 is connected to a rotor 30 of the alternator so that the hollow core shaft 140 and the rotor 30 corotate synchronously (as shown in FIG. 5 ). In addition, an end, corresponding to the second end 142 of the hollow core shaft 140 , of the outer wheel 110 is arranged with a dust cover 184 so as to prevent external dust from entering the outer wheel 110 .
[0080] With the structure described above, when a mechanical energy generating source provides an external force to drive the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously, and with the friction provided by the tight-fit component 160 , the hollow connecting shaft 130 drives the hollow core shaft 140 to rotate. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow core shaft 140 to rotate, the hollow connecting shaft 130 rotates relative to the hollow core shaft 140 , which causes the stop wall 134 at the second end 132 of the hollow connecting shaft 130 to press the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate. At this time, if a relative rotation angle between the hollow connecting shaft 130 and the hollow core shaft 140 exceeds a predetermined value (for example, 120 degrees), the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to avoid pressing the elastic element 150 excessively and damaging the structure thereof, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship; the hollow core shaft 140 also drives the rotor 30 to rotate so that the alternator generates an induced current.
[0081] In addition, if the outer wheel 110 is originally in a rotation state, when the mechanical energy generating source provides an external force to accelerate the rotation of the outer wheel 110 , an operating principle of the pulley 10 of the present invention is substantially the same as the aforementioned operating principle in the case of starting the outer wheel 110 to rotate, and therefore it is not repeated herein.
[0082] On the contrary, when the external force stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 . At this time, the hollow core shaft 140 drives, by using the friction provided by the tight-fit component 160 , the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 . At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 rotates relative to the hollow connecting shaft 130 ; if the elastic element 150 merely abuts against but is not fixedly connected to the hollow connecting shaft 130 and the hollow core shaft 140 , the hollow core shaft 140 keeps rotating relative to the hollow connecting shaft 130 until the second protruding portion 146 of the hollow core shaft 140 contacts the first protruding portion 133 of the hollow connecting shaft 130 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 and setting the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship so that the hollow connecting shaft 130 and the hollow core shaft 140 rotate relative to the outer wheel 110 in the second relative rotation direction.
[0083] If the elastic element 150 is fixedly connected to the hollow connecting shaft 130 and the hollow core shaft 140 , when the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 rotates relative to the hollow connecting shaft 130 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 . At this time, if rotation of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value (for example, 120 degrees), the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to avoid stretching the elastic element 150 excessively and damaging the structure thereof, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship so that the hollow connecting shaft 130 and the hollow core shaft 140 rotate relative to the outer wheel 110 in the second relative rotation direction.
[0084] In addition, if the external force driving the outer wheel 110 decreases, the operating principle of the pulley 10 of the present invention is substantially the same as the aforementioned operating principle in the case in which the outer wheel 110 stops rotating, and therefore it is not repeated herein.
[0085] In the pulley 10 of the present invention, a belt (not shown in the figure) may be wound on the belt groove 112 of the outer wheel 110 so that the mechanical energy generating source can provide an external force to drive the belt, thereby driving the outer wheel 110 to rotate. In addition, the pulley 10 of the present invention is applicable to an alternator system, such as a power generation system and an alternator system of a vehicle. The pulley of the present invention is especially suitable to be used as a stator structure of an automotive alternator. When the pulley of the present invention is applied to an automotive alternator, the mechanical energy generating source is an automobile engine.
[0086] In a preferred embodiment of the present invention, the tight-fit component 160 of the pulley 10 of the present invention may be omitted, and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . In this manner, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously; the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate. At this time, if a rotation angle of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to prevent the elastic element 150 from being pressed excessively, setting the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship, and drive the rotor 30 to rotate.
[0087] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 . At this time, if a rotation angle of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to prevent the elastic element 150 from being stretched excessively, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship, in which the hollow connecting shaft 130 and the hollow core shaft 140 idle in the outer wheel 110 . In addition, in a preferred embodiment of the present invention, in the pulley 10 of the present invention, the first protruding portion 133 and the second protruding portion 146 may not be disposed, the protruding ring 145 at the second end 142 of the hollow core shaft 140 is directly sleeved over the second end 132 of the hollow connecting shaft 130 , and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . Therefore, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously, and the hollow connecting shaft 130 drives, through the tight-fit component 160 , the hollow core shaft 140 to rotate. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow core shaft 140 to rotate, the stop wall 134 at the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate, so as to drive the rotor 30 of the alternator to rotate.
[0088] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and drives, through the tight-fit component 160 , the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 .
[0089] Further, in a preferred embodiment of the present invention, in the pulley 10 of the present invention, the tight-fit component 160 , the first protruding portion 133 , and the second protruding portion 146 may not be disposed; the protruding ring 145 at the second end 142 of the hollow core shaft 140 is directly sleeved over the second end 132 of the hollow connecting shaft 130 , and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . In this manner, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously; the stop wall 134 at the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate.
[0090] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 .
[0091] Although the present invention and advantages thereof are described in detail above, it should be understood that variations, alternative solutions, and modifications can be made herein without departing from the spirit and scope of the present invention which are defined in the appended patent application scope. Moreover, the scope of the present invention is not limited to the specific implementations of the process, machine, product, material composition, means, method, and steps described in the specification. For example, persons skilled in the art can easily learn from the disclosure of the present invention that existing or to-be-developed processes, machines, products, material compositions, means, methods and steps that substantially implement the same function or substantially achieve the same result as the corresponding implementation manner described herein may be used. Correspondingly, the appended patent application scope is intended to cover such processes, machines, products, material compositions, means, methods or steps.
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The present invention relates to a pulley for an alternator, and in particular, to a pulley applicable to an automotive alternator. The pulley effectively mitigates the problem that a belt and a tension pulley of an alternator vibrate because a rotation speed of a vehicle engine changes, thereby improving the overall operating efficiency of the alternator and the service life of the working belt and the tension pulley.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
SEQUENCE LISTING OR PROGRAM
[0003] Not applicable.
BACKGROUND
[0004] 1. Field
[0005] This application refers to a transit vehicle, more particularly to a ferry-like vehicle capable of transporting a plurality of roadway vehicles with their passengers and cargo.
[0006] 2. Background
[0007] Virtually all sizeable cities in the world face enormously expensive challenges in managing automobile traffic. Cities have invested many billions of dollars in efforts to manage automobile traffic, reduce traffic congestion and improve air quality. These investments have funded transit systems such as bus, light rail and commuter rail, subway, trolleys, vanpools and carpool lanes. Despite massive investments, traffic congestion and air pollution continue to grow.
The Texas Transportation Institute, widely accepted as an authority on U.S. traffic data and trends, reports in their 2009 Urban Mobility Report that traffic congestion has increased in every category of city (very large, large, medium and small) as measured by “Delay Hours” between 1982 and 2007. Very large cities have increased from 21 hours of delay per driver per year to 51 hours per driver per year, an increase of 143 percent. For large cities the increase is 218 percent, for medium cities the increase is 188 percent and for small cities the increase is 217 percent. The CIA World Factbook of 2006 reports that the U.S. and world populations are expected to continue growing into the foreseeable future. Growth is slowing from a high of 2.2 percent in the 1960's to 1.1 percent today. The rate of growth is expected to decline further but absolute numbers of people are forecast to increase until at least mid-century when the world population reaches approximately 9.2 billion.
[0010] The current U.S. nationwide adoption rate for public transportation is 4.9 percent (2008 ACS survey by the US Census Bureau). In numerical terms, 6.8 million out of 136 million commuters utilize public transportation. Public transit use is heavily skewed toward 1.) individuals without automobiles, and 2.) commuters in cities with robust subway systems, mostly along the east coast. Many sprawling western cities have public transit adoption rates of less than two percent.
[0011] At the same time, a recent Pew survey shows that fewer Americans like to drive. Many people, 31 percent, called driving a “chore”. The reason they felt this way is “the growing hassle of traffic congestion” (23 percent), “other drivers” (14 percent) and “the grind of commuting to work” (10 percent). Other factors such as “waste of time” (5 percent), “tiring” (4 percent) and “stressful” (3 percent) add up to a large body of people who would rather not drive.
[0012] The two primary reasons that motivate commuters to choose automobiles over mass transportation are: 1.) mobility—automobiles provide commuters a high degree of mobility where public transportation systems inhibit mobility, especially in large, sprawling cities, and 2.) time—end-to-end commutes on public transportation systems generally require more time because the journey includes a.) walking, biking or driving from the start location to the transit system embarkation point, b.) the journey on the transit system that might involve several stops, connections and/or modal changes, and c.) walking or biking to the end location. Current public transportation systems do not meet the mobility requirement or time efficiency demanded by commuters.
[0013] The costs associated with traffic congestion are staggering. From the perspective of commuters there are statistical data indicating significant costs in wasted time, wasted fuel, lost productivity and increased stress and anxiety. From the perspective of city, county, state and federal governments there are well documented costs of managing and maintaining existing roadways and transit systems, plus construction of new roadways and transit systems. These circumstances create significant demand for traffic abatement projects that reduce traffic congestion, air pollution, and the hefty ongoing socioeconomic costs associated with crowded roadways.
[0014] Prior art is extensive and varied as it pertains to public transit systems. Some transit system designs are all-encompassing mobility systems in which private automobiles have no role. Other designs require various types of guide ways through which various specialized vehicles travel. Some designs attempt to transport modified automobiles and their passengers via overhead rails while others require highly specialized vehicles. A few systems transport unmodified roadway vehicles and their passengers but are very clearly designed for long distance rather than intra-city commuter travel.
[0000] Prior art includes:
1. Closed loop systems represented by U.S. Pat. No. 3,403,634 to Crowder, U.S. Pat. No. 3,903,807 to Lee, U.S. Pat. No. 4,841,871 to Leibowitz, U.S. Pat. No. 5,016,542 to Mitchell, U.S. Pat. No. 5,797,330 to Li, and U.S. Pat. No. 6,810,817 to James. These systems share the objective of replacing automobiles with an all-encompassing urban transportation system. To utilize these systems commuters must leave their car behind and thereby forfeit mobility. Over the decades, commuters have shown consistently that they need and/or desire access to their automobiles at all times. Evidence of this is clear in the weak adoption rate of current transit systems. Closed loop systems suffer the burden of changing the behavior of urban commuters who cannot or will not abandon their automobiles during their daily commute. 2. Guideway systems represented by U.S. Pat. No. 5,063,857 to Kissel, Jr., U.S. Pat. No. 5,590,604 to Lund, U.S. Pat. No. 5,619,930 to Alimanestiano, U.S. Pat. No. 6,039,135 to Henderson, U.S. Pat. No. 6,182,577 to Billings, U.S. Pat. No. 6,202,566 to Hutchinson, U.S. Pat. No. 6,237,500 to Lund, U.S. Pat. No. 6,357,358 to Henderson, U.S. Pat. No. 6,353,857 to Kauffman, U.S. Pat. No. 6,668,729 to Richards, U.S. Pat. No. 6,721,985 to McCrary, and U.S. Pat. No. 6,923,124 to Roane. Widely varied, these systems utilize a variety of elaborate guide way designs to transport people and cargo (which can include automobiles) between points in the system. Some of the systems require highly specialized automobiles while others transport standard automobiles on pallet-like mechanisms. Disadvantages of these systems include: 1.) significant complexity, 2.) the requirement that commuters drive highly specialized automobiles designed specifically for the transit system (where applicable), and 3.) capacity is constrained in that the systems cannot accommodate hundreds of thousands of automobiles in a short period of rush hour traffic. 3. Monorail systems represented by U.S. Pat. No. 3,345,951 to Rethorst, U.S. Pat. No. 5,592,883 to Andress, III, and the TransDrive Transportation System. Similar to a monorail in principle, these systems transport modified automobiles between terminals utilizing a network of overhead rails. Automobiles must be fitted with external hardware mechanisms to which the monorail system attaches during transport. Disadvantages of these systems include: 1.) significant complexity, 2.) automobiles are not engineered in a manner that provides enough structural support to suspend the automobile by the roof, 3.) widely available evidence makes clear that drivers are highly selective about the design, features and performance of their automobiles and are unlikely to accept a costly and unsightly modification, and 4.) the capacity of these transit systems is limited by the speed at which automobiles can travel single-file while hanging from a monorail. 4. Automobile carriers represented by U.S. patent application Ser. No. 10/911,556 to Suematsu (of Japan), U.S. patent application Ser. No. 12/660,133 to Rigo (of Canada), U.S. Pat. No. 3,149,583 to Morrill and Republique Francaise brevet d′invention 1.274.220 to de Colnet. These systems transport both the passenger and automobile, albeit in separate transit vehicles. These systems share the disadvantage of a slow process for loading and unloading as commuters leave their automobile in a designated area and find their way to the passenger car while an employee of the transit system retrieves their car and loads it into the automobile carrier. Unloading of the vehicles and delivery to the passenger involves the same inherent delays. This category of transit system is not suited for the rapid pace of urban rush hour traffic involving hundreds of thousands of automobiles. 5. Automobile carriers with passengers in the same transit vehicle represented by U.S. Pat. No. 2,211,469 to King, U.S. Pat. No. 3,503,340 to Warren, U.S. Pat. No. 3,584,584 to Milenkovic, U.S. Pat. No. 3,892,188 to Warren, U.S. Pat. No. 4,397,496 to Drygas, and U.S. Pat. No. 7,275,901 to Carroll. These systems share the disadvantage of a very slow loading and unloading process as commuters leave their automobile in a designated area and find their way to the passenger cabin while an employee of the transit system retrieves their car and loads it into the automobile carrier portion of the transit vehicle. Unloading of the automobiles and delivery to the passenger involves the same inherent delays. This category of transit system is not suited for the rapid pace of urban rush hour traffic involving hundreds of thousands of automobiles. 6. U.S. Pat. No. 3,285,194 to Clejan. The Clejan transit system has several disadvantages which include: 1.) passengers exit their automobile and go to a lounge area elsewhere in the transit vehicle, 2.) automobile tires must be aligned with wheel guides mounted on the floor of the transit vehicle in order to precisely position the automobile in the transit vehicle, 3.) parking channels are very narrow, 4.) passengers may enter and exit their automobile through the driver side only, 5.) security of passengers and their property is compromised by the interconnected parking bays, 6.) adjacent automobiles are parked facing opposite directions, passenger side to passenger side, so that every other automobile is parked facing one direction while alternate automobiles face the other direction, a dangerous circumstance that requires crossing of oncoming traffic during entry and exit, and 7.) wide rollup bay doors operate slowly. The Clejan transit system is designed for intercity travel as evidenced by statements such as “it is contemplated that the system will serve two or more metropolitan areas, and that the two toll plazas mentioned will be arranged outside of the two respectively adjacent metropolitan areas and respectively connected thereto by highways”. The Clejan transit system is not suited for the rapid pace of urban rush hour traffic involving hundreds of thousands of automobiles. 7. U.S. Pat. No. 3,357,712 to Milenkovic. The Milenkovic transit system has several disadvantages which include: 1.) passengers exit their automobile and go to the lounge area elsewhere in the transit vehicle, 2.) automobile tires must be aligned with wheel guides mounted on the floor of the transit vehicle in order to precisely position the automobile in the transit vehicle, 3.) narrow parking channels allow passengers entry/exit via one side of the vehicle only, 4.) security of passengers and their property is compromised by the interconnected parking bays, and 5.) standard gauge railroad tracks almost certainly will not provide adequate stability for a transit vehicle of the described height and width traveling at speeds of 200 MPH. The Milenkovic transit system is designed for intercity travel, as opposed to the present application which serves primarily urban commuter travel, as evidenced by its reference to the Clejan system (above, U.S. Pat. No. 3,285,194) with statements such as “As illustrated therein, the railway train serves two or more metropolitan areas, and two toll plazas will be arranged outside of the two respectively adjacent metropolitan areas and respectively connected thereto by highways”. The Milenkovic transit system is not suited for the rapid pace of urban rush hour traffic involving hundreds of thousands of automobiles. 8. U.S. Pat. No. 3,785,514 to Forsyth et al., U.S. Pat. No. 3,896,946 to Forsyth et al., and U.S. Pat. No. 3,933,258 to Forsyth et al. The Forsyth transit systems are compatible only with small, highly specialized automobiles. Widely available evidence makes clear that drivers are highly selective about the design, features and performance of their automobiles and are unlikely to abandon their preferences. To utilize a transit system in this category while retaining their preferred automobile, a commuter must purchase an additional, highly specialized automobile. The new automobile represents significant expenses for purchase, maintenance, licensing and insurance, plus additional space in the garage or driveway. Where the family includes two commuters, a common circumstance, the financial burden is doubled. For these reasons the Forsyth transit systems are unlikely to meet with wide acceptance. 9. U.S. patent application Ser. No. 12/251,199 to Farooq. The Farooq transit system has several disadvantages: 1.) time delay as each transit vehicle is separated and spaced apart from other transit vehicles for loading and unloading, 2.) time delay as highly specialized tractor-trailer rigs are driven into place at either end of each transit vehicle to precisely position the loading/unloading ramps, 3.) time delay as automobiles carefully negotiate the tightly curving, sloping ramps to load and unload in single-file, 4.) assistance may be required by transit system staff to ensure that automobiles are parked closely enough together to permit a full complement of automobiles on each loading deck, and 5.) security of passengers and their property is compromised by the interconnected parking bays. Additionally, Farooq vaguely mentions and illustrates an embodiment of his transit system in which automobiles are transported transversely to the longitudinal direction of the transit vehicle but provides too little information to consider that concept a well formed embodiment. For example, no mention is made of how vehicles enter or exit the boxcars or whether passengers remain inside the vehicles. Farooq describes that his system can transport 200 commuter vehicles per train and that, with a 15-minute turnaround time, four trains can run per hour transporting a total of 800 commuter vehicles per hour. During a four-hour morning rush period (and same during the evening rush) his system can move a total of 3,200 commuter vehicles. This capacity is clearly inadequate for accommodating the rapid pace of urban rush hour traffic involving hundreds of thousands of automobiles.
SUMMARY
[0024] A transit vehicle for the transporting of roadway vehicles, may include:
a. an elongated longitudinally extending chassis, b. a housing being carried by said chassis and having a substantially box-like configuration including a substantially horizontal floor and a generally horizontal roof and a pair of upstanding end walls joining said floor and said roof, c. the floor being adapted to store thereupon a plurality of roadway vehicles extending substantially traversely with respect to the direction of travel of the transit vehicle and disposed in side-by-side relation with each other, d. a plurality of longitudinally spaced-apart bay dividers extending substantially traversely with respect to the direction of travel of the transit vehicle and extending the width of said floor and extending between said floor and said roof creating a plurality of laterally aligned bays whereby roadway vehicles may be driven onto or off of said floor between the bay dividers, e. a plurality of bay doors on opposing sides of the housing respectively associated with said bays and selectively moveable between an open and closed position, f. a motor for moving said doors between their open and closed positions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which:
[0032] FIG. 1 is a perspective view of one embodiment of the transit vehicle configured as a train of five transit vehicles and a motive source that travels on ground-level rails.
[0033] FIG. 2 is a perspective view of one embodiment of the transit vehicle configured as a train that travels on overhead rails with doors open as if ready to load and unload roadway vehicles.
[0034] FIG. 3 is a perspective view of one embodiment of a single transit vehicle with doors open and roadway vehicles onboard while additional roadway vehicles queue in approach lanes.
[0035] FIG. 4A is a top sectional view of one embodiment of the transit vehicle configured with an arbitrary number of parking bays with roadway vehicles loaded in each bay.
[0036] FIG. 4B is a top sectional view of one embodiment of the transit vehicle configured with a passenger area and an arbitrary number of parking bays with roadway vehicles loaded in each bay.
[0037] FIG. 5A is a side view of one embodiment of the transit vehicle configured with an arbitrary number of parking bays with bay doors open and roadway vehicles loaded in each bay.
[0038] FIG. 5B is a side view of one embodiment of the transit vehicle configured with an arbitrary number of parking bays with bay doors closed.
[0039] FIG. 6A is an end sectional view of one embodiment of the transit vehicle with bay doors closed and a roadway vehicle onboard.
[0040] FIG. 6B is an end sectional view of one embodiment of the transit vehicle with bay doors open and a roadway vehicle onboard.
DETAILED DESCRIPTION
First Embodiment
[0041] In accordance with one embodiment a transit vehicle is designed to a.) facilitate the simple and rapid loading onto the transit vehicle of a plurality of roadway vehicles by the drivers of the roadway vehicles via a plurality of laterally aligned doorways, b.) provide secure and rapid travel to a destination while drivers and passengers remain within their roadway vehicle, and 3.) facilitate simple and rapid unloading from the transit vehicle of the roadway vehicles by the drivers of the roadway vehicles. The transit vehicle may be joined to a plurality of other transit vehicles and motive source to form a train that is configured to travel on rails below or above the transit vehicle, or on roadways or waterways.
DRAWINGS
Reference Numerals
[0000]
10 Locomotive
12 Rails
13 Bogeys
14 Transit vehicle
16 Bay door
18 Connector
20 Parking bay
22 Roadway vehicle in bay
24 Bay divider
28 Roadway vehicle waiting
30 Approach lanes
32 End cap
34 Roof
36 Loading side of transit vehicle
38 Unloading side of transit vehicle
40 Bay door hinge
42 Access Door
44 Passenger seating, facilities and concession area
46 Chassis
48 Bay floor
[0062] As illustrated in FIG. 3 (perspective, loading), transit vehicle 14 may include a housing of a box like configuration that may include a substantially horizontal floor 48 with dimensions appropriate to accommodate a plurality of roadway vehicles 22 parked substantially transversely to the direction of travel of the transit vehicle. A plurality of such floors 48 , each a predetermined distance above the floor below, may be configured to accommodate additional roadway vehicles 22 . Upstanding end walls 32 and bay dividers 24 may provide support to the roof 34 which substantially opposes the floor 48 . The two longer sides of the transit vehicle which may extend between the roof 34 and the floor 48 and may extend between the end walls 32 may have an aperture appropriately sized and positioned to accommodate the entry and exit of roadway vehicles 22 into parking bays 20 . Each aperture may cooperate with an associated door 16 on either side of the transit vehicle 22 with a motor (not shown) for moving the doors 16 between their open and closed positions. When the doors 16 are closed, the parking bay 20 may be substantially enclosed and substantially sealed.
[0063] As illustrated in FIG. 6A (end view, doors closed), transit vehicle 14 may include structural components in the chassis 46 and roof 34 to provide support to transit vehicle 14 and may accommodate the attachment of bay doors 16 , wheels and/or other mobility devices, and such other devices as necessary to join transit vehicle 14 to other transit vehicles 14 and to a source of motive power. Structural components may vary depending on mode of travel (rail, roadway, or waterway) and whether the vehicle is positioned above the mode or suspended below the mode.
[0064] Referring again to FIG. 3 (perspective, loading), transit vehicle 14 may include a plurality of laterally aligned pairs of bay doors 16 on opposing sides of the deck floor 48 which may be sized appropriately to accommodate the passage of roadway vehicles 22 , whereby roadway vehicles 22 may be driven forward onto and forward off of the deck floor 48 without reversing. Parking bay doors 16 may be of the gull wing (shown), swinging, sliding, roll-up, drawbridge or other design as suits the circumstances of the deployment environment. Each parking bay 20 for roadway vehicles 22 may be separated from other parking bays 20 by bay dividers 24 which may extend from the deck floor 48 to the roof 34 in the substantial horizontal direction and deck floors 48 in the substantial vertical direction so that each parking bay 20 is private and secure. Parking bays 20 may be adequately ventilated to expel exhaust gases from roadway vehicles 22 that may be left running during transit.
[0065] As illustrated in FIG. 2 (perspective, bay doors open), transit vehicle 14 may be suspended below overhead rails 12 or, as illustrated in FIG. 1 (perspective, in motion) the transit vehicle 14 may be equipped to ride on ground rails 12 . In other configurations, not illustrated, transit vehicle 14 may be configured to travel on roadways or waterways. In all configurations, transit vehicle 14 may be configured to travel at grade level, overhead or underground to suit the circumstances of the deployment environment. As illustrated in FIG. 1 (perspective, in motion), a plurality of transit vehicles 14 may be joined together by connectors 18 and to a source of motive power 10 to form a train. A train segment is also illustrated in FIG. 2 (perspective, bay doors open) where a plurality of transit vehicles 14 may be joined together by connectors 18 and to a source of motive power 10 . As illustrated in FIG. 4A (top sectional view) transit vehicle 14 may include several safety and security features. Bay dividers 24 may provide security by isolating each parking bay 20 from other parking bays, and access doors 42 , here shown installed in bay dividers 24 but in other deployments might be installed within bay doors 16 , provide means of escape in the event of an emergency.
Operation
First Embodiment
[0066] It is an object of the present embodiment to provide a transit vehicle useful as a carrier for roadway vehicles driven by commuters in the deployment area. Acceptable roadway vehicles in the U.S. may include all makes and models of light cars and trucks, SUVs, vans, motorcycles, bicycles, and other roadway vehicles within the general size and weight range of these vehicles. Drivers, passengers and cargo may remain in the roadway vehicle during transit.
[0067] In operation, as illustrated in FIG. 3 (perspective, loading), bay doors 16 open on both sides of transit vehicle 14 allowing onboard roadway vehicles 22 to exit by driving forward out of parking bay 20 while other roadway vehicles 28 queued in approach lanes 30 drive forward into parking bay 20 . The deck floors 48 in the transit vehicle 14 may be constructed at substantially the same horizontal plane as approach lanes 30 and in close enough proximity that additional loading ramps are unnecessary. Queued roadway vehicles 28 drive into a parking bay 20 as easily as humans step into a subway train or elevator. Once transit vehicle 14 is loaded with roadway vehicles 22 , bay doors 16 are closed and transit vehicle 14 is ready for transport.
[0068] As illustrated in FIG. 4A (top sectional view), parking bays 20 are sized to accommodate roadway vehicles 22 without creating a challenging circumstance for the driver while entering or exiting transit vehicle 14 . Roadway vehicles 22 nearly always enter transit vehicle 14 from the loading side of the transit vehicle 36 and nearly always exit transit vehicle 14 toward the unloading side of the transit vehicle 38 . FIG. 6B further illustrates a roadway vehicle 22 in a parking bay 20 with the bay doors 16 open. Again, roadway vehicles 22 near always enter the transit vehicle 14 from the loading side of the transit vehicle 36 and near always exit the transit vehicle 14 toward the unloading side of the transit vehicle 38 .
[0069] It is envisioned that terminals for transit systems based on this transit vehicle will be located at strategic points around the deployment area, ideally near major freeway intersections. Each terminal may have enough loading gates to accommodate area traffic. In the following non-limiting example, a train may include five transit vehicles, each with a capacity of 10 roadway vehicles each, is considered. Turnaround time to unload and reload the 50 roadway vehicles may be 60 seconds or less. In this scenario, a terminal with 10 loading gates can handle 500 arriving roadway vehicles and 500 departing roadway vehicles per minute, 30,000 roadway vehicles per hour in each direction. During a three-hour rush period, a single terminal can send and receive 90,000 roadway vehicles. Terminals will be located and scaled to meet expected traffic volumes.
[0070] In summary, this embodiment is designed and engineered to be quickly loaded with roadway vehicles, transported to a destination as rapidly as the motive source permits, and unloaded quickly. A typical stop may require as little as 30 seconds to unload and reload regardless of how many roadway vehicles each transit vehicle is configured to accommodate and how many transit vehicles are joined together to form a train. Rapid loading and unloading allows completion of many iterations of a journey during a given time period and thereby provides meaningful reduction of roadway traffic.
Second Embodiment
[0071] As illustrated in FIG. 4B (top sectional view with passenger area) this embodiment is differentiated from the previous embodiment by the addition of a passenger area 44 . Passenger area 44 may be isolated from parking bays 20 to accommodate commuters without vehicles or, on longer journeys, to accommodate drivers and passengers of roadway vehicles 22 in addition to commuters without vehicles. The passenger area 44 may include a combination of seating, concessions and facilities appropriate to the circumstances of deployment. Passenger area 44 will occupy more space where commuters without vehicles are frequent and where additional facilities are required for longer journeys.
[0072] As illustrated in FIG. 3 (perspective, loading), transit vehicle 14 may include a housing having a box-like configuration that has a substantially horizontal floor 48 with dimensions appropriate to accommodate a plurality of roadway vehicles 22 being loadable and parked substantially transversely to the direction of travel of the transit vehicle. A plurality of such floors 48 , each an appropriate distance above the floor below, may be configured to accommodate additional roadway vehicles 22 . Upstanding end walls 32 and bay dividers 24 may provide support to the roof 34 which may be opposed to the floor 48 and which is substantially the same size as the floor 48 . The two longer an elongated sides of the transit vehicle may have apertures appropriately sized and positioned to accommodate the entry and exit of roadway vehicles 22 into parking bays 20 . Each aperture may have an associated and opposed door on either side of the transit vehicle with a motor (not shown) for moving the doors between their open and closed positions. When the doors are closed, the parking bay may be substantially fully enclosed and sealed.
[0073] As illustrated in FIG. 6A (end view, doors closed), transit vehicle 14 may include structural components in the chassis 46 and roof 34 as necessary to provide support to transit vehicle 14 and to accommodate the attachment of bay doors 16 , wheels and/or other mobility devices, and such other attachments and devices as necessary to join transit vehicle 14 to other transit vehicles 14 and to a source of motive power. Structural components may vary depending on mode of travel (rail, roadway, or waterway) and whether the vehicle is positioned above the mode or suspended below the mode.
[0074] Referring again to FIG. 3 (perspective, loading), transit vehicle 14 may include a plurality of laterally aligned pairs of bay doors 16 on opposed sides of the deck floor 48 , sized appropriately to accommodate the passage of roadway vehicles 22 , whereby roadway vehicles 22 may be driven forward onto and forward off of the deck floor 48 . Parking bay doors 16 may be of the gull wing (shown), swinging, sliding, roll-up, drawbridge or other design as suits the circumstances of the deployment environment. Each parking bay 20 for roadway vehicles 22 may be separated from other parking bays 20 by extending between opposed bay dividers 24 in the substantial horizontal direction and extending between deck floors 48 in the substantial vertical direction so that each parking bay 20 is private and secure. Parking bays 20 may be adequately ventilated to expel exhaust gases from roadway vehicles 22 that may be left running during transit.
[0075] As illustrated in FIG. 2 (perspective, bay doors open), transit vehicle 14 may be suspended below overhead rails 12 or, as illustrated in FIG. 1 (perspective, in motion) the transit vehicle 14 may be equipped to ride on ground rails 12 . In other configurations, not illustrated, transit vehicle 14 may be configured to travel on roadways or waterways. In all configurations, transit vehicle 14 may be configured to travel at grade level, overhead or underground in accordance with the circumstances of the deployment environment.
[0076] As illustrated in FIG. 1 (perspective, in motion), a plurality of transit vehicles 14 may be joined together by connectors 18 and connected to a source of motive power 10 to form a train. A train segment is also illustrated in FIG. 2 (perspective, bay doors open) where a plurality of transit vehicles 14 are joined together by connectors 18 and connected to a source of motive power 10 .
[0077] As illustrated in FIG. 4A (top sectional view) transit vehicle 14 has several safety and security features. Bay dividers 24 provide security by substantially isolating each parking bay 20 from other parking bays 20 , and access doors 42 , here shown installed in bay dividers 24 but in other deployments might be installed within bay doors 16 , provide means of escape in the event of an emergency.
Operation
Second Embodiment
[0078] It is an object of the present embodiment to provide a transit vehicle useful as a carrier for commuters and roadway vehicles driven by commuters in the deployment area. Acceptable roadway vehicles in the U.S. may include all makes and models of light cars and trucks, SUVs, vans, motorcycles, bicycles, and other roadway vehicles within the general size and weight range of these vehicles. Drivers, passengers and cargo may remain in the roadway vehicle during transit or, on longer journeys, may vacate to the passenger area of the transit vehicle.
[0079] In operation, as illustrated in FIG. 3 (perspective, loading), bay doors 16 open on both opposed sides of transit vehicle 14 allowing onboard roadway vehicles 22 to exit by driving forward out without reversing of parking bay 20 while other roadway vehicles 28 queued in approach lanes 30 drive forward into parking bay 20 . It is anticipated that deck floors 48 in the transit vehicle 14 may be constructed at substantially the same horizontal plane as approach lanes 30 and in close enough proximity that additional loading ramps are unnecessary. Queued roadway vehicles 28 drive into a parking bay 20 as easily as humans step into a subway train or elevator. Once transit vehicle 14 is loaded with roadway vehicles 22 and passengers are positioned in passenger area 44 , bay doors 16 are closed and transit vehicle 14 is ready for transport.
[0080] As illustrated in FIG. 4A (top sectional view), parking bays 20 may be sized to accommodate roadway vehicles 22 without creating a challenging circumstance for the driver while entering or exiting transit vehicle 14 . Roadway vehicles 22 nearly always enter transit vehicle 14 from the loading side of the transit vehicle 36 and nearly always exit transit vehicle 14 toward the unloading side of the transit vehicle 38 . FIG. 6B further illustrates a roadway vehicle 22 in a parking bay 20 with the bay doors 16 open. Again, roadway vehicles 22 nearly always enter the transit vehicle 14 from the loading side of the transit vehicle 36 and nearly always exit the transit vehicle 14 toward the unloading side of the transit vehicle 38 .
[0081] It is envisioned that terminals for transit systems based on this transit vehicle will be located at strategic points around the deployment area, ideally near major freeway intersections. Each terminal will have enough loading gates to accommodate area traffic. In the following non-limiting example a train comprised of five transit vehicles, each with a capacity of 10 roadway vehicles each, is considered. Turnaround time to unload and reload the 50 roadway vehicles is 60 seconds. In this scenario, a terminal with 10 loading gates can handle 500 arriving roadway vehicles and 500 departing roadway vehicles per minute, 30,000 roadway vehicles per hour in each direction. During a three-hour rush period, a single terminal can send and receive 90,000 roadway vehicles. Terminals will be located and scaled to meet expected traffic volumes.
[0082] In summary, this embodiment is designed and engineered to be loaded quickly with commuters and roadway vehicles, transported to a destination as rapidly as the motive source permits, and unloaded quickly. A typical stop may require a very few minutes to unload and reload regardless of how many commuters and roadway vehicles each transit vehicle is configured to accommodate and how many transit vehicles are joined together to form a train. Rapid loading and unloading allows completion of many iterations of a journey during a given time period and thereby provides meaningful reduction of roadway traffic. The inclusion of a passenger area allows longer journeys and intersection with other transit systems.
ADVANTAGES
[0083] From the descriptions above, a number of advantages of some embodiments become evident:
(a) In one or more embodiments, the transit vehicle transports roadway vehicles to a destination while commuters and cargo remain inside the roadway vehicle. At the destination, the driver of the roadway vehicle simply drives his roadway vehicle out of the transit vehicle and continues on his journey. This feature satisfies the desire of commuters to retain possession of their roadway vehicle at all times. (b) In one or more embodiments, the transit vehicle is designed to load and unload in a very rapid manner by the drivers of the roadway vehicles. Bay doors open on both sides of the transit vehicle so that exiting vehicles can drive forward out of the transit vehicle and entering roadway vehicles can drive in behind them, almost simultaneously. The process is as simple as driving into a garage with no need to precisely align the car with wheel guides or to negotiate inclined, curving ramps. Further, in one or more embodiments the transit vehicle is designed to travel as fast as the mode and motive power permit. Combined, these features satisfy the desire of commuters to arrive at their destination in a timely manner. (c) In one or more embodiments, the transit vehicle is capable of transporting a wide variety of roadway vehicles. Acceptable vehicles in the U.S. include all makes and models of light cars and trucks, SUVs, vans, motorcycles, bicycles and foot traffic. This feature satisfies the desire of commuters to drive a roadway vehicle with design, features and performance of their own choosing. (d) In one or more embodiments, the transit vehicle is designed with parking bays for roadway vehicles that are each separated from other parking bays by walls in the horizontal direction and floors in the vertical direction. This feature provides a safe and secure travel environment. (e) In one or more embodiments, the transit vehicle can be configured to travel via rail, roadway, waterway or other mode as best befits the deployment environment. This feature provides flexibility to transit systems based on this transit vehicle. (f) In one or more embodiments, the transit vehicle can intersect with other transit systems to create robust transportation capabilities. Buses, commuter rail, trolleys, subways and other forms of transit might bring commuters from distant neighborhoods to the station serving this transit vehicle for whisking to a distant terminal where local transit systems complete the journey. This feature adds value to existing community investments in public transportation. (g) In one or more embodiments, it is envisioned that terminals for transit systems based on this transit vehicle will be located at strategic points around the deployment area. Each terminal will have a plurality of loading gates, similar to an airport, with each gate having a specific destination. Terminals and gates will be scaled to accommodate area traffic. In the following non-limiting example, a train comprised of five transit vehicles, each with a capacity of 10 roadway vehicles, is considered. Turnaround time to unload and reload the 50 roadway vehicles in this example is 60 seconds. In this scenario, a terminal with 10 loading gates can handle 500 arriving roadway vehicles and 500 departing roadway vehicles per minute, 30,000 roadway vehicles per hour in each direction. This single terminal can handle 90 , 000 arrivals and 90,000 departures of roadway vehicles during a three-hour rush period. This feature provides enough capacity to reduce traffic congestion and improve air quality in the deployment area.
CONCLUSION, RAMIFICATIONS AND SCOPE
[0091] Professor Rolf Pendall of Cornell University analyzed suburban sprawl over the course of the 1980s in 282 metropolitan areas and found that population growth explains about 31 percent of the growth in land area. He found that even those areas that experienced no population growth increased in urbanized land area by an average of 18 percent. Data collected by the U.S. Department of Housing and Urban Development for its State of the Cities 2000 report (1994-1997 time period) show that our urban areas continue to expand at about twice the rate that the population is growing. Larger urban areas mean longer daily commutes to work.
This transit vehicle provides a robust transportation solution by transporting commuters with or without roadway vehicles in a quick and efficient manner. Roadway vehicles and commuters are loaded quickly, transported as fast as the mode and motive power permit, and unloaded quickly at the destination. Commuters never leave their vehicle. It is envisioned that all journeys utilizing this transit vehicle will be point-to-point. In a well-designed system there will be little need to change trains. During peak traffic hours, and even during non-peak hours, a transit system based on this transit vehicle can transport commuters and their roadway vehicles to a destination faster than it is possible to drive the roadway vehicle to the destination. This speed, combined with the convenience of retaining their roadway vehicle, provides great incentive for commuters to utilize a transit system based on this transit vehicle. As further incentive to utilize a transit system based on this transit vehicle, a commuter utilizing the system will reduce driving miles and thereby reduce the cost of automobile fuel, insurance, tires, scheduled maintenance and repairs. Further, an individual might save significant money by retaining a roadway vehicle longer if it has low mileage. Even lessees will enjoy reduced lease rates due to lower miles. With reduced traffic congestion, cleaner air and a convenient means of commuting across town quickly, municipalities with transit systems based on this transit vehicle will score higher in quality of life rankings. This transit vehicle can be equipped with cellular receivers for telephone communications and wireless access points for computer connectivity. Video screens can be mounted on the wall ahead of the vehicle to display instructions, news, weather and advertising. Other modes of public transit can make stops at terminals servicing this transit vehicle so that passengers can ride a bus ride or vanpool to this terminal, zip across town at high speed then connect with another bus or vanpool for the short trip to their workplace. Strategically, municipalities could re-deploy their bus fleets deeper into suburban neighborhoods since there will be less need for buses to travel long distances across town. With bus stops closer to home, suburban passengers might find the combination of bus and this transit vehicle an ideal commute solution. Transit systems based on this transit vehicle can be implemented as an area-wide system or as a targeted point-to-point link. One area might opt for a wide scale solution with terminals in a dozen strategic locations while another area may opt for a point-to-point link between a city and a distant airport, stadium or sister city.
[0099] Although the descriptions above contain much specificity, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of the presently preferred embodiments. For example, the transit vehicle might be configured with 10 parking bays as illustrated in the drawings or with 15 or even 20 parking bays or more; or with parking bays designed specifically for motorcycles or compact cars; or in a double-decked or triple-decked layout; or with pontoons for water deployments.
[0100] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.
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A transit vehicle for use in the transporting of roadway vehicles whose passengers and cargo remain inside the roadway vehicle during transit, and the transporting of roadway vehicles whose passengers travel in a separate passenger area. The transit vehicle is essentially an overland ferry wherein drivers park their roadway vehicles in easy-access bays and remain inside their vehicle during commuter journeys or take a place in the passenger area on longer journeys. With rapid loading and unloading functions, and capable of high speed when powered by an appropriate motive source, the transit vehicle can reduce traffic congestion and vehicle emissions by transporting a substantial number of commuters.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filler pipe for a packing machine for use in consecutively filling a traveling and continuous series of connected packing container blanks. More specifically, it relates to filling packing container blanks of two joined webs with a liquid product, such as yogurt, and a separate jam product and then sealing the packing container blank.
2. Prior Art
Conventionally, rectangular parallelepiped "bricktype" packing containers with triangular tops are widely used for packing liquid food products. In addition, packing containers for which the filler pipe described herein was designed, i.e., those formed of two joined webs in order to minimize the amount of packing container material required, have come into use. These packing containers are used for packing homogeneous liquids such as milk, juice, or yogurt, and the filling pipes used by the packing machines for each type of container are constructed to fill one container at a time.
The above-described packing containers could be filled with only one type of liquid food product. They could be filled with two types of liquid food products only by mixing the two types, thereby in actuality forming one homogeneous liquid food product such as yogurt mixed with jam or fruit particles. Two liquid food products could not be filled in a separated condition.
SUMMARY OF THE INVENTION
The present invention, therefore, has as its principal object the provision of a filling pipe capable of filling packing containers which are formed of at least two webs with a liquid product, such as yogurt, and a jam product in a separated condition, and sealing the packing containers, for use in a packing machine.
In order to fill a traveling and continuous series of connected packing container blanks, which are each formed of at least two webs with a liquid product and separate jam product, the invention comprises (1) a nozzle with multiple filling paths, each of which passes liquid to at least one of the packing container blanks; (2) a flat-shaped first delivery pipe connected to the end of the nozzle to deliver the liquid product to it; and (3) a second delivery pipe smaller in diameter than the first delivery pipe opening downward and positioned parallel to, and either inside of or on the outer lateral wall of the first delivery pipe at a predetermined distance above the junction of the first delivery pipe and the nozzle so as to pass the jam product to any of the packing container blanks.
The filler pipe of the present invention serves to dispense and charge smoothly and uniformly a liquid product into packing container blanks by means of a nozzle which is formed so that each of the multiple filling paths, which serve as the outlet for the liquid product, passes the latter to at least one of the packing container blanks. Prior to this charging action, however, a predetermined amount of jam product is charged into each of the packing container blanks. Because the liquid product is charged onto the top surface of the jam product, which is settled on the inner wall of the packing container blank, the liquid product does not mix with the jam product, thereby enabling both products to remain in a separated condition and to preserve the flavors particular to each.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show several views of the present invention in its preferred embodiment.
FIG. 1 is a plan view of the dispensing end of a filler pipe of the present invention.
FIG. 2 is a drawing of the back of FIG. 1 and shows the opening for jam product injection.
FIG. 3 is a cross section down the center of the filler pipe showing the filler pipe in operation in the packing machine shown in FIG. 4.
FIG. 4 is a side view of the main body of a packing machine equipped with a filler pipe of the present invention and containing charging and packing sections.
FIG. 5 is a cross section viewed along V--V of the filler pipe of FIG. 1, showing the relationship with a packing container blank.
FIG. 6 is a cross section viewed along VI--VI of the filler pipe of FIG. 1 showing the relationship with a packing container blank as it is being charged.
FIG. 7 is a pictorial view of the packing container produced by the packing machine of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described with reference to the attached drawings.
FIG. 1 is a plan view showing the main portion of the dn* of a filler pipe of the present invention, and FIG. 2 is a rear view of FIG. 1 showing an outlet for charging a jam product. The filler pipe is used in the section of a packing machine which forms and fills packing containers, as shown in FIG. 4.
With reference to FIG. 4, a packing machine frame 1 is equipped with a filler pipe of the present invention. A pair of packing material webs 5 and 6 for use in forming the main body of a container, and a homogeneous plastic piece 7 for use as a removable lid 7a (FIG. 7) are introduced from storage rolls held by multiple, so-called roller stands belonging to a packing material section on the left side (not illustrated) of FIG. 4. The pair of packing material webs 5 and 6 are, for example, extruded foam plastic webs of polystyrene material coated on both sides with a layer of homogeneous polystyrene. The packing material webs 5 and 6 are, for example, extruded foam plastic webs of polystyrene* material coated on both sides with a layer of homogeneous polystyrene. The packing material webs 5 and 6 and the plastic piece 7 are formed into a series of packing container blanks, into which a liquid product and jam product are charged.
As shown in FIG. 7, an arc-shaped side wall 5a for the packing container unit 9 is formed fromm the first packing material web 5, top and bottom walls 6a and a flat side wall 6b are formed from the second packing material web 6, and a lid/pouring spout 7a is formed fromm a plastic piece 7.
Referring again to FIG. 4, rotary drum 10 is supported on frame 1 of the packing machine, and the packing material web 6 is introduced by a guide roller 25 onto the rotary drum 10 and processed at a station along the margin surrounding the drum. Frame 1 has a molding mechanism 11 to form the packing material web 5. The mechanism 11 has a movable mold part 12 attached to an endless chain, and the mold part moves clockwise at a constant speed. A specified flow rate of a liquid product, such as yogurt, to be filled is fed from a level tank (not illustrated) by a measuring pump 2 to the filler pipe 15 via a feeder pipe 3. A specified flow rate of the jam product to be filled with the liquid product is fed from a separate level tank (not illustrated) by a separate measuring pump 38 through a feeder pipe 37 and supplied at the bottom of the above mentioned feeder pipe 3 to the second delivery pipe 22 for the jam product. Delivery pipe 22 is positioned on the longitudinal centerline of the first delivery pipe 16 (See FIG. 1) to be discussed later, which together comprise the filler pipe 15. The yogurt or other liquid product and the jam product flow to and are charged into continuously moving packing container blanks 8. A column 13 making a reciprocating motion on a slide bearing 14 attached to the frame has a tuck-in device 30, a sealing device 31, and a web-cutting device 32. All these devices move with column 13 in the abovementioned reciprocating motion. The column is arranged to move together with these devices when the mold part 12 is moving downward and to move faster than these devices when the mold part 12 is moving upward to return to its original position. A mold device 33 for the central area of web 6 is provided before the sealing device 31. The filler pipe 15 connected to the lower ends of feeder pipes 3 and 37 is brought into contact with the lower surface of the continuously moving web 6 on the upper side and extends obliquely downward to a specified position. A detailed description of filler pipe 15 will be presented later.
Still referring to FIG. 4, a packing machine equipped with filler pipe 15 of the present invention operates as follows:
A controlled amount of the creased first packing material web 5 is rolled out form the storage roll at a packing material section (not illustrated) at the left of the packing machine, heated by a heating device (not shown), and brought into contact with a mold part 12 by mold device 35, folded to form an endless band of U-shaped parts, and actually moved downward by mold device 35 into molding mechanism 11. The second packing material web 6 is also rolled out from a storage roll in the packing material section (not illustrated) in the same manner as described above, made to pass over a guide roller 25, and placed onto feeder drum 10. An oscillation plate 26, which is an outside rim of the feeder drum 10 rotating at a constant speed, has attached to it processing stations, such as a drill/lid strip support 27, a molding/cutting device 28, and a heater 29, and is driven around the drum 10. As web 6 passes processing stations 27, 28 and 29 via drum 10, a pouring spout is drilled, the lid strip is attached over the pouring spout, web 6 is heated, any possible thermoforming is performed on it, and it is cut crosswise to a desired length at the margins. A homogeneous plastic piece 7 is rolled out from a storage roll (not illustrated), held on the pouring spout in the web by lid strip support 27, securely attached to web 6 so that the pouring spout is covered by the strip, and the lid portion is cut free from the plastic piece 7. The edges of web 6 with the pouring spout and opening device (lid) are cut so as to form a series of tongue pieces protruding on both sides of a length approximately equal to the height of mold part 12. Web 6 is moved forward by feeder drum 10 at exactly the same speed as mold part 12, its central section is positioned on top of mold part 12, and the web edges, cut to the shape of tongues or ears, protrude from the mold part 12. Slots in the web, through the action of a speed governor (not illustrated), are moved forward such that they are positioned at right angles to the lateral flange of mold part 12, i.e., the partition wall.
While web 6 is moved forward together with mold part 12, column 13 reaches its upper position and starts to move downward together with mold part 12. Column 13 has a heater that can be connected to air sources via pipe 36, high-temperature air is blown by the heater against the edges of web 6, i.e., against the lower face of the tongue pieces, the plastic material is softened, and it is activated due to the tight sealing. High-temperature air is also blown against the edges of web 5 exposed at the sides of mold part 12. At the same time that the heater 34 is heating the areas of webs 5 and 6 to be sealed, the protruding part of web 6, i.e., the lower piece which has already been heated during the previously mentioned movement of column 13, is bent by the flap of tuck-in device 30 and pressed against the edges of the abovementioned U-shaped ends of web 5. These superimposed web parts are thus fused together to form a mechanically durable, effective seal, which is stabilized because the sealed part is cooled while the tuck-in device 30 is engaged with the folded area of web 6. After webs 5 and 6 are laterally sealed to each other as described above, contents are supplied through filler pipe 15. The filler pipe 15 is positioned under second web 6 and on top of mold part 12. The space formed beneath second web 6 constitutes a sort of partitioned area which is filled with the predetermined contents.
Webs 5 and 6 then pass through a molder 33 and the center of web 6 is flattened. The above mentioned space is sealed by a sealer 31 into a sealed unit so that second web 6 is sealed to the portion of first web 5 on the top of the erect portion of mold part 12. Sealer 31 is also attached to column 13 and makes a reciprocating motion following the column. The sealing process is completed while column 13 moves downward together with mold part 12. Formed and sealed packing containers are cut free from each other by a cutter 32 at a sealed section formed by sealer 31. The filled, sealed, cut and separated packing containers 9 are then transferred from the lower end of the endless-chain mold part 12 to a conveyor 4 for transfer to the next process.
A filler pipe of the present invention, i.e., a filler pipe 15 for charging a liquid product and jam product separately and in a separated condition, will now be described in detail.
FIG. 3 shows a cross section of a portion of mold part 12 positioned on a mold chain, the end of filler pipe 15 having a nozzle 17, a small diameter second delivery pipe 22 for charging jam, packing container blanks 8 consisting of two webs 5 and 6, a movable molder 33a and a sealer 31. Filling pipe 15 consists of a first delivery pipe 16 with a flat cross section, a nozzle 17 connected to the first delivery pipe 16, and a second delivery pipe 22 to feed jam product of smaller diameter than the first delivery pipe 16. Pipe 22 opens downward and is positioned parallel to and on the longitudinal centerline of the first delivery pipe 16 at a predetermined distance above the junction of first delivery pipe 16 and nozzle 17.
Referring to FIGS. 1, 2 and 3, nozzle 17 is formed from a long, thin substrate 18 made into a rectangular shape narrower than the height of wall 6b of the packing container to be produced (FIG. 7) and at least as long as two of the packing containers. Nozzle 17 is attached to the end of delivery pipe 16 so that the bottom surface of substrate 18 is a direct continuation of the bottom flat surface of the delivery pipe 16. The orifice 19 of the first delivery pipe 16 opens to the top of the substrate 18 at the junction between the first delivery pipe 16 and the substrate 18. A transverse wall 21a connected to orifice 19 is provided at the upstream end of guide blocks 20 to be described later, linking the left and right rows of guide blocks. Multiple guide blocks 20 forming paths to induce the liquid product 40 to flow to the left and right are provided on the upper surface of substrate 18. Guide blocks 20 are triangular when viewed from the top, and are arranged in symmetrical pairs along the longitudinal axis of substrate 18 so that one wall 20a of each guide block 20 faces upstream, the outer edge of each guide block 20 extends to the edge of substrate 18, and the inner edges gradually extend toward the center upstream to downstream, from both sides of the width of orifice 19. Guide blocks 20 are set at intervals to form filling paths 23 between orifice 19 and blocking wall 21 to stop liquid flow providing at a specified location downstream and lengthwise down substrate 18 from orifice 19. Because the gap between symmetrically positioned guide block 20 pairs is widest at the edge of substrate 18 connected to delivery pipe 16 and smallest on the opposite or downstream end of substrate 18, the liquid flow section in the center of substrate 18 is actually shaped like a long slender triangle.
FIG. 6 shows how the upper surfaces of guide blocks 20 arranged in two paired rows between the upstream and downstream blocking walls are formed to fit the inner surface of the higher arc-shaped central section of web 6, which links tongue pieces 6a of web 6 moving downward.
Referring again to FIGS. 1, 2 and 3, flat panel 24 of specified length, which is wider than substrate 18, attached as an extension of the substrate 18 on the downstream end of substrate 18, i.e., the end opposite first delivery pipe 16, and connected to nozzle 17 and opposite the downstream blocking wall 21, is attached with a common bottom surface to that of substrate 18 so that proper head space is formed and maintained when filling packing container blanks 8 with liquid product 40. Liquid product 40 passes through orifice 19 via first delivery pipe 16 and flows through the abovementioned long narrow triangular liquid flow section between substrate 18 and web 6 moving in contact with the top surfaces of the guide blocks 20 on the substrate 18. Liquid product 40 then passes out through the filling paths 23 via the any narrow filling outlets 23a between the guide blocks 20 so that any air inflow is prevented and air bubbles in the liquid product are removed, and is separated and charged via the wide discharge ports into packing container blanks 8.
Pressure drop in the downstream liquid product is actually compensated for by the triangular shape of the liquid flow section, and liquid product 40 is forced out evenly from the multiple filling paths 23 so that it contacts the tongue pieces 6a and charged the U-shaped pieces (FIG. 6). Because the jam product 42 is separately charged into the containers before the liquid product 40 is charged, the opening 22a of second delivery pipe 22 to supply jam is positioned in the bottom of first delivery pipe 16 at a location a specified distance, i.e., a certain number of container lengths (determined by the viscosity of the jam) upstream from orifice 19 at the junction between first delivery pipe 16 and nozzle 17.
As described previously (FIG. 4), a specified flow rate of jam is supplied to second delivery pipe 22 by measuring pump 38 from a level tank (not illustrated) via a feeder pipe 37, and a small, specified amount of the jam flows through the opening 22a into each of the continuously moving packing container blanks 8. After the packing container blanks 8 have moved a certain distance, yogurt or other liquid product 40 flows from nozzle 17 onto the top of jam product 42 previously charged into the packing container blanks 8 (See FIG. 6). Nozzle 17 is at least as long as two continuous packing container blanks 8, and the packing container blanks that move past it are gradually filled with the liquid product 40 and charging is completed with the jam product 42 on the bottom and the yogurt or other liquid product 40 on the bottom, maintaining a separated condition without intermixing.
After charging, the center of web 6 is leveled by molder 33a and sealed by sealer 31. During this interval, the sealed containers pass a flat panel 24 and, because charging does not take place, proper head space is ensured during sealing.
In the above embodiment the filling paths 23 from both sides of nozzle 17 are formed by using multiple triangular guide blocks 20 on substrate 18. This application is, however, not limited to these triangular guide blocks, i.e., other shapes could be used, such as straight, latter-shaped, or arc-shaped. Multiple holes could be opened in flat, prismoidial distribution spaced connected to first delivery pipe 16 and several horizontal walls formed to guide the liquid product 40 to both sides, or other forms could be devised to suit the liquid material to be charged.
Furthermore, although in the above embodiment the second delivery pipe 22 is positioned inside the first delivery pipe 16, the second delivery pipe 22 could be positioned on the outer lateral wall of first delivery pipe 16.
As the above discussion clearly indicates, the present invention relates to the production of packing containers charged with a liquid food product, such as yogurt, and also a jam product, which permits charging in a separated condition without intermixing, thus preserving the individual flavors of the products and providing a superior type of product not previously available.
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A filler pipe for a packing machine for consecutively filling a traveling and continuous series of connected packing container blanks, with a liquid product such as yogurt, and a separate jam product, without mixing the two types of product. This filler pipe is used in conjunction with blanks formed of two joined webs and provides sealing of the filled packing containers. The invention utilizes a nozzle with multiple filling paths each of which passes product to at least one of the packing container blanks. The nozzle receives the liquid product from a flat shaped larger delivery pipe, and the jam product from a smaller delivery pipe parallel to the larger pipe. The smaller pipe, which may be located inside or on the outer wall of the large pipe, is placed at a predetermined distance above the junction of the larger delivery pipe and the nozzle. In this way each container is first filled with its share of jam product and then with the liquid (yogurt) product with no mixing of the two products. This invention represents an advance over existing packing methods which can only supply mixed products.
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BACKGROUND
1. Field of the Invention
[0001] The present application relates to charging systems for vehicle batteries. In particular, the present application relates to charging systems that include a movable member, such as a wheel or a wind-powered element.
2. Description of Related Art
[0002] Most self-propelled vehicles, including automobiles, include a battery and a number of electrical systems. Many vehicles, such as automobiles and motorcycles, also include a gas powered engine that provides power for propelling the vehicle. Such vehicles rely on electrical power from the battery for starting the gas engine. Such vehicles also typically include a number of electrical systems, such as lights and radio, which rely on electrical power from the battery. Other vehicles are purely electric vehicles, such as electric cars, golf carts, and the like, which rely on power from the battery for propelling the vehicle, as well as for other electrical systems such as lights and radio that may be provided.
[0003] The vehicle battery is typically rechargeable. Vehicles equipped with a gasoline engine usually include an alternator that is driven by the gasoline engine and operable for generating electrical power to recharge the battery. While an alternator provides a useful means for recharging the battery, such vehicles do not typically include any additional or backup charging system in the event of an alternator failure.
[0004] Other purely electric vehicles must be charged from an external electrical power source, such as a generator or an AC power outlet. This requires the electric vehicle to be stationary, so the electric vehicle is out of service until the battery is recharged. As a consequence, the range of a typical electric vehicle is limited to the distance the vehicle can be driven before the battery is discharged to the point where the battery can no longer provide sufficient electrical power for propelling the vehicle.
[0005] Thus, there exists a need for improved charging systems for vehicle batteries.
DESCRIPTION OF THE DRAWINGS
[0006] The novel features believed characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
[0007] FIG. 1 shows a block diagram of a vehicle having a battery bank and a charging system;
[0008] FIG. 2 shows a block diagram of an alternative embodiment that includes multiple battery banks;
[0009] FIG. 3 shows a block diagram of an alternative embodiment that includes multiple battery banks and multiple drive motors;
[0010] FIG. 4 shows a block diagram of an alternative embodiment that includes multiple battery banks, multiple drive motors, and multiple drive systems;
[0011] FIG. 5 shows a block diagram of an alternative embodiment that includes a drop-down wheel for the charging system;
[0012] FIG. 6 shows a block diagram of a heating system for a vehicle cabin;
[0013] FIG. 7 shows a schematic block diagram of an embodiment that includes the use of the rotation of an axle and/or a drive shaft for driving one or more electric generators;
[0014] FIG. 8 shows a schematic block diagram of an electric generator that is belt-driven by a rotating drive shaft or axle; and
[0015] FIG. 9 shows a schematic block diagram of an electric generator that uses a rotating drive shaft or axle as a stator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIG. 1 in the drawings, a block diagram is shown of a vehicle 100 , which can be any type of vehicle. Examples of vehicle types include golf carts, motorcycles, all-terrain vehicles (ATVs), cars, trucks, vans, and sport utility vehicles. It will be appreciated that vehicle 100 can include numerous other conventional vehicle systems and components in addition to those shown in FIG. 1 .
[0017] The vehicle 100 has a charging system for charging a rechargeable battery bank 102 . The battery bank 102 can include one or more rechargeable batteries. In some embodiments, the vehicle is a battery electric vehicle (BEV) that uses chemical energy stored in the rechargeable battery bank for powering an electric motor, which is used instead of, or in combination with, an internal combustion engine for propelling the vehicle. In other embodiments, the vehicle can be a gas powered vehicle that uses an internal combustion engine for propelling the vehicle, but still has a rechargeable battery bank for providing electrical power for starting the engine and for various other systems, such as radios, lights, computers, and other systems requiring electricity to operate. Also, while various components are shown and/or described as part of a vehicle, it should be appreciated that such components can also be located outside of the vehicle, for example on a trailer that is configured to be attached to the vehicle.
[0018] The vehicle 100 includes an air inlet 104 . The air inlet 104 is configured to direct incoming air 106 in the direction of a fan 108 . The incoming air 106 can cause the fan 108 to rotate. The fan 108 is connected, directly or indirectly, to a shaft 110 extending from the rotor of an electrical generator 112 , such as an alternator. In some embodiments, the fan 108 can be attached directly to the shaft 110 . In other embodiments, the fan 108 can be attached indirectly to the shaft 110 . For example, the fan 108 can be connected to the shaft 110 via one or more drive belts, gear boxes, and/or clutches according to methods known by those skilled in the art. In some embodiments, the fan 108 can include one or more fans attached in series or disposed in series on shaft 110 . The fan 108 can include any known type of fan, including fans having radially-extending blades and/or centrifugal fans (also referred to as squirrel-cage fans). In some embodiments, the fan 108 can be made of a material that includes one or more of a metal, plastic, or other material that is lightweight and durable.
[0019] As the fan 108 rotates, the shaft 110 can cause the rotor of the generator 112 to rotate, resulting in generation of an electric current that can be used to charge the battery bank 102 . It will be appreciated by those skilled in the art that additional components can be included as part of the generator 112 , battery bank 102 , and/or therebetween, for example for power conditioning, timing, and power-surge protection, in order to allow for the battery bank 102 to be safely and properly charged by the generator 112 according to methods known in the art.
[0020] In the illustrated embodiment, the vehicle 100 can use electric power from the battery bank 102 to power an electric drive motor 114 that uses the electric power from the battery bank 102 to produce mechanical energy. For example, the drive motor 114 can be a brushed direct current (DC) motor or a brushless DC motor. In some embodiments, the vehicle 100 can be a hybrid vehicle wherein the drive motor 114 is used in combination with an internal combustion engine for providing mechanical energy to a drive system 115 that is configured for propelling the vehicle 100 . In other embodiments, the vehicle 100 can be an electric vehicle wherein the drive motor 114 is for providing mechanical energy to the drive system 115 for propelling the vehicle 100 without another engine. As further described below in connection with FIGS. 3 and 4 , the vehicle 100 can include multiple drive motors 114 for providing mechanical energy to one or more drive systems 115 for propelling the vehicle 100 .
[0021] The drive system 115 can be any conventional drive system that is capable of transferring mechanical energy from the drive motor 114 to one or more drive wheels (not shown). For example, the drive system 115 can include a drive shaft that is rotated by the drive motor 114 through suitable gearing. The drive shaft can be coupled with a driven shaft via a clutch mechanism. The driven shaft can rotate one or more axles attached to one or more drive wheels via a conventional differential mechanism.
[0022] The vehicle 100 can also use electric power from the battery bank 102 to power various other vehicle accessories, generally shown and referred to as vehicle accessories 116 . The vehicle accessories 116 can include any of a number of known vehicle accessories. Examples of vehicle accessories 116 can include radios, lights, computers, and other systems requiring electricity to operate.
[0023] The air inlet 104 can be configured to selectively allow the incoming air 106 to pass therethrough in an open position and prevent the incoming air 106 from passing therethrough in a closed position. For example, the air inlet 104 can include one or more retractable scoops that protrude from the body of the vehicle 100 when the air inlet 104 is in the open position, and are at least substantially flush with the body of the vehicle 100 when the air inlet 104 is in the closed position. In some embodiments, the air inlet 104 can include one or more doors or panels that can be opened and closed in order to selectively allow air to pass through the air inlet 104 . For example, the air inlet 104 can include one or more doors or panels that can be controlled to rotate and/or translate between open and closed positions. In some embodiments, the air inlet 104 can include a housing or scoop that includes one or more of plastic, cloth, burlap cloth, fiberglass, hemp cloth, rubber, any light fiber, and metal, including steel or a steel alloy.
[0024] The air inlet 104 can be positioned such that air is forced therethrough while the vehicle 100 is moving and the air inlet 104 is in the open position. For example, the air inlet 104 can be positioned such that it opens towards the front of the vehicle 100 so that air is forced into the air inlet 104 while the vehicle is moving forward and the air inlet 104 is in the open position. The exact location of the air inlet 104 can vary, and in some embodiments can depend on a number of factors associated with the vehicle 100 . Examples of such factors can include such things as vehicle aerodynamics, vehicle weight and balance, vehicle shape and styling, and locations of other components, such as the respective locations of the drive motor 114 , battery bank 102 , fan 108 , and generator 112 . Examples of locations for the air inlet 104 can include the front bumper, grill, fenders, hood, sides, roof, and under-side of the vehicle. In some embodiments, the air inlet 104 can include a protective grill or filter to prevent debris from passing through the air inlet 104 .
[0025] Also, as mentioned above, in some embodiments, the air inlet 104 can be located separate from the vehicle 100 , for example on a trailer that can be connected to and towed by the vehicle 100 . In such embodiments, the fan 108 and generator 112 can also be located proximate to the air inlet 104 , for example on the same trailer. The generator 112 can then transfer electric power to the battery bank 102 on the vehicle 100 via a wiring harness that includes a connector that can be connected and disconnected between the trailer and the vehicle 100 . Alternatively, in such embodiments, the fan 108 , generator 112 , and battery bank 102 can be located proximate to the air inlet 104 , for example on the same trailer. The battery bank 102 can then transfer electric power to the vehicle accessories 116 and/or drive motor 114 on the vehicle 100 via a wiring harness that includes a connector that can be connected and disconnected between the trailer and the vehicle 100 ; the battery bank 102 can also, or alternatively, be used to provide electric power for trailer components such as lights, tools, machinery, heating systems, and/or cooling systems.
[0026] In some embodiments, the air inlet 104 can be fixed such that it remains in the open position. This allows incoming air 106 to pass through the air inlet 104 whenever the vehicle 100 is moving. However, if the vehicle 100 is moving forward, and the incoming air 106 is passing through the air inlet 104 as a result of air being forced through the air inlet 104 by the forward motion of the vehicle 100 , an additional amount of drag is created since the incoming air 106 is forced to turn the fan 108 rather than being allowed to pass over the body of the vehicle 100 .
[0027] In other embodiments, the vehicle 100 can include any one, or any combination, of a number of systems for controlling the air inlet 104 to move between the open position and the closed positions. Examples of such systems for controlling the position of the air inlet 104 include systems that control the air inlet 104 such that the air inlet 104 is moved to the open position whenever extra drag is desirable, and the air inlet 104 is moved to the closed position whenever extra drag is not desirable. More specific examples include systems shown in FIG. 1 , including an accelerometer 118 , driver controls 120 , a braking system 122 , and a cruise-control system 126 , any one or combination of which can be used in combination with a processor 124 .
[0028] The accelerometer 118 can include one or more of any devices suitable for detecting and/or measuring acceleration and/or deceleration of the vehicle 100 . The presence and/or degree of acceleration and/or deceleration can then be used to determine a suitable position for the air inlet 104 . There are many well-known devices that are capable of measuring acceleration and/or deceleration and can be used for measuring acceleration and/or deceleration of the vehicle 100 . In some embodiments, such as the illustrated embodiment in FIG. 1 , the accelerometer 118 can operate using electric power received from the battery bank 102 . In other embodiments, the accelerometer 118 can operate using a different power source in combination with, or instead of, the battery bank 102 . The accelerometer 118 can include processor 124 , or can communicate with a separate processor 124 . In some embodiments, such as the illustrated embodiment in FIG. 1 , the processor 124 can operate using electric power received from the battery bank 102 . In other embodiments, the processor 124 can operate using a different power source in combination with, or instead of, the battery bank 102 . It should be appreciated that in this and other embodiments described herein, communication signals, such as between the processor 124 and the accelerometer 118 or between other components can include wired and/or wireless communications, and that wired communications can be implemented using a wide variety of known communication conduits, including conductive wiring and/or fiber optic wiring. In some embodiments, the accelerometer 118 can include, in place of or in combination with an actual acceleration and/or deceleration measuring and/or detecting device, means for measuring and/or detecting some other aspect or aspects of the vehicle 100 that can be used to derive information representative of a detection or measure of acceleration and/or deceleration of the vehicle 100 .
[0029] For example, in some embodiments, the accelerometer 118 can be configured to detect and/or measure the speed of the vehicle 100 and use the speed information in place of, in combination with, or for determining acceleration information about the vehicle 100 using known techniques for determining acceleration based on changes in speed. Many vehicles include well-known systems for determining the speed of the vehicle and display the determined speed information to the driver via a speedometer. In some embodiments, such speed-determination systems can constitute at least a portion of accelerometer 118 . For example, the speed information can be provided from a speed-determination system to the accelerometer 118 , which can use the speed information to calculate and/or verify a separately-calculated acceleration of the vehicle 100 using known techniques for determining acceleration based on changes in speed. Alternatively, the speed information can be provided from a speed-determination system to processor 124 , which can use the speed information to determine whether the vehicle 100 is accelerating or decelerating using known techniques for determining acceleration based on changes in speed.
[0030] As another example, the accelerometer 118 can detect and/or measure locations and/or changes in locations of the vehicle 100 and use the location information and/or location-change information in place of, in combination with, or for determining acceleration information about the vehicle 100 using known techniques for determining acceleration based on changes in position. There are many well known systems that are capable of detecting and/or measuring locations and/or changes in locations that can be used for detecting and/or measuring locations and/or changes in locations of the vehicle 100 . Examples of such systems include Global Positioning Satellite (GPS) systems, which receive and process signals from global positioning satellites to determine a location and/or changes in location over time. Other examples include cellular systems, which can determine location and/or changes in location by triangulating on nearby cell towers having known, fixed positions and/or GPS systems. In some embodiments, such systems can constitute at least a portion of accelerometer 118 . For example, the location information and/or location-change information can be provided to accelerometer 118 , which can use the location information and/or location-change information to calculate and/or verify a separately-calculated acceleration of the vehicle 100 using known techniques for determining acceleration based on changes in position. Alternatively, the location information and/or location-change information can be provided directly to processor 124 , which can use the location information and/or location-change information to determine whether the vehicle 100 is accelerating or decelerating using known techniques for determining acceleration based on changes in position.
[0031] The driver controls 120 can include one or more of any devices suitable for allowing a driver and/or passenger in the vehicle 100 to set, adjust, or request a position of the air inlet 104 . The input from the driver controls 120 can then be used by the processor 124 to determine a suitable position for the air inlet 104 . There are many well-known devices that are capable of receiving an input from a driver and/or passenger and converting the input into information that can be interpreted by the processor 124 . For example, the driver controls 120 can include one or more buttons, knobs, pedals, levers, triggers, and/or microphones. The driver controls 120 can also include one or more sensors and/or processors for detecting and/or processing user inputs to the driver controls 120 and transferring information representative of the user inputs to the processor 124 .
[0032] In some embodiments, such as the illustrated embodiment in FIG. 1 , the driver controls 120 can operate using electric power received from the battery bank 102 . In other embodiments, the driver controls 120 can operate using a different power source in combination with, or instead of, the battery bank 102 . The driver controls 120 can include processor 124 , or can communicate with a separate processor 124 . In some embodiments, such as the illustrated embodiment in FIG. 1 , the processor 124 can operate using electric power received from the battery bank 102 . In other embodiments, the processor 124 can operate using a different power source in combination with, or instead of, the battery bank 102 .
[0033] In some embodiments, the driver controls 120 can include one or more devices for setting and/or adjusting a position of the air inlet 104 without the use of processor 124 . For example, the driver controls 120 can include mechanical and/or hydraulic systems that set and/or adjust the position of the air inlet 104 based on input received by the driver controls 120 . In some such embodiments, the driver controls 120 can operate without the need for electric power. For example, the driver controls 120 can include a handle or lever that is mechanically connected to the air inlet 104 , e.g., via a series of one or more mechanical links, so that the position of the air inlet 104 can be adjusted and/or set without the need for processor 124 and electric power.
[0034] The braking system 122 can include a conventional air or hydraulic braking system for slowing and stopping a vehicle. Such conventional braking systems typically include a brake pedal, but in some cases include a brake lever, such as in the case of motorcycles. For convenience, this description will simply refer to brake pedals, but it should be understood that references to brake pedals are intended to include other types of brake controls including brake levers. Since additional drag can be desirable while braking, the braking system 122 can be used to control the position of the air inlet 104 to move to the open position while braking. For example, the air inlet 104 can be moved to the open position while the driver is pressing the brake pedal, and the air inlet 104 can be moved to the closed position while the driver is not pressing on the brake pedal.
[0035] There are many ways in which the braking system 122 can be used to control the position of the air inlet 104 .
[0036] In some embodiments, one or more brake sensors can be used to detect when the brake pedal is pressed. The brake sensors can notify the processor 124 that the brake pedal is pressed. In response, the processor 124 can move the air inlet 104 to the open position. The brake sensors can also notify the processor 124 once the brake pedal is no longer being pressed. In response, the processor 124 can move the air inlet 104 to the closed position.
[0037] In some embodiments, one or more accelerator sensors can be used to detect when an accelerator pedal is pressed, and notify the processor 124 when the accelerator pedal is pressed. In such embodiments, signals from the brake sensors can be used by the processor 124 for detecting a deceleration condition, and in response the processor 124 can move the air inlet 104 to the open position, and signals from the accelerator sensors can be used by the processor 124 for detecting an acceleration condition, and in response the processor can move the air inlet 104 to the closed position. In some embodiments, for example, the processor 124 can move the air inlet 104 to the open position when the brake pedal is pressed (i.e., while the vehicle 100 is decelerating), maintain the air inlet 104 in the open position when the brake pedal is released until the accelerator pedal is pressed (i.e., While the vehicle 100 is coasting from decelerating), move the air inlet 104 to the closed position when the accelerator pedal is pressed (i.e., while the vehicle 100 is accelerating), and maintain the air inlet 104 in the closed position when the accelerator pedal is released (i.e., while the vehicle 100 is coasting from accelerating) until the brake pedal is pressed again. Note that references to an accelerator pedal are intended to include conventional engine acceleration and/or throttle controls, including pedals such as those typically found in cars and trucks, levers such as those typically found on all-terrain vehicles, and twist-grips such as those typically found on motorcycles.
[0038] In some embodiments, the air or hydraulic system of the braking system 122 can be used to control the position of the air inlet 104 .
[0039] In typical hydraulic braking systems, increased hydraulic pressure between a master cylinder and one or more brake calipers is indicative of braking by the driver. In some embodiments, one or more sensors can be used to detect this increased hydraulic pressure and notify the processor 124 of the braking condition. In some embodiments, the hydraulic system can be used to operate one or more pistons, actuators, cams, or the like that are configured for opening and closing the air inlet 104 . For example, when the driver presses the brake pedal, the increased hydraulic pressure can cause a piston or actuator to open the air inlet 104 ; when the driver releases the brake pedal, the decreased hydraulic pressure can cause the piston or actuator to close the air inlet 104 .
[0040] In typical air braking systems, decreased air pressure in the air system is indicative of braking by the driver. In some embodiments, one or more sensors can be used to detect this decreased air pressure and notify the processor 124 of the braking condition. In some embodiments, the air system can be used to operate one or more pistons, actuators, cams, or the like that are configured for opening and closing the air inlet 104 . For example, when the driver presses the brake pedal, the decreased air pressure can cause a piston or actuator to open the air inlet 104 ; when the driver releases the brake pedal, the increased air pressure can cause the piston or actuator to close the air inlet 104 .
[0041] In some embodiments, the processor 124 can be a dedicated processor for controlling the air inlet 104 . In other embodiments, the processor 124 can be a processor that is also used for other tasks. For example, many vehicles include an engine control unit (ECU) or the like, which monitors numerous sensors throughout the vehicle and controls numerous systems throughout the vehicle. In some embodiments, an ECU or the like can serve as the processor 124 . The processor 124 can be configured to control the position of the air inlet 104 . For example, the processor 124 can receive input signals from various sensors as described above, for example speed, acceleration, and/or position data; driver input data; and/or data from the braking system.
[0042] The processor 124 can include instructions that provide rules for controlling the position of the air inlet 104 based on the various inputs. The rules can include rules based on the various embodiments described herein in connection with the accelerometer 118 , driver controls 120 , and braking system 122 . Examples of such rules can include:
Move the air inlet 104 to the open position if the accelerometer 118 indicates deceleration of the vehicle 100 Move the air inlet 104 to the closed position if the accelerometer 118 indicates acceleration of the vehicle 100 Move the air inlet 104 to the open position if the driver controls 120 indicate an open command from the driver Move the air inlet 104 to the closed position if the driver controls 120 indicate a closed command from the driver Move the air inlet 104 to the open position if the braking system 122 indicates that the driver is applying the brakes Move the air inlet 104 to the closed position if the braking system 122 indicates that the driver is not applying the brakes
[0049] The rules can also include rules for prioritizing inputs from different systems. For example, the driver controls 120 can be a highest priority, the accelerometer 118 can be a second-highest priority, and the braking system 122 can be a lowest priority in terms of dictating the position of the air inlet 104 . So, for example, if a driver wants to leave the air inlet 104 open during acceleration, the open command from the driver controls 120 will override the acceleration indication from the accelerometer 118 , where the acceleration indication from the accelerometer 118 would otherwise cause the processor 124 to close the air inlet 104 according to the rules listed above. The rules can also include rules for handling combinations of otherwise conflicting inputs from different systems in the absence of, or notwithstanding, prioritization rules. Examples of such rules can include:
Move the air inlet 104 to the open position if the braking system 122 indicates that the driver is not applying the brakes but the accelerometer 118 indicates that the vehicle 100 is decelerating (i.e., the vehicle 100 is coasting to a stop) Move the air inlet 104 to the open position if the braking system 122 indicates that the driver is applying the brakes, but the accelerometer 118 indicates that the vehicle 100 is accelerating (i.e., accelerometer failure or brake system failure)
[0052] More sophisticated rules can be provided, for example to prevent rapid opening and closing of the air inlet 104 and/or to account for driver inattention. Examples of such rules can include:
Determine an amount of time since the position of the air inlet 104 was last changed and do not change the position of the air inlet 104 unless a predetermined amount of time has elapsed Determine an amount of time since the driver provided an input to the driver controls 122 and disregard the driver controls 122 if a predetermined amount of time has elapsed
[0055] The predetermined amount of time between position changes can be set to any desired amount of time; for example, an amount of time that allows the air inlet 104 to fully open or fully close before the position of the air inlet 104 is changed again. The predetermined amount of time since driver input can be set to any desired amount of time; for example, an amount of time that prevents excessive drag while driving with the air inlet 104 in the open position. Still further rules can include rules for moving the air inlet 104 to the open position when the vehicle 100 is parked or powered down in order to allow incident wind to enter the air inlet 104 so that the battery bank 102 can be charged while the vehicle 100 is parked or not in use. Still further rules can include rules for closing the air inlet 104 when the battery bank 102 is fully charged and keeping the air inlet 104 closed unless the battery bank 102 needs to be charged.
[0056] In some embodiments, the driver controls 120 can include one or more communication devices for communicating information to the driver. Examples of communication devices can include a visual display, such as indicator lights, text, or other visual indicator, and/or an audible alert, such as a tone, computer-generated speech, and/or pre-recorded speech. The communication devices of the driver controls 120 can alert the driver to the current position of the air inlet 104 and/or provide confirmation feedback for inputs provided by the driver. The communication devices of the driver controls 120 can alert the driver when a predetermined amount of time has elapsed since the driver last provided input for opening and/or closing the air inlet 104 . The communication devices of the driver controls 120 can alert the driver to the charge level (e.g., fully charged, percent charged, almost or completely discharged) of the battery bank 102 .
[0057] In some embodiments, the vehicle 100 can include a conventional cruise control system 126 such as one of the many cruise control systems known by those skilled in the art. In some such embodiments, the processor 124 can be configured to receive cruise-control information about the state of the cruise control system 126 , which can include driver inputs to the cruise control system 126 . In addition to, or instead of, other information and rules described herein, the processor 124 can be configured to control the position of the air inlet 104 based on the cruise-control information. For example, if the processor 124 detects that the cruise control system 126 is ON and SET, meaning that the driver has activated the cruise control system 126 to maintain the vehicle at a set speed, then the processor 124 can move the air inlet 104 to the closed position. Then, if the processor 124 detects that the cruise control system 126 received a COAST input from the driver, meaning that the driver desires the cruise control system 126 to allow the vehicle to decelerate, the processor 124 can move the air inlet 104 to the open position. Then, if the processor 124 detects that the cruise control system 126 received a SET or RESUME input from the driver, meaning that the driver has again instructed the cruise control system 126 to maintain the vehicle at a set speed, then the processor 124 can move the air inlet 104 to the closed position. These and/or other rules can be used by the processor 124 to control the position of the air inlet 104 based at least in part on cruise-control information.
[0058] Turning next to FIG. 2 , a partial block diagram of an alternative vehicle is shown and generally designated as vehicle 200 , which can be any type of vehicle. Examples of vehicle types include golf carts, motorcycles, all-terrain vehicles (ATVs), cars, trucks, vans, and sport utility vehicles. It will be appreciated that vehicle 200 can include numerous other conventional vehicle systems and components in addition to those shown in FIG. 2 . The vehicle 200 can be substantially the same as vehicle 100 , but has at least a few significant differences. Embodiments of the vehicle 200 can include, in addition to the components shown in FIG. 2 , one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 shown in FIG. 1 and described above.
[0059] As shown in FIG. 2 , the vehicle 200 can include a plurality of battery banks 102 , including a first battery bank 102 a and a second battery bank 102 b . In alternative embodiments, the vehicle 200 can include any number of battery banks 102 in addition to the first and second battery banks 102 a and 102 b . The vehicle 200 allows for one or more battery banks 102 to be charged while one or more other battery banks 102 are used to provide electric power for one or more systems of the vehicle 200 .
[0060] The vehicle 200 includes a charge switch 202 for controlling which of the battery banks 102 will be charged by the generator 112 . There are many suitable known switches, including relays, that can be used as the charge switch 202 . In some embodiments, the charge switch 202 can be configured to select one of the plurality of battery banks 102 to be charged. In some embodiments, the charge switch 202 can be configured to select one or more of the plurality of battery banks 102 to be simultaneously charged.
[0061] The vehicle 200 also includes a power-source switch 204 for controlling which of the battery banks 102 will provide electric power to the drive motor 114 . The power-source switch 204 can also be used to control which of the battery banks 102 will provide electric power to other systems, including one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 in embodiments so equipped. There are many suitable known switches, including relays, that can be used as the power-source switch 204 .
[0062] In some embodiments, the charge switch 202 and the power-source switch 204 can be directly controllable by the driver. For example, the vehicle 200 can include driver controls for allowing the driver or a passenger to operate the charge switch 202 and/or the power-source switch 204 . The vehicle 200 can also include a display of the charge levels of the battery banks 102 so that the driver can make an informed decision about which of the battery banks 102 to charge and which of the battery banks 102 to use as a power source.
[0063] In some embodiments, the charge switch 202 and the power-source switch 204 can be automatically controlled by the processor 124 . For example, the processor 124 can be configured to monitor the charge levels of the battery banks 102 . This allows the processor 124 to set the charge switch 202 and the power-source switch 204 based on information about the battery banks 102 . For example, the processor 124 can be configured to set the charge switch 202 to charge the battery bank 102 having the lowest charge level, and the processor 124 can be configured to set the power-source switch 204 to set the power-source switch 204 to use the battery bank 102 having the highest charge level for providing electric power for one or more systems of the vehicle 200 .
[0064] Turning next to FIG. 3 , a partial block diagram of an alternative vehicle is shown and generally designated as vehicle 300 , which can be any type of vehicle. Examples of vehicle types include golf carts, motorcycles, all-terrain vehicles (ATVs), cars, trucks, vans, and sport utility vehicles. It will be appreciated that vehicle 300 can include numerous other conventional vehicle systems and components in addition to those shown in FIG. 3 . The vehicle 300 can be substantially the same as vehicle 100 , but has at least a few significant differences. Embodiments of the vehicle 300 can include, in addition to the components shown in FIG. 3 , one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 shown in FIG. 1 and described above.
[0065] The vehicle 300 allows for one or more battery banks 102 and respective drive motors 114 to be used for propelling the vehicle 300 , while the generator 112 charges one or more other battery banks 102 corresponding to one or more other respective drive motors 114 . As shown in FIG. 3 , the vehicle 300 can include a plurality of battery banks 102 , including a first battery bank 102 a and a second battery bank 102 b . In alternative embodiments, the vehicle 300 can include any number of battery banks 102 in addition to the first and second battery banks 102 a and 102 b . The vehicle 300 also includes a plurality of drive motors 114 , including a first drive motor 114 a and a second drive motor 114 b . In alternative embodiments, the vehicle 300 can include any number of drive motors 114 in addition to the first and second drive motors 114 a and 114 b . The vehicle 300 includes a battery bank 102 for each drive motor 114 . In alternative embodiments, the vehicle 300 can include multiple battery banks 102 for each drive motor 114 in a manner substantially the same as described above in connection with FIG. 2 .
[0066] The vehicle 300 includes a charge switch 202 for controlling which of the battery banks 102 will be charged by the generator 112 . The charge switch 202 can be substantially identical to the charge switch 202 of the vehicle 200 , and therefore the same reference numeral is shown in FIG. 3 . Also, the description of the charge switch 202 provided above in connection with vehicle 200 applies equally to the charge switch 202 of vehicle 300 .
[0067] The vehicle 300 also includes a differential 302 or other mechanical energy distribution device for controlling which of the drive motors 114 will provide mechanical energy to the drive system 115 .
[0068] The vehicle 300 can also include a power-source switch 204 for controlling which of the battery banks 102 will provide electric power to other systems, including one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 in embodiments so equipped. The power-source switch 204 can be substantially identical to the power-source switch 204 of the vehicle 200 , and therefore the same reference numeral is shown in FIG. 3 . Also, the description of the power-source switch 204 provided above in connection with vehicle 200 applies equally to the power-source switch 204 of vehicle 300 .
[0069] Turning next to FIG. 4 , a partial block diagram of an alternative vehicle is shown and generally designated as vehicle 400 , which can be any type of vehicle. Examples of vehicle types include golf carts, motorcycles, all-terrain vehicles (ATVs), cars, trucks, vans, and sport utility vehicles. It will be appreciated that vehicle 400 can include numerous other conventional vehicle systems and components in addition to those shown in FIG. 4 . The vehicle 400 can be substantially the same as vehicle 100 , but has at least a few significant differences. Embodiments of the vehicle 400 can include, in addition to the components shown in FIG. 4 , one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 shown in FIG. 1 and described above.
[0070] The vehicle 400 allows for one or more battery banks 102 , respective drive motors 114 , and respective drive systems 115 to be used for propelling the vehicle 300 , while the generator 112 charges one or more other battery banks 102 corresponding to one or more other respective drive motors 114 and drive systems 115 . As shown in FIG. 4 , the vehicle 400 can include a plurality of battery banks 102 , including a first battery bank 102 a and a second battery bank 102 b . In alternative embodiments, the vehicle 400 can include any number of battery banks 102 in addition to the first and second battery banks 102 a and 102 b . The vehicle 400 also includes a plurality of drive motors 114 , including a first drive motor 114 a and a second drive motor 114 b . In alternative embodiments, the vehicle 400 can include any number of drive motors 114 in addition to the first and second drive motors 114 a and 114 b . The vehicle 400 further includes a plurality of drive systems 115 , including a first drive system 115 a and a second drive system 115 b . In alternative embodiments, the vehicle 400 can include any number of drive systems 115 in addition to the first and second drive systems 115 a and 115 b . The vehicle 400 includes a drive system 115 for each battery bank 102 and respective drive motor 114 . In alternative embodiments, the vehicle 400 can include multiple battery banks 102 for each drive motor 114 and respective drive system 115 in a manner substantially the same as described above in connection with FIG. 2 .
[0071] The vehicle 400 includes a charge switch 202 for controlling which of the battery banks 102 will be charged by the generator 112 . The charge switch 202 can be substantially identical to the charge switch 202 of the vehicle 200 , and therefore the same reference numeral is shown in FIG. 4 . Also, the description of the charge switch 202 provided above in connection with vehicle 200 applies equally to the charge switch 202 of vehicle 400 .
[0072] The vehicle 400 can also include a plurality of power switches 402 , including a respective power switch 402 for each battery bank 102 /drive motor 114 /drive system 115 group. For example, as shown in FIG. 4 , the vehicle 400 can include a first power switch 402 a for controlling power from the battery bank 102 a to drive motor 114 a , and a second power switch 402 b for controlling power from the battery bank 102 b to drive motor 114 b . The power switches 402 can be controlled by the processor 124 so that power to a drive motor 114 and drive system 115 can be disconnected while the respective battery bank 102 is charging and/or according to input from the driver of the vehicle 400 .
[0073] The vehicle 400 can also include a power-source switch 204 for controlling which of the battery banks 102 will provide electric power to other systems, including one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 in embodiments so equipped. The power-source switch 204 can be substantially identical to the power-source switch 204 of the vehicle 200 , and therefore the same reference numeral is shown in FIG. 4 . Also, the description of the power-source switch 204 provided above in connection with vehicle 200 applies equally to the power-source switch 204 of vehicle 400 .
[0074] According to some embodiments, the vehicle 400 can be a four-wheel vehicle, such as an ATV, golf cart, car, or truck. The first battery bank 102 a, drive motor 114 a , and drive system 115 a can be configured for rotating the left rear wheel. The second battery bank 102 b , drive motor 114 b , and drive system 115 b can be configured for rotating the right rear wheel. The driver can choose to drive the vehicle 400 using the left rear wheel, but not the right rear wheel, by issuing an appropriate input to the processor 124 . In response, the processor 124 can be configured to close the power switch 402 a and open the power switch 402 b so that electric power is provided to the drive motor 114 a from the battery bank 102 a, but electric power is not provided to the drive motor 114 b from the battery bank 102 b . The processor 124 can also control the charge switch 202 to allow the battery bank 102 b to be charged by the generator 112 . The driver can similarly choose to drive the vehicle 400 using only the right rear wheel. The driver can also choose to drive the vehicle 400 using both rear wheels by issuing an appropriate input to the processor 124 . In response, the processor 124 can be configured to close both the power switch 402 a and the power switch 402 b so that electric power is provided to the drive motor 114 a from the battery bank 102 a and electric power is provided to the drive motor 114 b from the battery bank 102 b.
[0075] Alternative embodiments of the vehicle 400 can involve other wheels, for example front wheels rather than rear wheels. Alternative embodiments can also involve vehicles having any number wheels. For example, the vehicle 400 can have four, six, or more wheels, where one or more of the wheels can be independently driven by a respective a battery bank 102 /drive motor 114 /drive system 115 group. Alternatively, one or more of the battery bank 102 /drive motor 114 /drive system 115 groups can be used to drive two or more wheels. For example, the battery bank 102 a , drive motor 114 a , and drive system 115 a can be used to drive the front two wheels, while the battery bank 102 b , drive motor 114 b , and drive system 115 b can be used to drive the rear two wheels.
[0076] Turning next to FIG. 5 , a block diagram of an alternative vehicle is shown and generally designated as vehicle 500 , which can be any type of vehicle. Examples of vehicle types include golf carts, motorcycles, all-terrain vehicles (ATVs), cars, trucks, vans, and sport utility vehicles. It will be appreciated that vehicle 500 can include numerous other conventional vehicle systems and components in addition to those shown in FIG. 5 . The vehicle 500 can be substantially the same as vehicle 100 , but has at least a few significant differences. Embodiments of the vehicle 500 can include a battery bank 102 and a generator 112 as described above, as well as one or more of the vehicle accessories 116 , accelerometer 118 , driver controls 120 , braking system 122 , processor 124 , and cruise control system 126 shown in FIG. 1 and described above.
[0077] The vehicle 500 also includes a drop-wheel assembly 502 and a drop-wheel controller 504 . The drop-wheel assembly 502 includes a wheel 506 and a wheel support 508 . The drop-wheel controller 504 is operably associated with the wheel support 508 such that the drop-wheel controller 504 can control the position of the wheel 506 between a retracted position and an extended position. In the extended position, the wheel 506 is in contact with the ground; in the retracted position, the wheel 506 is lifted away from the ground.
[0078] When the wheel 506 is in the extended position, the wheel 506 will turn while the vehicle 500 is moving. The wheel 506 is operably associated with the generator 112 such that rotation of the wheel 506 causes rotation of the rotor 110 of the generator 112 . In some embodiments, the generator 112 can be supported by the wheel support 508 . This allows the rotor 110 of the generator 112 to be in closer proximity to the wheel 506 , allowing for a simpler transfer of rotational energy from the wheel 506 to the rotor 110 of the generator 112 .
[0079] In some embodiments, the wheel 506 can be fixed in the extended position rather than being retractable. However, the wheel 506 causes additional drag that can reduce the performance and efficiency of the vehicle 100 . Thus, in other embodiments, the vehicle 500 can include any one, or any combination, of a number of systems for instructing the drop-wheel controller 504 to move the wheel 506 between the extended position and the retracted positions. Examples of such systems for instructing the drop-wheel controller 504 to extend or retract the wheel 506 include systems that instruct the drop-wheel controller 504 such that the wheel 506 is moved to the extended position whenever extra drag is desirable, and the wheel 506 is moved to the retracted position whenever extra drag is not desirable. More specific examples include systems shown and described above, including an accelerometer 118 , driver controls 120 , a braking system 122 , and a cruise control system 126 , any one or combination of which can be used in combination with a processor 124 as described above for determining whether to reposition the wheel 506 (as opposed to the inlet 104 ), for example by determining whether excess drag is desirable and/or undesirable according to any of the embodiments described above.
[0080] Alternative embodiments of the vehicle 500 can include multiple battery banks 102 as described above in connection with FIG. 2 ; can include multiple battery banks 102 for providing electric power to respective drive motors 114 as described above in connection with FIG. 3 ; and/or can include multiple battery banks 102 for providing electric power to respective drive motors 114 for powering respective drive systems 115 as described above in connection with FIG. 4 .
[0081] Still further embodiments of any of the vehicles described herein can include combinations of one or more fixed and/or repositionable air inlets 104 and/or drop-wheel assemblies 502 . Still further embodiments of any of the vehicles described herein can also include additional electric charging systems for charging one or more battery banks 102 , for example one or more solar panels, manual (e.g., hand-crank) generators, generators driven by an internal combustion engine, or other known system for generating electricity. Still further embodiments of any of the vehicles described herein can also include a drive system 115 that has a drive shaft connected, directly or indirectly, to the rotor of a generator or alternator for charging one or more battery banks 102 . Still further embodiments of any of the vehicles described herein can also include a drive system 115 that has an axle connected, directly or indirectly, to the rotor of a generator or alternator for charging one or more battery banks 102 . Still further embodiments of any of the vehicles described herein can include a kill switch for turning off all electric power in the event of an accident. Still further embodiments of any of the vehicles described herein can include venting for providing ventilation for the one or more battery banks 102 . Still further embodiments of any of the vehicles described herein can include a compartment for the one or more battery banks 102 located underneath one or more passenger or driver seats.
[0082] Turning next to FIG. 6 , a block diagram of a heating system 600 is shown that can be used with any of the vehicles described herein, or elsewhere. It is also desirable to utilize systems that require as little electricity as possible in the vehicles described herein, so as to maximize the effective use of the battery banks 102 . This is especially true for embodiments that are purely electric vehicles. In vehicles having an internal combustion engine, the heat of the engine is typically used for providing the heat used for the cabin heater of the vehicle. Thus, such conventional systems cannot be used on electric vehicles that lack an internal combustion engine. One alternative would be to use electricity to heat a coil, but such systems would require a large amount of electricity, significantly increasing the discharge time for the battery banks 102 .
[0083] The heating system 600 provides a solution for this problem. Many batteries that can be used as battery bank 102 produce radiant heat (represented generally as broken lines 602 ) while in use, i.e., discharging. The heating system 600 includes a heating coil 604 disposed in close proximity to the battery bank 102 . In some embodiments, the battery bank 102 can be representative of any number of batteries or battery banks 102 , and one or more heating coils 604 can be disposed in close proximity thereto. Other components of the heating system 600 can be similar to conventional heating systems. For example, a blower fan 606 , which in some embodiments can be powered by the battery bank 102 , can be used to blow air across the coils 604 and into a duct system to the vehicle cabin. The blower fan 606 can be controlled in a manner similar to conventional heating systems to allow the driver to turn the blower fan 606 on, off, and to one of multiple speeds.
[0084] As mentioned above, still further embodiments of any of the vehicles described herein can also include a drive system 115 that has a drive shaft connected, directly or indirectly, to the rotor of one or more electrical generators 112 for charging one or more battery banks 102 and/or providing electrical power directly to the drive system 115 ; and still further embodiments of any of the vehicles described herein can also include a drive system 115 that has an axle connected, directly or indirectly, to the rotor of one or more electrical generators 112 for charging one or more battery banks 102 and/or providing electrical power directly to the drive system 115 .
[0085] FIG. 7 shows a drive system 115 for driving an axle 702 and/or a drive shaft 704 , which in turn drives an axle 706 . Each of the axle 702 , drive shaft 704 , and axle 706 includes one or more respective shafts that rotate as they are driving by the drive system 115 . However, in some embodiments the drive shaft 704 and/or one or both of the axles 702 and 706 can include a free-wheeling shaft that rotates with the rotation of one or more wheels rather than being driven directly by the drive system 115 . The rotation of the shafts can be used to drive one or more electric generators 112 that have a rotating element driven by the shaft and a stationary element supported by the vehicle chassis 708 . As shown in FIG. 7 , one or more of the axle 702 , drive shaft 704 , and axle 706 can be operably associated with respective electric generators 112 . In some embodiments, for example as shown in FIG. 8 , one or more electric generators 112 can be belt, strap, or chain driven by the axle 702 , drive shaft 704 , and/or axle 706 for generating electricity. In alternative embodiments, for example as shown in FIG. 9 , the electric generators 112 can use the axle 702 , drive shaft 704 , and/or axle 706 as a component thereof for generating electricity.
[0086] The system shown in FIG. 7 can also include one or more static collection wires 710 . The static collection wires 710 can include exposed electrically-conductive material for collecting static electricity from the atmosphere due to friction between the wires 710 and the surrounding air while the vehicle is moving.
[0087] In some embodiments, the electric generators 112 and/or static collection wires 710 can provide electrical power for charging one or more battery banks 102 part of the time, and the electric generators 112 can provide electrical power directly to the drive system 115 part of the time. For example, the electric generators 112 can provide electrical power for charging one or more battery banks 102 at relatively lower vehicle speeds, such as under 50 mph, and the electric generators 112 can transition to providing electrical power directly to the drive system 115 at relatively higher speeds, for example above 50 mph or at highway speeds. The transition from providing electrical power for charging one or more battery banks 102 to providing electrical power directly to the drive system 115 or vice-versa can be automatic based on predefined rules, such as ranges of vehicle speeds, or can be manually-controlled, for example by the driver operating driver controls.
[0088] FIG. 8 shows an embodiment of an operable association between an electric generator 112 and any one of the axle 702 , driveshaft 704 , and axle 706 . FIG. 8 shows a cross-sectional view of a shaft 710 , which can be a shaft of any of the axle 702 , driveshaft 704 , and axle 706 . In the illustrated embodiment, the shaft 710 is operably associated with an electric generator 112 by a drive belt 712 . The drive belt 712 extends around the shaft 710 and a flywheel 714 of the electric generator 112 . As the shaft 710 rotates, the belt 712 is sufficiently tensioned around the shaft 710 and flywheel 714 that the rotation of the shaft 710 causes rotation of the flywheel 714 by the drive belt 712 . The flywheel 714 is connected to a stator of the electric generator 112 so that rotation of the flywheel 714 can result in electricity being generated by the electric generator 112 .
[0089] FIG. 9 shows an embodiment of an operable association between an electric generator 112 and any one of the axle 702 , driveshaft 704 , and axle 706 . FIG. 9 shows a cross-sectional view of a shaft 710 , which can be a shaft of any of the axle 702 , driveshaft 704 , and axle 706 . In the illustrated embodiment, the shaft 710 is operably associated with an electric generator 112 by serving as a stator for the electric generator 112 . The shaft 710 includes one or more brushes 718 of the type commonly known for electric generators. The electric generator 112 includes a housing 720 that is supported by the vehicle chassis 708 (shown in FIG. 7 ) and is fixed in place relative to the shaft 710 . The housing 720 extends concentrically about the shaft 710 . As the shaft 710 rotates, the shaft 710 with the one or more brushes 718 serves as a stator for the electric generator 112 , the housing 720 of which remains fixed rather than rotating. Thus, rotation of the shaft 710 with the brushes 718 fixed thereto can result in electricity being generated by the electric generator 112 .
[0090] It will be apparent to those skilled in the art that an invention with significant advantages has been described and illustrated. Although the present application is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.
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A charging system and method for charging a battery of a vehicle is disclosed. The charging system includes a movable member, such as a wind-driven element. The charging system also includes means for exposing the wind-driven element during vehicle deceleration and for covering the wind-driven element during vehicle acceleration and coasting. The charging system further includes electrical power generating means operably associated with the wind-driven element and the battery such that the electrical power generating means provides electrical power for recharging the battery when the electrical power generating means receives mechanical power from the wind-driven element. Alternative embodiments can include a drop-wheel as a movable member.
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This is a division of application Ser. No. 909,209, filed May 25, 1978 now U.S. Pat. No. 4,209,331.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electroless deposition of copper (or possibly an alloy predominating in copper) from a solution in which copper ions are dissolved, in order to provide a metal deposit or film on a desired, suitably-prepared, substrate when immersed in or contacted by the solution, without the employment of external electrical energy to bring about such reduction. The invention relates more particularly to electroless copper baths employing a non-formaldehyde type reducing agent, and more particularly a soluble hypophosphite reducing agent, for effecting conversion of the copper ions to copper metal in order to form adherent, highly conductive metal films on controlled surfaces of substrates, particularly nonconductive substrates.
2. Description of the Prior Art
The conventional electroless plating art as commercially practiced in the deposition of copper onto various substrates, especially nonconductive substrates, almost without exception today uses highly alkaline formaldehyde solutions of divalent copper complexed with various well-known agents such as Rochelle salt, amines and others. A current survey of the practical art is summarized in an article entitled "Electroless Copper Plating", by Purhpavanam and Shenoi, published in "Finishing Industries", October 1977, pages 36 et seq. The article lists the various components of electroless copper plating solutions, and discusses useful alternatives in each category. With respect to available agents for reducing the copper ion of the bath, the article lists hypophosphites, phosphites, hyposulfites, sulfites, sulfoxylates, thiosulfates, hydrazine, hydrazoic acid, azides, formaldehyde, formate and tartrate as having been tried. Hypophosphite is stated to be "very effective in alkaline or acid solutions", but the article does not define what is meant by this and goes on immediately to report that "this operates only at higher temperatures and under these conditions there appears to be a rapid reduction of copper in the bulk of solution." In other words decomposition of the solution occurs, resulting in the bath being of no further use for electroless plating. Other reducing agents from the abovementioned list are also discussed, more particularly hydrazine, borohydride and dimethylamine borane. The article states that "The best reducing agent for copper is considered to be formaldehyde." and later concludes that "No other reducing agent is capable of replacing formaldehyde and hence on (sic) (only?) the Fehlings-formaldehyde solution with modifications is maintaining its superior position in electroless copper plating."
In an article entitled "Fabrication of Semitransparent Masks", Feldstein and Weiner, J. Electrochemical Soc., Vol. 120, pp 1654-1657 (December 1973), the use of hypophosphite reducing agent is described in connection with production of semitransparent resists or masks, using an alkaline copper sulfate, EDTA-complexed, bath. The article indicates that the resulting film deposited on a catalyzed substrate immersed in such bath is cuprous oxide (Cu 2 O), and concludes that reduction of copper ions to metallic copper does not take place to any appreciable extent in a hypophosphite-reduced system. The article further reports that the deposited cuprous oxide does not provide sufficient catalytic activity for continuation of the plating process.
An earlier study entitled "Electroless Copper Plating in Printed Circuitry", E. B. Saubestre, The Sylvania Technologist, Vol. XII, No. 1, January 1959, also considered the reactions of copper ions in solutions containing a hypophosphite reducing agent, and reported work on attempted reduction of copper in alkaline hypophosphite solution as well as in alkaline hyposulfite and formaldehyde solutions. In order to obtain copper by chemical reduction, it was found necessary by the author to have either a system in which there is little tendency for the cuprous ion to form, or one in which the cuprous ion is rendered soluble by formation of a suitable complex ion. Of the various solutions tested, only the following four combinations were found to offer promise:
(a) Fehling's solution with formaldehyde
(b) Fehling's solution with hydrazine sulfate
(c) Acid sulfate solution with sodium hypophosphite
(d) Acid sulfate solution with sodium hyposulfite.
It was reported that investigation of these possibilities revealed that copper is a pronounced reduction catalyst only in the Fehling's-formaldehyde solution, so further work was accordingly concentrated along that line. Supplementing this article is another by the same author which appears in Technical Proceedings of the Golden Jubilee Convention of American Electroplaters Society, Vol. 46, pages 264 et seq; 1959. In this article a comprehensive review is presented on reducing agents for copper, and particularly sodium hypophosphite in a series of different types of copper solutions. The conclusion reached was that "In general, this reducing agent shows little promise except in Fehling's and sulfate solutions operated at high temperatures and high hypophosphite concentratitons. However, under these conditions, there appears to be rapid reduction of copper in the bulk of the solution as well." In other words the solutions decompose and cannot be used on a continuing basis and particularly not over an extended period of time. Hyposulfite was also investigated and the conclusion reached was that it "is more effective than hypophosphite, but again, since deposition tends to occur throughout the solution, this reducing agent probably lends itself only to spraying applications". That is, one involving continuous spraying of separate streams, one containing copper ions, the other the reducer. Such conditions of operation are commercially non-economic and totally impractical.
The technical literature clearly establishes that while hypophosphite agents are effective and universally used as reducing agents in electroless nickel deposition techniques, they have been found useful practically for electroless copper deposition. For copper, formaldehyde is the overwhelming choice in commercial plating today. The only viable alternatives even mentioned are borohydride, dimethyamine borane and hydrazine.
The patent literature confirms the foregoing practical experience and conclusion. U.S. patents directed specifically to electroless copper issuing between 1960 and 1977 almost invariably list formaldehyde or formaldehyde precursors, many times giving these as the only reducing agents although borohydrides and boranes appear in several patents, and there is occasional reference to hydrazine. There are a few references to alkali metal hypophosphites and hydrosulfites; but in the case of hypophosphites the disclosures relate solely to acid solutions operating at pH levels of 3.0 or less. For example, U.S. Pat. No. 3,046,159 mentions the use of hypophosphite reducing agents in plating by chemical reduction from a solution containing a normally insoluble copper compound, such as cupric oxide, in conjunction with an ammoniacal compound such as ammonium sulfate or ammonium chloride, to which sodium hypophosphite is added as the reducing agent. In all examples the solution is strongly acid (pH 3.0 or less). In order to increase the plating rate the patent recommends that the solution temperature be increased, but also recognizes that this leads to instability and great difficulty in preventing complete collapse of the system. Attempts to duplicate the teaching of this patent using standard, properly cleaned copper-clad panels, have produced only a brownish oxide deposit. When the teaching is applied to a nonmetallic substrate, such as a standard ABS of platable grade suitably prepared (catalyzed) for electroless plating, the cupric oxide particles in the bath form on the surface along with a reddish, non-adherent deposit which rubs off on the fingers when touched. Attempts to electroplate the coated substrate failed completely because the deposit simply burns off, proving that it is essentially non-conductive, leading to the conclusion that it is not metallic copper or at least is not significantly so.
It is interesting to note that other patents, such as U.S. Pat. Nos. 3,403,035; 3,443,988; 3,485,643; 3,515,563; 3,615,737; and 3,738,849, these being the only others currently known to the present inventors which contain reference to hypophosphites as reducing agents in electroless copper baths, also relate to strongly acid copper solutions. It is clear from these patent disclosures that alkaline formaldehyde systems, which are generally always also mentioned, are those actually considered to be useful in practice.
A recent patent, U.S. Pat. No. 4,036,651 teaches incorporation of sodium hypophosphite as a "plating rate adjuster" in an alkaline formaldehyde type electroless copper solution. The patent states expressly "Although sodium hypophosphite is, itself, a reducing agent in electroless nickel, cobalt, palladium and silver plating baths, it is not a satisfactory reducing agent (i.e., will not reduce Cu ++ →Cu°) when used alone in alkaline electroless copper plating baths. In the baths of the present invention [U.S. Pat. No. 4,036,651], the sodium hypophosphite is not used up in the plating reaction. Instead, it appears to act as a catalyst." (Bracketed insert added).
In the prior patents, where both electroless nickel as well as copper baths are disclosed, the bath composition examples invariably employ formaldehyde-type reducing agents for the copper formulations and, in contrast, hypophosphites for the nickel formulations. There is no suggestion in the patent art that the hypophosphite of the nickel baths could be substituted for formaldehyde in copper baths. See U.S. Pat. Nos. 3,370,974; 3,379,556; 3,617,363; 3,619,243; 3,649,308; 3,666,527; 3,668,082; 3,672,925; 3,672,937; 3,915,717; 3,977,884; 3,993,801 and 3,993,491.
As is commonly known to those skilled in the electroless plating industry, commercially satisfactory electroless copper baths have required formaldehyde-type reducing agents and operate at high pH levels (11-13), using complexing agents to maintain the copper in solution. Such baths are effective from the standpoint of adequate rate of deposit, as well as quality of deposit and adherence to a substrate. Still, the baths are inherently unstable over long periods of use and require incorporation of "catalytic poisons" in carefully controlled trace amount to avoid spontaneous (bulk) decomposition. The plater must therefore always operate in a relatively narrow range between conditions which are conductive to satisfactory deposition on controlled areas of a substrate on the one hand, and random, unwanted, copper plate-out on tank walls, racks, etc., on the other. Continuous filtering of the solution and frequent cleaning of the plating tank, etc. is usually required. This is expensive in terms of time and labor, as well as in chemical component losses. Formaldehyde-type electroless copper baths are also prone to the Cannizzaro reaction, with accompanying wasted consumption of bath ingredients on that account. Additionally, formaldehyde is a volatile chemical. The bath vapors can be toxic and must accordingly be appropriately handled, which introduces environmental control problems.
SUMMARY OF THE INVENTION
The invention here relates to the discovery that non-formaldehyde-type reducing agents can be usefully employed in commercial installations as a reducer for divalent copper in electroless plating baths to produce an electrically conductive metallic base or film on suitably prepared substrates, and particularly on catalyzed non-conductive substrates. Such copper deposit has good conductivity, provides good adherence of the deposit to the substrates, and serves as an excellent base for electrolytic deposition of additional copper or other metals.
One of the important keys to this invention lies in the discovery that for each complexing agent employed in conjunction with the reducing agent, there is an optimum pH range for successful operation of the bath. Further supplementing this in ensuring satisfactory deposits under the invention are adequate surface preparation of the substrate, with special attention to catalytic preparation, and acceleration treatment of the catalyzed substrate. Additionally it is found desirable to avoid excessive work agitation or high turbulence of the plating solution in the novel baths. In the subsequent electrolytic deposition of additional metal on the electroless copper base, the plating should be carried out, at least initially, under controlled current density condition to avoid burning of the base at the contact points on the work where connection to the plating bus is made. Further discussion of these factors appears hereinafter.
One of the principal advantages of the novel non-formaldehyde-reduced electroless copper bath is that a more stable bath is provided, having greater tolerance to changes inevitably encountered in practical commercial operation. That is, the plating baths of this invention allow wider operating parameters in terms of component concentration, temperature, plating time, etc., so that such parameters are more nearly comparable to those typically encountered in commercial electroless nickel baths. The latter baths have characteristically not needed the sophisticated component monitoring and complex monitoring equipment that formaldehyde-reduced copper baths require. Bath maintenance is accordingly greatly simplified in the use of the novel baths, and consumption of ingredients is closely confined to plate-out on catalyzed surfaces only. Tank clean-out is infrequently necessary and the plating solution need not be so carefully filtered or completely replaced as is the case with formaldehyde-type baths. In addition, the novel baths, by eliminating formaldehyde, get rid of problems due to the volatility of that reducing agent, as well as its tendency to undergo the Cannizaro side-reaction. All of these considerations take on added significance under actual "plating shop" conditions where operation may be supervised by semi-skilled personnel or where the operations are partially automated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Plating solutions embodying the inventive concept include the usual major categories of components of conventional electroless copper baths; namely, a source of cupric ions and a solvent for these, usually water; complexing agent or mixtures thereof; and non-formaldehyde-type reducing agent. One such reducing agent found to be especially useful is hypophosphite. This is indeed surprising and quite unexpected, given the teaching and experience of the prior art.
The copper source in the plating solutions may be comprised of any available soluble copper salt. Copper chloride and copper sulfate are usually preferred because of availability, but nitrate, other halide, or organic copper compounds such as acetates can be used.
As will be discussed in detail presently, proper pH level of the copper bath is important to the operability of the novel copper solutions. If adjustment of pH is needed, any standard acid or base may be employed to return the level to correct operating range. Continued liberation of acid during plating lowers the pH of the bath with time, so some adjustment will be required for extended periods of use. In general it is preferred to use as pH adjusters those compounds which furnish at least one of the same ions as already introduced by the copper compounds. For example, hydrochloric acid is preferred where copper chloride is used; or sulfuric acid where copper sulfate is the copper source. In the case of alkaline adjusters, sodium or potassium hydroxide is preferred. However, so long as the extraneous ion introduced via the adjuster does not interfere with other components of the bath, its particular chemical identity is not important. Employment of a buffer, such as sodium acid phosphate, sodium phosphite, etc., aids in maintaining the selected pH range.
The most effective complexing agents now known for the preferred hypophosphite-reduced electroless copper baths of the invention are N-hydroxyethyl ethylenediamine triacetic acid (HEEDTA), ethylenediamine tetraacetic acid (EDTA), nitrilotriacetic acid (NTA), and alkali metal salts of these; also the tartrates and salts of these. The operating ranges in terms of pH of the plating solutions are generally effective from slightly acidic to an essentially alkaline condition. A minimum pH of at least 5 is found essential, at which level the copper deposit obtained may be suitable provided any imperfections will be adequately covered by subsequently applied other deposits. In general, amine type complexers show operability at pH of about 5-11, while tartrate complexers are operable from about pH 9-13. Optimum results are obtained by working within somewhat more restricted limits of the broad ranges mentioned; for example from about 6 to 10 for the amine-complexed baths, and about 10-11 for tartrate complexed baths, as will be more apparent hereinafter. However within the designated range, the system generally is more tolerant to small changes than conventional formaldehyde-reduced systems. Concentration of the amine complexer in solution is preferably at about one-to-one on a mole ratio basis with the cupric ion, while the tartrate and NTA complex concentration is on a two-to-one mole ratio basis. Lesser amounts of complexer will of course leave some copper uncomplexed. This can be tolerated within limits provided precipitation of particles is insufficient to interfere with the desired degree of luster, smoothness, etc. in the finished plate. Increased filtering can compensate to some extent for a condition of insufficient complexer concentration. On the high-ratio side, there is no problem, as excess of complexer does not hinder the operation of the bath and in fact a slight excess can be helpful to accommodate for conditions of temporary, locally high copper concentration which may arise during bath replenishment operations.
Sodium hypophosphite is the most readily available hypophosphite material and is accordingly the preferred form of this reducing agent. Hypophosphorous acid however is also available and could be used in conjunction with pH adjusters, which would probably be required in preparing a bath of this material. As to concentration, the optimum is that level which is sufficient to give an adequate copper film in a reasonable period of time. The system will work with less reducer but of course not all of the available copper can be deposited from such a solution unless more hypophosphite is added during operation of the bath. Working with a large excess of reducer over the stoichiometric amount needed to reduce all the copper in solution does not impede the bath operation, but neither does it have any advantage.
The reaction involved in electrolessly plating a catalytic substrate using bath compositions of the present invention is thought to be best represented by the following summarizing equation:
Cu.sup.++ +2H.sub.2 PO.sub.2.sup.- +2H.sub.2 O→Cu°+2H.sub.2 PO.sub.3.sup.- +2H.sup.+ +H.sub.2 ↑
The following examples illustrate preferred conditions for practicing the invention.
EXAMPLE I
A typical workpiece comprising an automotive component molded of standard commercial plating grade ABS is first cleaned to remove surface grime, oil, etc. An alkaline cleaning solution as typically used in prior plating systems may be used here also. This is followed by chemical etch using mixed chromic-sulfuric or all chromic acid, also standard in the industry. Typical operating conditions, concentrations and time of treatment are disclosed in U.S. Pat. No. 3,515,649. Following thorough rinsing, the workpiece is catalyzed. This can be accomplished in the "one-step" method using a mixed palladium-tin catalyst of commercial type. Such a catalyst is disclosed in U.S. Pat. No. 3,352,518, along with its method of use. Following rinsing, the catalyzed workpiece is next placed in a so-called "accelerating solution" to reduce or eliminate the amount of residual tin retained on the surface since tin tends to impede copper deposition. Again, many types of accelerating baths can be employed, for example the one disclosed in the above mentioned U.S. Pat. No. 3,352,518, such accelerating baths generally consisting of an acid solution. Alkaline accelerators such as sodium hydroxide solution have also been used successfully.
The workpiece is then ready after further rinsing for copper plating. The novel copper bath used in this example has the following composition:
CuCl 2 .2H 2 O: 0.06 M (10 g/l)
"Hamp-Ol" (HEEDTA): 0.074 M (26 g/l)
NaH 2 PO 2 .H 2 O: 0.34 M (26 g/l)
Water
pH adjuster (HCL/NaOH) (as needed): pH 9
The bath is maintained at 140°-150° F. (60°-66° C.) and when the work is immersed in it for 10 minutes, the thickness of copper plate obtained is 9.2 microinches. In 20 minutes the thickness of deposit is 10.5 microinches. The deposit is bright pink, a visual characteristic indicating good electrical conductivity. Coverage is complete on the catalyzed surface, and the deposit is well-adhered, is free of blisters and roughness. This electroless plated substrate is rinsed, then placed in a standard electrolytic copper strike bath similar to any of those described in U.S. Pat. Nos. 3,203,878, 3,257,294, 3,267,010 or 3,288,690, for example. Initially the electroplating is carried out at about 2 volts at a rate of about 20 amperes per square foot. Generally this is maintained for about 11/2 minutes, or until the thickness of deposit is sufficient to provide greater current-carrying capability. At such time the plating rate may then be increased, as for example to about 4 volts at 40 amperes per square foot, until the total required thickness of copper is obtained. The workpiece may be further electroplated with nickel, chromium, gold, etc., as may be required for any given application, using standard electroplating techniques. Much of the restriction on initial current density depends on the size and complexity of parts, along with the amount of rack contact area of workpiece available per area. If enough contacts are used, the need to monitor initial current densities is less critical; however in production experience, adequate rack contacts cannot always be found.
Peel strength tests on plated workpieces obtained from baths in accordance with this example show adherence values of about 8-10 pounds per inch for the copper deposit on ABS substrates. Similar levels of peel strength are obtained for other thermoplastic substrates including polyphenylene oxide, polypropylene, etc., as well as thermosetting substrates such as phenolic, epoxy, etc.
EXAMPLE II
An electroless copper bath identical in all respects to that of the foregoing example is prepared except that a different complexer is used. In this case, the complexer is "Hampene Na 4 " (tetrasodium EDTA) at the same concentration (0.074 M) as before and the pH is again 9. At a bath temperature of 140°-150° F., a bright pink electroless copper deposit of 6.6 microinches is obtained in 10 minutes, which increases to 8.3 microinches in 20 minutes. Coverage of the workpiece is complete on the catalyzed surface, and the deposit is free of blisters and roughness and is well adhered to the substrate. The deposit forms an excellent base for further metal plating to build up a desired total thickness. When so plated, adhesion tests made on the ABS substrate plated in accordance with this example show peel strengths which range from 8-10 pounds per inch.
EXAMPLE III
Another ABS workpiece is prepared for electroless plating in the manner described. The electroless copper bath here is again identical to that of the first example except for complexer, which in this case is nitrilotriacetic acid (NTA) at 0.148 M. At a solution pH of 9, a bright pink adherent copper deposit of 12.1 microinches is obtained. After being further plated with additional copper, nickel, chromium or the like, to build up a desired thickness, adhesion values of 8-10 pounds per inch peel strength on ABS is recorded.
EXAMPLE IV
The copper bath in this example is again the same as in the others except for complexer, which in this case is sodium potassium tartrate at 0.148 M and the bath pH is adjusted to 11. An ABS substrate, prepared as indicated above, when immersed in this solution developes a copper deposit of 19 microinches in 10 minutes at a bath temperature of 140°-150° F. Coverage is complete on the catalyzed surface and a peel strength of 8-10 pounds per inch is indicated after further electrolytic plating to build up the desired total thickness of the deposit.
In order to illustrate the effect of further variations in plating conditions, in terms of type of complexer used, changes in its concentration as well as in concentration of copper, incorporation of surfactants and some other factors, as will be noted, the following tabulations summarize results obtained in testing the four specific complexers of the foregoing examples. In every case except as otherwise noted in the tables, the bath composition and conditions are standard; i.e. are the composition and conditions given in Example I above.
TABLE A__________________________________________________________________________COMPLEXER - TRISODIUM N-HYDROXYETHYLETHYLENEDIAMINE TRIACETATE HYDRATE@ 0.074MCu.sup.++ @ 0.06M (b) (c)Ex. Moles (a) Plate Thickness % Deposit (d)No. Reduc. pH Ni.sup.++ 10 Min. 20 Min. Cover Color Accpt. Comment__________________________________________________________________________1 0.34 12 Yes 9.3 -- 100 dk.purple No2 " 12 No 11.8 -- 100 violet Minimal pink3 " 11 Yes 5.3 -- 100 purple "4 " 11 No 5.8 -- 100 bluish "5 " 9 Yes 8.8 -- 100 pink Yes6 " 9 No 9.3 -- 100 pink Yes7 " 6 Yes 8.4 -- 100 pink Yes8 " 6 No 9.6 -- 100 pink Yes9 " 4 Yes -- -- 40 dk.brown No Smut deposit pos- sibly Cu.sub.2 O10 " 4 No -- -- 10 dk.brown No Smut deposit pos- sibly Cu.sub.2 O11 " 2.5 Yes 0 -- 0 -- No No plate12 " 2.5 No 0 -- 0 -- No "13 0.68 12 No 8.5 -- 100 lt.purple Minimal14 " 9 No 6.6 -- 100 pink Yes15 " 6 No 7.9 -- 100 pink Yes16 0.34 6 No 7.8 11.4 100 pink Yes17 " 9 No 9.2 10.5 100 pink Yes18 " 6 No 7.4 -- 100 off-pink Yes surfactant #119 " 9 No 8.8 -- 100 pink Yes surfactant #220 " 9 No 7.7 -- 100 pink Yes surfactant #321 " 9 No 8.2 -- 100 pink Yes surfactant #4__________________________________________________________________________ (a) NiCl.sub.2 . 6H.sub.2 O @ 0.002M (b) Microinches (c) Surface coverage (d) Electroplating acceptability Surfactant #'s 1. 10 ppm Polyethelene Glycol 2. 10 ppm Diethylene Glycol 3. 10 ppm "Petro AG Special 4. 10 ppm "Triton X100
In Table A, all bath compositions are 0.06 molar in copper. Examples Nos. 1-12 illustrate the effect of varying the pH of the bath while reducer (hypophosphite) concentration (0.34 M) and complexer concentration (0.074 M) are kept constant. This is done by adding hydrochloric acid or sodium hydroxide as needed. The reducer concentration of 0.074 M is selected to provide a workable concentration in the overall system, taking into account component solubility (saturation) problems, bath speed, etc. This first group of examples also provides a comparison of copper deposits obtained with and without nickel ion as an autocatalysis promoter in the plating bath. There appears to be no appreciable effect on this system by the addition of nickel.
This same group of tests further demonstrates that a bath pH of over 5 on the acid side, and up to about 11 on the alkaline side, represents practical operating limits for effective copper deposits in this particular type of complexed solution. By "effective" it is here meant deposits that would be suitable for commercial plating, which includes both initial electroless deposit and subsequently applied electrodeposit of additional copper or other metals to provide a final thickness of metal required by the functional or decorative requirements of the workpiece. This comprehends not only good adhesion but also good color (pink), the latter indicating absence of significant amounts of cuprous oxide inclusions which give rise to poor conductivity and poor autocatalysis, hence poor acceptability for subsequent plating operations.
Examples 13-15 of Table A show the effect of doubling the reducer concentration. Example 13 demonstrates that doubling the reducer concentration for a solution (e.g. Ex. 2) which is borderline for electroplating acceptability does not substantially improve the bath in that respect. Examples 14 and 15 further demonstrate that doubling the reducer concentration of a preferred solution (e.g. Ex. 6) again does not appreciably affect the plating rate. However the examples do illustrate that the stability of the bath is not adversely affected by doubling the reducer concentration, thus illustrating that the baths of the invention offer wide operating tolerances in terms of reducer concentration parameters.
Examples 16 and 17 show that plate-out is nonlinear since a drop-off in rate occurs as thickness increases. This also is evidence of stability of the bath; i.e. there is virtually little unwanted or extraneous plate-out on tank walls, racks, etc.
Examples 18-21 demonstrate that the usual surfactants can be incorporated in the baths without any adverse effect upon the plate obtained. Inclusion of wetters in the plating bath helps to disperse gas bubbles (hydrogen) produced in the course of the plating reaction, such bubbles commonly causing "pitting" phenomena to occur in the deposit. The proprietary surfactant "Triton X-100" is an alkyl aryl polyether, while "Petro AG Special" is an alkyl naphthalene sodium sulfonate.
Table B presents similar data for hypophosphite-reduced copper solutions of the invention, in which the complexer is ethylenediamine tetraacetic acid.
TABLE B__________________________________________________________________________COMPLEXER - ETHYLENEDIAMINE TETRAACETIC ACID@ 0.074MCu.sup.++ @ 0.06M (b) (c)Ex. Moles (a) Plate Thickness % Deposit (d)No. Reduc. pH Ni.sup.++ 10 Min. 20 Min. Cover Color Accpt. Comment__________________________________________________________________________22 0.34 12 Yes 10.8 -- 100 dk. purple No23 " 12 No 12.0 -- 100 violet/ No pink24 " 11 Yes -- 100 purple Marginal25 " 11 No 5.7 -- 100 yellow/ Marginal bronze26 " 9 Yes 5.3 -- 100 pink Yes27 " 9 No 7.0 -- 100 pink Yes28 " 6 Yes 5.7 -- 100 pink Yes29 " 6 No 5.2 -- 100 gray/pink Yes30 " 4 Yes -- -- 80 dk. brown No Smut deposit31 " 4 No -- -- 100 dk. brown No Smut deposit32 " 2.5 Yes -- -- 0 -- No No Plate33 " 2.5 No -- -- 0 -- No No Plate34 0.68 12 No 9.1 -- 100 lt. purple Marginal35 " 9 No 5.0 -- 100 reddish/ Yes pink36 " 6 No 4.7 -- 100 pink Yes37 0.34 6 No 5.4 6.7 100/ pink/pink Yes 10038 " 9 No 6.6 8.3 100/ pink/pink Yes 10039 " 6 No 5.3 -- 100 pink Yes Surfactant #140 " 9 No 6.6 -- 100 pink Yes Surfactant #241 " 9 No 6.0 -- 100 pink Yes Surfactant #342 " 9 No 6.9 -- 100 bronze Yes Surfactant #4__________________________________________________________________________
With respect to Table B, it will be seen that the baths of this group show substantially similar results for EDTA-complexed solutions as are found for HEEDTA-complexed ones. Best operating limits of bath pH are again from slightly above 5 to 11. Reducer concentration does not significantly affect bath operation within this pH range. Nickel ion is again not significant. Thickness of deposit obtained is somewhat lower in these EDTA-complexed baths than in those using HEEDTA, within the same time period. Again the solutions are compatible with inclusion of the common wetting agents.
Table C summarizes data on hypophosphite copper baths of the invention in which the complexer is nitriloacetic acid.
TABLE C__________________________________________________________________________COMPLEXER - NITRILOTRIACETIC ACID@ 0.148MCu.sup.++ @ 0.06M (b) (c)Ex. Moles (a) Plate Thickness % Deposit (d)No. Reduc. pH Ni.sup.++ 10 Min. 5 Min. Cover Color Accpt. Comment__________________________________________________________________________43 0.34 12 Yes -- -- -- -- No Solution decomposed44 " 12 No -- -- -- -- No Solution decomposed45 " 11 Yes 5.2 -- 100 purple No Bath turbid46 " 11 No 6.4 -- 100 orange/ Marginal Solution decomposed pink47 " 9 Yes 9.7 -- 100 pink Yes48 " 9 No 12.1 -- 100 pink Yes49 " 6 Yes -- -- -- dk. brown No Smut deposit50 " 6 No 3.8 -- 100 dk. brown/ No Smut deposit pink51 " 4 Yes -- -- -- -- No No plate52 " 4 No -- -- -- -- No No plate53 " 2.5 Yes -- -- -- -- No No plate54 " 2.5 No -- -- -- -- No No plate55 0.68 12 No 10.1 -- 100 purple No56 " 9 No 10.5 -- 100 pink Yes Some blotches57 " 6 No -- -- 100 reddish No Smut deposit pink58 0.34 9 No 10.0 9.5 100/ pink/pink Yes 10059 0.68 9 No 9.8 9.2 100/ pink/pink Yes Some blotches 10060 0.34 9 No 7.2 -- 100 pink Yes Surfactant #161 " 9 No 10.9 -- 100 pink Yes Surfactant #262 " 9 No 9.8 -- 100 reddish Yes Surfactant #3 pink63 " 9 No 10.5 -- 100 pink Yes Surfactant #4__________________________________________________________________________
The examples of Table C all containing NTA as the complexer show similar trends in operating conditions when compared with those of Tables A and B; however the operating range of pH is somewhat narrower in this case, the optimum range being pH 8-10 and the preferred condition being close to 9, whereas the HEEDTA and EDTA complexed systems as has been shown exhibit a broader range of 5 to 11, with an optimum of from about 6 to 10 pH. The NTA baths are again not significantly affected by inclusion of nickel ion, nor by inclusion of standard wetting agents.
Sodium potassium tartrate is another complexer commonly used heretofore in formaldehyde-reduced electroless copper baths, and it is also useful in the baths of the present invention. It appears that with this complexer the optimum pH is around 10-12, as the examples in Tables D show. At this pH level, the inclusion of nickel appears to provide no significant improvement in terms of copper thickness obtained in the selected test period.
TABLE D__________________________________________________________________________COMPLEXER - SODIUM POTASSIUM TARTRATE @ 0.148MCu.sup.++ @ 0.06M (b) Plate (c)Ex. Moles (a) Thickness % Deposit (d)No. Reduc. pH Ni.sup.++ 10 Min. Cover Color Accpt. Comment__________________________________________________________________________64 0.34 2.5 No -- -- -- No No Plate Bath precipitated65 " 2.5 Yes -- -- -- No No Plate Bath precipitated66 " 4.0 No -- -- -- No No Plate Bath precipitated67 " 4.0 Yes -- -- -- No No Plate Bath precipitated68 " 6.0 No -- -- -- No No Plate69 " 6.0 Yes -- -- -- No "70 " 9.0 No (13) 100 Brown/ Marginal Solution Turbid Orange71 " 9.0 Yes (12) 100 Brown/ Marginal " Orange72 " 10.0 No 17 100 Stained Yes Deposit appears Copper tarnished upon removal from solution73 " 11.0 No 19 100 Stained Yes Deposit appears Copper tarnished upon removal from solution74 " 11.0 Yes 16 100 Stained Yes Deposit appears Copper tarnished upon removal from solution75 " 12.0.sup.1 No (13) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution76 " 12.0.sup.1 Yes (9) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution77 " 12.5.sup.2 No (7) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution78 " 12.5.sup.2 Yes (9) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution79 " 12.8.sup.3 No (8) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution80 " 12.8.sup.3 Yes (17) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution81 " 13.1.sup.4 No (10) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution82 " 13.1.sup.4 Yes (22) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution83 " 13.4.sup.5 No (10) 100 Stained No Deposit appears Copper tarnished upon removal from solution84 " 13.4.sup.5 Yes (27) 100 Stained No Deposit appears Copper tarnished upon removal from solution85 " 13.7.sup.6 Yes (29) 100 Stained No Deposit appears Copper tarnished upon removal from solution86 0.68 9.0 Yes (13) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution87 " 10.0 Yes 28 100 Stained Yes Deposit appears Copper tarnished upon removal from solution88 " 11.0 Yes 22 100 Stained Yes Deposit appears Copper tarnished upon removal from solution89 " 12.5 Yes (12) 100 Stained Marginal Deposit appears Copper tarnished upon removal from solution90 0.34 11.0 Yes 11 100 Stained Yes Surfactant #1 Copper91 " 11.0 Yes 12 100 Stained Yes Surfactant #2 Copper92 " 11.0 Yes 12 100 Stained Yes Surfactant #3 Copper93 " 11.0 Yes 11 100 Stained Yes Surfactant #4 Copper__________________________________________________________________________ (a) NiCl.sub.2 . 6H.sub.2 O @ 0.002M (b) Plate thickness where reported in parenthesis is calculated on the assumption the deposit is pure copper. (c) Surface coverage (d) In this system many deposits were obtained which gave the appearance of tarnished or stained copper film in contrast to a bright pink deposit. However utilization of a 5% sulfuric acid dip prior to subsequent electroplating reveals a pink copper deposit on pieces noted as acceptable. pH Notes (free caustic) .sup.1 0.3 Grams/liter free caustic .sup.2 2 Grams/liter free caustic .sup.3 5 Grams/liter free caustic .sup.4 10 Grams/liter free caustic .sup.5 20 Grams/liter free caustic .sup.6 40 Grams/liter free caustic
In Table D all bath compositions are 0.06 molar in copper. Examples 64-85 illustrate the effect of varying the pH of the bath while the reducer concentration (0.34 M) and complexer concentration (0.148 M) are kept constant. The examples also provide a comparison of copper deposits obtained with and without nickel ion.
Here again it is demonstrated that for this complexer only a certain range of pH values will give copper deposits acceptable for subsequent electrolytic plating. As noted, at least marginally acceptable deposits obtained in the pH range of 9-13; however the range of 10-11 is optimum.
The inclusion of nickel ion, at least in preferred pH range indicated above, again appears to have little effect on the system.
Doubling the reducer concentration shows some rate increase, especially in the preferred pH range of 10-11. Even at the higher reducer concentration, however, the bath does not show signs of instability.
Examples 90-93 demonstrate that usual surfactants can be incorporated in the baths without any adverse effect on the plate obtained.
In general it is found that the tartrate bath produces deposits which, when removed from solution, appear tarnished or stained. However, subsequent dip in 5-10% sulfuric acid prior to electroplating appears to remove the tarnish and reveal a pink copper deposit. It is also observed that incorporation of wetters into the system diminish or eliminate this tarnish or stained effect. The tarnish deposit obtained in the tartrate system is not to be confused with the dark brown or smutty deposits obtained in some of the other systems reported above which were poorly conductive and unacceptable for subsequent electroplating.
Additional hypophosphite-reduced copper solutions employing other complexers than those specifically mentioned but commonly used in formaldehyde type electroless copper baths also show operativeness, but the conditions required for acceptable plated copper deposits appear to be more restricted. Complexers such as N,N,N',N'-tetrakis (2 hydroxypropyl) ethylenediamine, iminodiacetic acid, methanol amine, for example, require a more restricted pH range of operation to provide any useful results. In accordance with the discovery of the present invention, however, it is thus seen that hypophosphite ion can serve as a useful reducing agent in electroless copper solution for many applications, if the bath pH is coordinated with the type of complexer employed. Having such basic understanding, many combinations of hypophosphite and complexer, or mixtures of complexers, become possible and the particular pH range for optimum operation then can be readily determined through routine trial by the artisan.
In the copper deposits formed from the invention baths incorporating the hypophosphite reducing agent, it is postulated, based on presently available evidence, that the resulting copper deposit may in fact be a copper-phosphorous alloy of unique properties resulting from the method of preparation. Certainly the deposit is essentially or predominantly copper, but the inclusion of small amount of phosphorous may account for some of the differences in hardness, conductivity, etc. that seem to exist in comparison with copper deposits obtained from formaldehyde-type electroless copper solutions.
EXAMPLES V-VIII
In order to further illustrate the capacity of the invention baths to accommodate substantial change in component concentration without adverse effect on the copper deposit, the following data is representative of the results obtained:
______________________________________ EXAMPLESBath composition V VI VII VIII______________________________________CuCl.sub.2 . 2H.sub.2 O 0.030M 0.060M 0.120M 0.240M"Hamp-O1" (HEEDTA) 0.037M 0.074M 0.148M 0.296MNaH.sub.2 PO.sub.2 . H.sub.2 O 0.340M 0.340M 0.340M 0.340MpH 9.1 9.1 9.1 9.1Thickness of Deposit in 7.86 11.12 13.98 19.1610 Minutes (microinch)Color Pink Pink Pink PinkCoverage % 100 100 100 100Acceptability for Subsequent Yes Yes Yes YesElectroplating______________________________________
ABS panels were used and processed through normal preplate techniques, as already described in connection with preceding examples. As Examples V-VIII show, all deposits completely covered the panel surfaces with a bright pink adherent deposit. The complexer concentration ("Hamp-Ol" crystals) was increased proportionately with the copper concentration to insure that all copper was chelated. The results show an increasing deposition rate with increasing copper concentration, and effectively illustrate the wide operating range of the solution. Acceptable operating parameters for the copper concentration would be, as a minimum, an amount sufficient to obtain deposition; and, as a maximum, an amount which would still maintain acceptable solubility of the bath constituents. Naturally, extremely high concentrations would add to the cost of operation through drag-out of a more concentrated solution. Also a maximum concentration would be reached at such point where precipitation of various components occurs. The balance would be determined by what is acceptable in practice in any given situation.
The data presented in the foregoing tables is based on use of standard platable grade of ABS substrate, such as Monsanto PG 298, used in plating of plastics with conventional formaldehydetype electroless copper baths. Tests made on other substrates molded of standard plating grade thermoplastics, such as "Noryl" (polyphenylene oxide) and polypropylene, show that the invention baths are applicable to those as well. Also thermosetting substrates of the phenol-formaldehyde as well as epoxy types can be plated in the invention baths, as can other types of thermoset plastics.
The invention is especially applicable to plating on plastic; that is, to applications where the plated part or workpiece is required to have a metal finish for decorative or protective purposes. Automobile, appliance and hardware parts are fields in which such applications more frequently arise. In such applications it is usually most practical to apply, initially, a thin deposit of copper by electroless deposition, after which additional thicknesses of copper, nickel, chromium, for example, or other metal can be added more rapidly and economically by standard electrodeposition procedures. The hypophosphite-reduced electroless copper baths of this invention are particularly suited for such applications. In this system the plating rate of copper on palladium/tin catalyzed plastic substrates is initially fast but slows as the copper thickness builds. It is assumed that this occurs because the copper deposit is not as catalytic to the system as is the palladium/tin. This however is an advantage in situations requiring only a thin conductive copper coating, as in plating on plastics, since any extraneous plate-out on tank walls, racks, heater coils, etc. will be inherently self-limiting and therefore reduces the extraneous plate-out and consequent tank clean-out and rack maintenance problems.
The preparation of the surface of the plastic substrate, particularly for plating on plastic applications, generally includes the chromic-sulfuric or all-chromic etch procedure mentioned above. The copper baths of the invention can be used, however, for printed circuitboard applications employing, for example, the "PLADD" process of MacDermid Incorporated, Waterbury, Connecticut, disclosed in U.S. Pat. No. 3,620,933. In that system, a different substrate preparation is used, preliminary to electroless deposition of the copper. This is illustrated by the following example.
EXAMPLE IX
The workpiece here is to comprise a printed circuit board which takes the form initially of a blank laminate consisting of aluminum foil bonded to a fiberglass reinforced epoxy resin substrate. In preparing the circuitboard, this blank laminate is placed in a hydrochloric acid bath to chemically strip off the aluminum foil, leaving the surface of the resin substrate especially suited for subsequent reception of electroless metal deposition. This preliminary operation replaces the chromicsulfuric etch step mentioned previously. The stripped substrate, after careful rinsing, is then catalyzed, following the same procedure of palladium-tin catalysis described in Example I. The catalyzed board is then copper plated, using the same copper solution described in that earlier example. This produces a thin copper deposit across the entire surface of the substrate. A mask or resist is then applied, as by screening, photopolymeric development, etc., to define a desired printed circuit. The masked (thin-plated) substrate is then further plated in an electrolytic bath, using the initial electroless deposit as a "bus" to build up additional metal thickness in the unmasked regions of the circuitboard. The resist or mask is next chemically dissolved and the board is placed in a suitable copper etchant solution, such as that disclosed in U.S. Pat. No. 3,466,208, for a time sufficient to remove the thin initial copper deposit previously covered by the resist, but insufficient to remove the substantially thicker regions of copper (or other metal) deposit built up in the electrolytic plating bath. This technique is sometimes referred to in the art as a semi-additive plating process.
In similar manner, the invention is applicable to the "subtractive" procedure for preparation of printed circuit boards having through-holes for interconnecting conductor areas on opposite surfaces of standard copper foil clad laminates. The through-holes are punched in the blank board and the walls of the through-holes plated with copper electrolessly, using the copper solution of this invention. Additional thickness of the wall deposit can be provided by electrolytic deposition, if desired. A resist is applied to produce a prescribed circuit pattern, and the exposed copper foil is then etched away, leaving the circuit pattern and through-hole interconnections. The resist may or may not then be removed, depending on further plating requirements, such as gold plating of connector tab areas on the circuit, solder coating, etc.
Although specific embodiments of the present invention have been described above in detail, it is to be understood that these are primarily for purposes of illustration. Modifications may be made to the particular conditions and components disclosed, consistent with the teaching herein, as will be apparent to those skilled in the art, for adaptation to particular applications.
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Electroless copper deposition solutions, and method of electrolessly depositing copper onto a workpiece using these solutions, are disclosed. The solutions contain, in addition to water as the usual solvent, a soluble source of copper ions, a complexing agent or mixture of agents to maintain the copper in solution, and a copper reducing agent effective to reduce the copper ions to metallic copper as a deposit or plating on a prepared surface of a workpiece brought into contact with the solution. The invention comprehends replacing the usual formaldehyde-type reducing agents of commercial electroless copper baths with inorganic non-formaldehyde-type agents, for example hypophosphites, by coordinating the particular complexing agents employed and the bath pH, to effect reduction of cupric ions to a metallic copper plating on a prepared surface of a substrate, wherein the resulting electroless metal deposit has conductive properties at least satisfactory for build-up of additional thickness of metal by standard electroplating techniques. Improvement over the prior formaldehyde-reduced electroless copper solutions is obtained in that the invention teaches those skilled in the art how to achieve satisfactory copper deposition over longer periods of bath operation than has been practical heretofore. Fluctuations in component concentration and bath temperatures are inherent and unavoidable in the course of commercial use of the bath and these are normally detrimental to protracted use of formaldehyde-reduced copper solutions. In the present invention, bath stability is maintained better, in spite of these inherent fluctuations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for strengthening building structures.
2. Description of the Related Art
Applicant believes that the closest reference corresponds to U.S. Pat. No. 3,449,874 issued to J. L. Beaupre in 1969 for a house anchorage. Beaupre's patent discloses anchoraging means for supporting and strengthening building structures during extreme weather conditions. However, it differs from the present invention in that the cables pass through slip plates 10, which are mounted to the wall of the building structure. In the present invention a plurality of removable support beams are erected around the building structure whereon fixed eyelet members are mounted. After the storm, the protecting structure is removed without leaving any irregularities on the building.
Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention.
SUMMARY OF THE INVENTION
It is one of the primary objects of the present invention to provide an apparatus for strengthening buildings, houses, mobile-homes and automobiles from external forces such as winds from hurricanes and storms.
It is another object of the present invention to provide an apparatus that is portable, removable and reusable in buildings, houses, mobile-homes and automobiles.
It is another object of this invention to provide an apparatus that, when removed, does not leave any detracting irregularities of the structure being protected.
It is still another object of this invention to provide an apparatus that is volumetrically efficient for storage.
It is yet another object of this invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness.
Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which:
FIG. 1 represents an isometric view of the present invention where the fishing net has been partially represented.
FIG. 1A shows an enlarged view of the bracket member selectively used at the cable's intersections shown in FIGS. 1 and 2.
FIG. 2 represents an elevational side view of a structure where elements of the present invention are shown above and below the ground level.
FIG. 3 shows an elevational view of a tension adjusting assembly used in this invention.
FIG. 4 is an isometric view of an anchorage assembly used in this invention.
FIG. 5 is an illustration of a ring used to connect different cables on different areas.
FIG. 6 represents an elevational side view of a mobile home being protected with the present invention.
FIG. 7 represents an elevational front view of the mobile home shown in FIG. 6.
FIG. 8 is a perspective illustration of another application for the present invention, namely, a multi-floor building.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, where the present invention is generally referred to with numeral 10, it can be observed that it basically includes elongated support beams 20, anchorage assemblies 40, roof net assembly 50, which along with tension adjusting assemblies 60 achieve the desired protection to the building structure.
As is shown in FIGS. 1 and 2, elongated support beams 20 include, in the preferred embodiment, spaced apart eyelet members 21; 22; 23 and 24, through which different cable members pass. Cable members 81; 82 and 83 pass through lower eyelet member 21, intermediate eyelet member 22 and anchorage eyelet member 23, respectively. Anchorage eyelet member 23 also receives cable member 63 which is tied to tension adjusting assembly 60. Cable member 61 is tied to the other end of tension adjusting assembly 60. The other end of cable member 61 is tied to eyelet member 42 of anchorage assembly 40. Cable members 81; 82 and 83 are flexible and preferably made out of steel, but a fiber or plastic cord can also be used. Supporting base 26 is integrally built at the end of support beams 20. Criss-crossed cable members 85 and 86 contribute to strengthen the building structure. Criss-crossed cable members 85 and 86 pass through lower eyelet member 21 and anchorage eyelet member 23 of different support beams 20 selectively and in zig-zag.
Several anchorage assemblies 40 are buried next to the structure being protected. As shown in FIG. 4, assemblies 40 include elongated rods 44 and helical ends 46. One end of cable 61 is tied to eyelet member 42. Anchorage assembly 40 is firmly anchored by turning it in combination with a downward force.
Roof net assembly 50, in the preferred embodiment, has horizontally disposed cables 54, running parallel and in a spaced apart relationship with respect to each other. Net assembly 50 also has cables 55, running substantially vertically and spaced apart from each other. Cords 52 are similar to cables 54 and 55 but with a smaller diameter. Cords 52 run vertically and horizontally with respect to each other, thereby conforming a criss-crossed net. Fishing net 70 is composed of criss-crossed threads that are flexible and form small dimensioned grids, as it is partially shown in FIG. 1. Only one small area of net 70 is shown in FIG. 1 to avoid overcrowded lining. The cooperative combination of all of the above mentioned elements conform the protecting assembly of the present invention for the top of the structures being protected. In FIG. 1 and 2, cable members 85 and 86 are tightened by tension adjusting assemblies 60. Assemblies 60 are preferably located near the entrance of the structure being protected. In case of emergency, if it is necessary to take away cable members 85 and 86, occupants may readily exit. Cables 55 are tied to upper eyelet members 24 through tension adjusting assemblies 60. Tension is adjusted by turning turn-buckle 62 of cable tension adjusting assembly 60, as is seen in FIG. 3.
FIG. 5 shows ring 57 providing a connecting hub to the ends of cables 54 and 55. Ring 57 keeps horizontal cables 54 and perpendicularly disposed cables 55 in a pre-determined relationship with respect to each other and ensures that net assembly 50 is properly adjusted, as is best seen in FIGS. 1 and 5. Clamp members 56, at the end of cable members 54 and 55, hold the cables to securely form a loop.
Once the roof of the building structure is covered by roof net assembly 50, the end or edge 58 of net assembly 50 is tensed by cable 59 as shown under the overhang in FIG. 2. This will ensure that net assembly 50 will be tight against the roof surface.
Roof net assembly 50, in the preferred embodiment, is the result of combining several elements that cover a building roof. Fishing net 70 is the lowermost component of roof net assembly 50. Cords 52 are superimposed over fishing net 70. Finally, cable members 54 and 55 are positioned over cords 52. In this manner, the structural integrity is enhanced to withstand the wind action.
In FIG. 3 one end of cable 63 is attached to threaded hook member 64 which is screwed in turn-buckle member 62. The other end of member 62 receives threaded eyelet member 65 which is tied to cable 61. By turning turn-buckle member 62 the tension of cables 61 and 63 can be adjusted transmitting the tension along the entire building structure. Clamp members 66, at the end of cables 63 and 65, hold the cables to securely form a loop.
In FIGS. 6, 7 and 8, other applications are illustrated using the present invention. Devices 10' is shown in FIGS. 6 and 7 protecting mobile-home M. As in device 10 protecting house H shown in FIGS. 1 through 5, device 10' uses similar components that have been mashed with a prime.
Also, in FIG. 8 device 10" is shown multi-floor building B protecting against hurricanes and strong wind-storms. As in devices 10 and 10' shown in FIGS. 1 through 5 and 6 and 7, device 10" uses similar components that have been mashed with a double prime.
To prevent cable members 54 and 55 from sliding out of place, bracket members 100 are selectively positioned at their intersections, as shown in FIGS. 1 and 1A. Member 100, in the preferred embodiment, includes two symmetrical blocks 101 and 102 sandwiching cable members 54 and 55. Block members 101 and 102 are fasten together by screw and nut members 110; 112;122 and 124.
The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.
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An apparatus for strengthening building structure against hurricanes and wind storms. Several support beams are removably mounted adjacent to the building structure. A net member is positioned over the roof of the building structure. Cables are used to interconnect the support beam members and to keep the net in place. Anchorage assemblies keep support beam members in place. Tension adjusting devices are used to tighten the cables against the structure being protected.
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BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to a method for patterning a layer on an oxide superconductor thin film and a superconducting device manufactured by the method, and more specifically to a method for patterning a layer on an oxide superconductor thin film without degrading the oxide superconductor thin film, and a superconducting device manufactured by the method.
2. Description of Related Art
Devices which utilize superconducting phenomena operate rapidly with low power consumption so that they have higher performance than conventional semiconductor devices. Particularly, by using an oxide superconducting material which has been recently advanced in study, it is possible to produce a superconducting device which operates at relatively high temperature.
Josephson device is one of well-known superconducting devices. However, since Josephson device is a two-terminal device, a logic gate which utilizes Josephson devices becomes complicated. Therefore, three-terminal superconducting devices are more practical.
Typical three-terminal superconducting devices include two types of super-FET (field effect transistor). The first type of the super-FET includes a semiconductor channel, and a superconductor source electrode and a superconductor drain electrode which are formed closely to each other on both side of the semiconductor channel. A portion of the semiconductor layer between the superconductor source electrode and the superconductor drain electrode has a greatly recessed or undercut rear surface so as to have a reduced thickness. In addition, a gate electrode is formed through a gate insulating layer on the portion of the recessed or undercut rear surface of the semiconductor layer between the superconductor source electrode and the superconductor drain electrode.
A superconducting current flows through the semiconductor layer (channel) between the superconductor source electrode and the superconductor drain electrode due to a superconducting proximity effect, and is controlled by an applied gate voltage. This type of the super-FET operates at a higher speed with a low power consumption.
The second type of the super-FET includes a channel of a superconductor formed between a source electrode and a drain electrode, so that a current flowing through the superconducting channel is controlled by a voltage applied to a gate formed above the superconducting channel.
Both of the super-FETs mentioned above are voltage controlled devices which are capable of isolating output signal from input one and of having a well defined gain.
However, since the first type of the super-FET utilizes the superconducting proximity effect, the superconductor source electrode and the superconductor drain electrode have to be positioned within a distance of a few times the coherence length of the superconductor materials of the superconductor source electrode and the superconductor drain electrode. In particular, since an oxide superconductor has a short coherence length, a distance between the superconductor source electrode and the superconductor drain electrode has to be made less than about a few ten nanometers, if the superconductor source electrode and the superconductor drain electrode are formed of the oxide superconductor material. However, it is very difficult to conduct a fine processing such as a fine pattern etching, so as to satisfy the very short separation distance mentioned above.
On the other hand, the super-FET having the superconducting channel has a large current capability, and the fine processing which is required to product the first type of the super-FET is not needed to product this type of super-FET.
In order to obtain a complete ON/OFF operation, both of the superconducting channel and the gate insulating layer should have an extremely thin thickness. For example, the superconducting channel formed of an oxide superconductor material should have a thickness of less than five nanometers and the gate insulating layer should have a thickness more than ten nanometers which is sufficient to prevent a tunnel current.
In the super-FET, since the extremely thin superconducting channel is connected to the relatively thick superconducting source region and the superconducting drain region at their lower portions, the superconducting current flows substantially horizontally through the superconducting channel and substantially vertically in the superconducting source region and the superconducting drain region. Since the oxide superconductor has the largest critical current density J c in the direction perpendicular to c-axes of its crystal lattices, the superconducting channel is preferably formed of a c-axis oriented oxide superconductor thin film and the superconducting source region and the superconducting drain region are preferably formed of a-axis oriented oxide superconductor thin films.
In a prior art, in order to manufacture the super-FET which has the superconducting channel of c-axis oriented oxide superconductor thin film and the superconducting source region and the superconducting drain region of a-axis oriented oxide superconductor thin films, a c-axis oriented oxide superconductor thin film is formed at first and the c-axis oriented oxide superconductor thin film is etched and removed excluding a portion which will be the superconducting channel. Then, an a-axis oriented oxide superconductor thin film is deposited so as to form the superconducting source region and the superconducting drain region.
In another prior art, at first an a-axis oriented oxide superconductor thin film is deposited and etched so as to form the superconducting source region and the superconducting drain region, and then a c-axis oriented oxide superconductor thin film is deposited so as to form the superconducting channel.
In the above methods, the oxide superconductor thin film is mostly processed by photolithography. Namely, the oxide superconductor thin film is masked by a photoresist and etched by a wet etching process using a weak H 3 PO 4 solution, or a dry etching process such as a reactive ion etching or an ion-milling using Ar ions. In order to process the oxide superconductor thin film without degradation, the oxide superconductor thin film should be prevented from contacting with water. Since the oxide superconductor has high reactivity so as to react with water and is degraded. Therefore, these etching process use little water.
However, an oxide superconductor also reacts with photoresist remover so that a surface of the oxide superconductor thin film on which a photoresist is formed and removed is roughened. It is very difficult to deposit another thin film or layer on the rough surface of the oxide superconductor thin film so as to manufacture a superconducting device or a superconducting circuit of a multi-layer structure. In addition, if another oxide superconductor thin film is formed so as to contact the rough surface, an undesirable Josephson junction or a resistance is generated at the interface. Furthermore, superconducting characteristics of the reacted oxide superconductor thin film is affected, so that the superconducting device does not have an enough performance.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for patterning a layer on an oxide superconductor thin film, which have overcome the above mentioned defects of the conventional ones.
Another object of the present invention is to provide a method for processing an oxide superconductor thin film, which have overcome the above mentioned defects of the conventional ones.
Still another object of the present invention is to provide a method for manufacturing an FET type superconducting device which have overcome the above mentioned defects of the conventional ones.
Another object of the present invention is to provide an FET type superconducting device having a superconducting region constituted of an extremely thin oxide superconductor film, which have overcome the above mentioned defects of the conventional ones.
The above and other objects of the present invention are achieved in accordance with the present invention by a method for patterning a layer which is formed on an oxide superconductor thin film characterized in that a weak HF solution, a buffer solution including HF or a mixture including HF is used for etching the layer.
Preferably, the HF concentration of the weak HF solution, the buffer solution including HF or the mixture including HF is 5 to 15 wt %. An oxide superconductors is not affected by this weak HF solution so that the exposed portion of the oxide superconductor thin film is not roughened.
According to another aspect of the present invention, there is provided a method for patterning an oxide superconductor thin film, comprising a step of forming a SiO 2 layer on the oxide superconductor thin film, patterning the SiO 2 layer so as to form the same pattern as that of the oxide superconductor thin film which will be patterned, etching the oxide superconductor thin film by using the patterned SiO 2 layer as a mask, and removing the SiO 2 layer by using a weak HF solution, a buffer solution including HF or a mixture including HF.
In this method, the HF concentration of the weak HF solution, the buffer solution including HF or the mixture including HF is preferably 5 to 15 wt %. This weak HF solution selectively etches SiO 2 , therefore, the oxide superconductor thin film is not affected.
In one preferred embodiment, the SiO 2 layer is also patterned by using a weak HF solution, a buffer solution including HF or a mixture including HF.
According to still another aspect of the present invention, there is provided a method of manufacturing a superconducting device, comprising the steps of forming on a principal surface of a substrate a non-superconducting oxide layer having a similar crystal structure to that of a c-axis oriented oxide superconductor thin film, forming a c-axis oriented oxide superconductor thin film having an extremely thin thickness on the non-superconducting oxide layer, forming an insulating layer on the c-axis oriented oxide superconductor thin film, forming a gate electrode of polycrystalline silicon on a center portion of the insulating layer, etching the insulating layer by using the gate electrode so as to form a gate insulating layer under the gate electrode and forming an a-axis oriented oxide superconductor thin film so as to embed the gate electrode and to form an insulating region by diffused silicon from the gate electrode, and etching back the a-axis oriented oxide superconductor thin film so that an upper surface of the a-axis oriented oxide superconductor thin film is planarized and the gate electrode is exposed at the planarized upper surface of the a-axis oriented oxide superconductor thin film and a superconducting source region and superconducting drain region are formed at the both sides of the gate electrode.
It is preferable that the insulating layer is etched by using a weak HF solution, a buffer solution including HF or a mixture including HF. In this case, the superconducting channel of the extremely thin c-axis oriented oxide superconductor film is not affected by the etching process. Therefore, the superconducting device has a high performance.
According to further another aspect of the present invention, there is provided a superconducting device comprising a substrate having a principal surface, a non-superconducting oxide layer having a similar crystal structure to that of the oxide superconductor, an extremely thin superconducting channel formed of a c-axis oriented oxide superconductor thin film on the non-superconducting oxide layer, a superconducting source region and a superconducting drain region formed of an a-axis oriented oxide superconductor thin film at the both sides of the superconducting channel separated from each other, which are electrically connected each other by the superconducting channel, so that superconducting current can flow through the superconducting channel between the superconducting source region and the superconducting drain region, and a gate electrode of a material which includes silicon through a gate insulator on the superconducting channel for controlling the superconducting current flowing through the superconducting channel, in which the gate electrode is embedded between the superconducting source region and the superconducting drain region and is isolated from the superconducting source region and the superconducting drain region by an insulating region formed by diffused silicon from the gate electrode.
In the superconducting device in accordance with the present invention, superconducting current flows along the insulating region which is formed by diffused silicon and has a smooth profile next to the superconducting source region and the superconducting drain region, the superconducting current efficiently flows into and flows from the superconducting channel. Therefore, superconducting current flow into or from the superconducting channel efficiently so that the current capability of the super-FET can be improved.
The gate electrode is preferably formed of polycrystalline silicon, single crystalline silicon or silicide of a metal.
In the superconducting device in accordance with the present invention, the non-superconducting oxide layer preferably has a similar crystal structure to that of a c-axis oriented oxide superconductor thin film. In this case, the superconducting channel of a c-axis oriented oxide superconductor thin film can be easily formed on the non-superconducting oxide layer.
Preferably, the above non-superconducting oxide layers is formed of a Pr 1 Ba 2 Cu 3 O 7- ε oxide. A c-axis oriented Pr 1 Ba 2 Cu 3 O 7- ε thin film has almost the same crystal lattice structure as that of a c-axis oriented oxide superconductor thin film. It compensates an oxide superconductor thin film for its crystalline incompleteness at the bottom surface. Therefore, a c-axis oriented oxide superconductor thin film of high crystallinity can be easily formed on the c-axis oriented Pr 1 Ba 2 Cu 3 O 7- ε thin film. In addition, the effect of diffusion of the constituent elements of Pr 1 Ba 2 Cu 3 O 7- ε into the oxide superconductor thin film is negligible and it also prevents the diffusion from substrate. Thus, the oxide superconductor thin film deposited on the Pr 1 Ba 2 Cu 3 O 7- ε thin film has a high quality.
In a preferred embodiment, the oxide superconductor is formed of high-T c (high critical temperature) oxide superconductor, particularly, formed of a high-T c copper-oxide type compound oxide superconductor for example a Y-Ba-Cu-O compound oxide superconductor material, a Bi-Sr-Ca-Cu-O compound oxide superconductor material, and a Tl-Ba-Ca-Cu-O compound oxide superconductor material.
In addition, the substrate can be formed of an insulating substrate, preferably an oxide single crystalline substrate such as MgO, SrTiO 3 , CdNdAlO 4 , etc. These substrate materials are very effective in forming or growing a crystalline film having a high degree of crystalline orientation. However, the superconducting device can be formed on a semiconductor substrate if an appropriate buffer layer is deposited thereon. For example, the buffer layer on the semiconductor substrate can be formed of a double-layer coating formed of a MgAl 2 O 4 layer and a BaTiO 3 layer if silicon is used as a substrate.
Preferably, the superconducting channel is formed of a c-axis oriented oxide superconductor thin film and the superconducting source electrode and the superconducting drain electrode are formed of a-axis oriented oxide superconductor thin films.
The above and other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1F are diagrammatic sectional views for illustrating an embodiment of the method in accordance with the present invention for patterning an oxide superconductor thin film; and
FIGS. 2A to 2J are diagrammatic sectional views for illustrating an embodiment of the method in accordance with the present invention for manufacturing the super-FET.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
Referring to FIGS. 1A to 1F, the method in accordance with the present invention for patterning an oxide superconductor thin film will be described.
As shown in FIG. 1A, a Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is deposited on a MgO (100) single crystalline substrate 5 having a substantially planar principal surface.
As shown in FIG. 1B, a SiO 2 layer 32 having a thickness of 200 nanometers is formed on the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 by a CVD. The SiO 2 layer 32 is formed under a condition in which the substrate temperature is lower than 350° C.
Then, as shown in FIG. 1C, a photoresist layer 34 having an opening 36 is formed on the SiO 2 layer 32 and a portion of the SiO 2 layer 32 is exposed at the opening 36. The portion of the SiO 2 layer 32 exposed at the opening 36 is etched by a wet etching using a 10% HF solution or a dry etching process such as a reactive ion etching, an ion-milling using Ar ions.
The portion of SiO 2 layer 32 is completely removed so that an opening 37 is formed and a portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is exposed. Then, the photoresist 34 is removed, as shown in FIG. 1D. The portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is affected by the photoresist remover at this time.
Thereafter, the portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is etched by a wet etching using a 0.1% H 3 PO 4 solution or a dry etching process such as a reactive ion etching, an ion-milling using Ar ions so that the portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is completely removed and a portion 38 of the substrate 5 is exposed, as shown in FIG. 1E. The portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 which is degraded by the photoresist remover is removed simultaneously.
Finally, as shown in FIG. 1F, the remaining SiO 2 layer 32 is removed by using a 10% HF solution. This weak HF solution does not affect the Y 1 Ba 2 Cu 3 O 7- δ superconductor thin film 1. Therefore, the surface of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film is not roughed and is as smooth as that of an as-grown Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film. Also, the superconducting characteristics of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film is not affected.
As explained above, if an oxide superconductor thin film is patterned in accordance with the embodiment of the method of the present invention, the surface of the oxide superconductor thin film is not roughened and the superconducting characteristics is not affected. Therefore, another thin film or layer can be easily formed on the oxide superconductor thin film so that a superconducting device or a circuit of a multi-layer structure is easily manufactured.
Embodiment 2
Referring to FIGS. 2A to 2J, the process in accordance with the present invention for manufacturing the super-FET will be described.
As shown in FIG. 2A, a MgO (100) single crystalline substrate 5 having a substantially planar principal surface ((100) surface) is prepared.
As shown in FIG. 2B, an oxide layer 20 having a thickness of 50 nanometers composed of a Pr 1 Ba 2 Cu 3 O 7- ε thin film is deposited on the principal surface of the substrate 5, by an MBE. While the Pr 1 Ba 2 Cu 3 O 7- ε thin film is growing, the surface morphology of the Pr 1 Ba 2 Cu 3 O 7- ε thin film is monitored by RHEED. A condition of forming the Pr 1 Ba 2 Cu 3 O 7- ε oxide thine film by MBE is as follows:
______________________________________Molecular beam source Pr: 1225° C. Ba: 600° C. Cu: 1040° C.Pressure 1 × 10.sup.-5 TorrTemperature of the substrate 750° C.______________________________________
Then, the Pr molecular beam source is exchanged to a Y molecular beam source and the temperature of the substrate is lowered to 700° C. so that a c-axis oriented Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 having a thickness of about 5 nanometer is continuously formed on the oxide layer 20 of Pr 1 Ba 2 Cu 3 O 7- ε thin film, as shown in FIG. 2C. A condition of forming the c-axis oriented Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 by MBE is as follows:
______________________________________Molecular beam source Y: 1250° C. Ba: 600° C. Cu: 1040° C.Pressure 1 × 10.sup.-5 TorrTemperature of the substrate 700° C.______________________________________
Then, as shown in FIG. 2D, an insulating layer 17 of SrTiO 3 having a thickness of 10 to 20 nanometers is formed on the c-axis oriented Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 by a sputtering. A polycrystalline silicon layer 14 having a thickness of 200 nonometers is formed on the insulating layer 17 by CVD, as shown in FIG. 2E.
Thereafter, the polycrystalline silicon layer 14 is etched by a reactive ion etching so as to form a gate electrode 4, as shown in FIG. 2F. Then, the surfaces of the gate electrode 4 is oxidized so as to form a SiO 2 layer having a thickness of 50 to 100 nanometers, as shown in FIG. 2G.
Thereafter, as shown in FIG. 2H, the insulating layer 17 of SrTiO 3 is etched so as to form a gate insulating layer 7 by using a mixture of HF and NH 4 OH. The mixture of HF and NH 4 OH selectively etched the insulating layer 17 of SrTiO 3 and does not affect the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1. Therefore, the characteristics of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is maintained. A portion of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 under the gate insulating layer 7 becomes a superconducting channel.
Thereafter, the substrate 5 is heated to a temperature of 350° to 400° C. under a pressure lower than 1×10 -9 Torr so as to clean the exposed surface of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1. This heat treatment is not necessary, if the exposed surface of the c-axis oriented Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 is clean enough. Then, a a-axis oriented Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 having a thickness of 500 nanometers is deposited on the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 1 by an off-axis sputtering so as to encapsulate the gate electrode 4, as shown in FIG. 2I. A condition of forming the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 by an off-axis sputtering is as follows:
______________________________________Temperature of the substrate 640° C.Sputtering Gas Ar: 90% O.sub.2 : 10%Pressure 10 Pa______________________________________
While the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 is deposited, silicon diffuses from the gate electrode 4 so as to form a insulating region 50 around the gate electrode 4. The insulating region 50 is formed of a Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor which does not show superconductivity by the diffused silicon.
Finally, in order to planarize an upper surface of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11, a photoresist layer (not shown) is coated on the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 in such a manner that the deposited photoresist layer has a flat upper surface, and then, the coated photoresist layer and the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 are etched back, until the upper surface of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 is planarized and the gate electrode 4 is exposed at the planarized upper surface of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11, as shown in FIG. 2J. Portions of the Y 1 Ba 2 Cu 3 O 7- δ oxide superconductor thin film 11 at the both sides of the gate electrode 4 become a superconducting source region 2 and a superconducting drain region 3.
Metal electrodes may be formed on the superconducting source region 2 and the superconducting drain region 3, if necessary. With this, the super-FET in accordance with the present invention is completed.
The superconducting channel of the above mentioned super-FET manufactured in accordance with the embodiment of the method of the present invention is formed on an oxide layer which has similar crystalline structure to that of the oxide superconductor. Therefore, the bottom portion of the superconducting channel is not degraded so that the substantial cross-sectional area of the superconducting channel of the super-FET is larger than that of a conventional super-FET.
Additionally, since superconducting current flows along the insulating region which is formed by diffused silicon next to the superconducting source region and the superconducting drain region, the superconducting current efficiently flows into and flows from the superconducting channel. By all of these, the current capability of the super-FET can be improved.
Furthermore, according to the present invention, the oxide layer, the superconducting channel, the gate insulating layer and the gate electrode are self-aligned. The insulating region 50 which isolates the gate electrode from the superconducting source region and the superconducting drain region is also automatically positioned. Therefore, the limitation in the fine processing technique required for manufacturing the super-FET is relaxed.
Additionally, according to the present invention, the gate insulating layer is formed by an etching process using a mixture of HF and NH 4 OH. The mixture of HF and NH 4 OH selectively etched the insulating layer of SrTiO 3 on the oxide superconductor thin film which will constitutes the superconducting channel and does not affect the oxide superconductor thin film. Therefore, the superconducting characteristics of the oxide superconductor thin film is maintained.
In the above mentioned embodiment, the oxide superconductor thin film can be formed of not only the Y--Ba--Cu--O compound oxide superconductor material, but also a high-T c (high critical temperature) oxide superconductor material, particularly a high-T c copper-oxide type compound oxide superconductor material, for example a Bi--Sr--Ca--Cu--O compound oxide superconductor material, and a Tl--Ba--Ca--Cu--O compound oxide superconductor material.
The invention has thus been shown and described with reference to the specific embodiments. However, it should be noted that the present invention is in no way limited to the details of the illustrated structures but converts and modifications may be made within the scope of the appended claims.
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A superconducting device comprising a substrate having a principal surface, a non-superconducting oxide layer having a similar crystal structure to that of the oxide superconductor, an extremely thin superconducting channel formed of a c-axis oriented oxide superconductor thin film on the non-superconducting oxide layer, a superconducting source region and a superconducting drain region formed of an a-axis oriented oxide superconductor thin film at the both sides of the superconducting channel separated from each other, which are electrically connected each other by the superconducting channel, so that superconducting current can flow through the superconducting channel between the superconducting source region and the superconducting drain region, and a gate electrode of a material which includes silicon through a gate insulator on the superconducting channel for controlling the superconducting current flowing through the superconducting channel, in which the gate electrode is embedded between the superconducting source region and the superconducting drain region and is isolated from the superconducting source region and the superconducting drain region by an insulating region formed by diffused silicon from the gate electrode.
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FIELD OF THE INVENTION
[0001] The present invention relates to an optical device, comprising a first surface with a plurality of micro sized facets, each facet having a respective orientation, said plurality of facets having an optical axis which extends parallel to the normal vector to an average orientation of all said respective orientations.
BACKGROUND OF THE INVENTION
[0002] Conventional techniques for homogenizing light make use of arrayed micro-lenses, diffractive diffusers, ground glass diffusers, and holographically-generated diffusers. Micro-lens arrays homogenize light by creating an array of overlapping diverging cones of light. Each cone originates from a respective micro-lens and diverges beyond the focal spot of the lens. In the conventional arrays, the individual lenses are identical to each other. Ground glass diffusers are formed by grinding glass with an abrasive material to generate a light-scattering structure in the glass surface.
[0003] Micro-lens arrays, ground glass diffusers and holographic diffusers all have the disadvantage of not being able to control the angular spread of the homogenized, diverging light. Light in general has an angular spread that is fairly uniform over a desired angular region, but the boundaries of the angular region are blurred. With the conventional diffuser methods, the energy roll-off at the edge of the desired angular spread can extend well beyond this region.
[0004] Diffractive diffusers can be used to control the angular spread of the output light, but such diffusers are limited with respect to the amount of spread that they can impart to the output light. Due to fabrication limitations for short wavelength sources, visible or below, and limitations in the physics of the structures for longer wavelengths the maximum angular spread is limited. Further, diffractive diffusers used in their traditional binary form can include a significant amount of background energy and the patterns must be symmetric about the optical axis.
[0005] To overcome said disadvantages of these conventional devices, US20070223095 discloses an optical device having a plurality of square facets formed by a plurality of optical elements. The facets are used to direct portions of an incident light beam in predetermined, respective directions. The facets are formed adjacent to each other in a two-dimensional array. The locations of the facets in the array are random with respect to the directions of the corresponding light beam portions. It is a disadvantage of this known optical device that identification of the optical device is relatively difficult.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide an optical device of the type as described in the opening paragraph with an improved performance. It is another object of the invention to provide for a method of making an improved optical device. This object is attained by an optical device of the type as described in the opening paragraph which is characterized in that it comprises a meaningful pattern forming sub-set of facets of the plurality of facets, the facets of the sub-set mutually at least have one of essentially equal orientation (same tilt angle a and azimuth angle φ), similar color, similar marked (frosted, scratched, ribbed) surface, similar spacing with adjacent facets. Preferably the sub-set comprises in numbers 1% to 15% of the plurality of facets. Thus the sub-set of facets forms a type of meaningful pattern, further referred to as watermark (pattern), of the optical device, which could serve as an identification label and/or to provide readily readable information about the optical device. Alternatively or simultaneously it could serve to detect and hence discourage manufacture of Chinese copies by third parties. To that end the watermark could be provided in an unobtrusive way, for example by limiting it to comprise at the most 5% of the plurality of facets. If the number of the sub-set is higher than 15% it is no longer unobtrusive and is more likely to exhibit visual degradation of the quality of the optical device. If the number of the sub-set is less than 1% it becomes difficult to discern the watermark and detection is less evident, furthermore the risk on circumvention has increased as an essentially new design for the lens is no longer required and only a relatively low number of facets have to be altered to break up the watermark. Alternative ways to create a watermark are by providing gaps or spacings between the facets, or by making small scratches on the facets, ribbed facets, frosted facets or by coloring the facets, however, without influencing to an observable degree (by ordinary users) the performance of the optical device.
[0007] Compactly arranged in this respect means that within a group of facets, the facets are not arranged widespread but are closely arranged together as one, for example in that at least 50% of the facets is fully surrounded or bordered by facets of the same group or, for example, in that the group of facets has a surface S and a perimeter P and that the ratio P to √S is at the most 6. Neighboring in this respect means that within the group of facets essentially all the facets of the group are directly connected to each other via facets of their group.
[0008] The optical device is formed of a tiled array of group of facets, where each group has a number of facets, for example (pseudo-) randomly arranged facets, a pattern may be formed by individual matching sub-patterns issued by contributions of (a) respective group(s). Facets are determinable by a facet surface with a specific orientation, the facets surface being bounded by a perimeter, and generally bordering adjacent facets in a non-continuous way, i.e. the orientations of the adjacent facet surfaces being different. Transition surfaces connecting adjacent facets at their perimeters may have significant heights due to the mutually different orientations of the adjacent facet surfaces. Said transition surfaces may not be perfectly formed and hence may not extend perfectly steep, however, these transition surfaces are not to be considered as separate facets. An embodiment of the optical device according to the invention is characterized in that each group of facets is associated with a respective sub-pattern, with the relative position of the group of facets on the optical device being essentially equal to the relative position of the sub-pattern in the displayed pattern during operation of the optical device. Instead of randomly redirecting light rays of an incident light beam in predetermined, respective directions, the redirection of light rays is done groups-wise in the optical device of the invention. In one way to describe the principle of said redirection of light rays by the optical device, a Cartesian coordinate system is to be considered, with the x-y axes perpendicular to the optical axis, with x=0 and y=0 on the optical axis and viewing downstream, i.e. along the optical axis in the direction from the light source towards the displayed pattern. Light rays incident on the first group of facets having said first group optical axis and which group, for example, is located in a first quadrant of the coordinate system of the optical device, will mainly, for example for at least 75%, be redirected (pseudo-) randomly in the direction of said first group optical axis to the corresponding first quadrant of the displayed pattern, the remaining 25% may be projected (pseudo-) randomly in one or more of the other quadrants. Similar reasoning applies for the second, third and fourth group of facets located in respectively the second, third and fourth quadrant, which respectively redirect light rays along their respective group optical axis to the second, third and fourth quadrant of the displayed pattern, respectively. If the displayed patterns requires a spread of light by the optical device over a relatively large angles with respect to the optical axis (like spread over a cone with a large apex angle), each quadrant and group optical can de sub-divided yet further, for example into halves or into four sub-quadrants each with its respective associated group optical of facets. A similar relationship between sub-quadrants in the optical device and the displayed patterns could then be maintained. Thus, relatively large (or even too large) refraction of light beams is counteracted or even avoided and the tilt of the facets could be reduced compared to fully random arranged facets. Thus the efficiency of the optical device is improved as less reflection occurs at the facet surface, since the angle of incidence of light rays on said facet surface on average is closer to the normal to said facet surface. To further reduce undesired reflection of light by the optical device, the direction of light as issued by a point-like light source is at relatively small angles with the group optical axis of the group of facets on which said issued light is incident. In other words, on average the light seems to propagate somewhat more in the same direction before and after being passed through the optical device of the invention than is the case for propagated light through the known optical device. Furthermore, each facet has a perimeter edge by which it borders its adjacent facet, said perimeter edge is a source for distortion of the displayed pattern. As a result of the abovementioned inventive technical features, distortion of the displayed pattern/image caused by perimeter edges is reduced as the average height of the perimeter edge is lower than in the known optical device without said group optical partition but with fully randomized facet orientations, hence the quality of the image is improved.
[0009] As the part of the image associated with a group of facets is to be built up by said group of facets in a desired resolution/detail, an embodiment of the optical device is characterized in that the number of facets comprised in a group of facets is at least 100. The desired minimum number of facets comprised in the group depends on the size, complexity and desired detail of the part of the image built up by said group, therefore said number of facets in the group could easily amount 1000 or even 10.000.
[0010] An embodiment of the optical device is characterized in that the at least first and second group of facets essentially have the same size and/or the same shape. In this way it is enabled to obtain a relatively simple partition of the first surface of the optical device in groups. Optionally said groups are mutually separated by small spacings, or the groups form a superstructure, for example in which each group forms a superfacet, of the first surface. Furthermore the optical device with groups of essentially the same size and/or shape is more balanced with respect to redistribution/redirection of light. In this respect its appeared favorable when the respective number of facets in the first group of facets and the respective number of facets in the second group of facets is in the range of 1:1 to 1:10. Said groups furthermore are relatively simple distinguishable from each other when they are separated by spacings thus enabling easy manipulation/correction of a specific group. If groups of facets are not directly distinguishable or determinable on the optical device, methods to (virtually) divide the plurality of facets on the first surface into groups of facets is to consider one selected facet, preferably not at the border of the first surface. At least all the facets that can be reached in three steps over adjacent/bordering facets or that are within a distance of <=3* averaged facet size from said selected one facet are considered to be part of said group of facets. This method automatically renders the group of facets to be compactly arranged and have more or less the same size and shape. Note that for determination of group optical axes and angles B between said group optical axes, a facet cannot be part of more than one group of facets.
[0011] An embodiment of the optical device is characterized in that essentially each facet within a group has a tilt angle α t with the respective group optical axis, wherein said tilt angle α t is within a range determined by the equation:
[0000] α t <=0.8*α c , preferably α t <=0.6*α c ,
[0012] in which α c =arcsin(n 2 /n 1 ) and α c is the critical angle for total internal reflection with n 1 is a higher refraction index and n 2 is a lower refraction index.
[0013] In particular this criterion is applicable on refractive optical devices, but to a certain extent also on reflective optical devices. Limiting the upper limit range of tilting angles only to angles significantly lower than α C , i.e. less than 0.8*α c , will have the effect that the perimeter edges have an absolute lower upper limit for their maximum height compared to the known similar optical device without said limitation in tilt angle. This generally will result in an average lower height of the perimeter edges and hence in a lower perimeter edge surface to facet surface ratio and hence in an improved performance of the optical device over the known optical device. Furthermore, a light beam incident on a surface at angles higher than the critical angle for TIR always is partly reflected and partly transmitted. Hence, as in the optical device of the invention the facets in general are oriented more transverse to the incident light beam than in the known optical device, less light will be reflected and more light will be transmitted, thus enhancing the efficiency of the inventive optical device over the known optical device. Furthermore if the optical device is characterized in that α t <=0.6*α c , the tilt of the facets with respect to the optical axis is thus limited to relatively low values, which tilt, however, is yet sufficient to redirect in desired directions light originating from a light source issuing a parallel beam. By this measure the performance of the optical device is further improved with respect to efficiency, reduction in glare and thickness of the optical device. Light originating from a point source impinges as a diverging light beam on the optical device at a relatively wide angle range. Hence, for fully random refraction of this diverging light in desired directions, generally facets with larger tilt angles are required in the known device. However, in the optical device according to the invention the occurrence of unfavorable larger tilt angles is yet counteracted by the sub-division of the first surface in said groups of facets. Limiting the tilt angle to α t <=0.8*α c can be considered as an invention as such.
[0014] Suitable high refractive index materials for the optical device are, for example, glass, PMMA, polyethylene, polycarbonate, the low refractive index material generally is air.
[0015] To obtain sufficient randomizing effect by the optical device, preferably adjacent first and second facets within a group of facets generally have a minimum mutual difference in orientation and thus to direct incident light beams in significantly different directions. Said minimum mutual different orientation can be defined as an angle between the normal vectors of said first and second facet surface, this angle being at least 3°. However, not all the adjacent facets need to have a different orientation as, for example, with adjacent facets with the same orientation a watermark pattern can be provided to the optical device.
[0016] The optical device may be formed of transparent or reflective materials. The individual facet surfaces and/or a combined plurality of facet surfaces may be flat and planar or they may be curved and non-planar. According to another aspect of the invention, the optical device may be used to form an angular pattern. The optical device may be arranged to split the incoming beam into sub-beams. Generally an optical device comprises at least 100 facets, typically 5.000 or 10.000 facets, even up to 100.000, 1.000.000 facets or more. Appropriate phase tare surfaces may be used to divide the facets surfaces into stepped or terraced facet surfaces as is known in the prior art, to thereby reduce the overall thickness of the optical device. Furthermore, the ratio between perimeter edge (P f ) and facet surface (S f ), defined as P f :√S f ratio, preferably is at the most 4.6, to counteract undesired displayed pattern distortion effects as possibly caused by a relatively large amount of perimeter edge compared to the facet surface.
[0017] Preferably for at least for 85% of the adjacent facet surfaces, said facets surfaces of adjacent facets are non-continuous, more preferably the normal vectors are mutually angled at at least 3°, preferably at at least 5° or at at least 7°. More diverged directions of the redirected light by adjacent facets are thus obtained which typically enhances a desired effect of homogenization by the optical device.
[0018] An embodiment of the optical device is characterized in that of the high refractive index materials the high refraction index n 1 is at least 1.45 as then less tilt of the facets is required for the same refraction compared to materials having a refraction index of less than 1.45, (examples of materials with a refraction index of less than 1.45 are fluoropolymers for example PVDF (=polyvinylidene difluoride, n 1 =1.41), ETFE (=Ethylene tetrafluoroethylene, n 1 =1.40), or Cytop (=Cyclized Transparent Optical Polymer, n 1 =1.34)). Said less tilt generally reduces the edge height and hence improves the performance of the optical device. Suitable materials with a refraction index of at least 1.45 with respect to air for λ=589 nm are SiO2 (fused silica or quartz glass, n 1 =1.45), various types of glass (n 1 ranges from about 1.45 to 1.9), PMMA (Polymethylmethacrylate, n 1 =1.49), PET (polyethylene terephthalate, n 1 =1.57), and polycarbonate (n 1 =1.59).
[0019] An embodiment of the optical device is characterized in that it is made in one piece. Preferably from a foil or plate as these materials are relatively easy to handle, and relatively easily adaptable in shape and size to substrates and/or lighting devices. The advantage of being in one piece is that cumbersome mutual attachment of the plurality of microwedges, as is done in some of the known optical devices and which are parts corresponding to the plurality of facets of the present invention, is avoided. In particular the use of material with high refractive index and the limitation in tilt angle of the facets enable the use of relatively thin foils as optical device. Said facets are easily obtainable in sheet, plate or foil material via laser ablation, thus the plurality of facets being formed in sheet, plate of foil material made in one piece. Said one piece material could easily be shaped into a desired shape, for example as a body of revolution of a branch of a parabola or ellipse, alternatively it could be slightly wavy, curved or flat.
[0020] An embodiment of the optical device is characterized in that it comprises a sub-set of facets, forming a pattern, of the plurality of facets, all of the facets of the sub-set mutually having essentially equal orientation, i.e. an equal tilt angle and azimuth angle, preferably the sub-set comprises in numbers 1% to 15% of the plurality of facets. Thus the sub-set of facets forms a type of meaningful pattern, for example a watermark pattern of the optical device, which could serve as an identification label and/or to provide readily readable information about the optical device. Alternatively or simultaneously it could serve to detect and hence discourage manufacture of Chinese copies by third parties. To that end the watermark could be provided in an unobtrusive way, for example by limiting it to comprise at the most 5% of the plurality of facets. If the number of the sub-set is higher than 15% it is no longer unobtrusive and is more likely to exhibit visual degradation of the quality of the optical device. If the number of the sub-set is less than 1% it becomes difficult to discern the watermark and detection is less evident, furthermore the risk on circumvention has increased as an essentially new design for the lens is no longer required and only a relatively low number of facets have to be altered to break up the watermark. Alternative ways to create a watermark are by providing gaps or spacings between the facets, or by making small scratches on the facets, ribbed facets, frosted facets or by coloring the facets, however, without influencing to an observable degree (by ordinary users) the performance of the optical device. Providing the optical device with a watermark according to the abovementioned measures can be considered as an invention as such.
[0021] The invention further relates to a lens comprising at least one optical device according to the invention. Lenses find wide application in display devices, projection devices, and lighting devices like for example luminaries or car headlight systems. Said lenses are extremely suitable for controlling the light beam issued by said devices.-The lens may comprise multiple mutually equal optical devices as sub-devices. According to this aspect of the invention, an optical device is formed of a tiled array of sub-devices, where each sub-device has (pseudo-) randomly arranged facets. Such a tiled optical device may be used, for example, to handle large diameter input beams or to handle a plurality of separate (diverging) beams. It is thus enabled, for example by using a plurality of LEDs through superposition of the beams generated by each sub-device and associated LED, to generate relatively very homogeneous light beams or beam patterns with relatively very sharp edges between light and dark areas, which is of particular relevance for the requirements of the typical dim light beam as issued by car headlight systems. Each sub-device (tile) then generates the whole pattern essentially in the same way, for n sub-devices the patterns is then n times projected with essentially full overlap. It is thus enable to design car headlight devices not using one very bright light source, but a matrix of less bright light sources instead, and yet obtaining a specific dim headlight beam light pattern fulfilling the requirements posed on such dim car headlight beams.
[0022] An alternative embodiment of the lens is characterized in that it comprises multiple mutually different optical devices as sub-devices. As in the previous embodiment each sub-device (tile) may generate the whole pattern, be it now in mutually different ways. For n sub-devices the pattern is then n times projected with essentially full overlap, typically n is in the range from 4 to 100, for example 49 or 60, but, for example, it could amount 400. The tiled device may be used, for example, to handle large diameter input beams or to handle a plurality of separate (diverging) beams as issued by a plurality of LEDs. Similar to the previous embodiment, this embodiment is also very suitable in motor headlight systems. Furthermore, in such a device, as well as in the previous one, possibly present small distortions in the light beam due to possibly present defects in a sub-device, are averaged out. This is of relevance for the image edges of the dark and light areas of the displayed image. The shape of each facet as present on the optical device/lens, as it were is displayed as said shape, often for example a polygon such as a square, rectangle or hexagon, in the displayed image, resulting in a stepped profile of said edges. Because of mutually slight displacement of superposition of said beams it is enabled that said edges are appearing less stepped but are appearing more fluent/smooth, thus enhancing the virtual resolution of the displayed image. The magnitude of said displacement is chosen in dependency of the desired size and desired resolution/detail of the displayed image. This principle of superposition with the optical device/lens of the invention could be considered as an invention as such. The size of each tile may be slightly different from the neighboring tiles to eliminate interference effects that might otherwise be caused by a repeating pattern. The intensity of light transmitted through each tile may be different, which may cause a slight change in the amount of energy imparted to each sub-pattern location in the pattern. This effect is reduced, however, by the random placement of facets within each tile. Alternatively each sub-device may generate a respective part of the pattern, i.e. a sub-pattern, the sub-patterns together forming the whole pattern. If the number of sub-patterns in the pattern is less than the number of facets desired to be arranged in the optical device, then some of the facet surfaces may have the same tilt angle, azimuth angle and optionally even the same size. The similar facets then will direct light to the same location or sub-pattern region or location. However, the facet surfaces with similar tilt angle and azimuth angle preferably are not to be located adjacent one another.
[0023] The invention further relates to a lighting device comprising at least one light source and at least one optical device according to the invention. Lighting devices could, for example, be a lamp/reflector unit, a luminary, or display device. In the case of a lamp/reflector unit, a light emitting element is provided inside at the focal point of a parabolic reflector and said reflector is closed by a, preferably exchangeable, plate comprising the optical device. The combination of light emitting element and reflector form a light source which could serve as a generator of a parallel light beam incident on the plate. Hence the light issued by the lamp/reflector unit is easily controllable by simple selection/exchange of the plate. Similar constructions are obtainable by luminaries and direct lit or side-lit backlights for display devices which issue parallel beam of light onto the optical device. Alternatively, the lighting device is characterized in that the lighting device is a LED comprising a LED dye and with the optical device/lens as primary optics. Generally the LED dye is provided with a dome lens as a first, primary optics. When the optical device is the primary optics of the LED, each individual LED could be given a desired beam pattern issued by each individual LED. The design of the optical device depends on the ratio in size of the LED dye and the dome. If, for example, the size of the dye (=light emitting element) is small compared to the dome (=optical device), for example the hemi-sphere shaped dome has a diameter at least a factor 10 in larger, the light emitting element is roughly taken by the optical device as a point light source when the LED die is positioned in the centre of the (hemi-) sphere dome. A sub-pattern of the pattern is then formed by an associated group of facets redirecting a sub-beam of the beam of light issued by the light emitting element. Alternatively, if, for example, the size of the die (=light emitting element) and the dome (=optical device) are about of the same size, for example the hemi-sphere shaped dome has a diameter at the most a factor 2 larger, the light emitting element could be treated as a source issuing a parallel beam of light. In this case the optical device is a lens preferably consisting of only one optical device with only one unit and a limited number, for example, 2, 3, or 4, groups of facets. In the ratio 2 to 10 a transition area from point source to a light source issuing a parallel beam applies, and hence in the design of the optical device the specific dimensions of the light emitting element have to be taken into account.
[0024] The present invention also relates to an optical system that has a plurality of light sources and at least one optical device. Alternatively, a plurality of optical devices is provided, even to such an extent that each light source is associated with a respective optical device. The plurality of light sources mutually may cooperate to generate a single pattern by overlapping of the pattern issued by each individual light source, hence enabling easy dimming of the lighting pattern. Alternatively, a pattern may be formed by individual contributions of matching sub-patterns issued by individual light sources, thus enabling an easy change of the patterns by independently switching of at least one individual light source or a sub-set of the plurality of light sources. In a preferred embodiment of the invention, adjacent facets may be formed with different three-dimensional conjurations.
[0025] The present invention also relates to a method of making a multi-faceted optical device. The method includes the steps of:
[0026] (1) selection of a desired pattern to be displayed,
[0027] (2) dividing the pattern into sub-patterns with specific locations,
[0028] (3) determining groups of facets and configurations for facets comprising group optical axis for (re-)directing beam portions to the sub-pattern locations, taking into account
[0029] that for at least one combination of a respective first group optical axis of the first group of facets with a respective second group optical axis of the second group of facets, said first group optical axis and said second group optical axis are mutually angled at an angle β of at least 5°,
[0030] (4) generating a plurality of facets, according to the determined configurations.
[0031] Optionally, to yet another aspect of the invention, groups of facets, tilting angle and azimuth angle for the facet surfaces are calculated by a programmed general-purpose computer based on the locations of the respective sub-pattern location in the desired pattern, this is, for example, the case with the arrangement of individual facets of the groups of facets. Specific algorithms and software to translate a desired light pattern into a design for the corresponding array of facets are developed. A prototype of a thin transparent foil with facets engraved into it has been realized, making use of this technology. The technology requires imaging a mask with the layout of the facets onto a layer of transparent plastic by means of a pulsed laser beam and a projection lens in between the mask and the layer of transparent plastic. Material is removed from the transparent plastic at the locations where the laser beam hits the plastic thus to create the specific tilt angle and azimuth angle of the facet surfaces. The higher the laser fluence, the more material is removed by (laser-) ablation. The facets were designed such as to transform a parallel beam or a point-source like beam into a pattern of light in the far field on a wall.
[0032] Thus, the present invention provides a method and device for controlling a beam of light. The invention makes use of micro-structures partitioned over a surface of a plurality of facets where practically each optical element or facet surface is different from its adjacent neighbor in size, rotational orientation and tilt angle (slope). The partitioned different facets can control, for example homogenize, light beams issued by light sources without the disadvantages of the prior art. Various combinations and alterations to the partitioned facets may include: adding a phase bias to the facet to further scramble the incoming light beam and/or adding a lens function to the first surface comprising the plurality of facets surface or to a back surface, positioned opposite to the first surface, of the optical device.
[0033] The smaller the angular spread of the light that crosses the facets, the sharper the features that can be projected onto a wall. An angular spread of less than 20° FWHM (full-width-at-half-maximum) is preferred. More preferred is an angular spread less than 10°. Even more preferred is a spread less than 5°.
[0034] The larger the size and the tilt (slope) of a facet surface, the larger the facet height. A maximum height that does not exceed 100 μm is preferred. The advantage of a limited height is the possibility of using (hot) embossing as a technology for mass manufacturing at low cost. It also enables roll-to-roll processing for mass-manufacturing at low cost. The lowest cost solutions are expected to be those that are based on foil-shaped optics: it is foreseen that a thin transparent optical foil provided with a dedicated micro-structured surface can fulfill the optical function of shaping the beam of light emitted by the LEDs. It is the benefit of this invention that manufacture of such a low-cost solution is enabled.
[0035] Facets that have a size less than 250 μm are preferred: a limited facet size implies a limited facet height and the possibility to have a large facet slope without having a large facet height. A large facet slope implies being able to redirection light into large angles. The minimum facet size preferred is about 25 μm. Smaller facets are more difficult to make in low-cost solutions and may result in undesired diffraction of the light crossing them.
[0036] The present invention may be used to perform beam splitting operations, homogenize light sources, and/or to redirect light in a given direction, for example the light beam exiting in the first and second directions contributing to a portion of a predetermined pattern. The optical device may be provided onto a substrate, for example a plate or a sheet, the substrate comprising a smooth regularly shaped exterior surface opposite to the facet surface of the optical device.
[0037] These and other advantages and features of the invention will become apparent from the following detailed description of the invention which is provided in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1A shows a schematic perspective view of a lighting device according to a first embodiment of the invention;
[0039] FIG. 1B shows the optical device of FIG. 1A in more detail;
[0040] FIG. 2 shows a schematic side view of a lighting device according to a second embodiment of the invention;
[0041] FIG. 3 schematically shows a plan view of an optical device according to the invention suitable to constitute a pattern shown next to it;
[0042] FIG. 4A-4B show two embodiments of a lighting device according to the invention, the one in FIG. 4A shows an optical device provided on a TIR collimator of a LED, the one in FIG. 4B shows a LED as a point light source with a directly associated optical device;
[0043] FIG. 5A-5B show positions of facets in an embodiment of an optical device according to the prior art in relationship with their associated positions in the displayed/generated pattern;
[0044] FIG. 6A-6B show positions of facets in an embodiment of an optical device according to the invention in relationship with their associated positions in the displayed/generated pattern, with a sub-division into groups of facets/quadrants;
[0045] FIG. 7A-7B show a lens according to the invention comprising four optical devices and the pattern as generated by said lens;
[0046] FIG. 7C-7D show a lighting device according to the invention and typical beam patterns as generated by the lighting device;
[0047] FIG. 8 shows some examples of patterns obtainable by various optical devices according to the invention;
[0048] FIG. 9A shows a 3D plot of an optical device according to the invention with an array of facets having a regular hexagonal shape;
[0049] FIG. 9B shows a scanning electronic microscope image of a part of a physical optical device according to the invention as shown in FIG. 9A ;
[0050] FIG. 10A-B show abstracted (mathematical) representations of physical parameters as facet, tilt angle, azimuth angle and orientation angle;
[0051] FIG. 11 shows a Voronoi surface partition of a first surface of an optical device according to the invention as obtained by a method according to the invention;
[0052] FIG. 12 shows a histogram of the number of facets with n-nodes of the optical device of FIG. 11 ;
[0053] FIG. 13A-B show examples how to determine group of facets.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0054] Referring now to the drawings, where like reference numerals designate like elements, there is shown in FIG. 1A a schematic perspective view of a lighting device 1 according to a first embodiment of the invention. The lighting device comprises a lamp/reflector unit 35 as a light source 3 with a light emitting element 5 , preferably a point-shaped light, for example a LED, or a high pressure gas discharge lamp, such as a UHP-lamp, positioned in a focal point 7 of a reflector body 9 . The lamp/reflector unit, during operation, generates a parallel beam of light 11 which subsequently is incident on a transparent optical device 13 . Said optical device being positioned transverse to the parallel beam and comprises a plurality of facets 15 sub-divided into at least a first 16 a and a second group of facets 16 b and further groups of facets 16 c - 16 g, which facets for the sake of simplicity are shown as squares, the average orientation of the facet surfaces defines an optical axis 17 . Each group of facets has a respective perimeter 53 . Each facet via refraction at its facet surface redirects a light beam (or light ray) incident on said facet in a specific direction towards a display screen 19 , shown with a Cartesian coordinate system comprising an x- and an y-axis. Said specific direction being dependent on the tilt angle and azimuth angle, measured with respect to the positive y-axis of said facet surface and is chosen such that, if desired, a homogenization in the light intensity is obtainable of a displayed pattern 21 , or alternatively, that a patterns is obtainable with predetermined values of shades and/or parts with predetermined (different) values of light intensities. In the figure each group of facets 16 a - g is associated with a respective sub-pattern 39 of the displayed pattern 21 . The relative position of a group of facets on the optical device is associated with the “same” relative position of the sub-patterns in the displayed pattern. Hence, as an example shown in the figure, the first group of facets 16 a is located in a first quadrant I of the first surface and is associated with a sub-pattern 39 located in a first quadrant I of the pattern. In the figure the optical device is made of PMMA.
[0055] FIG. 1B shows the optical device 13 of FIG. 1A in more detail. The optical device is slightly concavely curved towards a light source (not shown), has an optical axis 17 and comprises a first surface 25 with a plurality of facets 15 . Said first surface is subdivided into groups of facets 16 a - 16 g, with each group of facets having its respective perimeter 53 . The separations between groups of facets are indicated by bold lines, representing small spacings. As shown in the figure, each group forms a superfacet 61 of the first surface 25 . Each group of facets has a respective group optical axis 17 a - 17 g (only shown are 17 a - 17 c ) as defined by the normal to the average orientation of facets 27 belonging to a respective group of facets. Each facet having a respective perimeter edge 51 . The group optical axes are mutually angled at a respective angle β, as shown in the figure for groups of facets 16 b and 16 c with respectively axes 17 b and 17 . The angle β between axes 17 b and 17 c is about 10°, the respective angle β between other pairs of group optical axes need not all have the same value but may have different values.
[0056] FIG. 2 shows a schematic side view of a lighting device 1 according to a second embodiment of the invention. The lighting device comprises a lamp/reflector unit 35 as a light source 3 with a light emitting element 5 positioned in a reflector body 9 . The lamp/reflector unit, during operation, generates a converging beam of light 11 which subsequently is incident on a reflective optical device 13 . Said optical device comprises a plurality of facets, the average orientation of the facets defines an optical axis 17 . The plurality of facets are sub-divided into a first 16 a, a second 16 b, third 16 c and fourth group of facets 16 d. Each group of facets has a respective group optical axis 17 a - 17 d, of said axes at least one pair is mutually angled by an angle β, β′ of at least 5°, in the figure between group optical axes 17 a - 17 b β=15° and between group optical axes 17 c - 17 d β′= 10°. Each facet redirects via reflection a light beam (or light ray) incident on said facet in a specific direction towards a display screen 19 , said specific direction being dependent on the tilt angle and azimuth angle of said facet. In the figure the optical device is made of glass, coated with a specularly reflective aluminum layer 23 . Note that in the case of a reflective optical device the limitation requirement of TIR (as applicable for refractive optical devices) does not apply. Yet, the tilt angle and angle between adjacent facets could be limited similarly in order to limit the ratio of perimeter wall and facet surface to reasonable values below 4.6. The perimeter surface area ratio requirement for the refractive optical device remains equally applicable for the reflective optical device. As is evident form FIGS. 1A-B and 2 , the first surface can be essentially flat, or concavely curved or convexly curved towards the light source.
[0057] FIG. 3 schematically shows (a part of) a plan view of a first surface 25 of an optical device 13 according to the invention suitable to generate a pattern 21 as shown next to the optical device. The first surface is sub-divided into a first 16 a and a second group of facets 16 b, the first group of facets randomly building up the part “PHILI” and the second group of facets randomly building up the part “ILIPS” of the pattern “PHILIPS”. The first surface is partitioned by regular hexagonal facets (hexagons) 27 , the shading of a respective hexagon being an indication for tilt angle α and azimuth angle φ of the facet surface of said hexagon with respect to an optical axis 17 oriented perpendicular to the plane of the drawing. Light incident on said optical device propagates through said optical device and is subsequently refracted by the facets on said partitioned surface to constitute the pattern “PHILIPS”, as is shown in the right part of FIG. 3 . In principle a practically infinite number of arbitrary patterns can be generated by various optical devices according to the invention. Some illustrative examples are shown in FIG. 8 . Note that a projection lens is not needed. As a result, the pattern of light projected onto a wall does not need to be manually focused. It will be in focus irrespective of the distance of the wall to the optical device with facets as long as this distance is large compared to the diameter of the beam of light propagating through the optical device. Furthermore the optical device comprises a watermark 55 , i.e. the symbol “®”, which for the sake of clarity and as an example is represented by black colored facets.
[0058] FIG. 4A-4B show two embodiments of a lighting device 1 according to the invention. For the sake of clarity the facets are drawn with oversized dimensions with respect to the dimensions of the optical device. The lighting device 1 in FIG. 4A shows a transparent foil 29 with engraved facets 27 provided as an optical device 13 on an exit surface 31 of a TIR collimator 33 of a LED 37 as a light source 3 . The facets can also be embossed directly into the exit surface of the collimator or another optical element. A TIR collimator has a rotationally symmetric shape and relies on total-internal-reflection for the outer part of the beam and on refraction for the inner part. The function of the TIR collimator is to collect most of the light rays emitted by the LED and to reshape them into a parallel beam that has, at each location where rays cross the foil with engraved facets, no or only a small angular spread, i.e. in the figure the spread is less than 5°.
[0059] The embodiment of the lighting device 1 in FIG. 4B comprises a LED 37 as a point light source 3 accommodated in a reflective box 38 with a directly associated plate shaped optical device 13 as a first primary optics. The wall 38 a of the box could be light absorbing or alternatively could be designed such that light from the LED is reflected in a desired direction towards the optical device 13 . Typically the ratio of diameter d of the LED die and the diameter D the optical device is in the order of 10 or more, for example 25, the LED die then is considered a point light source compared to the optical device. Having a light source with a diverging beam can be advantageous as will be illustrated by the next example: Suppose one wants to project a rectangular pattern of light onto a wall. In that case, the distance between the collimator and the wall and the divergence (optionally by means of an additional diverging collimator) of the light source (and optional diverging collimator) can be chosen such that the (collimator and) LED alone project a circle pattern of light on the wall having an area equal to that of the intended rectangular pattern. The function of the plate-shaped optical device with facets is now to simply reshape the circular pattern into a rectangular one with refracting the light only over small angles and hence only facets with relatively small tilt angles are required, thus improving the performance of the optical device. Contrary thereto, in the case the collimator projects a parallel beam into a small spot on the wall, the diverging beam has to be realized only by means of the plate-shaped optical device, i.e. the optical device has to reshape this small spot into a relatively large rectangle and hence to refract over large angles, especially for the corners of the rectangle pattern. This requires facets with a relatively large tilt angles and a more accurate shape, which is a disadvantage.
[0060] FIG. 5A-5B show positions of facets 27 in an embodiment of an optical device according to the prior art, i.e. in a random in relationship with their associated positions in the displayed/generated pattern 21 . Although, for the sake of clarity, only sixteen facets are shown which are distributed over four groups of four facets 16 a - d each having a perimeter 53 , the optical device 13 may have ten thousand or more facets. One object of the invention is to enable the projection of any desired pattern of light on a wall at some distance from this plurality of facets 15 without GOBO's. FIG. 5A shows a periodic array of facet with each facet numbered, for facet number “ 2 ” a perimeter edge 51 is indicated in bold, as an example. Another object of the invention is to make a pattern of light in the far field (i.e. at a relatively large distance from the foil with the facets engraved), for example a pattern that is shaped as the character ‘A’ as shown in FIG. 5B . This pattern is divided into a number of sub-patterns 39 ; the same number of sub-patterns as the number of facets. Each of these sub-patterns is given a number. Each facet having a certain number is now linked to or associated with the sub-pattern of the pattern of light that has the corresponding number. Since now the coordinates for each part of the pattern of light on the wall are known, it subsequently is possible to calculate the slope and orientation of the corresponding facet, given the formulas described at FIGS. 10A-B . It is an optional feature of the embodiment that the positions of each facet within the array of facets are randomized, this is shown in FIGS. 5A and 5B .
[0061] FIG. 6A-6B show positions of facets 27 in an embodiment of an optical device 13 according to the invention in relationship with their associated positions in the displayed/generated pattern 21 . Contrary to what is shown in FIGS. 5A and 5B , in FIGS. 6A-and 6 B the positions of each facet within the plurality of facets 15 are not fully randomized, but are pseudo-randomly associated. In particular, both the first surface with facets of the optical device ( FIG. 6A ) and the pattern ( FIG. 6B ) is divided into four quadrants 41 , applying a same x,y Cartesian coordinate system on both optical device and pattern. Each quadrant of the optical device forms a group of facets which group is associated with the same, corresponding quadrant in the pattern and in this respect the association of facets with pattern is not random. However, within each group of facets the association of facets with the sub-pattern 39 in the corresponding quadrant again is fully random. Thus a pseudo-random relationship of facets positions with their associated positions in the displayed/generated pattern is obtained. For each group of facets a perimeter 53 is indicated.
[0062] FIG. 7A shows a lens 43 according to the invention comprising four optical devices 13 , each optical device comprising sixteen, identically arranged plurality of facets 27 , which however, is here only done for the sake of simplicity as in reality each optical device could easily comprise some thousands, for example 5000 facets. Also the lens comprising four optical devices is done for the sake of simplicity, generally a lens could well comprise ten to hundred of identical, or slightly, but essentially different optical devices. As the lens in FIG. 7A has four optical devices with a mutually identical arrangement of facets, the pattern/image 21 as shown in FIG. 7B is constituted four times by the lens when illuminated with a parallel light beam 11 . FIG. 7B shows four times the overlapping pattern as constituted by the lens of FIG. 7A . The overlap of superpositioned images is not 100% as a result of a small mutual displacement/shift 6 which is done on purpose to counteract the visibility of stepped edges at dark and light areas of the displayed image. This shift could be in one direction, but could also be done in more directions (as shown in the FIG. 7B ) and results in the edges to be more fluent/smooth, the magnitude of 6 is of course dependent on the complexity and/or detail of the displayed image (see for example FIG. 8 ), but generally the overlap of superpositioned images per facet is in the order of 50% to 95%, for example 80%.
[0063] FIG. 7C shows a lighting device 1 according to the invention comprising a lens 43 and, as an example, fifty optical devices 13 a,b, the optical devices 13 a forms a first set of optical devices comprising identically arranged plurality of facets, similarly optical devices 13 b forms a second set of optical devices comprising identically arranged plurality of facets different from the set of optical devices 13 a. The number of LEDs and their respective associated optical devices amounts for example 25, 50 or 100 LEDs and 25, 50 or 100 essentially identical optical devices on one lens. The lens in FIG. 7C has a first set of twenty-six optical devices 13 a associated with a with a first set of twenty-six LEDs 37 a with a mutually identical arrangement of facets, the pattern/image part 82 as shown in FIG. 7D is constituted twenty-six times by the lens when illuminated by the first set of LEDs 37 a. The pattern/image parts 88 and 90 are to be constituted by the second set of twenty-four LEDs 37 b and their associated set of twenty-four optical devices 13 b. In the embodiment shown in FIGS. 7C-D , the two sets of combinations 13 a - 37 a and 13 b - 37 b together constitute a high beam of the motor headlight device during operation of both combinations. Alternatively it is possible that one combination, for example 13 b - 37 b issue a dim light beam, and that the other combination, for example 13 a - 37 a as such issues a high beam, the combination 13 b - 37 b then being switched off. Such an essentially interdigitated (or more or less alternating) arrangement of two combinations of LEDs and associated optical devices is in particularly suitable in luminaires enabling it to issue a narrow beam light (spot-like), a broad beam light (flood light), for example a batwing-shaped light beam, or the combination of narrow and broad beam light. Yet the luminaire in all operation conditions has a practically constant appearance and emits light in a homogeneous way from its whole light emission window. Such a device/luminaire could be considered as an invention as such.
[0064] FIG. 7D shows the dim light beam pattern as issued by a motor headlight device which is built up according to the principle as shown in FIGS. 7A and 7C , hence without screening part of the light beam as is generally the case in conventional motor headlights. A measuring screen 80 is arranged in FIG. 7D at a distance in front of the headlight and is illuminated by the light emitted by the headlight. Horizontal central plane of the measuring screen 80 is identified as HH and the vertical central screen is identified as VV. The horizontal central plane HH and the vertical central plane VV intersect one another in a point HV. The light which is emitted by the light source illuminates the measuring screen 80 in a region 82 . The region 82 is limited from above by a dark-light limit produced by the specific redirecting properties of the lens in total, i.e. by superposition of all the light beams as issued by each respective LED in combination with its associated respective optical device. The shown embodiment, the headlight is determined for the right traffic and the bright-dark limit has on the counter traffic side, or at the left side of the measuring screen 80 a portion 84 which extends substantially horizontally under the horizontal central plane HH. At the traffic side, or in other words at the right side of the measuring screen 80 , the bright-dark limit has a raising portion 86 which extends from the horizontal portion 84 to the right edge of the measuring screen 80 or the horizontal central plane HH outwardly. Alternatively, the bright-dark limit at the traffic side can have a portion which is arranged higher than the portion 84 and is also horizontal. The distribution of the illumination intensities in the region 82 is provided by legal considerations, and in a zone under the point HH the highest illumination intensities are available. The measuring screen 80 above the bright-dark limit 84 , 86 is not illuminated or poorly illuminated by the light as issued by the LEDs 13 a and redirected by the optical devices 37 a of the lens 43 . For example, in view of acting ECE regulations a measuring point 92 is defined, in which the illumination intensities amounts maximum to 0.4 lux, to avoid a blinding of the counter traffic. The illumination intensity distribution can be selected for example so that in a region 90 located directly above the bright-dark limit 84 , 86 on the measuring screen 80 , which extends for example up to approximately 2° above the horizontal central plane HH and under substantially 4° at both sides of the vertical central plane VV, the light as issued by the headlight illuminates only poorly. The falling region 88 which is located above and laterally over the region 90 extends for example vertically above up to 4° over the horizontal central plane HH and laterally at both sides of the vertical central plane VV up to substantially 80° and is stronger eliminated in the region 90 .
[0065] It is an optional feature of the embodiment that the positions of each facet within each of the optical devices are randomized. This has the advantage that in case the transparent foil having many of such facets engraved in it, and is illuminated with a narrow beam of light, the light will cross a few facets only. The result is that only a fair representation of the desired pattern of light is obtained. In case the beam is broadened, the light of the beam will cross more facets and the representation of the pattern of light improves. In other words, randomizing the position of each facet within the array of facets makes that the foil with facets behaves in a predictable manner: the more facets are illuminated, the better the quality of the pattern of light on the wall. In this respect, the inventive optical device has a strong similarity to the behavior of a hologram. However, contrary to holograms the inventive optical also works well for white light (i.e. a broad spectrum of light), but is not limited thereto, and appears to be wave-length independent. This is an advantage over diffractive diffusers since diffractive diffusers are tuned to a particular wavelength and have decreased efficiency at different wavelengths. Also in the case the beam is not homogeneous, the randomization of the positions of the facets takes care that yet a good representation of the pattern of light on the wall is obtained.
[0066] FIG. 9A shows a computer calculated 3D plot 45 of an optical device 13 according to the invention with a plurality of facets 15 having a regular hexagonal shaped facet surface. FIG. 9B shows a scanning electronic microscope image of a part of a physical optical device according to the invention as shown in FIG. 9A . The meaning of the characteristics ‘tilt’, ‘azimuth’ and ‘orientation’ of facet surfaces 27 a, 27 b of facets 27 are clearly shown in FIGS. 9A-B . A cross-section of the physical optical device of FIG. 9B along line X-X is shown in FIG. 10A .
[0067] As is shown in FIG. 10A , from an optics point of view, the function of each facet 27 is to redirect the rays of light that are transmitted by this facet. Each facet 27 has a respective facet surface 27 a, 27 b. Said facet surfaces 27 a, 27 b have a respective normal vector 28 a, 28 b, which normal vectors, for adjacent facet surfaces, preferably are mutually angled at at least γ=3°. In the example shown in the figure, γ=45° for the normal vectors 28 a, 28 b of the adjacent facet surfaces 27 a, 27 b.
[0068] It is assumed that a parallel beam of light 11 issued by a plurality of light emitting elements or light sources (not shown) and is directed perpendicular to an optical device comprising a thin transparent foil 29 having a first surface 25 with facets 27 engraved into it. Each individual facet will intercept an equal part of the parallel beam of light and redirect it.
[0069] Given a vector, n=(x,y,z), normal to a facet, the slope (tilt angle α) and rotational orientation (azimuth angle φ) of this facet are (see also FIG. 10B ):
[0000]
α
=
tan
-
1
(
x
2
+
y
2
z
)
,
φ
=
tan
-
1
(
y
/
x
)
.
[0070] The angle θ, into which the light intercepted by this facet will be redirected follows from the relation:
[0000] θ= a sin( n sin(α))−α.
[0071] In this relation, n is the index of refraction of the material the transparent substrate is made of. Given both θ, φ as well as the distance z′ to a wall that intercepts the light redirected by this facet, the position (x′,y′) at which the light hits the wall follows simply from the relations:
[0000] x′=z ′ tan(θ)cos(φ+π),
[0000] y′=z ′ tan(θ)sin(φ+π).
[0072] Hence, a collection of facets engraved in a transparent substrate and its effect on a beam of light is described.
[0073] FIG. 11 shows a Voronoi surface partition 47 of a first surface 25 of an optical device 13 according to the invention as obtained by a method according to the invention. Instead of partitioning the first surface into a grid of squares, it is to be preferred to partition it into polygons of, on average, more nodes than four, more preferably the polygons are convex. To obtain n facets 27 , firstly n dots in a plane are drawn. If facets of more or less constant size are desired, the dots are drawn such that they are more or less equally spaced. If, on the other hand, varying sizes are wanted, the distance between the dots is varied. A large density of vertices will result in small facets, a small density of dots in large facets. Subsequently, Fortune's algorithm is applied to obtain a Voronoi diagram for the nodes. This diagram can be interpreted as a plate of facets: each cell of the Voronoi diagram corresponds to a facet. Finally, of the facets thus obtained, the orientation of each facet has to be determined in dependency on the total pattern to be displayed and the sub-pattern to be displayed by a respective facet. FIG. 11 gives an example of a Voronoi diagram. FIG. 12 shows for this diagram a histogram 49 , with the number of nodes in the polygons on the x-axis and the fraction (or percentage) occurring with said number of nodes on the y-axis. It shows that the facets resulting from the Voronoi diagram have the advantageous property that many of them have many nodes, i.e. at least five.
[0074] FIG. 13A-B show some examples how to (virtually) divide the plurality of facets 15 on the first surface 25 into a group of facets 16 a is to consider one selected facet 59 , preferably not at the border of the first surface. At least all the facets that can be reached in three steps over adjacent/bordering facets, as shown in FIG. 13B by the numbers 1, 2, 3, or that are within a distance of <=3* averaged facet size from said selected one facet, as shown in FIG. 13A and indicated as R, are considered to be part of said group of facets. This method automatically renders the groups of facets to be compactly arranged and have more or less the same size and shape.
[0075] Reference has been made to preferred embodiments in describing the invention. However, additions, deletions, substitutions, or other modifications which would fall within the scope of the invention defined in the claims may be implemented by those skilled in the art without departing from the spirit or scope of the invention. Accordingly, the invention is not to be considered as limited by the foregoing description, but is only limited by the scope of the appended claims.
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An optical device comprising a first surface with a plurality of micro sized facets, each facet having a respective orientation. Said plurality of facets having an optical axis which extends parallel to the normal vector to an average orientation of all said respective orientations. The plurality of micro-sized facets comprises a meaningful pattern forming sub-set of facets. Said sub-set has at least one feature chosen from: equal orientation (tilt and azimuth), similar color, similar marking(scratching, frosting, ribbing), similar spacing with adjacent facets.
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The present Application is a Continuation of U.S. patent application Ser. No. 13/451,524, filed on Apr. 19, 2012, which is a Continuation of U.S. patent application Ser. No. 13/024,181, filed on Feb. 9, 2011 and issued as U.S. Pat. No. 8,680,845 on Mar. 25, 2014, and claims priority thereto under 35 U.S.C. 120. The disclosure of the above-referenced Parent U.S. Patent Application is incorporated herein by reference.
This invention was made with government support under DE-EE0002897 awarded by the Department of Energy. The government has certain rights to this invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to sensors providing input to power measurement systems, and more specifically to a non-contact sensor that includes an electrostatic voltage sensor and an electromagnetic current sensor that can be used to detect the voltage and current at a wire of a power distribution system.
2. Description of Related Art
A need to measure power consumption in AC line powered systems is increasing due to a focus on energy efficiency for both commercial and residential locations. In order to provide accurate measurements, the characteristics of the load must be taken into account along with the current drawn by the load.
In order to determine current delivered to loads in an AC power distribution system, and in particular in installations already in place, current sensors are needed that provide for easy coupling to the high voltage wiring used to supply the loads, and proper isolation is needed between the power distribution circuits/loads and the measurement circuitry.
Therefore, it would be desirable to provide a sensor that can provide isolated current draw information and permit load characteristics to be taken into account using outputs of a single sensor in an AC power distribution circuit.
BRIEF SUMMARY OF THE INVENTION
The invention is embodied in a current and voltage sensing device and its method of operation. The current sensing device includes a current sensor and a voltage sensor both integrated in a housing that can be detachably coupled to a wire and provides outputs indicative of the current passing through the wire, as well as an electric potential on the wire.
The housing may be a clamshell containing portions of a current sensor formed from a ferrite cylinder, which when closed around the wire, form either a complete ferrite cylinder, or one with a gap along the circumference. A semiconductor magnetic field sensor may be included in the gap and used to measure the current passing through the wire, or a winding may be provided around the ferrite cylinder along its axis. The voltage sensor may be a separate cylindrical plate, another wire or other suitable conductor either offset from the current sensor along the length of the wire, or may be a foil located inside of the ferrite sensor or a film deposited on an inside surface of the ferrite.
The foregoing and other objectives, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of the invention when read in conjunction with the accompanying Figures, wherein like reference numerals indicate like components, and:
FIG. 1A and FIG. 1B are isometric views and FIG. 1C is a cross-section view of a sensor according to an embodiment of the present invention.
FIG. 2A is an isometric view and FIG. 2B is a cross-section view of a sensor according to another embodiment of the present invention.
FIG. 3A is an isometric view and FIG. 3B is a cross-section view of a sensor according to yet another embodiment of the present invention.
FIG. 4A is an isometric view and FIG. 4B is a cross-section view of a sensor according to still another embodiment of the present invention.
FIG. 5 is an electrical block diagram illustrating circuits for receiving inputs from sensors according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention encompasses sensors for current and voltage sensing features for providing input to power measurement systems. For example, the present invention can provide input to power monitoring equipment in computer server rooms, in which branch circuits distribute power to various electronic chassis power supplies, and in which it is beneficial to provide power usage information for the various branch circuits to power monitoring and/or system control utilities within a computer operating environment. Other applications include power monitoring for commercial and/or residential energy management.
Referring now to FIGS. 1A-1C , a sensor 10 in accordance with an embodiment of the present invention is shown. A plastic sensor body 12 encloses a current sensor and a voltage sensor, that provide information about a magnitude and phase of a current passing through a wire 3 around which sensor body is detachably secured as shown in FIG. 1B . A latch 13 secures a top portion and a bottom portion of sensor body 12 together, along with a hinge formed on sensor body 12 at an opposite side from latch 13 . A current sensing portion of sensor 10 is formed by three ferrite pieces 14 A, 14 B that form a ferrite cylinder around wire 3 , when sensor body 12 is closed. Top ferrite piece 14 A forms a half-cylinder, while ferrite pieces 14 B define a gap between ferrite pieces 14 B and in the circumference of the ferrite cylinder, in which current sensing element 17 , which is generally a semiconductor magnetic field sensor, such as a Hall effect sensor, is disposed. Current sensing element 17 is shown as having interface wires 15 extending from its body, but other types of terminals may be used as an alternative manner of providing connections to current sensing element 17 . An aperture is formed through sensor body 12 to receive current sensing element 17 . A voltage sensor is formed by metal plates 18 A, 18 B, which provide capacitive coupling to branch circuit wire 3 and provide an output via interface wire 15 A, which may also alternatively be replaced with a terminal or other suitable electrical connector. The voltage sensor provides an AC waveform that is at least indicative of the phase of the voltage on wire 3 and may be calibrated to provide an indication of the magnitude of the voltage if needed. Electrical connection to metal plate 18 B is provided by interface wire 15 A and electrical connection to metal plate 18 A is provided by contact between metal plates 18 A and 18 B when sensor body 12 is latched closed. Metal plate 18 A includes a contact 27 and metal plate 18 B includes a mating recess 29 to improve electrical contact between metal plates 18 A and 18 B, so that connection of one of metal plates 18 A and 18 B to the measurement system is needed to provide voltage sensing. Contacts 27 and mating recesses 29 are optional and may be omitted in other embodiments of the invention, and electrical connection may be provided only by contact between metal places 18 A and 18 B, or alternatively by other suitable connection improvement techniques. FIG. 1C illustrates such an embodiment so that metal plates 18 A and 18 B making contact when sensor body 12 is closed, and shows the connection of interface wire 15 A to metal plate 18 B.
Referring now to FIGS. 2A and 2B , a sensor 10 A in accordance with another embodiment of the invention is shown. Sensor 10 A is similar to sensor 10 of FIGS. 1A-1C , so only differences between them will be described below. Rather than including current sensing and voltage sensing elements that are laterally displaced along the axis of the cylinder formed by sensor body 12 as in sensor 10 shown in FIG. 1A , in sensor 10 A, the voltage sensor and current sensors are concentrically arranged, reducing the length of sensor 10 A over that of sensor 10 , while providing similar capacitive area for the voltage sensing and ferrite volume for the current sensing. Therefore, sensor 10 A includes metal plates 18 C and 18 D having shapes differing from that of than metal plates 18 A- 18 B in sensor 10 , and ferrite pieces 14 C- 14 D differ from ferrite pieces 14 A- 14 B of sensor 10 , as well. Metal plates 18 C and 18 D, provide metal layers within sensor 10 A that may be inserts mechanically secured by sensor shell 12 A, or metal films bonded to or deposited on the interior surfaces of ferrite pieces 14 C- 14 D. In the illustrated example, metal plates 18 C and 18 D include jogs at their ends in order to provide electrical contact between them and ferrite pieces 14 C- 14 D do not make contact as in sensor 10 of FIGS. 1A-1C , and therefore the total circumferential gap in the ferrite cylinder is increased slightly. However, in alternative embodiments, the jogs may be omitted from metal plates 18 C and 18 D and alternative electrical connection techniques may be employed, by including a second interface wire 15 A bonded to metal plate 18 C and/or additional interface metal along the edges of sensor body 12 outside of the ends of ferrite pieces 14 C- 14 D, which can then be extended to make contact as in sensor 10 of FIGS. 1A-1C .
Referring now to FIGS. 3A and 3B , a sensor 10 B in accordance with yet another embodiment of the invention is shown. Sensor 10 B is similar to sensor 10 A of FIGS. 2A-2B , so only differences between them will be described below. Rather than locating current sensing element 17 in a gap between two ferrite pieces 14 B as in sensor 10 A of FIGS. 2A-2B , in sensor 10 B, current sensing element is located between two ferrite pieces 14 E and 14 F that extend around the entire circumference of sensor 10 B, excepting the thickness of current sensing element 17 , and therefore only one circumferential gap is formed provided that ferrite pieces 14 E and 14 F are in contact when sensor 10 B is closed at the area opposite the hinge in sensor body 12 B. Recesses are formed in sensor body 12 B to accept current sensing element 17 , which may be bonded to, or molded within sensor body 12 B, as may also be performed for any of the integration of current sensing element 17 in the present application. Metal plates 18 E and 18 F are shown as having jogs only opposite of the hinged portion of sensor body 12 B, to provide for ferrite pieces 14 E and 14 F extending all of the circumferential distance to the body of current sensing element 17 and since ferrite pieces 14 E and 14 F are not in contact along the hinged portion of sensor body 12 B. However, in accordance with an alternative embodiment of the invention, metal plates 18 E and 18 F may include features within the gap formed between ferrite pieces 14 E and 14 F along the hinged portion of sensor body 12 B to provide additional electrical contact between metal plates 18 E and 18 F. Further, in accordance with another embodiment of the invention, if sensor body 12 B is made of a sufficiently flexible material and/or the hinged portion of sensor body 12 B is sufficiently elastic, ferrite pieces 14 E, 14 F may extend all of the way to the inside faces of sensor body 12 B on both sides of sensor body 12 B. In such an embodiment, sensing element 17 is inserted in either the hinged side or the latching side of sensor body 12 B between the faces of ferrite pieces 14 E, 14 F to form the gap and make contact with ferrite pieces 14 E, 14 F.
Referring now to FIGS. 4A and 4B , a sensor 10 C in accordance with yet another embodiment of the invention is shown. Sensor 10 C is similar to sensor 10 of FIGS. 1A-1C , so only differences between them will be described below. Rather than including metal plates 18 A and 18 B and the portion of sensor body 12 that extends to provide the voltage sensing portion of sensor 10 in FIG. 1A , interface wire 15 A extends within the cylindrical cavity formed by sensor body 12 C and ferrite pieces 14 A- 14 B to provide voltage sensing, which can provide sufficient coupling to perform voltage sensing, in particular when only the phase of the voltage on wire 3 is to be measured.
Referring now to FIG. 5 , a circuit for receiving input from the current/voltage sensors of FIGS. 1A-1C, 2A-2B, 3A-3B and 4A-4B is shown in a block diagram. Interface wires 15 from current sensing element 17 provide input to a current measurement circuit 108 A, which is an analog circuit that appropriately scales and filters the current channel output of the sensor. The output of current measurement circuit 108 A is provided as an input to an analog-to-digital converter (ADC) 106 , which converts the current output waveform generated by current measurement circuit 108 A to sampled values provided to a central processing unit (CPU) 100 that performs power calculations in accordance with program instruction stored in a memory 104 coupled to CPU 104 . Alternatively, current measurement circuit 108 A may be omitted and current sensing element 17 may be connected directly to ADC 106 . The power usage by the circuit associated with a particular sensor can be determined by assuming that the circuit voltage is constant (e.g., 115 Vrms for electrical branch circuits in the U.S.) and that the phase relationship between the voltage and current is aligned (i.e., in-phase). However, while the assumption of constant voltage is generally sufficient, as properly designed properly distribution systems do not let the line voltage sag more than a small amount, e.g., <3%, the phase relationship between voltage and current is dependent on the power factor of the load, and can vary widely and dynamically by load and over time. Therefore, it is generally desirable to at least know the phase relationship between the branch circuit voltage and current in order to accurately determine power usage by the branch circuit.
Interface wire 15 A from the voltage channel of the sensor is provided to a voltage measurement circuit 108 B, which is an analog circuit that appropriately scales and filters the voltage channel output of the sensor. A zero-crossing detector 109 may be used to provide phase-only information to a central processing unit 100 that performs power calculations, alternatively or in combination with providing an output of voltage measurement circuit to an input of ADC 106 . Alternatively, voltage measurement circuit 108 B may be omitted and interface wire 15 A connected directly to ADC 106 . An input/output (I/O) interface 102 provides either a wireless or wired connection to a local or external monitoring system. When power factor is not taken into account, the instantaneous power used by each branch circuit can be computed as:
P BRANCH =V rms *I meas
where V rms is a constant value, e.g. 115V, and I meas is a measured rms current value. Power value P BRANCH may be integrated over time to yield the energy use. When the phase of the voltage is known, then the power may be computed more accurately as:
P BRANCH =V rms *I meas *cos(Φ)
where Φ is a difference in phase angle between the voltage and current waveforms. The output of zero-crossing detector 109 may be compared with the position of the zero crossings in the current waveform generated by current measurement circuit 108 A and the time ΔT between the zero crossings in the current and voltage used to generate phase difference Φ from the line frequency (assuming the line frequency is 60 Hz):
Φ=2π*60 *ΔT
In general, the current waveform is not truly sinusoidal and the above approximation may not yield sufficiently accurate results. A more accurate method is to multiply current and voltage samples measured at a sampling rate much higher than the line frequency. The sampled values thus approximate instantaneous values of the current and voltage waveforms and the energy may be computed as:
Σ( V n *I n )
A variety of arithmetic methods may be used to determine power, energy and phase relationships from the sampled current and voltage measurements.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form, and details may be made therein without departing from the spirit and scope of the invention.
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A detachable current and voltage sensor provides an isolated and convenient device to measure current passing through a conductor such as an AC branch circuit wire, as well as providing an indication of an electrostatic potential on the wire, which can be used to indicate the phase of the voltage on the wire, and optionally a magnitude of the voltage. The device includes a housing formed from two portions that mechanically close around the wire and that contain the current and voltage sensors. The current sensor is a ferrite cylinder formed from at least three portions that form the cylinder when the sensor is closed around the wire with a hall effect sensor disposed in a gap between two of the ferrite portions along the circumference to measure current. A capacitive plate or wire is disposed adjacent to, or within, the ferrite cylinder to provide the indication of the voltage.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an improved display carton of the front loaded type with an interior product containing pocket located beneath a display opening in one wall of the carton. Cartons of this type are generally loaded through one end and are provided with dividers or interior panels for stopping, positioning, retaining and guiding the product as it is loaded in the carton. Examples of such cartons may be found for instance in U.S. Pat. No. 2,807,404 which includes a pair of false interior walls for supporting a product located therein; U.S. Pat. No. 3,682,297 which teaches a pilfer proof carton with interior partition walls; and, U.S. Pat. No. 4,113,086 which discloses stop panels and retaining panels. However, none of the cartons disclosed employ the unique one-piece construction and arrangement of interior panels disclosed herein.
SUMMARY OF THE INVENTION
The present invention relates generally to an improvement in the construction of display-type cartons and more particularly has for its principal purpose the provision of a front loaded carton with a unique interior formed by two glue applications and no more than two or three folding steps. The carton blank of the present invention is cut and scored from a single piece of foldable material (e.g. paper board or the like), and comprises an outer carton structure with a display opening and an integral interior product containing pocket portion for accepting, positioning and retaining a front loaded product. The carton is intended to package small items such as gifts, promotional sizes of larger products, cassette tapes and the like in such a manner that the products are isolated in a protected environment. This objective is achieved in the present invention by the strategic location of header panels and stop panels within the carton structure.
The present invention is carried out by including an extension panel on the blank structure for the carton which is cut and scored to form a first generally U-shaped section which is adhered to the interior of one wall of the carton and a second generally T-shaped section which is adhered to the interior of another wall of the carton. These sections are spaced from one another by strategically located header and stop panels for locating the product in the product containing pocket interiorly of the carton. Meanwhile one wall of the carton, preferably the top or front wall, is provided with a display opening located over the product pocket so that the carton can be loaded from the front. The loaded product is retained in its pocket by the header panels and stop panels, and by product retaining tabs located on the inner edges of the display opening.
DESCRIPTION OF DRAWINGS
FIG. 1 is a plan view of a blank for making a first embodiment of the carton of the present invention;
FIG. 2 illustrates the blank of FIG. 1 after the first folding step;
FIG. 3 shows the blank completely folded to form the carton in its collapsed condition;
FIG. 4 is a perspective view of the carton of FIG. 3 in its set-up condition;
FIG. 5 is a perspective view of the carton of FIG. 4 with its top panel partially cut away to show the product-containing interior compartment;
FIG. 6 is a cross sectional view taken along the lines 6--6 of FIG. 5;
FIG. 7 is a plan view of a blank for making a second embodiment of the carton of the present invention;
FIG. 8 illustrates the blank of FIG. 7 after the first folding step;
FIG. 9 shows the blank completely folded to form the carton in its collapsed condition;
FIG. 10 is a perspective view of the carton of FIG. 9 in its set-up condition;
FIG. 11 is a perspective view of the carton of FIG. 10 with its top panel partially cut away to show the product-containing interior compartment;
FIG. 12 is a cross sectional view taken along the lines 12--12 of FIG. 11;
FIG. 13 is a plan view of a blank for making a third embodiment of the carton of the present invention;
FIG. 14 illustrates the blank of FIG. 13 after the first and second folding steps;
FIG. 15 shows the blank completely folded to form the carton in collapsed condition;
FIG. 16 is a perspective view of the carton of FIG. 15 in its set-up condition;
FIG. 17 is a perspective view of the carton of FIG. 16 with its top panel partially cut away to show the product-containing interior compartment; and,
FIG. 18 is a cross sectional view taken along the lines 18--18 of FIG. 17.
DETAILED DESCRIPTION
Referring now to FIG. 1 of the drawing, a typical carton blank 10 will be seen to comprise in sequence a rear panel 11, first side wall 12, a front panel 13, a second side wall 14 and an extension panel 15 connected together by parallel spaced apart scored lines 16-19. Panels 11-14 with the end closure flaps 20 and 21 located at the ends thereof constitute the outer structure of the carton of the present invention while the extension panel 15 forms the interior compartment of the carton. Extension panel 15 is divided by cut and scored lines to provide a first generally U-shaped section 22 and a generally T-shaped section 23. These sections are separated from one another by spacer panels 24, 25 and 26 formed by separate, parallel scored lines and a pair of cut lines 27, 28. As shown in FIG. 1, the extension panel 15 is cut and scored symmetrically to provided a centrally located pocket that is located beneath a cut-out 29 provided in the front panel 13. One or more product retaining tabs 30 are provided along the inner edges of the cut-out 29 which extend into the cut-out area for retaining products in the product pocket. It will be understood that the product pocket and cut-out may be shifted away from the center of the carton merely by relocating the cut lines 27, 28 and cut-out 29.
When the carton blank 10 of FIG. 1 is prepared for forming into its carton configuration, adhesive is applied to the U-shaped section 22. The extension panel 15 is then folded at F 1 along scored line 19 to adhere the U-shaped section 22 to the inside of front panel 13. Adhesive is also applied to the T-shaped section 23 before folding the blank at F 2 along scored line 17 to adhere the T-shaped section 23 to the inside of rear panel 11. The adhesive applications may take place simultaneously or in steps, depending upon the type of equipment used to form the carton. FIG. 2 shows the blank structure after the first folding step F 1 and FIG. 3 shows the blank structure after the second folding step F 2 . The carton is fully formed but in its collapsed condition for shipment to the user in FIG. 3. While not shown in the drawing, it will be understood that the extension panel 15 may require pre-breaker scores for the spacer panels 24, 25 and 26 as well known in the art.
When the carton is squared as shown in FIG. 4, the end closure flaps 20, 21 are folded and adhered together so that the carton is ready for loading. The structure is of the front loading type where the product is inserted into the cut-out 29 provided in front wall 13 and secured behind the product retaining tab 30 (only one shown). The loaded carton may then be overwrapped if desired. FIGS. 5 and 6 illustrate details of the inner product containing pocket of the carton. In the embodiment shown in FIGS. 1-6, panel 24 is generally referred to as a header panel while panels 25 and 26 are referred to generally as stop panels. These panels keep the product properly located beneath the cut-out 29 in top panel 13. In particular, FIG. 6 illustrates the spacial location of the header panel 24 and one of the stop panels 26.
The forming of the carton as described hereinbefore in substantially conventional, and is accomplished mechanically on suitably programmed folding and gluing machinery. The application of compressive force to the folded blank after each folding step tends to aid the set of the adhesive and to maintain the carton in its preferred collapsed condition for shipment to the ultimate user. The generally U-shaped and T-shaped sections of the extension panel 15 are shown shaded for contrast and to proved clarity to the inventive concept. Adhesive is not generally applied to the complete shaded areas shown but only to portions thereof to achieve the full effect of the present invention.
A second embodiment of the invention is shown in FIGS. 7-12. For this embodiment, the blank 40 comprises in sequence a front panel 41, first side wall 42, a rear panel 43, a second side wall 44 and an extension panel 45, connected together by parallel, spaced part scored lines 46-49. As in the case of the embodiment disclosed in FIGS. 1-6, panels 41-44 with the end closure flaps 50 and 51 located at the ends thereof constitute the outer structure of the carton while the extension panel 45 forms the interior product containing pocket of the carton. Extension panel 45 is divided by cut and scored lines to provide a first generally U-shaped section 52 and a T-shaped section 53. Like the previous embodiment, these sections are separated from one another by spacer panels 54, 55, 56 formed by separate parallel scored lines and a pair of cut lines 57, 58. Also, as in the previous embodiment, front panel 41 includes a product display cut-out 59 with at least one product retaining tab 60.
When the carton blank 40 of FIG. 7 is prepared for folding into its carton configuration as shown in FIGS. 8 and 9, adhesive is applied to the T-shaped section 53 prior to the first folding step F 1 along scored line 49. Adhesive is also applied to the U-shaped section 52 before the second folding step F 2 along scored line 47. FIG. 8 shows the blank 40 after the first folding step F 1 and FIG. 9 illustrates the carton in its fully formed, collapsed condition after the second folding step F 2 .
When the carton is squared as shown in FIG. 10, the end closure flaps 50, 51 may be closed for preparing the carton for loading. FIGS. 11 and 12 illustrate details of the inner product containing pocket of the carton. In particular, the pocket is formed by the header panel 54 and the two product stop panels 55, 56. The generally U-shaped section 52 is adhered to the inside of top panel 41 and the generally T-shaped section 53 is adhered to the bottom panel 43. The same features and alternatives described hereinbefore for the first embodiment also apply to this second embodiment.
A third embodiment of the present invention is shown in detail in FIGS. 13-18. For this embodiment, the blank 70 comprises in sequence a front panel 71, first side wall panel 72, rear or bottom panel 73, second side wall panel 74 and an extension panel 75 connected together by parallel, spaced apart scored lines 76-79. Panels 71-74 in conjunction with the end flaps 80, 81 form the outer structure of the carton of the third embodiment while the extension panel 75 is designed to provide a product retaining pocket. Extension panel 75 is divided by cut and scored lines to yield a generally U-shaped section 82 (shown in FIG. 14) and a generally T-shaped section 83 shown in FIG. 13. These sections are separated from one another in this embodiment by spacer panels 84, 85, 86 and 87 formed by separate parallel score lines and cut lines, or in the illustrated embodiment, narrow cut-outs 88 and 89. Cut-outs 88, 89 are shown only to provide a slightly staggered relationship between the spacer panels to accommodate a specific product. Also, as in the previous two embodiments, the front panel 71 includes a product display cut-out 90 with at least two product retaining tabs 91.
When the carton blank 70 of FIG. 13 is prepared for folding into its carton configuration, as shown in FIGS. 14 and 15, adhesive is applied to the T-shaped section 83 of extension panel 75 prior to the first folding step F 1 along scored line 79. At that point, the T-shaped section 83 is adhered to the inside of rear wall 73. Next, the second folding step F 2 is carried out along scored line 92, as shown in FIG. 14, where adhesive is applied to the U-shaped section 82 of extension panel 75. At this point, the blank is folded along score line 77 to carryout folding step F 3 which adheres the U-shaped section 82 to the inside of front wall 71 and fully forms the carton in its collapsed condition as shown in FIG. 15.
When the carton is squared as shown in FIG. 16, the end closure flaps 80, 81 may be closed to complete the carton and prepare it for loading. FIGS. 17 and 18 illustrate details of the inner product pocket of the carton. In particular, the pocket is formed by header panels 84 and 87 and the product stop panels 85, 86° The generally U-shaped section 82 of the extension panel 75 is adhered to the inside of the front panel 71 and the generally T-shaped section 83 is adhered to the inside of bottom panel 73 as in the prior embodiments. As in the case of the prior embodiments, it will be understood that the product pocket and display cutout 90 may be readily relocated within the carton as desired.
It may thus be seen that the present invention provides an improved collapsible display carton with a display opening located over a product containing pocket which is easy to manufacture, assemble and erect. The carton of the present invention is economical of material used, economical of labor to produce, and fully protects and isolates the packaged product. The specification and the accompanying drawing have described and illustrated several embodiments of the invention, each of which incorporate a common theme of using a cut and scored extension panel with generally U-shaped and T-shaped glued sections which produce the novel product containing pocket. However, even though these preferred embodiments have been described in detail, it will be apparent to those skilled in the art that changes and variations may be made in the construction of the carton within the scope of the invention as defined in the appended claims.
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A front loaded display carton is formed from a one-piece, cut and scored blank of paperboard or the like that is preglued and shipped to the user in a collapsed condition. The carton when squared is of essentially rectangular configuration with a display opening in the front wall and a product containing pocket located interiorly of the carton beneath the display opening. The product containing pocket is formed by internal walls known generally as header panels and stop panels which are cut from the one-piece blank.
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BACKGROUND OF THE INVENTION
The present invention relates to a device for the spray-coating of objects which are moved past the spray coating device. The device of the invention is preferably used as a so-called "roof machine" for the automatic coating of the front, roof and rear surfaces of automobile bodies with paint, normally enamel. The automobile bodies are transported past the device on a conveyor belt.
Such a roof machine is known from Federal Republic of Germany OS 39 11 454 A1. The machine includes a roof beam which extends horizontally and transversely over the conveyor belt. The beam is provided with spray coating atomizers. The roof beam is supported on two vertical columns. One column contains drive elements for the roof beam and the atomizers. The other column contains paint supply means for supplying the atomizers with paint. The roof beam is connected to the vertical columns via crank-like levers so that the roof beam can be moved upward and downward and can have rotary movement around its longitudinal axis. The atomizers are jointly movable back and forth, are tiltable and are adjustable individually with respect to their lateral distances apart. Particularly when devices of this type are used as roof machines for automatically coating automobile bodies, they spray the paint or enamel from containers or pipe lines in optimum quality and quantity onto the objects to be sprayed, particularly automobile bodies. In practice, a large number of problems arise with such machines:
a) economy of the transfer of the paint, particularly the transfer of the paint from atomizers to the object to be coated with minimum loss of paint and minimum expenditure of energy;
b) good coating quality;
c) avoidance of electric voltages which are dangerous or otherwise detrimental;
d) dirtying of the device by particles of paint;
e) rapid change from one type of paint to another without the presence of disturbing residues of the first type of paint (rapid change of paint);
f) consideration of the flow of air in the spray booth in which the device is used;
g) small disturbances of the slight but continuous and laminar flow of air necessary in the spray booth lead to losses of paint on the path of the paint between the atomizer and the object to be coated and cause dirtying of the device;
h) as a roof machine, the device is intended to coat not only the roof but also the front and rear surfaces of the automobile bodies; for this purpose, the atomizers must be moved through spaces between successive automobile bodies and past the bodies and must be directed in different directions of spray;
i) since the automobile bodies are moved on a conveyor belt, the atomizers must be movable toward or transversely to the automobile bodies, depending on where the coating is required;
j) upon a change in or improvement of any of the above mentioned requirements, no other disadvantages may result.
In known devices for automatic spray coating of objects, many of their parts are arranged within the spray booth, which is made necessary by their construction. As a result, the parts are dirtied by paint and this disadvantageously affects the stream of air flowing in laminar form slowly downward in the spray booth.
SUMMARY OF THE INVENTION
The object of the invention is to reduce or avoid the above noted disadvantages and particularly to provide a device which is less disturbing to the air flow in the spray booth and which is dirtied less than the known devices. Another object is to develop the device so that one or more atomizers can be moved in any desired linear or curved paths of movement, in each case without any of the other above noted problems arising.
A device for automatically spray coating of objects which move along a path, along a theoretical Y axis. A first rotatable disk is supported to rotate around its first axis, the disk is in a plane that extends generally along the path of the objects and perpendicular to the path of the objects, but does not cross the path of the objects as to obstruct the movement of the objects, and the first disk is arranged outside the path of movement of the objects. The first disk is rotatable around an axis that extends across the path of the movement. A second disk is supported on the first disk and has a second rotary axis which is eccentric to the first rotary axis of the first disk and is generally parallel to the first axis. The spray device includes a carrier supported on the second disk on a third rotary axis eccentric to the second rotary axis, whereby rotation of the first disk with respect to the support, the second disk with respect to the first disk and the carrier with respect to the second disk orients the spray device. The spray device carrier may also be moveable along its own third axis to position the spray device. Alternately, there may be two sets of disks on opposite sides of the path and the carrier extends between the two second disks which rotate together.
The invention enables many parts of the roof machine to be placed outside the spray booth rather than within it. In particular, it is possible to arrange essential parts of the device in a plane and to develop them as part of the inner wall of the spray booth. This enables substantially maintaining the advantageous linear flow of air in the spray booth and greatly reduces the dirtying of the device. Even with the device of the invention in a plane of an inner wall of the booth, any desired curved and linear movements can be produced and transmitted to a spray device. Another important advantage is that the device of the invention can be easily integrated into existing spray booths. For this, it is merely necessary to remove parts of a wall of the spray booth and replace them by the device of the invention.
Other objects, features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically shows a side view of the device of the invention for the automatic, preferably electrostatic, spray coating of automobile bodies, and seen from the inside of the booth and along the plane I--I of FIG. 2;
FIG. 2 is a cross-sectional view of the device of FIG. 1, and seen along the plane II--II of FIG. 1;
FIG. 3 is a diagrammatic perspective view of the device according to FIGS. 1 and 2;
FIG. 4 is a direction diagram which explains various direction indications; and
FIG. 5 is a diagrammatic cross section similar to FIG. 2 but of another embodiment of a device according to the invention for the automatic, preferably electrostatic, spray-coating of automobile bodies.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device in accordance with the invention shown in FIGS. 1 to 3 replaces parts of one side wall of a spray booth or preferably both side walls on both opposite, longitudinal sides of the booth by a respective support frame 2 of the device. Within each frame 2, a disk 4 of large diameter is rotatably mounted. The interior surface 6 of the disk 4 preferably lies in the same plane as the inner surface 8 of the frame 2 and that plane is outside of, but generally parallel to, the path of the objects being coated and would not intersect the path of the objects. The disks 4 on the two opposite wall frames 2 are arranged opposite each other and the disks 4 are on a common axis. The disks 4 are each located near and to the sides of the path of movement of the automobile bodies 10 to be coated. The automobile bodies 10 are transported on a conveyor belt 12 in known manner through the booth and thus also between the two disks 4. The parts of the side walls of the booth which lie alongside the frame 2 are provided with the reference numbers 14 and 16 in FIG. 1. The bottom of the booth is formed in known manner by a grate 18. The roof of the booth is formed by a filter 20 which filters the air which, in known manner, flows slowly downward in laminar form through the booth.
The large disks 4 on opposite sides of the booth, referred to below as first disks, are driven to rotate by motors 22a and 22b, respectively. These motors are arranged on the outside of the booth and they are fastened on the frame 2. The two motors 22a and 22b drive the two first disks 4 synchronously, i.e. at the same speed of rotation to rotate around their respective first axes of rotation. The synchronous travel of the two first disks 4 can be assured by known electrical circuits or mechanically by a shaft 24 connecting the disks 4 to each other. However, an electric circuit is preferred, since the shaft 24 can interfere with the flow of air in the booth. The motors can be electric motors or some other known drive device. Each first disk 4 has a gear toothed rim 26 which engages a gear 28 which is seated on and driven to rotate by the shaft of each motor 22a and 22b.
In a receiving space in the first disk 4, eccentric to its first axis of rotation 30, there is integrated a smaller second disk 32. The inner surface 34 of the disk 32 lies on the inside of the booth and is preferably flush with the inner surface 6 of the first disk 4 which is, in turn, flush with the inner surface 8 of the frame 2 so that the first and second disks are in the same plane. The second axis of rotation 36 of the second disk 32 is displaced eccentrically from and extends parallel to the first axis of rotation 30 of the first disk 4. Motors 28a and 28b are fastened on the respective ones of the two first disks 4 on the respective booth outer sides. The gears 28 are fastened on their shafts and engage with a gear toothed rim 40 of the respective second disks 32. The two motors 28a and 28b must drive the two second disks 32, which are axially spaced from each other, at the same speed of rotation. This synchronous travel can be obtained, in a manner similar to the motors 22a and 22b of the first disks 4, by an electric synchronization circuit or mechanically in known manner. Here also, electric synchronization is preferred to mechanical synchronization, so that no components within the booth can disturb the flow of air through the booth.
In the two first disks 4, there is rotatably mounted at least one carrier 44 having a third axis of rotation 46 which is eccentric to and is a parallel axis to the axis of rotation 36 of the second disks 32. A motor 48 is fastened on the outside of one of the two second disks 32. A gear 50 is seated on the shaft of the motor and engages a gear rim 52 of the carrier 44 so that the motor 48 can turn the carrier 44 around its axis of rotation 46. The motors 22a, 22b, 28a and 28b as well as 48 are preferably electric motors. Hydrostatic motors could, however, also be used.
In a modified embodiment, a different known drive device could also be used. Instead of the transmission of the rotary movement by gears 28 and 50 and gear rims 26, 40 and 52, it is also possible to drive the first disks 4 and second disks 2 as well as the carrier 44 by other drive means, for instance, by chains or belts. The radial mounting of the first disks 4 can be effected by guide wheels, in the present case guide gear wheels 54, which are rotatably mounted on the frame 8. In a similar fashion, the second disks 32 can also be radially mounted. For the axial guidance of the first disk 4, guide elements 56 can be fastened on the frame 2. By means of similar guide elements 56 (not shown) on the first disks 4, the second disks 32 can also be axially guided in the first disks.
The carrier 44 carries a spray device which is in the form, for instance, of three atomizers 60. Furthermore, a linear reciprocation device 62 is integrated in the carrier 44. This enables the atomizers as desired, to be moved jointly or individually in the direction along the axis of rotation 46 of the carrier 44 and thus parallel to the respective axes of rotation 30 and 36 of the first disks 4 and the second disks 32. The linear reciprocation device 62 can, for instance, contain an electric motor 64, which in known manner drives a threaded nut by which a threaded spindle 66 of the linear reciprocation device 62 is moved axially. However, other drive means are also possible, for instance toothed belt drives or piston-cylinder drives. By rotary movements of the first disks 4 in the frame 2 combined with rotary movements of the second disks 32 in the first disks, the carrier 44 can be moved optionally linearly and along any desired curved paths of movement in the longitudinal direction of the booth and the vertical direction of the booth. In this way, the carrier 44 together with the spray device 60 can be brought to any desired place above, in front of, or behind an automobile body to be coated. Furthermore, by turning the carrier 44 around its axis of rotation 46, the spray device 60 can be set in any desired direction of spray relative to the automobile body 10 to be coated. In this way, it is also possible to move the spray device 60, with respect to a conveyed automobile body 10, either in the same direction as, or opposite the direction of movement of the body or in such a way that the spray device 60 does not carry out any relative movement with respect to the automobile body 10.
In this embodiment, the device constitutes a so called roof machine, since, with it, the upward facing surfaces of the automobile bodies can be coated. It is also possible with the device to coat the automobile body surfaces which face toward the front and toward the rear. Further, the device of the invention has more universal applicability, as it can be used in the spray coating and/or painting of almost any article which can be moved through a spray coating booth.
For robots, the different robot movements are defined in German VDI Guidelines 2861, Sheet 1, corresponding to FIG. 4 shown here. If this definition is applied to the movements of the device in accordance with the invention, then the different possibilities of movement can be designated as follows:
Y-axis: horizontal direction of movement (left or right) of the objects to be coated through the spray booth.
X-axis: horizontal direction of movement (up and down) at right angles to the Y-axis.
Z-axis: vertical direction of movement (forward and back) in each case at right angles to the Y and X axes.
In accordance with this standard, furthermore, rotations around the Y-axis are referred to as "B" rotations; rotations around the X-axis as "A" rotations; and rotations around the Z axis as "C" rotations.
If these designations are transferred to the device in accordance with the invention, then the automobile bodies 10 to be coated are moved along the Y-axis. The axes of rotation 30 and 36 of the first disks 4 and the second disks 32 extend along the X-axis and make an "A" rotation of each individual disk possible. The axis of rotation 46 of the carrier 44 also extends in the direction of the X-axis and permits "A" rotations.
By combination of the above-mentioned rotary movements and the linear movements of the spray device 60, the following possible movements of the device of the invention result:
Z-axis: simultaneous vertical movements, adapted to each other, of the first eccentric disks 4 and of the second disks 32 which are arranged eccentrically the first disks.
Y-axis: simultaneous forward and rearward movements, adapted to each other, of the first disks 4 and of the second disks 32 arranged eccentrically thereto.
X-axis: linear lateral movements of the spray device 60 caused by the linear reciprocation device 62.
A-rotation: rotation of the carrier 44 around its axis of rotation 46 by means of the motor 48.
Included herein also are the possibilities of having the spray device 60 follow the automobile body 10 as it is moved by the conveyor belt 12 or of having the spray devices travel in the direction opposite that of the automobile body 10 which is to be coated. All of the above noted movements can be combined and together provide an optimal possibility for coating automobile bodies and any other objects.
The device of the invention can replace conventional roof machines and robots which were previously used for the spray coating of roofs, engine hoods and trunk lids of automobile bodies and for coating other objects.
One essential advantage of the invention is, furthermore, that the fluid conduits required for the spray device or the atomizers 60 can be passed in simple manner through the carrier 44 without their providing a disturbance in the booth or becoming dirty.
The embodiment of the device of the invention shown in FIG. 5 is identical to the device shown in FIG. 2, with the exception that the carrier 44, which is designated 44/2 in FIG. 5, is supported only by a set comprised of one first disk 4 and one second disk 32, shown on the left. This permits the carrier 44/2 to be of shorter length. The second set of a first disk 4 and a second disk 32, which is shown on the right in FIG. 2, is omitted in the embodiment of FIG. 5. Instead of this, a closed wall part 70 of the booth is provided there. In FIG. 5, similar parts have the same reference numbers as are used for the embodiment of FIGS. 1, 2 and 3. Since their functions are the same, they are not described again here. Nevertheless, it is possible to attach as many devices as desired for stabilizing the carrier 44 outside the booth, parallel to FIG. 5.
Another possibility of the invention, which is not shown in the drawing, is to not arrange the device shown in FIG. 5 in a side wall of a booth but to instead arrange it in the roof of a booth and to therefore turn it 90° in the clockwise direction. In this case, however, no air can be drawn through the roof of the booth inside the booth in the region of the device.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A device for automatically spray coating objects which move along a path along a theoretical Y axis. A first rotatable disk is supported to rotate around its own first axis. The disk is in a plane that extends generally along a side of the path of the objects. The first disk is rotatable around an axis that extends across the path of the objects. A second disk is supported on the first disk and has a second rotary axis which is eccentric to and generally parallel to the first axis. A spray device includes a carrier supported on the second disk on a third rotary axis eccentric to the second rotary axis. Rotation of the first disk with respect to the support, or the second disk with respect to the first disk or the carrier with respect to the second disk orients the spray device. The spray device carrier may also be moveable along its own third axis to position the spray device. Alternatively, there may be two sets of disks on opposite sides of the path and the carrier extends between the two second disks which rotate together.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention pertains to a device and system for applying thermally-printed indicia to a sheeting in a direction normal to the direction of movement of the sheeting past a print head. The present invention relates generally to a printing device usefully employed as a time recorder, printing the time, date, location and other information onto a time card or document.
[0003] 2. Description of the Prior Art
[0004] Time stamps are commonly used for printing time, date and other information on a time card or other media.
[0005] However, traditional time clocks employ dot matrix printers and have many bulky components, such as a cam, motor, drive train, printer and printer ribbon, which can obscure the view of the operator and making it difficult to line up the time card at the appropriate position. Typically, these devices employ only a small window through which the operator must view the time card from an obscure angle.
[0006] It is therefore desirable to provide a printing device in which some of the bulky components, e.g., the motor and drive train are removed from the front of the top portion of the device so that the size of the top portion can he reduced thereby improving the ability of the operator to view the alignment of the time card or other media in relation to the printer. It is also desirable to reposition or remove other elements, e.g., a cam shaft, to allow for improved viewing of the time card alignment. This invention utilizes a thermally-activated printer to achieve these objectives.
[0007] Present designs for the mechanical time and date stamps also require a manual operation to synchronize the display of the time and date to what is printed and it is desirable to have the display of the time and date be synchronized to what is being printed or stamped.
[0008] It is also desirable to maintain the time and date during the loss of power. For mechanical time and date stamps, the time and/or date need to be manually altered to reflect the current time and/or date that is to be printed or stamped.
SUMMARY OF THE INVENTION
[0009] In order to overcome the noted problems associated with conventional time clocks, the present invention uses a thermal printing apparatus having a print head arrangement that comprises a driven roller and a thermal print head. A thermal print receptive sheeting is disposed therebetween. The thermal print head may comprise heatable resistive elements in a thermal heating system. External standard paper sheeting, time card sheeting, or envelopes are used as the printable media. The ribbon of thermally sensitive material is held upon and tensioned by a reel and is collected on a driven reel. The sheeting is transported beneath the ribbon by a sheeting transport means known in prior art, for example, a friction drive mechanism using a stepper motor. The print head remains stationary and makes contact with thermal transfer ribbon and transfers the image from the print head to the sheeting as the sheeting moves past the print head. When transfer of the image is completed, in this instance a time and date, the print head and ribbon assembly may be retractably disengaged from the document feeder.
[0010] By use of a time recording mechanism that incorporates a thermal printing device to print time and date information on a record paper to record the time and date, the record paper or document, the following objectives are achieved in a time stamp:
1. The time clock is less bulky than possible heretofore and the time and date printed on the paper record is readily viewable to the operator; 2. The time and date information can be permanently maintained within the thermal time stamp printer. 3. Time and date information for the Time Stamp, can be set via a control panel independently of an external computing device or if desired, the time and date information for the Time Stamp, can be set via an external computing device. 4. Through an external computing device, the time stamp time and date can be merged with an image that is downloaded to the thermal time stamp printer that can be transferred to a record paper or document. 5. The thermal time stamp device does not have to be connected to an external computing device to operate. 6. The thermal time stamp device stated is capable of transferring a graphic image or insignia to simulate an official seal. 7. The thermal time stamp device is capable of transferring a graphic image to simulate a written signature. 8. Via a computing device, the time and date stamped on said record can be recorded; and 9. A graphic image that is to be transferred to a paper record or document can be permanently set in a secure memory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Further objects and advantages of the invention will become more apparent from the following description and claims, and from the accompanying drawings, wherein:
[0021] FIG. 1 is a perspective view of the thermal printing device of the present invention; and
[0022] FIG. 2 is a schematic block diagram illustrating the controls for the printer device of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring now to the drawings in detail, wherein like numerals indicate like elements throughout the several views, the thermal printer 10 of the present invention includes a paper guide 12 for presenting a printable area of paper sheeting or other recordable media (not shown) insertable by the operator-user beneath a thermal transfer ribbon 14 and thermal print head 16 . The print head 16 will transfer a graphic from the ribbon 14 to the paper and in the embodiment of the invention illustrated in FIG. 1 a time and date illustrated on a suitable LCD digital display 18 . The paper or printable area is limited in movement by an adjustable stop 20 disposed in the path of movement of the paper. A platen roller 22 driven by a stepping motor or the like 24 advances the paper until it is positioned beneath the ribbon 14 and thermal print head 16 and is in contact with the paper through a slot 25 in paper guide 12 . The ribbon 14 is positioned beneath the print head 16 above the paper guide 12 between a ribbon feed roll 26 controlled by the ribbon feed roll motor 31 and a ribbon take-up roll 28 rotated by a take-up motor 30 . The moveable paper guide stop 32 determines the position from the side edge of the paper that the time and date stamp or print will be located. The printed material is sensed by the document sensor or stop 20 upon which the printing process will begin. The document sensor or stop 20 is also positioned so that at a predetermined distance from the leading edge of the document, the printing will begin. Upon activation of the thermal print head 16 after location of the paper beneath the ribbon and print head, the time and date on display 18 is recorded and stamped on the paper.
[0024] The operation of the thermal time stamp device 10 is synchronized and controlled as illustrated in FIG. 2 .
[0025] With reference to FIG. 2 , there is shown the control electronics 40 necessary to operate the Thermal Time Stamp Printer 10 . The controller 42 is the central processing unit that controls the operation of the Thermal Transfer Time Stamp. The controller 42 is preferably a microprocessor with sufficient computing capacity to perform all operations of the Thermal Transfer Time Stamp.
[0026] Connected to the controller 42 is the LCD display 18 , a communications interface 44 , keypad 46 , platen sensor 48 , motor control electronics 50 , ribbon motor sensor 52 , paper sensor 54 , and the thermal print head 16 .
[0027] In operation, the controller 42 receives data through the communications interface 44 which can be Ethernet, USB, Serial, or other means necessary to transfer data to the memory contained within the controller 42 to cause the thermal printing process to occur. Once the data has been transferred, the thermal time stamp can be removed from the external communications device or computing device to operate independently. The keypad 46 connected to the controller 42 allows the user to enter information as to the quantity, initial printer setup, or other input required by the operator to facilitate printing. The LCD display 18 is to display the current status, e.g., time and date, of the thermal time stamp printer 10 or may be used to display requests of the user-operator for further information regarding the operation.
[0028] The paper sensor 54 detects the presence of the material to which a time stamp date, time or other graphic material is to be printed on. This sensor can be an optical sensor which operates by interrupting an infrared light beam or this sensor can be a mechanical switch or stop 20 which will detect the material in the printing path to be printed upon.
[0029] The motor control electronics 50 controls the platen motor 24 and ribbon motor 30 to cause the thermal ribbon material and paper sheeting to be printed upon to move thru the printer feed path. The ribbon motor 30 has a sensor 52 to control the operation of the ribbon motor 30 . The platen motor 24 has a sensor 54 to control the operation of the platen motor. These sensors 52 and 54 sense the current drawn by their respective motor to ensure that proper tension is applied to the ribbon and to cause the material to be printed upon to be advanced in synchronization with the ribbon through the printing path.
[0030] The primary function of the controller 42 is to receive data from an external source, such as a personal computer, and to operate upon this data to form an image that is to be applied to the print material. This data that is operated upon is then digitized and serialized and sent to the thermal print head 16 , which has a series of heat sensitive resistor elements to form and transfer the image through the ribbon 14 to the material being printed upon, as is well known in the art.
[0031] Using a personal computer, graphics-based indicia may be printed, as opposed to the less versatile single-character-based indicia. In reference to the present invention, graphics-based indicia are images that are produced by electronically formatting the image so that more than one character can he produced per electronic transmission.
[0032] With print head data processing mechanisms within thermal print head 16 , the operator input is assembled by software into code suitable for controlling actuation, disengagement and transfer by the print head.
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A thermal time date stamp including a printing apparatus, system and method for recording the date and time on a flat paper sheet includes a paper guide for transporting the paper beneath a thermal print head and thermal transfer ribbon, a display for confirming the time and date that is synchronized to the print, and a microprocessor for inputting a graphic image of the time and date displayed to the print head.
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TECHNICAL FIELD
[0001] The present invention relates to methods and apparatus for forming apertures in foamed polystyrene, and other foamed plastic panels.
BACKGROUND OF THE INVENTION
[0002] Concrete walls and other concrete structures, are typically made by building a form. Unhardened concrete is poured into the form space provided by the form. Once the concrete hardens, the form walls can be removed. In some cases the form walls can remain in place after the structure has been made, and can for example serve an additional purpose such as providing insulation.
[0003] It is known to make the form walls from a series of interconnected panels. It is also known to use foamed plastic materials, including foamed polystyrene, for such panels.
[0004] Typically, the panels are held in place to provide the form when the concrete is poured in the form space, by providing tie-rods that stretch between two spaced panels. Typically the rods pass from an inner surface of the panels and join with some kind of end connector.
[0005] With reference to United States patent application publication no. 2002/0092253 published Jul. 18, 2002, a method is described whereby an anchor member is embedded in a foam panel. During the formation of the foam panel, the panel is injection formed so as to surround the anchor member. This may create a relatively strong connection between the panel and the anchor member. Despite the obvious advantages of such a connection, manufacturing of such plastic panels requires special molding equipment, which allows panels to be formed with installed anchor members. Such equipment and associated methods are expensive and don't allow the use of a common foam panel produced by industry for wall and roof thermal insulation. In some foamed panel applications for formwork, it is not desirable that the anchor member be fixed relative into the panel during the forming process. In particular, in some applications, it is desirable that the anchor member or connector be free to rotate relative to the panel so it can be secured firmly to an end of a tie-rod.
[0006] The building of forms using such foam plastic panels is assisted by the availability of numerous apertures in order to receive corresponding tie-rods and/or connectors.
[0007] It should be noted that known methods of forming apertures, such as milling, are not effective for forming apertures in foam plastic due to its low strength. Additionally, apertures formed with mechanical impacting on foam plastic, is very complicated to control because of the coarse structure of foam plastic.
[0008] U.S. PTO application Ser. No. 10/253,843 filed on Sep. 24, 2002 by the same applicant, the contents of which, are hereby incorporated by reference, discloses a method and a design for apparatus for forming apertures in foamed plastic panels. The method and apparatus include a carriage mounted on tracks to travel on the frame. The carriage is adapted to hold the panels and there is a mechanism mounted above the panel to move the aperture forming instruments towards the panel. The aperture forming instruments consist of a longitudinal tubular probe heated by an electrical resistance coil with no contact with the panel and cause apertures to be formed there through. The coil is heated by electrical current, using transformers.
[0009] However, this apparatus has a relatively low production output if a large number of apertures are required for the panel that will be used in the form. The design of the instrument results in a relatively unheated (“cold”) end. To heat the end portion of the instrument to generate a suitably hot thermal field under the instrument's end, the amount of beating of the main body of the instrument must be significantly increased. However, in heating the end for non-contact entering into a panel made of a foamed plastic material, the heat in the body is so high that it is difficult to form commensurable apertures with a diameter just a small amount larger than the diameter of the instrument. Additionally, this instrument doesn't allow forming the aperture with a complicated shape. Also, because the instrument is moving toward and through the panel, it becomes colder under the airflow movement and this causes a disruption to the thermal field around the heating instrument. This results in a decrease in temperature of the thermal field, which leads to a need to increase the consumed electrical power volume, to provide a given temperature and thermal field. In addition, use of the transformers as the electricity source for coils increases the cost of such a machine.
[0010] Accordingly, it is desirable to provide an improved method and apparatus for efficiently providing a plurality of apertures in foam plastic panels, particularly of the type that are used for construction.
SUMMARY OF INVENTION
[0011] According to one aspect of the present invention, there is provided an apparatus for forming a plurality of apertures in a panel made from a meltable foamed plastic material. The panel has first and second opposed surfaces defining a panel body there between. The apparatus comprises: (a) a movable panel supporting device for supporting the panel; (b) a heating array comprised of a plurality of heating elements mounted to a support frame. The heating array is disposed opposite to the panel supporting device and each of the heating elements is adapted to emit sufficient heat to melt the plastic material when a panel is positioned proximate the heating elements. A driving mechanism is provided for moving the panel supporting device toward and away from the plurality of heating elements. The driving apparatus is used to move the panel supporting device and a panel supported thereon, towards and away from the plurality of heating elements. The plurality of heating elements are positioned opposite and proximate the first surface of the panel held by the supporting device. This allows for the panel to be moved by the supporting device to a position proximate the plurality of heating elements enabling the heating elements to melt a plurality of apertures in the panel at the first surface of the panel.
[0012] According to another aspect of the present invention, there is provided a method of forming a plurality of apertures in a panel made from a meltable foamed plastic material. The panel has first and second opposed surfaces defining a panel body there between. The method comprises the step of moving the panel toward a plurality of heat elements in a first direction so that the first surface of the panel is heated by the plurality of heating elements to melt the plastic material at a plurality of locations.
[0013] According to another aspect of the present invention, there is provided a heating apparatus that comprises an outer tube having a hollow interior cavity and a first end and a second end. The first end has a hot tip. The apparatus also has a high resistance element extending in the cavity from proximate the first end to proximate the second end. The high resistance element is connected to a source for electricity to pass an electric current through the high resistance element to thereby generate heat capable of melting a plastic material when the plastic material is proximate the heating element. Also there is a heating disc mounted to the outer tube at a distance from the first end. The heating disc is adapted to generate heat capable of melting
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In drawings that illustrate by way of example only, preferred embodiments of the present invention:
[0015] [0015]FIG. 1 is a plan view of a machine in accordance with an embodiment of the invention;
[0016] [0016]FIG. 2 is a side elevation view of the machine of FIG. 1;
[0017] [0017]FIG. 3 is a front elevation view of the machine of FIG. 1;
[0018] [0018]FIG. 4 is a cross sectional view at 4 - 4 in FIG. 1;
[0019] [0019]FIG. 5 is a cross sectional view at 5 - 5 in FIG. 1;
[0020] [0020]FIG. 6 is a cross sectional view through a pre-form for an example of a heating element used to form part of a heating cartridge used in the machine of FIG. 1;
[0021] [0021]FIG. 7 is a schematic view showing the bending operation carried out on the pre-form of FIG. 6; and
[0022] [0022]FIG. 8 is a schematic view showing the shape of the heating element after the bending operation of FIG. 7 has been carried out on the pre-form of FIG. 6;
[0023] [0023]FIG. 9 is a front elevation view, partially cut away, of a heating cartridge employing the heating element of FIG. 8, and illustrating a preferred thermal heating field produced thereby;
[0024] [0024]FIG. 9 a is a front view of an alternate embodiment to the heating cartridge of FIG. 9, and illustrating a preferred thermal heating field produced thereby
[0025] [0025]FIG. 10 a is a cross sectional view of a secondary disk heating element used in the heating cartridge of FIG. 9 a;
[0026] [0026]FIG. 10 b is a plan view of disk heating element of FIG. 10 a with removed top part;
[0027] [0027]FIG. 11 a is one example of a shaped aperture formed in a polystyrene panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 or 9 a;
[0028] [0028]FIG. 11 b is another example of a shaped aperture formed in a polystyrene panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 or 9 a;
[0029] [0029]FIG. 11 c is a third example of a shaped hole formed in a polystyrene panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 a;
[0030] [0030]FIG. 12 a shows the initial step of one aperture forming in a foamed plastic panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 or 9 a;
[0031] [0031]FIG. 12 b shows the intermediate step of one aperture forming in a foamed plastic panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 or 9 a;
[0032] [0032]FIG. 12 c shows the final step of one aperture forming in a foamed plastic panel by the machine of FIG. 1 with a mounted heating cartridge in FIG. 9 a;
[0033] [0033]FIG. 13 is a perspective view of the frame and heating elements of the machine of FIG. 1;
[0034] [0034]FIG. 14 is a perspective view of the lifting table which is another part of the machine of FIG. 1;
[0035] [0035]FIG. 15 is an isolated view of several heating elements mounted to a supporting beam in the machine of FIG. 1;
[0036] [0036]FIG. 16 is a perspective view showing a panel stripper forming another part of the machine of FIG. 1;
[0037] [0037]FIG. 17 is a schematic layout showing the control console for the machine of FIG. 1; and
[0038] [0038]FIG. 18 is a schematic functional layout of several of the components of the machine of FIG. 1.
DETAILED DESCRIPTION
[0039] With reference first to FIGS. 1, 2, 3 , 4 and 5 a machine 30 for providing a plurality of apertures in a foamed plastic panel 31 is illustrated. Machine 30 can be adapted for use with a variety of foamed plastic panels, including expanded polystyrene panels (eg. grade EPS ASTM C 578-00 Type 1 ×) and extruded polystyrene panels (eg. grade XPS ATM C 578-00 Type VI). Panels 31 are typically in the range of approximately 2-20 cm in thickness, but can be larger and smaller in thickness.
[0040] Machine 30 includes a frame generally designed 39 , a lift table 41 movable relative to the frame, and a heating array generally designated 63 positioned above the lift table and immovably fixed to the frame 39 . Machine 30 also has a ventilation system generally designated 51 , a control system 61 and a transport conveyor system 37 .
[0041] As best shown in FIGS. 14 and 16, lift table 41 is generally formed from longitudinal beam members 46 interconnected with a series of transverse members 48 . Mounted at the four outer corners of lift table are bushing and block members 49 . A bushing 49 a in block 49 is configured to receive a guide rail 43 . Bushing 49 a and block 49 can thus slide up and down along guide rail 43 . An upper end of each guide rail 43 is affixed to a mounting block 42 a , which is mounted to frame 39 . Likewise, a lower end of each guide rail 43 is affixed to a mounting block 42 b , which is mounted to a lower part of frame 39 . Thus, lift table 41 is mounted for vertical movement relative to frame 39 , such movement restricted on guide rail 43 within the limits imposed by the abutment of block 49 with blocks 42 a and 42 b . Various different configurations for lift table 41 are of course possible. By way of example only, lift table 41 in said machine 30 can be configured as a scissors lift table.
[0042] Also, as shown in FIG. 16, a panel stripper apparatus includes a plurality of transversely and horizontally mounted stripper bars 77 secured to vertical bars 78 . The vertical bars 78 have guides, which slide along vertical tracks or slots (not shown) in vertical bars 79 . Bars 79 are fixedly mounted to the frame 39 and have vertical movement stoppers 80 that restrict the vertical movement of bars 78 in the guides and thus the vertical movement of bars 77 . The stripper bars 77 and 78 are configured so that they can move vertically upward accompanying, and lifted by, the upward motion of lift table 41 . This lifting movement will preferably commence after the panel has already been lifted free of transport conveyor 37 , but before the panel comes into the vicinity any significant degree of heat generated by the thermal field from the heating array 63 . The upward movement of bars 77 however can continue as the heating elements penetrate the body of the panel. Once the apertures have been formed, the lift table 41 will move downward. During this movement of lift table 41 , bars 77 will likewise move down from their own weight, and apply a downward force on an upper surface of panel 31 , preferably until panel 31 has cleared the heating elements and most preferably exited the thermal field. This results in preventing the panels from staying in a position between the heating cartridges. Other devices or apparatus can be employed in machine 30 to provide a stripping mechanism for the panel. For example, a loose chain (possibly weighted) connected to frame 39 at two ends, can be employed that rests upon the top of the panel when lifted to heating array. When the lift table is lowered, it can apply a downward force onto panel 31 .
[0043] Returning to the construction and operation of lift table 41 , as shown in FIG. 4, lift table 41 also has a plurality of upstanding pusher members 73 which, as will be explained in detail hereinafter, are used to lift a panel 31 towards the heating array 63 in order to create the apertures in the panel. A plurality of pusher members 73 are mounted to each of transverse members 48 of table 41 (not shown in FIG. 14). As is illustrated in FIG. 5, transverse members 48 of lift table 41 are positioned vertically below the belts 85 of conveyor 37 , and pusher members 73 extend between the belts. Thus, if a panel 31 is positioned on belts 85 , upward movement of pushers 73 will cause the panel to be raised upwards from belts 85 , toward heating array 63 .
[0044] Table 41 is vertically raised and lowered relative to heating array 63 and frame 39 by a table drive system generally designated 65 . Table drive 65 can, for example, comprise a DC elective drive motor interconnected to a typical gear mechanism, which translates the rotary movement of the drive motor into vertical upward and downward motion of the table. Other suitable linear drive mechanisms, which can be suitably controlled and drive lift table 41 up and down, can be used.
[0045] With reference to FIG. 13, frame 39 generally includes a series of pairs of longitudinal beams, 29 a , 29 b and 29 c each pair being interconnected at its ends to an end of a transverse member, namely transverse members 53 a , 53 b , and 53 c respectively. Each combination of longitudinal beams and transverse members 29 a , 53 a ; 29 b , 53 b ; and 29 c , 53 c is attached to four columns 27 . Thus a frame 39 is formed and serves to support the lift table 41 for vertical movement in relation thereto. Frame 39 also supports heating array 63 having a plurality of heating cartridges 122 , from top beams 29 a.
[0046] With reference to FIGS. 13 and 15, heating array 63 comprises a plurality of transversely mounted heat array support beams 83 , secured at each end to a longitudinal beam 29 a . Secured to, and depending down from, each heat array support beam 83 are a plurality of heating cartridges 122 , which are described in detail hereinafter.
[0047] In this preferred embodiment, the heating array 63 is fixed in space. It will however be appreciated that in some embodiments, the heating array 63 might be capable of a small amount of movement, without substantially disrupting the thermal field around the heating cartridges 122 . Nevertheless, most of the movement between heating array 63 and the panel support apparatus that takes place relative to the surrounding environment, is movement by the panel support apparatus.
[0048] With reference to FIGS. 1 and 2, transport conveyor 37 is configured to be able to transport panels 31 from a loading station A, to an aperture forming station B, to an unloading station. Conveyor 37 comprises a pair of spaced apart continuous conveyor belts 85 driven around spaced drive wheels 87 a , 87 b which can be powered by conventional drive mechanisms. A plurality of freely rotating rollers 89 , affixed to frame 39 , are provided to support the belts 85 as they move from station A, to station B and finally to station C. Conveyor belts 85 are configured so as to be able to support thereon one or more panels 31 through stations A, B and C. Mounted at a leading position and trailing position on each belt 85 , are movable guide members or flights 81 , which guide the transverse edges of panels 31 . It will be appreciated that several sets of guides will be provided on belts 85 . Mounted longitudinally on frame 39 are also fixed guides 83 which serve to guide the longitudinal edges of panels 31 . Thus, each panel 31 is guided in its movement by a leading guides 81 and a trailing pair of guides 81 , such that each panel 31 will move with belts 85 and generally maintain its orientation. The guides 81 joined to the transport conveyer belt are used to fix the position said panels 31 in the loading position, lifting and lowering positions and the unloading position. Usually guides 81 are simply L-shaped metal profiles.
[0049] Ventilation system 51 includes a hood 35 with a centrally positioned opening 38 in communication with an exhaust duct 33 . A fan (not shown) is driven by a fan motor 36 . The exhaust fan is disposed at the opening 38 of hood 35 and is configured to be able to draw up into the exhaust duct 33 , air, noxious gases and other fine particle materials which it is desired to remove from the vicinity of the machine 30 , and which results from the operation of the machine, as described hereafter.
[0050] Heating array 63 includes a plurality of heating cartridges 122 , and in a preferred embodiment, there are a total of 72 cartridges arranged in longitudinally and transversely spaced orientation to provide a rectangular grid. The effect of employing machine 30 to a panel 31 , is to create a grid of apertures in a pattern shown at station C in FIG. 1. Of course, the specific arrangement of the heating cartridges in the heating array 63 can be modified to provide for any particular grid pattern that is required.
[0051] With reference to FIG. 6, a pre-form 101 component for one of several of the preferred heating elements 100 (See FIG. 9 a ) employed in an example of a heating cartridge 122 used in heating array 63 is illustrated. Pre-form 101 includes a spiral wire 117 made from a material with a long-life durability and thermal stability having high electrical resistance such as Nichrome (nickel chromium alloy). Wire 117 has attached to each end a connector wire 115 a , 115 b which is a wire having much less resistance to permit electric current to be delivered to wire 117 . Wires 115 a , 115 b would typically be made of a material like copper with typical electrical resistivity in the order of 1.7 μOhms×cm. By comparison, wires 117 would typically have an electrical resistivity of in the range of 100-110 μOhms×cm.
[0052] The inner wall of tube 121 is also insulated with powdered ceramic material or other suitable insulator to ensure there is no short circuit between wire 117 and the inner wall of tube 121 . Wire 117 is thus held in inner cavity 119 of hollow steel tube 121 in an insulated state. Except for permitting the passage of wires 115 a and 115 b to extend from the ends of the tube 121 , the inner cavity is sealed at both ends 121 a and 121 b with a stopper 133 made with an insulating material such as a suitable ceramic material 123 . Wires 115 a , 115 b pass through apertures in stoppers 123 and are interconnected to a suitable source of electricity of a suitable voltage to provide the desired current and consequent heating. It is not necessary that the cavity 119 be air tight due to the fact that the tube is made from heat-resistant material.
[0053] To provide the apertures that are formed substantially commensurate with the diameter of the heating cartridge, a uniform temperature field is required around the heating cartridge tip.
[0054] To make the heating element 100 with a hot tip used in the heating array 63 from pre-form 101 , the pre-form 101 is folded about an axis x as shown in FIGS. 7 and 8. It will be appreciated that tube 121 will have a configuration that is suitable for such bending. It will be appreciated that heating element 100 , thus formed, is of a general U-shaped configuration and has, particularly at the bottom end portion of the U-shape, a generally intensified heat emission when electric current is passed through wire 117 . This results in a “hot-tip” heating element.
[0055] The cross section of tube 121 can take a variety of cross sectional shapes including half circles, triangles, rectangles, depending upon the desired configuration of the apertures to be formed in the panel 31 . The cross sectional shape of the initial tube 121 , will of course determine the cross sectional shape of the bent tube and thus heating element 100 .
[0056] With reference to FIG. 9, heating element 100 is shown housed in a holder 120 and thus forms a heating cartridge 122 . Holder 120 comprises a hollow tube, in which is held heating element 100 . Holder 120 is preferably made from stainless steel although other suitable materials can be used which include but are not limited to aluminum alloys.
[0057] Heating element 100 can be attached to holder 120 by, for example, spot welding. The upper end 120 a of holder 120 is open to permit wires 115 a , 115 b to extend therefrom for connection to an electric circuit.
[0058] A flange member 124 is affixed (for example by spot welding) to holder 120 proximate upper end 121 a of tube 121 and flange 124 assists in mounting the heating cartridge 122 to a beam member 83 as shown in FIG. 15. An aperture or bore in beam 83 permits cartridge 122 to be received there through and is suspended from the beam by the abutment of flange 124 with the upper surface of beam 83 . Cartridge can be attached to beam 83 securely or preferably with a relatively easy mechanism for detaching the cartridge from its supporting beam. This allows easy-to-do repairs to be performed on the heating array. It will be appreciated that it is quite beneficial if the heating cartridges can be replaced easily if for example, a cartridge burns out.
[0059] In a preferred embodiment, cartridge 122 comprises generally a WATT-FLEX (trade mark) split-sheath cartridge heater made and sold by Dalton Heating Co., Inc. of Ipswich Mass., employing a heated tip. This cartridge design can supply an appropriate thermal field for each cartridge 122 of heating array 63 .
[0060] It is preferred in cartridge 122 that a thermal field be provided that produces a thermal field which generally stretches ahead of the heating element 100 , so that heating of a panel in a relatively narrow area can be achieved without the heating element having to contact the panel surface.
[0061] With reference to FIGS. 9 a and 10 a , an alternate configuration for a heating cartridge is shown. Heating cartridge 222 employs a heating element 200 configured like heating element 100 . Cartridge 222 also has a tube 221 configured generally like tube 121 , with a flange 224 and wires 215 a , 215 b extending out from an upper end 221 a thereof. In addition to heating element 200 , cartridge 222 includes a secondary heating disc 290 . As best shown in FIG. 10 a , heating disc 290 essentially has three separate components: an upper cover member 292 , a lower holder member 294 and wire member 295 . Disc 290 also has a central bore 293 to permit the disc to be received onto tube 222 , which is preferably affixed thereto by for example spot welding.
[0062] Cover 292 is made from a relatively a material with relatively high degree of thermal insulation (ie. low thermal conductivity), such as for example aluminum oxide ceramic. Other possible materials for cover 292 include but are not limited to sintered and compact barium oxide ceramic, nickel alloy. On the other hand holder 294 , which is secured to cover 292 , is made from a material with relatively high thermal conductivity such as a metal like copper or aluminum. Holder 294 is preferably affixed to cover 292 by common fasteners (screw or bolt and nut). It is thus preferred that holder 294 can be detached from cover 292 to make repairs and the like.
[0063] Formed in an upper surface of holder 294 , is a continuous spiral groove 291 extending from a position near the outside perimeter of the disc, inward toward the center aperture 293 . Inset in groove 291 is a continuous spiral wire cartridge 295 made from a material, such as nickel-chrome alloys having a relatively high electric resistance When electric current is run from an electric power source through cartridge 295 from contacts 296 a to 296 b (or in the reverse direction) heat is generated in the cartridge 295 , which in turn heats holder 294 . However, as cover 292 is made from a material with a relatively high degree of thermal insulation, the cover itself will not become unduly heated.
[0064] An example of a suitable heater that can be incorporated as a heating disc 290 is a DIFF-THERM (trade mark) Platen Heater also made and sold by Dalton Electric Heating Co., Inc.
[0065] It is important that the heating elements and disc be able to heat the panel up to, or above its melting temperature (which for expanded polystyrene is about 250 degrees C.) but that the temperature not reach or exceed the flash point of that material. In other words, it is important that the material not be heated to such a degree that it ignites.
[0066] Preferably the supply of electrical current to each of the cartridges 122 and to discs 190 , is not by way of simply one or more transformers. Rather it is preferred that electronic devices (eg. teristor—triac with special IC) be associated with each cartridge. Each teristor (triac with special IC) can be provided with a specific duty cycle (eg. current on for 3 secs, current turned off for 2 sees, repeated). Alternatively, the teristor (triac with special IC) can be provided with a feedback look that is interconnected with temperature control device(s) [also provided]. In this way, the actual temperature of the heating elements can be monitored in real time and the teristor (triac with special IC) turned on and off as required. In this way, the supply of electric current to a particular cartridge can be turned off and on, to ensure that the temperature or thermal field emitted by the cartridge, stays within a desired range. This should have the effect of reducing the overall amount of electrical energy consumed by the machine 30 .
[0067] One safety feature that can also be provided, is a mechanism for detecting if a particular cartridge has failed. This can be conveyed to an operator by way of a light emitting diode which is activated if there is a failure in the circuit. For example could be set up so that the diode will alternately be illuminated and then turn off during normal operation as the heat of the heating cartridge is maintained within a desired range, but will stay un-illuminated if the cartridge has failed.
[0068] With reference to FIG. 17, an example layout for control console 61 (shown in FIGS. 1 and 2) is illustrated in detail.
[0069] With reference to FIG. 18, an example schematic layout is shown of the operational features of machine 30 .
[0070] In general the control system, which can operate in either a manual or automatic mode, performs a number of functions. The control system, including the PLC:
[0071] 1. Provides for automatic temperature control for the heating cartridges and heating disc (if applicable), by controlling the supply of electricity to the heating elements therein.
[0072] 2. Can control the movement of the panels on the conveyor 37 through stations, A, B and C.
[0073] 3. Can operate the movement of the lift table up and down thus controlling the position of the panel in relation to the heating elements, including providing for intermittent motion during the aperture forming process caused by the heating elements.
[0074] 4. Provides for machine shut-down or disablement in certain situations, particularly to ensure the safe operation of the machine 30 .
[0075] The control system can also be used to automatically operate the transport conveyor 37 , to deliver panels from station A, to B and to C.
[0076] With reference to FIGS. 1 a , 11 b and 11 c , three different shaped apertures H 1 , H 2 and H 3 respectively, are shown in a panel 31 , as formed by machine 30 .
[0077] With respect to FIG. 11 a , aperture H 1 is a straight forward cylindrical aperture extending from the upper surface 31 a through the body of the panel to lower surface 31 b and has cylindrical walls 71 .
[0078] With respect to aperture H 2 shown in FIG. 11 b , this aperture has a cylindrical portion 171 like aperture H 1 in FIG. 11 a . However, extending downward for a short distance from upper surface 31 a is a frustum of cone or sphere portion 173 . Frustum of cone portion 173 provides an inset portion in the surface 131 a of the panel that can be utilized for example to inset the leg of a connector element used to connect to a tie rod (not shown). Finally, with respect to FIG. 1I c, aperture H 3 in panel 231 comprises an aperture which is similar to aperture H 2 in FIG. 11 b but includes an additional cylindrical disc portion 275 positioned above frustum of cone portion 273 and cylindrical portion 271 . Disk portion 275 has a much larger radius than cylinder portion 271 and cone portion 273 and can be utilized to provide an inset for a large mushroom-shaped connector nut or the like.
[0079] Now with reference to FIG. 12 a , the formation of an aperture H 1 in FIG. 11 a is illustrated. When the lift table 41 is raised, the panel is brought gradually into the thermal field emitted from the element 100 . As the temperature reaches the melting point of the polystyrene at the surface, the emitted heat start to melt the polystyrene sheet and start to form the aperture H 1 . If the element 100 is held at a fixed distance from panel 131 for an extended period of time, this will tend to cause the formation of the frustum of insert portion 173 . Assuming that the thermal field around the bottom of the heating element is generally comprised of isotherms (akin to iso-lines—being positions in space having the same temperature) each formed to outline a semi-spherical shape, the opening 173 will tend to initially be formed in partial spherical shape as well. In a preferred embodiment, the tip of the heating element will be held approximately 0.5-2 cm from the upper surface of panel 31 for a time period in the range of 3-10 secs. Thereafter, as illustrated in FIG. 12 b , as the panel is brought upwards the heating element 100 , the element will pass into the body of the panel melting the polystyrene as it moves into the body and forming the cylindrical portion 171 of aperture H 2 . The formation of the cylindrical portion is assisted by the shape of the thermal field. Around the exposed body portion of heating element 100 the thermal field has cylindrical shaped or cylinder defining isotherm. Preferably, the rate of movement of panel 31 relative to the heating element 100 during the cylinder portion ( 171 in FIG. 11 b ) forming stage is in the range of 3-60 mm/sec.
[0080] It should be noted, that because the panel is moved relative to the environment, and the heating array 63 remains fixed relative to the environment, the disruption of the thermal field around each heating cartridge is minimized. This enable the desired shaped aperture in the panel to more easily form.
[0081] It will be appreciated that the particular shape and size of the aperture formed in the polystyrene sheet will be determined by features such as the amount of heat emitted from the heating element 100 , the particular shape of the cross section of heating element 100 as well as the duration of the application of heat at any particular position in the vicinity of the polystyrene panel.
[0082] With reference to FIG. 12 c , the use of secondary heating disk 290 on a cartridge 122 is illustrated to form a disk portion 275 in upper surface 231 a of panel 231 .
[0083] Generally, the operation of the machine is as follows. With reference again to FIGS. 1, 2 and 5 in particular, first a polystyrene sheet 31 is positioned on transport conveyor 37 between guides 81 and guides 83 . This could be done manually or by a robot or other automated placement device. Conveyor 37 could be synchronized so that the loading at Station A of a panel 31 takes place at the same time as the other operations at Stations B and C as described hereinafter occur. In other words, loading, aperture forming and unloading can all take place while conveyor 37 is stationary, on three different panels 31 .
[0084] Once panel 31 has been loaded at Station A, the conveyor is advanced to move panel 31 to Station B where it is positioned immediately above lift table 41 and the pusher elements 73 thereof. Then, either manually or by automation controlled by the PLC, the lift table will operate such that pushers 73 extend between conveyor belts to lift panel 31 upwards towards the heating array 63 . In one embodiment, the lift table 41 will, as described above, stop for a period of time to permit a conical portion such as portion 173 in FIG. 11 b and 12 a to be formed. Thereafter, once the appropriate amount of melting of the polystyrene has occurred, the lift table is raised either manually or automatically such that movement upwardly of the polystyrene sheet initiates melting but is at such a speed that there is no contact directly between heating element 100 or in the other part of cartridge 122 . Thus, the speed is controlled to ensure there is sufficient melting so that no contact occurs.
[0085] Once the heating element 100 has passed from the upper surface 131 a to the lower surface 131 b of the polystyrene sheet, it will be appreciated that there may be some dripping downwards of melted polystyrene material. However, because the heaters are below the heater ray 63 , there is no dripping of material onto the heating elements 100 or any other part of heating array 63 .
[0086] Once the aperture such as aperture H 2 or H 1 has been formed in the panel 31 , the lift table is then lowered such that the sheet 31 is positioned back on conveyor 37 between guides 81 and 83 . This preferably takes place relatively quickly so that no further melting of material occurs. Conveyor 37 can then be operated to move the sheet 37 to Station C where panel 31 is moved from machine 30 again either manually or automatically with a robot or the like.
[0087] When an aperture like H 3 shown in FIG. 1I c is desired, the movement of the cartridge 122 including heating element 100 and disk 290 is slightly varied. Once the panel has been pierced, and disk 290 is in a position above upper surface 231 a (as shown in FIG. 12 c ), the lift table is stopped for a predetermined period of time to allow the formation of the disk portion 275 in surface 231 a . The reverse movement through the panel to extract the cartridge 122 and heating element 100 is done at relatively high speed (preferably in the range of 50-150 mm/sec.) so that further melting and distortion of the opening is minimized.
[0088] Although preferred embodiments of the invention have been described in detail herein and illustrated in the drawings, it is to be understood that the invention is not limited to those precise embodiments and that various changes and modifications may be effected therein without departing from the scope or spirit of the invention.
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An apparatus is adapted to form a plurality of apertures in a panel made from a meltable foamed plastic material. The apparatus has a movable panel support device for supporting said panel and a heating array. The heating array has a plurality of heating elements mounted to a support frame. The heating array is disposed opposite to the panel support device. Each of the heating elements is adapted to emit sufficient heat to melt the foamed plastic material when a panel is positioned proximate the heating elements. A driving mechanism is provided for moving the panel support device toward and away from said plurality of heating elements. The panel supporting device moves a panel supported thereon, towards and away from the plurality of heating elements and during them movement melts a plurality of apertures in the panel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a method for the deposition of wear resistant coatings onto parts under high vacuum with plasma assisted physical vapor deposition. The carrying out of this method requires a particular type of equipment which is also subject of this invention.
2. Description of Related Art
Many methods for the physical vapor deposition were proposed over the last 30 years. Many of them have found widespread application since then. (see E. Bergmann and E. Moll: plasma assisted PVD coating technologies published in Surface Coatings and Technologies volume 37 (1989), pages 483 ff.). All these methods can be described as a combination of 3 process steps: conditioning, deposition, and deconditioning. Conditioning comprises in most cases several conditioning steps: cleaning, putting under high vacuum, heating and plasma etching. Deconditioning Comprises in most cases the deconditioning steps: cooling, removing from high vacuum and conservation. This sequence of steps is used in almost all methods for the plasma assisted high vacuum physical vapor coating of parts with wear resistant coatings. Exceptions are of course the coating of temperature sensitive parts, where one skips heating. Parts are considered as temperature sensitive, if they are not to be heated without damage to more than 650° K. The state of the art of conditioning for methods for the plasma assisted physical vapor coating of parts with wear resistant coatings has been described in the patent applications DE 3936550 and DE 104998. These two patent applications recommend putting the parts under high vacuum and radiation heating. In the case of radiation heating heat flows as a beam of infrared photons from a heater to the parts to be heated. A heater is a surface, whose temperature is higher than the temperature of the parts to be heated. The set point temperature is the temperature the parts should reach in the conditioning step.
The different variants of plasma etching are not discussed being not a subject of this invention. All plasma etching methods used today are executed under high vacuum although one could conceive rough vacuum methods.
Any physical vapor deposition can be considered as sequence of 3 processes each of them being stationary in time: Evaporation of components of the material that will form the coating in a suitable installation, called source. Transport of these components that will form the coating and, if appropriate, gaseous components to the parts. Conversion of these components on the surface of the parts to coatings with the required properties. Numerous forms of vapor sources are known and used today. (see E. Bergmann and E. Moll op. cit. ). In the case of the physical vapor deposition of wear resistant coatings they are based either on sputtering or on arc evaporation. The evaporated components for forming the coating are transported to the parts by a free molecular flow or by means of an electrostatically and/or electromagnetically managed molecular flow. Thereby a mass flow of components of the material constituting the coating is formed. The following transport configurations have been realized so far, each being specific to a certain equipment and vapor source configuration:
(1). A flat source facing a flat part: Not suitable for wear protection coatings, where most parts are complex shaped. Mainly used in load-lock systems.
(2). Flat sources on a cylinder and a radial mass flow to the parts in the center of the cylinder.
(3). Moving point sources or rod sources in the center and radial mass flow towards the components on the cylinder surface.
(4). Point source in the center or on the bottom and radial flow to the substrates mounted onto the segment of a sphere.
Flat sources are evaporation installations, where the components of the material that will form the coating are emitted from an extended surface and where this surface is flat. Point sources are evaporation installations where the components of the material, that will form the coating are emitted from a surface whose extension, typically in the range of 0.001-0.003 m, is very small compared to the vessel surface,. Rod sources are evaporation installations, where the components of the material, that will form the coating are emitted from a rod.
State of the art methods use radiation also for cooling of the parts.
State of the art methods for the plasma assisted high vacuum physical vapor coating of parts with wear resistant coatings use transport configurations with either parallel heat and mass flows or heat and mass flows, that are coradial. Coradial means both are in the radial direction of the same cylinder.
The reasons for the restriction to these transport configurations are considered evident. Under high vacuum heat flow in the form of a photon beam as well as mass flow of the components, that will form the coating, in the form of a molecular flow are directed flows. There sequential combination requires therefore a parallel or coradial direction of heat flow and mass flow, to assure equal uniformity of exposure of the parts to both flows. Since heat transport in high vacuum is limited to photons, the state of the art is limited to radiation heating.
The use of radiation heating brings many disadvantages in the practical application of these methods. Heat transport from the radiating surfaces to the core of the parts is poor, because it depends strongly on the surface finish of the parts and non-uniform temperatures can not be avoided: shading leaves some parts too cold, intensive irradiation overheats some parts. These problems arise from the fact, that the heat flow associated with radiation depends very strongly on the temperature difference between heater and part to be heated. The heat flow is proportional to the 4th power of this temperature difference. FIG. 1 shows the temperature evolution of 3 parts with different weight in different areas of an equipment with conditioning according to the state of the art. Curve (a) was measured with a twist drill made from H2 high speed steel, diameter 6 mm, fixed at half-height of the part carrier on a spindle at its periphery, loaded in a quiver executing a further rotation around its axis. Curve (b) was measured with a milling cutter, diameter 150 mm, length 200 mm, also fixed at half height of the part carrier on a spindle but free standing on a holder plate. Curve (c) was measured with a forming punch, diameter 300 mm, sitting in the center of the part carrier. The temperature of the heater was identical in all three experiments, namely 1270° K. The target temperature for all three parts was 770° K. The milling cutter reached this temperature after 2,5 hours. By that time the temperature of the twist drill had long exceeded his tempering temperature -810° K., the drill had softened and was scrap. The punch never reached his target temperature. This lower than specified temperature of the punch during the subsequent coating step affected the adhesion of the plasma assisted coating adversely. In this experiment a heater temperature largely exceeding the target temperature of the parts had been chosen. In this way the light parts respectively the parts closer to the heater did exceed the target temperature and had approached the temperature of the heater, while heavy parts respectively parts at a larger distance from the heater had remained significantly below the target temperature. If one sets a small difference between heater temperature and target temperature, the heat flow becomes very small and the heating time excessively long.
These problems prevent currently the profitable coating of heavy parts with plasma assisted physical vapor deposition by job coaters. They also require from the operators of such equipment great skill in arranging mixed batches. The effect of the parallel or coradial arrangement of heat and mass flows leads to a heating of the part of similar non uniformity than the coating.
SUMMARY OF THE INVENTION
The subject of the invention is a method for the plasma assisted high vacuum physical vapor coating of parts with wear resistant coatings characterized by the fact, that the conditioning step heating is carried out with gas molecules and/or atoms as heat transport medium.
The problems of the state of the art coating processes can be solved if instead of photons gas atoms and/or molecules are used as energy carriers. This requires a gas flow from the heaters to the parts. The principle is known since centuries in bakeries and was introduced in the baking stoves in households in the last two decades. A radiation stove can only bake breads of equal or similar size, a convection stove is suitable for the simultaneous baking of biscuits and cakes. But the high vacuum of the evaporation process has a low gas density, which would make heating by gas extremely inefficient. This problem is overcome with a novel procedure: The chamber with the parts to be coated is first pumped down to fine vacuum, then refilled with a protective gas to a rough vacuum, which will be used for the conditioning by heating. Only when heating is completed will the chamber be put under high vacuum and the coating process will be continued either by the conditioning step of plasma etching or by high vacuum deposition. In principle any gas that will not react with the parts at the target temperature can be used as a protective gas. Mixtures of noble gases, nitrogen and/or hydrogen have proven well suited, in particular, mixtures, where nitrogen or helium are the main components.
Furthermore, we found, that configurations, where the heat flow is approximately orthogonal to the mass flow lead to particularly good results. Heating and cooling can be made much more uniform for most shapes of parts. The fact, that the method claimed makes heating more uniform than coating is not a disadvantage.
The heating with protective gases uses electrical energy and consists of a heater and a blower, that transports the protective gas from the heaters to the parts and back to the heaters. In the art of furnace design two variants of realization are known: In the case of external heating the blower sucks in the gas cooled down by the contact of the parts from the chamber and blows it over a heater, from where it again will flow across the chamber. Inlet and outlet fitting determine the heat flow. In the case of an internal heating conditioning space and heater space are separated by sheets incorporated in the chamber. A blower sucks the protective gas cooled down by the contact with the parts from the conditioning space and blows it over the heater in the heater space, from where it flows back into the conditioning space.
Both spaces are part of one same chamber.
Both variants of realization are state of the art for sintering furnaces but have never been proposed for use in the high vacuum vapor coating of parts with wear resistant coatings probably because they did not seem compatible with methods for the deposition of wear resistant coatings onto parts under high vacuum with physical vapor deposition. In the case of an external heating with protective gases the fine dust created continuously in the methods for plasma assisted high vacuum vapor coating of parts with wear resistant coatings would settle partly on the valve seats thereby making the chamber quickly unsuitable for high vacuum operation. In the case of an internal heating motors, that run in the chamber are used, because it seemed not possible to design high vacuum rotary feed-through compatible with the high rotation speeds of efficient blowers. Slowly rotating blowers do not produce a controlled gas flow. However since these motors run in the vacuum chamber emit copious amounts of gases they can not be used with methods of plasma assisted high vacuum vapor coating of parts with wear resistant coatings.
A further object of this invention is therefore a blower linked to a magnetic transmission, which is a preferred device for protective gas heating in processes of plasma assisted high vacuum vapor coating of parts with wear resistant coatings.
Similar considerations are valid for cooling. In this case the heater should be replaced by a gas/gas or gas/water heat exchanger. It is therefore a further object of the present invention to use the wall of the high vacuum vessel as a gas/water heat exchanger. A further part of the invention is the use of movable gas flow management sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the heat up of three different parts compared with the stat of the art;
FIG. 2 is a diagrammatic illustration of a preferred apparatus of the invention; and
FIG. 3 shows a preferred embodiment of the magnetic clutch of the apparatus of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The equipment for carrying out the process must comprise means for creating gas flows, preferably a blower, which in the preferred embodiment is driven through a magnetic clutch. The equipment comprises gas flow management sheets, which in the preferred embodiment also serve as heat flow barriers. They can be moved in a way to create a different gas flow during heating than during cooling. It was established, that the process efficiency increases, if the heaters are positioned close to the blower. Close means for example a disposition within the range of 50-200 mm. It will not be possible to place all the heating elements in this range for every equipment and installed heating power. What matters above all is the installation in the proximity of the blower intake. This disposition is made easy by the use of the magnetic clutch. Since with a magnetic clutch there are no lubricated parts in the vicinity of the blower, a higher temperature of the blower body can be tolerated. The following is the preferred sequence of process steps for the method claimed. After closing the high vacuum coating equipment a two stage mechanical pump creates a fine vacuum. During this process step no high vacuum pumps are used The terms and definitions used correspond to W. Pupp, H. K. Hartmann Vakuumtechnik, Grundlagen und Anwendungen, Carl Hanser Verlag Munchen 1991). A pressure of 5-10 Pascal is created. As soon as this pressure is reached, a valve is opened, bleeding protective gas into the chamber. If the pumping unit does not have sufficient pumping power in the range of 5-20 Pascal the following process sequence can be taken as an alternative: One creates only a pressure in the range of 100-1000 Pa., this corresponds to a rough vacuum, and provides ample rinsing of the equipment with protective gases, before the parts reach too high a temperature. In both versions a protective gas pressure of at least 0.01 bar is established. In the case, where one wants to coat ground shank type tools, a pressure in the range of 0,8-1 bar is used. If a more intense degassing of the parts is sought, for example with polished or honed tools, we found it advantageous to work at lower pressure at the expense of longer heat-up times. As soon as the target protective gas pressure is reached, the blower is put in operation creating a strong flow of protective gas. The flow of protective gas is taken in through heaters placed in the vicinity of the blower. A heat flow from the heaters to the parts is created. The direction of the heat flow corresponds to the direction of the gas flow. Very unexpectedly indeed, we found, that it is very advantageous if during heating in the space, where the parts are loaded the heat flow is essentially orthogonal to the mass flow, which will take place during high vacuum coating. By orthogonality of the two flows we mean, that the vector of the total gas flow (17) and the vector of the total mass flow (18) form an angle, that is essentially a right angle. FIG. 2 explains, how this rule must be applied. Because of flow deviations by the parts and whirls, the gas flow and therefore the heat flow may of course have locally (14) another even an opposite direction. But the majority of the flow lines (15) and therefore the macroscopic flow (17) will have a single and unique direction whose meaning is evident for a skilled person. Similar deviations have to be taken into account for the mass flow of the plasma assisted high vacuum evaporation processes. In these processes the mass flows is essentially directed (16) pointing away from the vapor sources. Since part of the vapor will be ionized, some electrostatic deviation will occur. Despite these deviations the application of the rule will be evident to anybody skilled in the art: It is a clear rule for the disposition of vapor sources, parts to be coated, and the disposition of blower and gas flow direction sheets. The details depend on the vapor sources selected and will be further detailed by the following 2 examples. If one chooses planar magnetrons and a cylindrical vessel one will incorporate the vapor sources in the cylinder side wall and reserve the chamber center for the parts just the way described e.g. in U.S. Pat. No. 4,877,505. In this case one should use the faces of the cylinder for the blowing (sucking) blower respectively the protective gas recirculation (feed) device. If one chooses a rod as vapor source as described in EP 508612, one will dispose the parts around this rod. In this case one will either use the two lateral walls of a rectangular chamber or two facing cylinder segments of a cylindrical chamber for blower and protective gas recirculation (feed) device. The reasons for this unexpected effect of improvement with orthogonal flows appear to be the following--although no completely satisfactory answer has been found so far: Shank type tools, which constitute the bulk of parts to be coated are usually loaded with their axis of revolution normal to the mass flow. If then the heat flow is parallel or coradial the heat intake of the parts is limited to the cylindrical half-face exposed to the heat flow. With an optimally tuned heating, the surface of this half-face will immediately reach the target temperature. Heat will then diffuse from this surface to the bulk of the tool. The form of the shank type tools will cause an orthogonal heat flow to be taken in on the whole cylinder face, whose surface will reach immediately the target temperature with an optimally tuned heating. In the framework of the validity of this simple model, one gets half the heating time for orthogonal flow when compared with parallel or coradial flow.
When the parts have reached the target temperature for the parts, the conditioning step heating is terminated. The energy input into the heaters is shut off. After that the blower drive is shut down.
All the plasma etching steps currently used are carried out under high vacuum (see E. Bergmann und E. Moll op. cit.). Under these circumstances the bleeding gas inlet will be closed after the shut down of the blower and the chamber will be pumped down to high vacuum with the high vacuum pumping device. High vacuum pumping devices are usually of the three stage type. A significant advantage of the method claimed when compared with state of the art methods is the fact that for a given high vacuum pumping device the time that elapses until high vacuum is reached is considerably shortened. In the state of the art methods the equipment is first pumped down to high vacuum before the conditioning step heating is started. In this case high vacuum must be produced in a cold or warmed up chamber. Usual high vacuum evaporation practice consists in warming the chamber up to 45° C. with water. The installations for this conditioning of the walls is significant (Usually 10-20% of the equipment costs). But this practice ignores the fact, that equipment for the plasma assisted high vacuum coating with wear resistant coatings is run in a different way than other high vacuum coaters. The thickness of the coatings deposited is relatively high, in the range of 2-10 μm for each batch. Since the parts are usually shank type or complex shaped, this coating thickness on the parts corresponds to a coating thickness deposited on the walls of 6-30 μm per batch. The usual applications of high vacuum deposition processes, from which the state of the art practice had been taken deposit 0,1 μm on flat parts. The pump down in a high vacuum equipment is determined by two different processes (Pupp und Hartmann op. cit.). Pumping down to fine vacuum is achieved by removing the gas filling the volume of the chamber. The transition from fine vacuum to high vacuum requires the removal of the gas adsorbed on the walls and surfaces. This leads to problems particular for equipment for plasma assisted high vacuum deposition of wear resistant coatings because of the large coating build-up on the walls involved. Since the kinetics of gas desorption are governed by Arrhenius' law, an economic operation requires for this application a transition from fine vacuum to high vacuum under high temperature. This fact was overlooked in the state of the art methods derived from the practice of high vacuum coating of other parts. The choice of a high temperature for the transition from fine vacuum to high vacuum, which is a subject of the present invention solves another problem, which is characteristic for processes where the heating step is carried out under protective gas. Chambers for such processes are equipped with protection shields between the chamber walls and the parts for reasons that will be detailed in the section of this patent description, where the equipment is discussed in detail. This requirement multiplies the surfaces covered with gas and would therefore handicap the economic operation of the equipment subject of the present invention, had we not found a method where the transition from fine vacuum to high vacuum takes place out under high temperature. When high vacuum has been achieved the selected plasma etching process is carried out followed by the selected high vacuum vapor deposition process.
FIG. 1 shows the heat-up of three different parts and the comparison with the state of the art, whose results have already been discussed. Curve (d) was measured with a twist drill, diameter 6 mm, mounted on the periphery of a rotating plate at half the height of the substrate carrier. Curve (e) shows the result for an end mill, diameter 150 mm, length 200 mm, also loaded on the periphery of the substrate carrier, but standing on the carrier plate. Curve (f) was measured with a forming punch, diameter 300 mm, loaded on the center of the substrate carrier. The temperatures of the heaters were the same in all three cases, namely 1170° K. The target temperature for the parts was 770° K. After 40 minutes even the most heavy part had reached the target temperature. None of the parts was overheated.
After the high vacuum vapor deposition process(es) the parts are subjected to a further conditioning step: cooling. Cooling is a conditioning step by which the temperature of the parts is brought down from the temperature after the coating step to another target temperature, the venting temperature. In the process of the present invention protective gas is used again for the heat transport in this conditioning step. For this purpose the chamber is back-filled again with protective gas up to a pressure between 0,5 and 1 bar. Following this, the blower is again put into operation and brought up to a rotating speed of at least 500 revolutions per minute, preferably to a rotation speed of 2000-2500 revolutions per minute. This is also the preferred rotation speed for heating. A change in the gas flow management device will now direct the flow along the chamber wall. As a consequence the chamber wall cools down the gas to the temperature close to the chamber wall cooling water. This cooled down gas is then blown or sucked over the parts by the blower. During this pass the gas cools down the parts picking up heat. To avoid overheating of the chamber cooling water during this process step, the blower rotational speed is regulated at least part of the time in the following way: A temperature sensor measures continuously the temperature of the chamber cooling water and transmits a corresponding signal, the actual value to the regulating unit. This unit compares the signal with the set value, that corresponds to a threshold of the temperature. This threshold temperature will depend on the design of the chamber water cooling unit. It will be in the range of 60°-95° C. When the signal reaches the threshold value, the regulating unit will reduce the rotation speed of the blower. When the signal is inferior to the threshold by a value corresponding to 5° C., the regulating unit starts increasing the rotation speed of the blower, until either the signal reaches again the threshold value or the rotation speed the set maximum. When the parts reach the venting temperature, the chamber is brought back to atmospheric pressure by opening the nitrogen bleeding valve followed by an opening of the air venting valve or simply by opening the air venting valve.
FIG. 2 shows a preferred embodiment of the invention
The vacuum vessel (1) is a cylindrical chamber (21) with the following dimensions: diameter 600 mm and height 800 mm. The relation between height and diameter reflects in the usual way the dimensions and quantities of the parts to be coated. On the chamber wall several rectangular cathodic arc evaporators (13) are mounted. The cathodic arc evaporators are of the externally mounted type of the state of the art design as it is described e.g. in DE 126040. The parts(12) are the parts to be coated by plasma assisted high vacuum physical vapor deposition. The holders carrying the parts consist of a carrying plate(11) with a feed-through (23) and a drive for the carrying plate which is not shown. Further details concerning the substrate holder can be taken from U.S. Pat. No. 4,485,759. The vessel is evacuated through the pumping port (2). He is fed with protective gas, a mixture of 10 volume % of hydrogen and 90 volume % of nitrogen through the valves (5). The admission duct for the protective gas and the reactive gases for the plasma assisted high vacuum vapor deposition process is designated by (6). The chamber lid is equipped with an axial blower (3), connected to the motor (20) by an axis (19) and the magnetic clutch (4). Details of the magnetic clutch are shown in FIG. 5. The heating elements are disposed in the immediate neighborhood of the blower. They heat up the protective gas before it is sucked in by the blower. The preferred embodiment allows the placing of the heating element in the top of the chamber in a space, where the distance to the fan ranged from 30 to 300 mm. The gas management sheets (9) and (8) direct the gas heated or cooled by the parts from the chamber bottom back to the chamber top. In the embodiment shown the lower gas management sheet was simply a dumb bell shaped vessel cylinder face of diameter 550 mm and 2 mm thickness. The two vertical sheets are cylinders with rectangular openings in the sections where the evaporator(s) is(are) fitted into the chamber wall. In the embodiment shown, their diameters were respectively 560 and 510 mm. The protection sheet (8) consists of a stack of 3 sheets. The chamber described therefore contained a total of 5 protection sheets between the parts and the chamber wall. One of the gas flow management sheets (8) can be moved to two positions opening or closing the channel (25) formed by sheet (8) and (9) to the protective gas flow. This is achieved by the shut off device (26). It is linked to a linear feed-through (10) connected to a lever (27), whose action produces a movement of the sheet (8) during the transition from the conditioning step heating to high vacuum or during the transition from high vacuum to the deconditioning step cooling or any time in between these two transitions. Other designs like chain drives or pneumatic cylinders are of course equally suitable. Other movements like rotations or opening or closing of traps can replace the lifting. During the conditioning step heating the gas management sheets are positioned in a way to produce a preferred flow of the protective gas between sheets (8) and (9) through the heating channel (25). During the deconditioning step cooling the two gas management sheets are in a position, that forces the protective gas flow through the cooling channel (24), formed by the chamber wall (21) and the gas management sheet (8). This cooling channel (24) can be equipped with cooling fins (22), to enhance the heat exchange between the chamber wall (21) and the protective gas.
A preferred embodiment of the magnetic clutch is shown in FIG. 3. A pot with crossbeams(38) carrying two rolling bearings (29) is connected to the chamber flange (36). The pot contains the driven part of the clutch. The bearings support the blower shaft (19) which carries firmly linked to it a plate (33) separated from the chamber flange surface by a gap not exceeding 3 mm but superior to 0,2 mm. The periphery of this plate is connected to a ring(31), the driven ring. This ring consists either of permanent magnet material which is magnetized axially or of bars and fins of permanently magnetic material mounted in an appropriately designed yoke. The other side of the chamber flange is connected through a seal (37) with a pot (34), which carries the driving part of the clutch. The pot is equipped with at least one rolling bearing (29), whose inner ring is riveted to or coinciding with the shaft(28) of the motor, which is not shown. The shaft carries a yoke made from soft iron or another appropriate ferromagnetic material like a nickel or cobalt alloy. The yoke is linked to a ring of permanently magnetized material (30) which is designed in the same way as the driven ring (31). The design of the whole ensemble is executed in a way to maximize the attractive force between the driving and the driven parts of the clutch. In a preferred embodiment the yokes and the shapes of the permanent magnet material are such that the gap of 0,2-3 mm between the flange and the plate (33) and the thickness of the flange correspond essentially to the total air gap of the magnetic circuit. The mechanical design of the flange should be such, that the thickness of the membrane (39) in the gap does not exceed 2 mm. This thin membrane has to be properly supported to withstand the pressure of 1 bar. A preferred realization of the invention uses rings made from permanently magnetic material that are alloys of rare earths with cobalt or iron. A further preference in the realization of the embodiment of the invention uses alloys made essentially from the elements neodymium, iron and boron. The pot (34) is closed by a membrane made from stainless steel (39), whose thickness must not exceed 2 mm.
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The present invention relates to a novel method for the plasma assisted high vacuum vapor coating of parts with wear resistant coatings where the method comprises at least the process steps heating and conditioning and where the process step conditioning comprises heating. A protective gas is used for the heating. It is circulated at a pressure of at least 0.01 bar. Significant advantages are realized over state of the art methods using radiation heating. The method is preferentially carried out in an apparatus conceived for it, which comprises a blower (3), protective shields (8) and gas flow management sheets(9).
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/560,047, filed Apr. 6, 2004, and Canadian Application No. 2,463,354, filed Apr. 6, 2004, which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a telemetry system, and in particular to a measurement while drilling (MWD) system. More particularly, the present invention relates to a servo-actuator for a downhole mud pulser for sending information from downhole to surface.
BACKGROUND OF THE INVENTION
The desirability and effectiveness of well logging systems where information is sensed in the well hole and transmitted to the surface through mud pulse telemetry has long been recognized. Mud pulse telemetry systems provide the driller at the surface with means for quickly determining various kinds of downhole information, most particularly information about the location, orientation and direction of the drill string at the bottom of the well in a directional drilling operation. During normal drilling operations, a continuous column of mud is circulating within the drill string from the surface of the well to the drilling bit at the bottom of the well and then back to the surface. Mud pulse telemetry repeatedly restricts the flow of mud to propagate signals through the mud upward to the surface, thereby providing a very fast communication link between the drill bit and the surface. Depending on the type of drilling fluid used, the velocity may vary between approximately 3000 and 5000 feet per second.
A telemetry system may be lowered on a wireline located within the drill string, but is usually formed as an integral part of a special drill collar inserted into the drill string near the drilling bit. The basic operational concept of mud pulse telemetry is to intermittently restrict the flow of mud as it passes through a downhole telemetry valve, thereby creating a pressure pulse in the mud stream that travels to the surface of the well. The information sensed by instrumentation in the vicinity of the drilling bit is encoded into a digital formatted signal and is transmitted by instructions to pulse the mud by intermittently actuating the telemetry valve, which restricts the mud flow in the drill string, thereby transmitting pulses to the well surface where the pulses are detected and transformed into electrical signals which can be decoded and processed to reveal transmitted information.
Representative examples of previous mud pulse telemetry systems may be found in U.S. Pat. Nos. 3,949,354; 3,958,217; 4,216,536; 4,401,134; and 4,515,225.
Representative samples of mud pulse generators may be found in U.S. Pat. Nos. 4,386,422; 4,699,352; 5,103,430; and 5,787,052.
A telemetry system capable of performing the desired function with minimal control energy is desirable, since the systems are typically powered by finite-storage batteries. One such example is found in U.S. Pat. No. 5,333,686, which describes a mud pulser having a main valve biased against a narrowed portion of the mud flowpath to restrict the flow of mud, with periodic actuation of the main valve to allow mud to temporarily flow freely within the flowpath. The main valve is actuated by a pilot valve that can be moved with minimal force. The pilot valve additionally provides for pressure equalization, thereby increasing the life of downhole batteries.
Another example of an energy efficient mud pulser is described in U.S. Pat. No. 6,016,288, the mud pulser having a DC motor electrically powered to drive a planetary gear which in turn powers a threaded drive shaft, mounted in a bearing assembly to rotate a ball nut lead screw. The rotating threaded shaft lifts the lead screw, which is attached to the pilot valve.
Solenoid-type pulser actuators have also been used to actuate the main pulser valve, however, there are many problems with such a system. The use of a spring to bias the solenoid requires the actuator (servo) valve to overcome the force of the spring (about 6 pounds) and of the mud prior to actuating the main valve. A typical solenoid driven actuator valve is capable of exerting only 11 pounds of pressure, leaving only 5 pounds of pressure to actuate the pulser assembly. Under drilling conditions requiring higher than normal mud flow, the limited pressures exerted by the solenoid may be unable to overcome both the pressure of the return spring and the increased pressure of the flowing mud, resulting in a failure to open the servo-valve, resulting in the main valve remaining in a position in which mud flow is not restricted, and therefore failing to communicate useful information to the surface.
A further problem with the use of a solenoid to actuate the pulser assembly is the limited speed of response and recovery that is typical of solenoid systems. Following application of a current to a solenoid, there is a recovery period during which the magnetic field decays to a point at which it can be overcome by the force of the solenoid's own return spring to close the servo-valve. This delay results in a maximum data rate (pulse width) of approximately 0.8 seconds/pulse, limiting the application of the technology.
Moreover, the linear alignment of the solenoid must be exactly tuned (i.e. the magnetic shaft must be precisely positioned within the coil) in order to keep the actuator's power characteristics within a reliable operating range. Therefore, inclusion of a solenoid within the tool adds complexity to the process of assembling and repairing the pulser actuator, and impairs the overall operability and reliability of the system.
Existing tools are also prone to jamming due to accumulation of debris, reducing the range of motion of the pilot valve. Particularly when combined with conditions of high mud flow, the power of the solenoid is unable to clear the jam, and the tool is rendered non-functional. The tool must then be brought to the surface for service.
Stepper motors have been used in mud pulsing systems, specifically, in negative pulse systems (see for example U.S. Pat. No. 5,115,415). The use of a stepper motor to directly control the main pulse valve, however, requires a large amount of electrical power, possibly requiring a turbine generator to supply adequate power to operate the system for any length of time downhole.
Repair of previous pursers has been an as yet unresolved difficulty. Typically, the entire tool has been contained within one housing, making access and replacement of small parts difficult and time-consuming. Furthermore, a bellows seal within the servo-poppet has typically been the only barrier between the mud flowing past the pilot valve's poppet and the pressurized oil contained within the servo-valve actuating tool, which is required to equalize the hydrostatic pressure of the downhole mud with the tool's internal spaces. Therefore, in order to dissemble the tool for repair, the bellows seal had to be removed, causing the integrity of the pressurized oil chamber to be lost at each repair.
Furthermore, a key area of failure of MWD pulser drivers has been the failure of the bellows seal around the servo-valve activating shaft, which separates the drilling mud from the internal oil. In existing systems, the addition of a second seal is not feasible, particularly in servo-drivers in which the servo-valve is closed by a spring due to the limited force which may be exerted by the spring, which is in turn limited by the available force of the solenoid, and cannot overcome the friction or drag of an additional static/dynamic linear seal.
It remains desirable within the art to provide a pulse generator that has an energy efficiency sufficient to operate reliably and to adapt to a variety of hostile downhole conditions, has reduced susceptibility to jamming by debris, and is simpler to repair than previous systems.
SUMMARY OF THE INVENTION
It is an object of the present invention to obviate or mitigate at least one disadvantage of previous mud pulsers and pulse generators.
In a first aspect, the present invention provides a downhole measurement-while-drilling pulser actuator comprising a servo valve movable between an open position which permits mud flow through a servo-orifice and a restricted position which restricts mud flow through the servo-orifice, the servo-valve powered to the open position and powered to the closed position by a reversible electric motor.
In one embodiment, the servo valve includes a servo-poppet powered by the motor in reciprocating linear movement towards and away from the servo-orifice.
In a further embodiment, the actuator may include a rotary to linear conversion system for converting rotary motion of the reversible electric motor into linear reciprocating movement of the poppet. The rotary to linear conversion system may include a threaded lead screw held stationary and driven in rotation by a rotary motor. In this embodiment, the lead screw may be threadably attached to a ball nut from which the poppet depends, whereby the rotary motion of the motor causes rotation of the screw to result in driven linear movement of the ball nut and the poppet in either direction.
In a further embodiment, there is provided a servo-controller for controlling the powering of the servo-valve by the electric motor. The servo-controller may further be capable of sensing the position of the poppet with respect to the servo-orifice, such that the poppet position is sensed when mud flow through the servo-orifice is restricted or unrestricted, and wherein the amount and direction of rotation of the motor from the sensed poppet position is counted and stored by the controller.
In another embodiment, the sensed position of the orifice restriction is calibrated as the fully closed position of the poppet. The poppet's travel is thereby monitored and controlled during operation to avoid unneeded collision or frictional wear between the poppet and the servo-orifice. The servo controller may sense the position of the poppet by sensing whether movement of the poppet is impeded, and the servo-controller counts the number of rotations of the motor until the poppet is impeded and compares the number of rotations to an expected number of rotations to determine the position of the poppet with respect to the servo-orifice. The expected number of rotations can be preset to allow a predetermined rate of mud flow past the servo-orifice when the poppet is moved away from the servo-orifice by the preset expected number of rotations.
In a still further embodiment, the servo-controller may include a debris clearing command that is initiated when the number of rotations counted is not equal to the expected number of rotations. The debris clearing command may cause the motor to rapidly reciprocate the poppet to dislodge any debris present between the poppet and the servo-orifice.
In another embodiment, the attachment between the poppet and the motor comprises a dynamic seal to isolate the motor, rotary to linear conversion system and related drive components from the drilling mud in which the poppet and orifice are immersed when in operation.
In a further aspect, the present invention provides a method for causing the generation of a mud pulse by a controlled pulser's main pulse valve comprising the steps of: powering a pulser servo-valve in a first direction using a rotary motor such that mud is permitted to flow past a servo-orifice to activate a main mud pulse valve; and powering the servo-valve in a second direction using the rotary motor such that mud flow past the servo-orifice is restricted to deactivate the main mud pulse valve.
In one embodiment, the method further comprises the step of cutting power to the motor to hold the servo-valve in a particular position within its range of motion to tailor the actuator's effect on the main pulse valve and thereby tailor the pressure and duration characteristics of a mud pulse.
In another aspect, the invention provides a servo-controller for use with a downhole measurement-while-drilling pulser actuator, the servo-controller comprising a sensor, memory, control circuitry, and an operator interface.
In one embodiment, the sensor is a mudflow sensor, pressure sensor, temperature sensor, rotation-step counter, position sensor, velocity sensor, current level sensor, battery voltage sensor, timer, or an error monitor.
In another embodiment, the memory stores time-stamped or counted sensed events together with an event-type indication. The servo-controller may be programmable to cause an action within the actuator responsive to a sensed event, a time, an elapsed time, a series of sensed events, or any combination thereof.
In a further embodiment, the user interface provides information from memory to the operator, and may allow an operator to alter the programming of the control circuitry.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIGS. 1A and B are a longitudinal cross sectional view of the upper and lower portions of an embodiment of the mud pulser during mud flow through the servo orifice; and
FIGS. 2A and 2B are a longitudinal cross sectional view of the upper and lower portions of an embodiment of the mud pulser during mud flow restriction by the poppet.
DETAILED DESCRIPTION
The present invention relates to an apparatus and method for actuating a mud pulser telemetry system used during well-drilling operations. The present apparatus allows a servo-valve to be powered both in opening and closing to activate a main mud pulser valve, and does not rely on a solenoid system. The powered opening and closing of the servo-valve results in various functional and economic advantages, including the ability to clear debris from the restricted portion of the mud flowpath, and faster data rates due to elimination of inherent operating delays in the solenoid systems of previous tools, with the end result of providing a pulser driver which consumes a minimal amount of DC power while providing more force with which to drive the servo-valve's poppet in each direction. Therefore, the actuator remains functional at a comprehensive range of downhole drilling conditions.
Furthermore, in the embodiment shown in the Figures, the present device is designed to have several independent, interconnected housings, and employs a double seal between the oil compartment and the drilling mud, which simplifies assembly and repair of the tool. The assembly/disassembly is simplified to reduce repair turnaround time by using modular components.
Additionally, the use of a stepper motor, electric load sensors, and control circuitry in a powered-both-directions servo-valve system will allow for self-calibration of the tool and self-diagnosis and error correction unavailable in other systems. In an embodiment of the invention, as shown in FIGS. 1A and 1B , a three-phase stepper rotary motor 1 is monitored and controlled by a servo-controller 10 , the rotary movement of the motor 1 being converted into linear movement of a poppet 21 , thereby opening and closing a servo-valve 20 to actuate a mud pulser main valve (not shown). Communication of information to the well surface is accomplished by encoded signals, which are translated to produce pressure surges in the downward flow of the pressurized mud. It is recognized that although the drilling fluid is generally referred to as mud, other drilling fluids are also suitable for use with the present invention, as is well known in the art.
With reference to the Figures, the mud pulser actuator is lowered downhole and, in the embodiment shown, generally includes a plurality of serially interconnected housings 2 , 3 , 4 , 5 , 6 , 7 , and 8 , an electrical connector 9 , a servo-controller 10 for controlling the operation of a rotary motor 1 , and a servo-valve assembly 20 that is driven in linear motion by the rotary motor 1 . The servo-valve assembly includes a poppet 21 capable of linear reciprocating movement to and from a seal surface 22 of a servo orifice 23 , thereby opening and closing the servo orifice 23 to allow or prevent the passage of pressurized mud and thereby actuate a pulser (not shown, connected to the lower end 2 a of the lowermost housing 2 ) to generate a pressure pulse for telemetric purposes.
Mechanical System
A rotary-to-linear coupling system 30 a , 30 b (hereinafter referred to as coupling system 30 ) is used to translate the torque from the rotary motor 1 into linear movement of the servo-valve shaft 24 , which is preferably a series of connected shafts for transferring linear movement from the coupling system 30 to the servo poppet 21 . Preferably, the servo shaft includes a spline shaft 24 a , which passes through a spline coupling 24 b that can be used to prevent rotation of the shaft 24 a when necessary. The coupling system 30 also includes seals which serve to isolate the rotating mechanism from the downhole mud.
In the embodiment pictured in FIGS. 1A and 1B , the rotary motor 1 , is electrically powered through an electrical connection 9 , by a power source (not shown). When activated, the motor 1 rotates a lead screw 31 that is mounted within a bearing support 32 , causing a ball nut 33 to move threadably along the lead screw 31 . Linear movement of the ball nut 33 results in dependent linear movement of the servo shaft 24 , and servo poppet 21 . When driven in the forward direction, the rotary motor 1 will cause linear movement of the poppet 21 away from the servo-valve seat 22 , to allow passage of pressurized mud through the servo-orifice 23 to activate the main mud pulser valve to close. When the motor 1 drives the lead screw 31 in the reverse direction, poppet 21 is urged towards the seal surface 22 to cover the servo orifice 23 , as shown in FIG. 2B , and mud is therefore prevented from passing through the servo orifice 23 to actuate the mud pulser main valve to open.
The spline shaft 24 is surrounded by lubricating fluid, which must be pressurized against the downhole hydrostatic pressure. As shown, a pressure compensator in the form of a membrane or bellows 42 allows reservoir fluid to substantially equalize the pressure via a part 43 . The pressure compensator be a membrane, bellows, piston type or other type known in the industry. In addition to a bellows seal 40 , an additional seal 41 may be added to hold oil inside the chamber of the tool, with the bellows seal 40 preventing mud from reaching the additional seal 41 . The dual seal 40 , 41 maintains the integrity of the lubrication chamber during operation and during replacement of the bellows seal 40 during maintenance. The addition of this seal 41 does not negatively impact performance of the actuator due to the improved power characteristics of the system, as will be discussed below.
In a preferred embodiment, the construction of the device allows most downhole clogs, where debris in the mud may stop the poppet 21 from sealing with the seal surface 22 , to be easily cleared as will be described below, and the serially interconnected housing design allows simple and rapid repair of the tool when necessary.
The valve assembly 20 is preferably composed of a wear resistant material such as tungsten carbide or ceramic to maximize the efficiency of the tool and to minimize maintenance of the tool, and is preferably replaceable.
Operation
When restriction of mud flow by the main valve is desired, the rotary motor 1 will be activated by the servo-controller 10 in the forward direction. As shown in FIG. 1B , forward powering of the rotary motor 1 will cause the lead screw 31 to turn in the forward (for example, clockwise) direction, thereby raising the ball nut 33 and lifting the servo poppet 21 from the servo-valve seat 22 . This will allow mud flow to pass unrestricted through the servo-orifice 23 to actuate the main mud pulse valve, restricting mud flow to generate a pulse that is transmitted to the surface. The current-consuming portion of the circuit is then shut down until a further signal is received from the servo-controller 10 . The lack of current to the motor 1 results in the motor 1 being immovable and therefore acting as a brake to prevent further movement of the poppet 21 until further activation of the motor 1 .
Subsequently, when the servo-controller 10 initiates reverse motion by the motor 1 , the lead screw 31 is rotated in the reverse direction (in the example, counterclockwise) by the motor 1 , causing the ball nut 33 and servo shaft 24 to move towards the servo-valve seat 22 as shown in FIG. 2B . Closure of the servo-valve 20 causes opening of the main mud pulser valve to allow mud to flow unrestricted to the surface. The current-consuming portion of the circuit is then shut down until a further signal is received from the servo-controller 10 . The motor again acts as a brake until further power is applied (by shorting its coils together).
The lead screw 31 and ball nut 33 may be replaced by an alternate system of rotary to linear conversion, however a lead screw 31 and ball nut 33 are advantageous as they are relatively small in size and may be provided with bearings to provide a low-friction mechanism with high load capacity, durability, and low backlash tolerance. The lead screw 31 may be held in contact with the motor 1 by a bearing support 32 or any other suitable means.
The presently described system of using a stepper motor 1 to drive a servo-valve has several advantages. The powering of the servo-valve 20 in both directions allows greater direct control of the servo-valve 20 , avoids the previous necessity of using a return spring in the servo assembly, and therefore the energy required is similar to that of the force of the downhole mud flow. This results in an energy efficient system, and results to date indicate that the presently described system can supply a force of 100 pounds of pressure for less energy than previous systems, particularly than those which employ a solenoid activator. Thus, the present system can overcome higher pressures on the poppet valve 21 , allowing the system to clear itself of debris, and permitting use in a wide range of downhole conditions, including conditions of higher pressure and higher volume mud flow, and in conditions when the mud is contaminated or is very dense.
Use of a rotary motor powering the servo-valve in both directions also allows the system to be more responsive than solenoid systems, resulting in a faster data rate with more accurate or precise pulse-edge timing. Experimental results indicate that data rates of 0.25 seconds/pulse are possible with this system, as compared to 0.8 to 1.5 seconds/pulse in solenoid systems.
Flow Detection & Diagnostic Software
The servo controller detects the position of the poppet 21 against the servo-valve seal 22 by counting the number of rotations made by the motor until further movement of the poppet is impeded. For example, if the poppet 21 is generally programmed to attain an unseated position that is three forward motor rotations away from the seated position, upon seating activation by the servo-controller 10 , the motor will turn three reverse rotations, at which point further rotation will be impeded due to seating of the poppet 21 on the seal 23 . On unseating activation by the servo controller 10 , the motor will turn three complete forward rotations to return the poppet to its pre-programmed unseated position. Seating can be sensed by an increase in current drawn by the motor, from which a large opposing force (like stopped motion due to valve seating) is inferred. The control circuitry also senses rotation of the motors and can count rotations and direction of rotation.
Debris may enter the device with the mud, potentially causing jamming of the poppet. The servo controller 10 can be programmed to detect and clear jams from the servo-valve 20 . For example, debris may become lodged at the servo-valve seal 22 , preventing the poppet from fully sealing against the valve seal 22 . In such a situation, the motor would be prevented from completing its three reverse rotations. This is sensed by the servo-controller 10 , which will then attempt to dislodge the debris. The dislodging sequence may include rapid reciprocation of the poppet 21 towards and away from the seal 22 , or may include further reverse rotations on the subsequent reverse rotation. For example, if the motor was able to turn only two reverse rotations, the servo-controller 10 will recognize that the valve did not properly close, and will adjust one or more subsequent forward and/or reverse rotations to ensure that the poppet 21 is able to seat against the valve seal 22 . Similarly, debris may cause the poppet to not fully open, resulting in appropriate corrective action by the servo-controller on the next motor 1 activation. In either case, a processor provides a report of measurements recorded and controls the following cycle of the brushless motor's rotation accordingly.
The ability to detect and clear most jams within the tool allows a more robust design of the tool in other respects. For example, as the tool can easily clear particulate matter from the servo-valve assembly, the tool can be provided with larger and fewer mud ports, and may include reduced amounts of screening. Screening is susceptible to clogging, and so reducing screening leads to longer mean time between operation failure of the device in-hole; and will reduce the velocity of any mud flow through the tool, reducing wear on the bladder and other parts. Further, the removal of several previously necessary components (such as the return spring, transformer, and solenoid and related electronics) contributes to a tool of smaller size (in both length and diameter) that is more versatile in a variety of situations. For example, embodiments with outside diameter less than 1⅜″ (approaching 1″) or length less than four feet have been achieved, although these dimensions are not by way of limitation, but by example only.
Custom software also has the ability to track downhole conditions, and also uses a sensor to detect mudflow. When mudflow is detected, a signal is sent to the Directional Module Unit (not shown), to activate the overall system. The system also has the ability to time stamp events such as start or end of mudflow, incomplete cycles or system errors, low voltages, current, and the like, as well as accumulated run-time, number of pulses, number of errors, running totals of rotations or motor pulses. Wires or conductors may also be easily passed by the pulser section to service additional near-bit sensors or other devices. The software that detects the mudflow can be configured for different time delays to enable it to operate under a larger variety of downhole drilling conditions than its predecessors. The mudflow detection capability can also be used to calibrate or confirm the closed position of the poppet.
In addition, a user may monitor such data as well as any downhole sensors using a user interface attachable to the tool. Such sensors may include pressure or temperature sensors, rotation step-counters, travel or depth sensors, current levels, battery voltage, or timers. The user could monitor each component of the actuator to determine when the tool must be removed from downhole for repair. A user may, in turn, program an activity to cause an action or correction in response to a sensed event.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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An improved energy efficient intelligent pulser driver used for generating a mud pulse in a MWD (measurement while drilling) application. In the pulser driver, a direct current (DC) powered control circuit activates a three-phase DC brushless motor that operates a servo-valve. Opening of the servo-valve equalizes pressure in a plenum causing the operation of a main valve reducing flow area and causing a pressure spike in the mud column. Closing of the servo-valve creates a reduction in mud pressure that operates the main valve and increases the flow area causing an end to the pressure spike. The servo-valve is powered both in opening and closing operations by the motor.
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BACKGROUND OF THE INVENTION
One type or style of a refuse container is that in which the container has an opening in the upper portion thereof. Refuse is dumped into the container through the opening. Then a packer mechanism compacts the refuse by moving the refuse in a direction away from the opening.
Packer mechanisms and power units therefor have been created to provide a high degree of compression and compaction upon refuse within a refuse container.
It is an object of this invention to provide a power unit for refuse container packer mechanism which is capable of a very high magnitude of compaction forces in consideration of the physical size of the power unit.
Another object of this invention is to provide such a power unit which is capable of operation at a relatively high rate.
Another object of this invention is to provide such a power unit which is relatively simple in construction and which can be constructed and maintained at relatively low costs.
Another object of this invention is to provide such a power unit which can be employed in various types of situations.
Other objects and advantages of this invention reside in the construction of parts, the combination thereof, the method of production and the mode of operation, as wilI become more apparent from the following description.
SUMMARY OF THE INVENTION
A power unit of this invention is of the type which moves a compaction head along between the ends of a refuse container for packing the refuse and for removing the compacted refuse from the refuse container. The power unit is attached to the interior of the refuse container and to the compaction head.
The power unit of this invention comprises a housing provided with a chamber therein. A first piston of a given transverse dimension is positioned within the chamber. Attached to the first piston and coaxial therewith are spaced-apart coaxial cylinders. A second piston which has a smaller transverse dimension than the first piston is also within the chamber and is coaxial with the first cylinder and is between the cylinders which are attached to the first piston.
Fluid is introduced through a main passage of the housing for operation of the pistons. A valve mechanism is located within the main passage. The fluid is conducted into the main passage and then through an auxiliary passage into a space between the cylinders which are attached to the first piston, for movement of the second piston or smaller piston, for initial operation of the power unit and for initial movement of a compaction head which is attached to the power unit. Fluid which moves the first piston or smaller piston is of a given initial pressure. This fluid of the given pressure moves the smaller piston until this fluid pressure is unable to move the smaller piston farther.
Then the pressure of fluid flowing into the main passage increases. This increase in fluid pressure causes valve operation in the main passage which closes the auxiliary passage and closes fluid between the main passage and to the smaller piston. Thus, fluid which has moved the smaller piston is trapped within the chamber of the housing. The valve operation within the main passage almost simultaneously opens a second auxiliary passage for flow of fluid to the first piston or larger piston. The larger piston then moves, and applies increased pressure upon the fluid which is trapped within the chamber and which is engaging the smaller piston. Thus, increased pressure is applied to the smaller piston for additional movement of the compaction head.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
FIG. 1 is a side sectional view of a power unit of this invention, showing the parts thereof in deactuated positions.
FIG. 2 is a side sectional view, drawn on a smaller scale than FIG. 1, but similar to FIG. 1, and showing the power unit of this invention in its first stage of operation.
FIG. 3 is a side sectional view, similar to FIGS. 1 and 2, drawn on substantially the same scale as FIG. 2, showing the power unit in its second stage of operation.
FIG. 4 is a side sectional view, drawn on substantially the same scale as FIGS. 2 and 3, and illustrating the first stage in return movement of the power unit.
FIG. 5 is a side sectional view drawn on substantially the same scale as FIGS. 2, 3, and 4 and illustrating the second stage of return movement of the power unit.
FIG. 6 is a side sectional view, with parts broken away, drawn on a smaller scale than FIGS. 1-5 and showing a refuse container vehicle in which the refuse container is provided therewithin with a compaction head. This view shows a power unit of this invention attached to the compaction head for movement of the compaction head. This figure shows the position of the compaction head and the power unit prior to a packing operation.
FIG. 7 is a side sectional view, with parts broken away, similar to FIG. 6, and showing the position of the compaction head and the power unit following the first stage of the packing operation.
FIG. 8 is a side sectional view, with parts broken away, similar to FIGS. 6 and 7, and showing the position of the compaction head and the power unit following the second stage of packing operation.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-5 show in detail a power unit 16 of this invention. The power unit 16 comprises an e1ongate housing 18. Attached to the elongate housing 18 is a mounting bracket 19. Adjacent the mounting bracket 19, the elongate housing 18 is provided with a main fluid passage 20. Within the main fluid passage 20, at the upper part thereof, is an annular snap-ring 22. A cup shaped retainer 24 is also within the main passage 20 and is encompassed by a coil spring 26. The cup-shape retainer 24 has a part which is engaged by the coil spring 26 and is urged by the coil spring 26 into engagement with the snap-ring 22. The cup-shape retainer 24 is also encompassed by a tubular valve member 30, which has a part encompassed by the coil spring 26. Thus, part of the tubular valve 30 encompasses the cup-shape retainer 24. The coil spring 26 engages a shoulder 32 formed on the tubular valve 30 and urges the tubular valve 30 in a direction away from the snap-ring 22.
The tubular valve 30 extends along the main passage 20 and has an end portion engaged by an abutment valve 38. The abutment valve 38 has a cylindrical extension part 38b extending downwardly therefrom and which encompasses a coil spring 40. The coil spring 40 engages the abutment valve 38. The coil spring 40 also engages a wall 42, shown at the lower portion of the main passage 20. The coil spring 40 thus urges the abutment valve 38 toward the tubular valve 30. The abutment valve 38 has an orifice 44 therethrough. The wall 42 has an orifice 48 therethrough. The orifice 48 is larger than the orifice 44.
Normally positioned within the orifice 48, and closing the orifice 48, is a dart valve 50. The dart valve 50 is engaged by a coil spring 52. The coil spring 52 also engages an adjustment screw 54. The coil spring 52 urges the dart valve 50 into the orifice 48. The dart valve 50 and the coil spring 52 are within an outlet passage 56. The outlet passage 56 is in communication with a return conduit 60 which leads to a fluid reservoir 62.
The tubular valve 30 has a cylindrical wall, provided with openings 66 therein which are normally in communication with internal passages 68 within the housing 18. The cylindrical wall of the tubular valve 30 also has openings 70 which are spaced axially from the openings 66. The openings 70 are normally closed by the cylindrical internal walls of the main passage 20.
The internal passages 68 are in communication with a tubular conduit 74 which is within the housing 18 and attached thereto. The housing 18 also has internal passages 75, which are shown in FIG. 1 adjacent the abutment valve 38. The internal passages 75 are normally closed by the abutment valve 38, as shown in FIG. 1. The internal passages 75 lead to a passage 77, which leads into the housing 18. The tubular conduit 74 has attached thereto an annular encompassing collar 76 which supports a seal member 78. The collar 76 is encompassed by a cylinder 80 which has attached thereto a piston 82. The piston 82 encompasses the cylinder 80. The cylinder 80 has openings 83 therethrough. Encompassing the cylinder 80 and attached thereto is a guide collar 84. The guide collar 84 has attached thereto a slide member 86.
Encompassing the guide collar 84 is a cylinder 90 which has an end wall 92 external of the housing 18. A connector bracket 94 is attached to the end wall 92.
Encompassing the cylinder 90 and attached thereto is a ring 95. Attached to the cylinder 90 at the end thereof opposite the end wall 92 is a piston 96. Seal members 98 are attached to the piston 96. The seal members 98 engage a cylinder 100 which encompasses the piston 96. The cylinder 100 is attached to the piston 82 Thus, the piston 96 and the cylinder 90 are between the cylinders 80 and 100 which are attached to the piston 82. Attached to the cylinder 100 and slidably encompassing the cylinder 90 is a seal unit 106.
A conduit 126 leads from the reservoir 62 to the main passage 20 of the housing 18. Suitable pump means, not shown, are employed to pump fluid from the reservoir 62.
Encompassing the cylinder 100 and attached thereto, adjacent the piston 82, is a collar 110 which has attached thereto seal members 112. The seal members 112 and the collar 110 slidably engage a cylindrical wall 116 of the elongate housing 18. Also, encompassing the cylinder 100 and attached thereto is a ring 120. Attached to the cylindrical wall 116 adjacent the end thereof is an annular seal unit 124 which encompasses and engages the cylinder 100.
Attached to the cylinder 100 at the end thereof and adjacent the seal unit 106 is a collar 130. Attached to the collar 130 is a bracket 134. The bracket 134 has attached thereto a rigid conduit 138, which extends into a conduit housing 140.
Within the conduit housing 140 and attached thereto is a seal unit 144 which encompasses and slidably engages the rigid conduit 138. Encompassing the rigid conduit 138 and attached thereto and positioned within the conduit housing 140 is a seal unit 139. Adjacent the seal unit 139 the rigid conduit 138 is provided with openings 145. The seal unit 139 slidably engages the internal walls of the conduit housing 140.
The conduit housing 140 is attached to brackets 146 and 148, which are also attached to the elongate housing 18. A connector conduit 150 extends from the cylinder 100 and into the rigid conduit 138 for fluid communication therebetween. A connector conduit 154 extends from the housing 18 to the conduit housing 140, for communication between the housing 18 and the conduit housing 140. The conduit housing 140 has attached thereto, in communication therewith, a conduit 160, which is also joined to the reservoir 62 for communication between the conduit housing 140 and the reservoir 62.
As shown in FIGS. 6, 7, and 8, the power unit 16 is mounted within a refuse container 250. The mounting bracket 19 of the housing 18 is pivotally attached to an inner forward end part 251 within the refuse container 250. The refuse container 250 is shown herein as being mounted upon a vehicle 252. However, if desired, the refuse container 250 may be one which is not mounted upon a vehicle. The refuse container 250 has an opening 254 in the upper portion thereof. The opening 254 is closed by a movable cover member 256. The cover member 256 is shown in an open position. The refuse container 250 also has a gate 258 at the rear end thereof, through which refuse is ejected when the gate 258 is open.
Within the refuse container 250 is a compaction head 260 which is movable along the length of the interior of the refuse container 250. Pivotally attached to the compaction head 260 is the connector bracket 94 which is attached to the end wall 92 of the cylinder 90.
Refuse is dumped into the refuse container 250 through the opening 254. Then the power unit 16 is operated to move the compaction head 260 toward the rear of the refuse container 250 for compaction of the refuse.
In the operation of the power unit 16 for movement of the compaction head 260 fluid from the reservoir 62 is forced through the conduit 126 and into the main passage 20 of the housing 18. The fluid flows through the tubular valve member 30. Fluid flows from the tubular valve member 30 through the orifice 44 of the abutment valve 38. Fluid flows to the wall 42 but cannot flow through the orifice 48 because the dart valve 50 closes the orifice 48. Fluid flows outwardly from the tubular valve member 30 through the openings 66 in the tubular valve member 30.
As shown in FIG. 1, the openings 66 of the tubular valve member 30 are in alignment and communication with the internal passage 68. Therefore, fluid flows out of the tubular valve member 30, through the openings 66 thereof and through the passage 68 and into the tubular conduit 74. The fluid flows through the tubular conduit 74 and from the tubular conduit 74 into the cylinder 80 and engages the end wall 92 of the cylinder 90. The fluid also flows through the openings 83 in the cylinder 80 and into the cylinder 90. The fluid flows into the space between the cylinder 80 and the cylinder 100. The fluid flows between the piston 82 and the piston 96 and applies pressure upon the piston 96.
The pressure of the fluid upon the piston 96 and upon the end wall 92 forces the piston 96 and the cylinder 90 to move to the right as illustrated in FIG. 2. The cylinder 90 moves to the right until the resistance of the compaction head 260 prevents further movement or until the ring 95 abuttingly engages the seal unit 106, is shown in FIG. 2. Thus, the compaction head 260 is moved from the position thereof shown in FIG. 6 to the position thereof shown in FIG. 7.
When the cylinder 90 is positioned as shown in FIG. 2, the cylinder 90 is extended to its maximum position with respect to the cylinders 80 and 100. No additional movement of the cylinder 90 with respect to the cylinders 80 and 100 is possible. However, fluid pressure applied within the main passage 20 continues, and fluid pump pressure is capable of applying increased fluid pressure within the main passage 20. When fluid pressure within the main passage 20 increases, increased fluid pressure is exerted through the orifice 44 of the abutment valve 38. Also, increased fluid pressure is exerted upon the end wall 42 and into the orifice 48 of the end wall 42. Thus, the dart valve 50 is forced away from the orifice 48, and the orifice 48 is opened for flow of fluid therethrough, as shown in FIG. 3.
The orifice 48 in the end wall 42 is larger in area than the orifice 44 in the abutment valve 38. Therefore, fluid flows through the orifices 44 and 48, and fluid pressure imbalance occurs. As a result of fluid pressure imbalance, fluid pressure upon the abutment valve 38 moves the abutment valve 38 downwardly within the main passage 20, as shown in FIG. 3. Such downward movement of the abutment valve 38 is against the forccs of the spring 40. When the abutment valve 38 moves downwardly, the spring 26 moves the tubular valve 30 downwardly, as the tubular valve 30 remains in engagement with the abutment valve 38.
Fluid which flows through the orifice 48 flows outwardly through the outlet passage 56 and into the return conduit 60. Then the fluid flows through the conduit 60 into the reservoir 62.
When the abutment valve 38 moves downwardly and the tubular valve 30 moves downwardly, the openings 66 in the tubular valve 30 are moved from communication with the internal passage 68. Thus, the openings 66 in the tubular valve 30 are closed. Therefore, the entrance to the internal passage 68 is closed by the cylindrical wall of the tubular valve 30, as shown in FIG. 3. Therefore, all the fluid which has entered the housing 18 through the passage 68 is trapped within the housing 18. The trapped fluid comprises fluid within the tubular conduit 74, within the cylinder 90 and between the cylinders 80 and 100.
Also, downward movement of the tubular valve 30 moves the openings 70 of the tubular valve 30 into communication with the internal passage 75, as shown in FIG. 3. Therefore, high pressure fluid flows from the tubular valve 30 through the openings 70 and into the passage 75 and into the passage 77 within the housing 18, as illustrated in FIG. 3. This fluid engages the piston 82. Thus, high pressure fluid is applied to the piston 82, and the piston 82 is moved to the right, as shown in FIG. 3. Movement of the piston 82 to the right applies pressure upon fluid which is within the cylinder 90 and which is located between the cylinders 100 and 80 and upon the fluid between the piston 82 and the piston 96.
The pressure of the trapped fluid is increased as the piston 82 moves toward the right and toward the piston 96, and applies pressure upon the trapped fluid as shown in FIG. 3. In view of the fact that the piston 82 is significantly larger in area than the piston 96, the increased fluid pressure applied for movement of the cylinder 90 is significant. Thus, the piston 82, the cylinder 90 and the end wall 92 and the connector bracket 94 are moved farther to the right, as shown in FIG. 3. Thus, the forces moving the compaction head 260 toward the right from the position shown in FIG. 2 to the position shown in FIG. 3 are greater than the forces moving the compaction head 260 from the position thereof shown in FIG. 1 to the position thereof shown in FIG. 2. Thus, the compaction head 260 is moved farther toward the rear of the refuse container 250, as illustrated in FIG. 3.
As the pistons 96 and 82 move toward the right, as shown in FIGS. 2 and 3, fluid within the housing 18 is forced therefrom through the connector conduits 154 and 150 and into the conduit housing 140, as illustrated in FIGS. 2 and 3. The fluid flows from the conduit housing 140 into the conduit 160 and flows into the reservoir 62. As the cylinder 100 moves toward the right as shown in FIG. 3, the rigid conduit 138 slidably moves outwardly with respect to the conduit housing 140. Thus, fluid communication between the rigid conduit 138 and the conduit housing 140 continues as the cylinder 100 moves to the right, as illustrated in FIG. 3.
FIG. 8 illustrates the maximum rearward position of the compaction head 260 as the cylinders 90, 80, and 100 are in the maximum extended position thereof.
When it is desired to discharge refuse from the refuse container 250, the gate 258 is opened, and the compaction head 260 is moved rearwardly by operation of the power unit 16. In the position of the compaction head 260 shown in FIG. 8 refuse within the container 250 can be forced from the container 250 when the gate 258 is opened.
When it is desired to move the compaction head 260 toward the left, fluid pressure ceases to be forced into the main passage 20 through the conduit 126. When fluid pressure into the main passage 20 through the conduit 126 ceases, the dart valve 50 is returned to its position within the orifice 48 by the spring 52, and the spring 40 moves the abutment valve 38 and the tubular valve 30 upwardly to their normal positions as shown in FIGS. 1, 2, and 5. Thus, the openings 66 in the tubular valve 30 are again in communication with the passage 68, and the abutment valve 38 returns to its position closing the passage 75.
Fluid is forced from the reservoir 62 through the conduit 160 and into the conduit housing 140, as illustrated by an arrow 300 in FIG. 4. The fluid travels from the conduit housing 140 through the conduits 154 and 150 and into the housing 18, as illustrated by arrows 300 in FIGS. 4 and 5. Also, as shown in FIG. 4, the fluid flow into the housing 18 is applied to the piston 82 and the piston 96, and the cylinders 80 and 100 are moved toward the left. Also, as shown in FIG. 5, fluid flows through the connector conduit 150 into the housing 18. Thus the piston 82 and the piston 96 and the cylinders 100, 80, and 90 are forced toward the left. As this movement occurs, fluid is forced through the passages 77 and 75 and into the main passage 20. Due to the fact that the abutment valve 38 is tapered as shown, fluid flow from the passage 75 forces the abutment valve 38 downwardly, as illustrated in FIG. 4, and fluid flows past the abutment valve 38 and into the tubular valve 30 and into the main passage 20. Fluid flows outwardly from the main passage 20 and into the conduit 126 and flows through the conduit 126 to the reservoir 62.
Thus, it is understood that the power unit 16 of this invention is capable of moving a compaction head for compaction of refuse in a refuse container. The power unit 16 is capable of applying high forces. In fact, during operation of the power unit 16 the power unit 16 is capable of applying increasingly greater fluid forces upon a compaction head for movement thereof.
It is also to be understood that a power unit 16 made according to this invention can be employed in types of environments other than for movement of a compaction head within a refuse container.
Although the preferred embodiment of the power unit of this invention has been described, it will be understood that within the purview of this invention various changes may be made in the form, details, proportion and arrangement of parts, the combination thereof, and the mode of operation, which generally stated consist in a power unit within the scope of the appended claims.
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A fluid operable power unit which is particularly adapted for movement of a compaction head in a refuse container. However, the power unit is also useful in other types of mechanism.
The power unit comprises a plurality of telescopically movable cylinders and pistons. Fluid pressure is applied for movement of the first cylinder. Then increased fluid pressure is applied for movement of the second cylinder. As the first cylinder ceases to move, fluid pressure increases and automatically operable valve means traps the fluid which has moved the first cylinder. Then increased fluid pressure moves the second piston and second cylinder. As the second piston and the second cylinder move under the influence of increased fluid pressure, the fluid which is trapped is increased in pressure.
Thus, high pressure forces act to move an actuator member for compaction or for any other purpose.
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RELATED CASE
U.S. patent application Ser. No. 09/033,351, entitled “AN IMPROVED METHOD FOR RENDERING A 3D COMPUTER IMAGE OF A TRIANGLE”, has been filed on Mar. 2, 1998. Now U.S. Pat. No. 6,266,065 and is assigned to the assignee of the present application. The above application contains subject matter related to the subject matter of the present application and is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a computing method for 3D graphics. More specifically, the present invention relates to a pixel based fast area-coverage computing method for anti-aliasing in 3D graphics applications.
BACKGROUND OF THE INVENTION
In the prior art of high-end 3D computer graphics, the pixels of an image are sub-divided into sub-pixels, and an area-coverage computing technique is employed to resolve the aliasing effect common to graphics imaging. That is, an anti-aliasing method is used which assigns pixel colors based on the fraction of the pixel area that is covered by the image being rendered. Various prior art examples of anti-aliasing methods are described in U.S. Pat. No. 4,908,780, by Priem, et al. (1990); and U.S. Pat. No. 5,299,308, by Suzuki, et al. (1994).
For real time anti-aliasing operation in the prior art, the segment based area-coverage computing method is generally used. That is, a set of consecutive pixels on a scan line constitute a segment, which is evaluated as an entity, utilizing existing graphics pipelines within a system, so that no additional hardware is required. However, because the pixel data is accumulated in segments, there are inherent time delays involved, which adversely affect the overall system pixel yield rate.
To illustrate the need for an anti-aliasing technique, FIG. 1 shows a screen geometric of pixels and an aliased triangle image. The dash-lined lattice constitutes the geometric coordinate system for pixels. The geometric center of each pixel is located at the point where the vertical and horizontal dash lines intersect. The solid-lined lattice is appended to indicate the pixels' shape. Scan lines are horizontal lines which cross the geometric center of the pixels. The scan lines are shown as horizontal dash lines.
In graphics without anti-aliasing, as in FIG. 1, not all of the pixels on the edges are drawn. That is, a pixel is drawn only when it is interior to the edges of the triangle. More specifically, for a pixel on the left edge, it is drawn only if the point where the left edge and scan line intersect is located to the left of the pixel's geometric center. Similarly, for a pixel on the right edge, a pixel is drawn only if the point where the right edge and scan line intersect is located to the right of the pixel's geometric center. A pixel on an edge is considered to be covered when it is interior to the edge. For example, pixels A and B in FIG. 1 illustrate the left and right edge cases, respectively, and are considered to be covered. Therefore, for a pixel to be drawn on an aliased triangle, it must be either interior to the triangle, or it must meet one of the edge conditions, as described above. This is the primary rule for determining whether or not a pixel should be drawn on an aliased image.
As a result, the pixel edges are drawn in a staircase fashion, as shown in FIG. 1 . The staircase shape is known in the art as “jagged”, and the phenomenon that causes the “jaggies” is called aliasing.
There are two approaches used in the graphics art to suppress the aliasing effect. First, all the pixels that intersect the edge lines, whether covered or not, are taken into account. Second, a pixel is drawn by blending its color (foreground color) with the background color. The amount of blending (ratio of foreground color to background color) is proportional to the pixel's area that is covered by the edge line. FIG. 2 illustrates the same triangle as in FIG. 1, with the addition of all the “uncovered” pixels that intersect the edge lines. As shown in FIG. 2, the jaggies are reduced. However, a method is required for computing the area-coverage of an edge over a pixel.
Calculating a pixel's area-coverage may be accomplished by dividing each physical pixel into logical sub-pixels. FIG. 3 depicts an enlargement of the second row of the triangle and pixels shown in FIG. 2 . In general, a pixel is divided linearly in both the x-direction and y-direction by a number n, which is a power of two. Accordingly a total of n 2 sub-pixels are generated. In FIG. 3, n=4, so that n 2 =16 sub-pixels for each pixel.
After dividing each pixel into sub-pixels, each sub-pixel is tested to determine whether or not it is interior to the edges. The same edge intersection rule is applied as in the aliased case, described above, except that the test is now run on sub-pixels, rather than on pixels. Testing of the sub-pixels can be implemented without the need for additional hardware, since the same hardware module used for testing pixels can be implemented to test sub-pixels. This is the most commonly used approach in the prior art.
The outcome of each sub-pixel's test is accumulated in a memory buffer. When all of the sub-pixels of a pixel have been tested, the accumulated test result is retrieved from memory. This accumulated test result represents the area-coverage of the pixel.
In the prior art implementation, the tests must be performed in scan-line order. Consequently, the test operation has to complete all n sub-pixel scan-lines of a segment before the coverage of a pixel is determined. Since the aperture of this type of test operation is the entire segment, this method is categorized as a segment based area-coverage computing algorithm.
In the FIG. 3 example, there are approximately 3xn 2 sub-pixels along the path to be tested. Since the computation of area-coverage for each pixel must wait for n sub-pixel scan-lines to be completely tested, delays are introduced into the test operation. As such, the segment based area-coverage method has the disadvantage of slowing down the rate of pixel yield.
Accordingly, it is an object of the present invention to overcome this disadvantage of the prior art by using a pixel based method and apparatus for sub-pixel area-coverage, which does not incur the inherent testing delays of the segment based method.
SUMMARY OF THE INVENTION
In accordance with an illustrative embodiment of the present invention, a pixel based method for computing the area-coverage of an image bounded by edges is as follows:
a) selecting a segment of the image to be evaluated for area-coverage, the segment being made up of a set of consecutive pixels on a scan-line section which intersects at least one of the boundary edges,
b) dividing each of the pixels into an n by n sub-pixel array, with n rows and n columns, where n is a number equal to a power of 2, and where the sub-pixel array has n sub-pixel scan-lines, with each sub-pixel scan-line crossing the geometric center of each row of sub-pixels,
c) selecting one of the sub-pixel arrays to constitute a current pixel for area-coverage evaluation,
d) determining the x-axis coordinates of the intersection points of the sub-pixel scan-lines of the current pixel with at least one of the boundary edges of the image,
e) comparing these x-axis coordinates with the x-axis coordinate of the current pixel,
f) determining from this comparison an area-coverage value for each of the sub-pixel rows within the current pixel,
g) accumulating the area-coverage values for all of the sub-pixel rows within the current pixel, and
h) normalizing the accumulated area-coverage values to determine an area-coverage value for the current pixel.
The inventive method described above is implemented in an inventive hardware module which is appended to a conventional graphics rendering engine. The resulting increase in overall system pixel yield rate as compared to the prior art segment based method is more than adequate compensation for the additional cost of the inventive hardware module.
An illustrative embodiment of the present invention is more fully described below in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a screen geometric of aliased pixels and triangle.
FIG. 2 is a screen geometric of anti-aliased pixels and triangle.
FIG. 3 is a sub-pixel detail of a segment of FIG. 2 .
FIG. 4 is a block diagram of a graphics rendering engine, in accordance with the present invention.
FIG. 5 illustrates the geometric attributes of a segment.
FIG. 6 depicts the computation of sub-pixel area-coverage, in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention is shown in FIG. 4, which depicts a graphics rendering engine in block diagram form. There are five modules in the diagram, which are functionally described below.
Rendering of a pixel is initiated by the Color Generator module and the Coordinate Generator module. The Color Generator module provides the color attributes of a target pixel, including Source Red (S R ), Source Blue (S B ), Source Green (S G ), and Source Alpha (S A ). The Coordinate Generator module provides the geometric attributes of the corresponding segment in which the target pixel resides. The geometric attributes include the left edge starting position (Start_x), the right edge ending position (End_x), the current pixel position (Current_x), the gradient of the left edge (Gradient_l), and the gradient of the right edge (Gradient_r).
These geometric attributes are inputted to the Area Coverage Computing module, which is the inventive apparatus disclosed herein. Importantly, the Area Coverage Computing module implements the inventive pixel based area-coverage computing algorithm, in order to compute the effective area of the target pixel.
The computed pixel area-coverage (A C ) is outputted to the Alpha Adjustment module and combined with the source alpha (S A ) from the Color Generator. The resulting modified source alpha (M A ) is outputted from the Alpha Adjustment module to the Alpha Blending module.
In the Alpha Blending module, the modified source alpha (M A ) is combined with Source Red (S R ), Source Blue (S B ), and Source Green (S G ) from the Color Generator module. Together, they define the current pixel's color, or the so-called foreground color. The Alpha Blending module also blends the pixel's color (foreground color) with the background colors (D A ,D R ,D B , D G ) that follow the modified alpha value M A . The output of the Alpha Blending module is then drawn on a screen.
Notwithstanding the aforementioned assumptions, the inventive algorithm can be applied directly to the general case.
The present invention provides a method and apparatus for computing the current pixel's effective area covered by an edge line. The inventive apparatus is the Area Coverage Computing module, as shown in the rendering engine of FIG. 4 . The inventive method is a pixel based area-coverage computing algorithm, which is implemented by the Area Coverage Computing module. Unlike the prior art segment based area-coverage computing algorithm, the inventive algorithm tests n 2 sub-pixels of the target pixel “locally”. That is, the pixel is tested independently of the other neighboring pixels of its segment. Therefore, the excessive processing latency of the prior art segment based method is avoided, as explained in the following discussion.
In the following description of the inventive algorithm, a few assumptions have been made for simplification. These include:
1. The direction of drawing a segment is always from left to right.
2. The description only covers monochrome color.
3. The rendering of pixels is ordered in a front to back fashion.
Referring again to FIG. 4, the inputs to the Area Coverage Computing module from the Coordinate Generator module are the coordinate attributes of a segment (Gradient_l, Gradient_r, Current_x, End_x, and Start_x). The geometric attributes of the segment are illustrated in FIG. 5, where the shaded pixels constitute the segment.
As shown in FIG. 5, start_x is the starting edge point of the segment, end_x is the ending edge point of the segment, and current_x is the current pixel position. Please note that current_x can assume any pixel position in the segment.
The inventive algorithm is implemented by the Area Coverage Computing module to calculate the current pixel's area-coverage value (A C ), based on the input segment attributes described above.
Geometric attribute start_x represents the x-coordinate of the left edge intersection with the current segment. Similarly, attribute end_x represents the x-coordinate of the right edge intersection with the current segment. Note that these coordinate values are real numbers, and are common to all of the pixels in the segment. Also, current_x is an integer value, which indexes the particular pixel to be drawn.
The inventive algorithm divides the current pixel into n by n sub-pixels. To index these sub-pixels, the original integer coordinate system is expanded fractionally, with a resolution of 1/n. This is illustrated in FIG. 6, where pixels ( 3 , 10 ) and ( 10 , 10 ), from FIG. 5, are shown in expanded detail. In the FIG. 6 example, each pixel is divided into a 4 by 4 sub-pixel array, and the intersection points of the edges and the sub-pixel scan-lines are indicated by round dots.
The inventive algorithm traces the edge lines by using the gradient information (Gradient_l and Gradient_r) inputted to the Area Coverage Computing module, and determines the edges intersection points at each sub-pixel scan-line. As a result, the intersection points are identified on both left and right edges, and are represented by xs[i] and xe[i], respectively. The symbol i designates the sub-pixel scan-line number, where i=0, . . . , n−1. The values of xs[i] and xe[i] are common to all the sub-pixels on the same sub-pixel scan-line i of the segment.
The value of current_x is then compared to xs[i] and xe[i]. This comparison is made n-entries of the row at a time. Note that the current_x pixel position is an integer. Then, if current_x=x, the current pixel's left edge=x−0.5, and the current pixel's right edge=x+0.5. In FIG. 6, the two expanded pixels are shown at x=3 and x=10.
For each row [i] of the current pixel, the following conditions are examined:
(Condition — 0) if xs[i]<=x−0.5,
(Condition — 1) if x−0.5<xs[i]<x+0.5
(Condition — 2) if x+0.5<=xs[i],
(Condition — 3) if xe[i]<=x−0.5
(Condition — 4) if x−0.5<xe[i]<x+0.5
(Condition — 5) if x+0.5<=xe[i]
Based on the above comparisons, a set of weights ws[i] and we[i] are assigned to each row [i]. The contribution to the coverage area by a row [i] is determined by subtracting ws[i] from we[i]. The following rules determine the values of ws[i] and we[i]:
Rule 1: Condition — 2 and Condition — 3 indicate that a row [i] of the current pixel is neither on the edge nor inside the triangle. Therefore, the area contribution to the pixel is zero.
Rule 2: Condition — 0 and Condition — 5 indicate that a row [i] is interior to the triangle. The weights ws[i] and we[i] are assigned to be 0 and n, respectively. Therefore, the row contributes area n to the pixel.
Rule 3: Condition — 1 indicates that the left edge passes through the current row, and Condition — 4 indicates that the right edge passes through the current row. When condition — 1 is true, the exact number of sub-pixels of the row [i] which are covered by the edge must be determined. This is done as follows:
Step 1: Extract the fractional part of the (xs[i]−0.5) and multiply it by n.
Step 2: Round the resultant value to the nearest integer value from the set of [0,1,2, . . . ,n−1].
This value is the weight of ws[i] of the row [i].
FIG. 6 illustrates the values resulting from the application of the aforementioned procedures to pixel ( 3 , 10 ) and pixel ( 10 , 10 ). Referring to pixel ( 3 , 10 ) at sub-pixel scan line 0 , where xs[0 ]=2.78 and x=3, it is shown that: x−0.5<xs[0]<x+0.5, which satisfies Condition — 1. Then, ws[0]=round(fract(xs[0]−0.5)x4)=round(0.28x4)=round(1.12)=1. Note that round (x) returns the rounded number of x and fract (x) returns the fractional part of x.
When Condition — 4 is true, a similar procedure is applied to determine we[i], except that xs[i] is replaced by xe[i] in Step 1. Referring to pixel ( 10 , 10 ) at sub-pixel scan line 2 , where xe[2]=9.8 and x=10, it is shown that: x−0.5<xe[2]<x+0.5, which satisfies Condition — 4. Then, we[2]=round(fract(xe[2]−0.5)x4)=round(0.3x4)=round(1.2)=1.
Finally, the areas contributed by each row are accumulated into an overall sub-pixel coverage value. This sub-pixel coverage value is then normalized by multiplying by 1/n 2 , as shown in Equation (1), below: 1 n 2 × ∑ i = 0 n - 1 ( w e [ i ] - w s [ i ] ) Equation ( 1 )
Referring again to FIG. 4, the sub-pixel area-coverage value (A C ) is outputted from the Area Coverage Computing module to the Alpha Adjustment module. The Alpha Adjustment module obtains the adjusted alpha value (M A ) by multiplying the area-coverage value (A C ) by the source alpha (S A ), from the Color Generator. The adjusted source alpha value (M A ) is then outputted from the Alpha Adjustment module to the Alpha Blending module. The Alpha Blending module blends the pixel's foreground color (S G ,S 3 ,S R ) with the background color (D G ,D B ,D R ,D A ) that follows the adjusted alpha value (M A ).
In short, a pixel based area-coverage method and apparatus are disclosed which evaluate pixel area-coverage individually, rather than on a segment basis. That is, the inventive operation aperture is the current pixel only, and not the neighboring sub-pixels within the segment. As such, the inventive pixel based technique avoids accumulating the latencies from processing other pixels, as is done in the prior art segment based area-coverage computing algorithm.
The above described embodiments of the invention are intended to be illustrative only. Numerous alternative embodiments may be devised by those skilled in the art without departing from the spirit and scope of the following claims.
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A pixel based method for the computation of sub-pixel area-coverage is implemented in an area-coverage hardware module, within a 3D computer graphics rendering engine. Unlike the prior art segment based method which requires an operating aperture of an entire segment, the present invention only requires an operating aperture of one pixel. Therefore, the overall system pixel yield rate is increased.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to the subject matter of U.S. patent application Ser. No. 10/383,095, incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed to the field of improvements in pallets for securing electronic circuit boards during the manufacturing process.
BACKGROUND OF THE INVENTION
Circuit board manufacturing is well known in the art. Electrical components (i.e. processors, memory, capacitors, diodes, resistors, and the like) are generally added to a blank circuit board to create a board which is later installed in an electrical device such as a computer. The blank circuit board must be held in place during the manufacturing process. This is usually accomplished through the use of a circuit board pallet.
There are many different patents directed towards methods of securing the circuit board to the pallet. The most common method is to use a plurality of pins extending upwardly from the pallet which fit into holes on the circuit board. The pallet typically has adjustment arms that create either a tensile or compressive force between these pins to hold the circuit board in place. The most common method of attaching the pins to the pallet is to drill a hole either partially through the pallet from the top or completely through the pallet and wedge a portion of the pin into the hole. These two pin attachment methods are illustrated in FIGS. 1A and 1B . This configuration leaves a portion of the pin methods are illustrated in FIGS. 1A and 1B . This configuration leaves a portion of the pin protruding from the top surface of the pallet so that the circuit board can be attached to the pallet. If the pin is too high, it will interfere with the various component positioning and soldering devices which pass over the circuit board during the manufacturing process. If the pin is too low, it will not sufficiently hold the circuit board in place. Therefore, the distance the pin protrudes from the pallet is an important consideration in the manufacturing process and as a result, the tolerances for pin height are very tight. Furthermore, this pin height must remain within these tight tolerances throughout thousands of cycles of heating and cooling. If the pin height falls out of the tolerance range, then the pallet must be discarded and replaced with a new pallet.
Once the circuit board has been affixed to the pallet, the components may be added to the circuit board, typically by soldering. In order for the components to be soldered in place, they must be properly positioned over the circuit board using a component support structure. The components must be held in place sufficiently long for the solder process to be completed and for the solder to cool and harden. Once the solder has cooled and hardened, it securely affixes the component to the circuit board and the component support structure may be removed from the components.
The frequent and repetitious soldering and other manufacturing processes subject the pallet to intense heat, often in excess of 550° F. Because the pallet is made from a non-conductive material (i.e. fiberglass) and the pins are metal, the pallet and the pin expand and contract at different rates. The differing rates of contraction and expansion eventually cause the pin to move out of the tolerance range. Therefore, a need exists for a method of installing a pin into a pallet such that it will not fall out of tolerance range after repeated heating and cooling.
Moreover, although there have been a myriad of different devices proposed to position the components in place, the previous solutions to this problem have been bulky, complicated, and/or cumbersome to operate. Virtually all of the previous solutions are specific to a certain type of component and/or a certain configuration of components on the board. The prior art does not contain a device that is adaptable to a plurality of different component types and configurations on the circuit board. Consequently, a need also exists for an apparatus and method for efficiently positioning components over a circuit board during the soldering process that is adaptable to a variety of different components. Furthermore, a need exists for a component positioning apparatus that is robust enough to be adaptable to a plurality of different component sizes, shapes, and configurations on the circuit board.
SUMMARY OF THE INVENTION
The present invention, which meets the needs stated above, is a circuit board pallet with an improved circuit board retention pin and component positioning arms. The improved pin of the present invention is cylindrical in shape with an enlarged head. A countersunk hole is drilled in the bottom of the pallet to accommodate the pin. The pin is inserted into the countersunk hole and secured with a high-temperature epoxy resin. The epoxy holds the pin securely in place and keeps the pin from moving up or down.
The present invention also comprises at least one arm. The arm is affixed at one end to a swivel joint. The swivel joint allows the arm to rotate about a vertical axis. The upper portion of the swivel joint is hinged such that the arm can rotate about a horizontal axis. The combination of movement about the horizontal and vertical axis allows the arm to be positioned at any point over the pallet, and consequently, the circuit board.
In the manufacturing process, the blank circuit board is secured to the pallet using the securement pins. Next, the arm is positioned away from the circuit board and the components are secured to the arm. The arm is then positioned over the circuit board and secured to the anchor. Finally, the components may be soldered to the circuit board. Additional components may be secured to the arm and installed on the circuit board as needed.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIGS. 1A and 1B are cross-sectional elevation views of prior art circuit board retention pins;
FIG. 2A is a perspective view of the present invention with the arm in the lowered position;
FIG. 2B is a perspective view of the present invention with the arm in the raised position;
FIGS. 3A and 3B are cross-sectional elevation views of the pin of the present invention;
FIG. 4 is a cross-sectional elevation view of the rail and swivel joint of the present invention taken along line 4 — 4 in FIG. 2B ;
FIG. 5 is a cross-sectional elevation view of the anchor assembly of the present invention taken along line 5 — 5 in FIG. 2A ;
FIG. 6 is a plan view of the anchor assembly of the present invention; and
FIG. 7 is a perspective view of a circuit board and the present invention with components attached to the arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2A is a perspective view of pallet 100 . The bottom of pallet 100 consists of a flat, rectangular base 102 . A circuit board depression 120 in base 102 is sized to accept the circuit board (not shown). Base 102 contains a plurality of pins 112 , which are used to secure a circuit board to base 102 . Two of the pins 112 in FIG. 2A are attached to adjustable arms 114 . The circuit board has holes that accommodate pins 112 . The circuit board holes are slightly closer together than the pins 112 in base 102 . Thus, when the circuit board is placed in the circuit board depression 120 , an operator (not shown) moves adjustment arms 114 inward so that pins 112 will mate up with the holes in the circuit board. The operator can move adjustment arms 114 by pushing tabs 118 , which are easily accessed through tab access depression 116 . Adjustment arms 114 are spring loaded such that they will create a tensile force on the circuit board when released. After the circuit board has been installed, the operator releases tabs 118 and the tensile force between pins 112 will hold the circuit board in place. Aperture 122 is cut out of base 102 so that the soldering equipment (not shown) can access the bottom of the circuit board.
Four rails 104 are attached to the perimeter of base 102 . Rails 104 are “T” shaped when viewed in cross-section. Rails 104 are secured to base 102 with screws inserted up through the bottom of base 102 into rails 104 . Swivel joint 108 slides along one of rails 104 and is rotatably attached to the arm 100 . Swivel joint 108 is located at the proximate end of arm 110 . If desired, a plurality of swivel joints 108 and arms 110 can be employed on pallet 100 . The distal end of arm 110 extends across pallet 100 to another rail 104 . Arm 110 is secured to rail 104 by anchor 106 . Anchor 106 slides along rail 104 similarly to swivel joint 108 . If desired, swivel joint 108 and/or anchor 106 may be secured to base 102 using a screw so that they remain in a fixed position with respect to rail 104 . Additionally, a plurality of anchors 106 may be utilized for any of the swivel joint 108 and arm 110 combinations.
FIG. 2B is a perspective view of the present invention with arm 110 detached from anchor 106 and positioned away from base 102 . Swivel joint 108 allows arm 110 to be positioned away from base 102 with rotational freedom both parallel and perpendicular to the base 102 . In other words, arm 110 has at least a hemisphere of movement. Positioning arm 110 away from base 102 allows an operator (not shown) to attach circuit board components (not shown) to arm 110 .
FIG. 3A is a cross-sectional elevation view of pin 112 and base 102 . A high temperature epoxy is used to secure pin 112 inside base 102 . The use of a high temperature epoxy to secure pin 112 inside base 102 is much more reliable than the wedging method used in the prior art. Moreover, when pallet 100 is repeatedly heated and cooled in the manufacturing process, the high temperature epoxy will keep pin 112 affixed in place and ensures that pin 112 does not fall outside the narrow tolerance range.
FIG. 3B is an alternative embodiment of pin 112 and base 102 . Although FIGS. 3A and 3B illustrate two geometrical embodiments of the present invention, they are not meant to be limiting in any way. Persons skilled in the art will be aware of a myriad of different geometrical configurations of pin 112 and base 102 . For example, the shank of pin 112 that is unexposed may be threaded to engage opposing threads in base 102 . In other words, pin 112 could partially screw into base 102 in addition to being held in place with the high temperature epoxy. Furthermore, if a more secure connection between pin 112 and base 102 is desired, the bottom of pin 112 can be recessed with respect to the bottom surface of base 102 . In this configuration, the high temperature epoxy can be added over the bottom surface of pin 112 creating an even more secure connection between pin 112 and base 102 .
FIG. 4 is a detailed illustration of the connection between swivel joint 108 , rail 104 , and base 102 . Rail 104 is affixed to base 102 by a plurality of screws 130 . Screws 130 are inserted from underneath base 102 and are threaded into rail 104 . Threaded screws 130 are not the only method for affixing rail 104 to base 102 and other methods of attachment are known by persons skilled in the art.
Swivel joint 108 comprises upper member 109 and lower member 107 . Lower member 107 comprises two sections: one that is “C” shaped to accommodate “T” shaped rail 104 , and another that is “L” shaped, the lower part of which is flush with base 102 . The “C” shaped portion of lower member 107 freely slides laterally along rail 104 . The “L” shaped portion of lower member 107 has a hole to accommodate a screw 130 which may be screwed into base 102 . Screw 130 inserted through lower member 107 into base 102 secures lower member 107 in place and prevents swivel joint 108 from traveling laterally along rail 104 .
Swivel joint 128 connects lower member 107 to upper member 109 . Washer 124 is disposed between the lower member 107 and upper member 109 to reduce the friction associated with rotation of upper member 109 with respect to lower member 107 . Alternatively, washer 124 could be a bearing or any other friction reducing item as determined by persons skilled in the art.
Upper member 109 is “C” shaped in cross-section. Upper member 109 freely rotates about swivel joint pin 128 and has 360° of movement in a plane parallel to base 102 . Arm pin 126 runs through arm 110 and the two prongs of upper member 109 . In FIG. 4 , arm 110 is positioned away from the viewer (going into the page), parallel to rail 104 . Arm 110 freely rotates about arm pin 126 and has at least 180° of movement in a plane perpendicular to base 102 . In other words, arm 110 in FIG. 4 is hinged about arm pin 126 such that arm 110 can be repositioned to come out of the page instead of going into the page.
Swivel joint 108 is novel in that it allows arm 110 to be positioned away from pallet 100 to receive components, and then positioned over pallet 100 to attach the components to the circuit board. When a plurality of arms 110 are utilized, some of arms 110 can be positioned away from the circuit board so that they may receive the components. Simultaneously, other arms 110 can be positioned over the circuit board so that the components can be soldered to the circuit board.
FIG. 5 is a detailed illustration of the connection between anchor 106 and arm 110 . Connector 138 is disposed at the distal end of arm 110 in relation to swivel joint 108 . Connector 138 comprises a cylindrical center shaft and a shorter cylindrical member perpendicularly attached to each end of the center shaft of connector 138 . Connector 138 freely rotates 360° within arm 110 . Spring 140 is disposed between arm 110 and connector 138 such that the spring force is always attempting to bring the lower portion of connector 138 in contact with the lower face of arm 110 .
Similarly to lower member 107 in FIG. 4 , anchor 106 has a “C” shaped portion and an “L” shaped portion. The “L” shaped portion of anchor 106 can be secured to base 102 with screw 130 , similar to lower member 107 . The “C” shaped portion of anchor 106 slides along rail 104 similar to lower member 107 . However, the inside surface of the “C” shaped portion of anchor 106 does not contact the upper surface of rail 104 . Instead, an anchor aperture 139 is created. Anchor aperture 139 is defined as the cavity between anchor 106 and rail 104 . As seen in FIG. 6 , anchor aperture 139 has an elongated opening on the upper portion of anchor 106 . When arm 110 is positioned over anchor 106 , connector 138 can be vertically displaced downward and the lower portion of connector 138 will pass through the elongated slot of anchor aperture 139 . If connector 138 is then rotated 90° and released, spring 140 will cause the lower portion of connector 138 to come into contact with the inside face of anchor 106 and the lower face of arm 110 will come into contact with the upper face of anchor 106 . In this manner, arm 110 can be secured to anchor 106 .
FIG. 7 is an illustration of circuit board 132 installed in pallet 100 . Components 134 have been attached to arm 110 via component holders 136 . Arm 110 holds components 134 in place over circuit board 132 while a soldering machine (not shown) solders component 134 into place on circuit board 132 . In alternative embodiments, arm 110 is connected to anchor 106 at both the proximate and the distal end. This embodiment yields an arm 110 that is fully detachable from the pallet 100 . In further alternative embodiments, a plurality of arm 110 and swivel joint 108 combinations are used to attach components 134 to circuit board 132 .
With respect to the above description, 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. The novel spirit of the present invention is still embodied by reordering or deleting some of the steps contained in this disclosure. The spirit of the invention is not meant to be limited in any way except by proper construction of the following claims.
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A circuit board pallet with an improved securement pin and component positioning arms is disclosed. The improved pin of the present invention is cylindrical pin with an enlarged head. A countersunk hole is drilled in the bottom of the pallet to accommodate the pin. The pin is inserted into the countersunk hole and secured with a high-temperature epoxy resin. The epoxy holds the pin securely in place and keeps the pin from moving up or down.
The present invention also comprises at least one arm affixed at one end to a swivel joint. The swivel joint allows the arm to rotate about a vertical axis. The upper portion of the swivel joint is hinged such that the arm can rotate about a horizontal axis. The combination of movement about the horizontal and vertical axis allows the arm to be positioned at any point over the pallet.
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RELATED APPLICATION
This application is related to copending application Ser. No. 452,713, filed Mar. 20, 1974, now U.S. Pat. No. 3,868,821 dated Mar. 4, 1975.
BACKGROUND OF THE INVENTION
The invention relates to hydraulic control systems useful for example, in controlling fixed displacement pumps wherein a plurality of pumps are provided for performing different functions, and especially to systems wherein some of the pumps in a circuit may be provided in pairs. The invention is especially useful in hydraulic systems used in heavy equipment such as earth-moving vehicles. An example is an excavator having an excavating bucket pivotally mounted on a stick which is in turn pivotally mounted on a boom. In such an excavator, a pair of pumps may be provided in a hydraulic circuit for operating hydraulic cylinders which move the stick and bucket and another pair of pumps may be provided in a second circuit having another pair of cylinders for operating the boom. In addition, in such equipment, the pumps may be used for other functions. For example, pumps in one of the circuits may also operate one track of the vehicle and the pumps in the other circuit may operate the other track. All pumps are typically driven by the vehicle engine through a common gear box.
In prior art systems, the pumps are generally driven by the operator at a constant speed. As is recognized, the input horsepower required of the prime mover which drives all of the pumps rises linearly with the pressure in the circuits and when the pressure rises substantially, as may occur when an obstruction is encountered during a digging operation, the torque requirements imposed on the prime mover may exceed the available torque. When this occurs, the diesel or gasoline engine used as a prime mover will stall. In the prior art, various arrangements are provided for unloading a pump in a circuit when an overload condition is encountered in that circuit which might cause the engine to stall or to cause damage to the equipment.
In the above-identified copending application an improvement in prior systems is disclosed in which positive displacement pumps driven by a common prime mover are arranged in operating circuits in a "crossover" unloading arrangement so that a pump in one circuit will be unloaded in response to pressure in either or both circuits. With the system disclosed in the prior copending application, one or more pumps in a plurality of circuits may be unloaded in response to pressure in one or more of the circuits so as to prevent the sum of the horsepower requirements from exceeding rated horsepower.
In certain applications, as for example in backhoes and various other kinds of excavators or earth-movers, it is desirable to allow the operator to exceed rated horsepower of the prime mover for short periods of time. In use of equipment not provided with pressure responsive unloading means, skilled operators recognize that they can exceed rated horsepower for short periods of time when encountering heavy or unusual loading conditions owing to the available flywheel or inertial energy of the prime mover. Thus, a skilled operator of manual equipment may rapidly break through an obstruction without stalling the prime mover whereas with the usual apparatus equipped with load sensing means, the operator will be unable to do so or may not be able to complete the job as rapidly since the pressure responsive mechanism will operate to prevent him from operating in a manner which results in rated horsepower being exceeded.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention provides an engine responsive arrangement which is sensitive to overload conditions as represented by a reduction in flow of operating fluid and which allows the operator to utilize flywheel energy as he so desires and thereby exceed rated horsepower for short periods of time without unloading a pump. In common with the above-identified copending application, one embodiment of the present invention uses a crossover unloading arrangement. In the preferred embodiment of the present invention, a crossover arrangement is used to prevent reloading of a pump if the sum of the pressures in the circuits exceeds a predetermined value.
More particularly, the present invention provides a device for sensing fluctuations in engine or pump speed above and below a predetermined value. When the pump speed and hence engine speed drops below the predetermined value, as when the torque requirements imposed on the prime mover increase to a predetermined value, above which the prime mover may stall, a pump will be unloaded. The invention provides an extremely flexible unloading system for reloading the unloaded pump when the engine speed exceeds the predetermined value provided that the pressures imposed on the system are below a predetermined value. Thus, the invention provides a system which is pressure responsive in the unloaded mode only in the sense that the pressure responsive means will prevent reloading of a pump when engine speed exceeds a predetermined level if the sensed pressure indicates that this would result in unloading of the prime mover. Desirably, the pressures used to influence reloading may be derived from a plurality of sources, as for example, all hydraulic circuits which might produce an overload on the system. In a dual pump system, when both pumps of a dual pump package are in operation, both pumps will remain in the circuit and pressure in the circuit will have no influence on unloading so long as the speed remains above the predetermined value.
Accordingly, it is an object of the invention to provide an engine speed responsive system for unloading a pump in a hydraulic system.
Stated in another way, it is an object of the invention to provide a pump unloading control system which monitors all demands made on the prime mover driving the pump.
It is another object of the invention to unload a pump in a hydraulic system when speed drops below a set value and to provide a pressure override which prevents reloading of the pump if pressure in the hydraulic system is above a predetermined value.
A still further object of the invention is the provision of a speed responsive system for unloading pumps of a plural pump system which prevents reloading of any unloaded pump except when pump speed is above a predetermined value and hydraulic circuit pressures are below a predetermined value.
It is a still further object of the invention to provide an unloading system for a pump in a plural pump system which is not pressure responsive so long as engine speed remains above a predetermined value, thereby allowing an operator of equipment having the system to exceed rated horsepower for brief periods of time.
The above and various other objects of the invention are achieved in a hydraulic control system for an earth-moving vehicle or the like by the use of means for limiting the torque requirements imposed on the prime mover by loads encountered by said mechanism, comprising means for unloading a pump in response to a reduction in prime mover speed below a predetermined value and for only reloading the unloaded pump when load pressure is below a predetermined value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an excavator incorporating the principles of the present invention;
FIG. 2 is a schematic view of one circuit comprising a pair of pumps used in the excavator of FIG. 1;
FIG. 3 is a sectional detailed view of control valving shown in schematic form in FIG. 2; and
FIG. 4 is a right sectional view of the valving of FIG. 3 taken along the line 4--4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, the hydraulic system in a preferred embodiment of the present invention typically comprises pump circuits 10 and 11, the pump circuit 10 including pump means comprising pumps 12 and 13, while the pump circuit 11 comprises pumps 14 and 15. A common prime mover 16 drives the pumps via a gear box schematically shown at 17. In the illustrative embodiment of the invention the combined output of pumps 12 and 13 is used, in an excavator, to drive the right track schematically shown at 18, a stick cylinder schematically shown at 19 and a bucket cylinder schematically shown at 20. The combined output of pumps 14 and 15 supplies operating fluid to the left track 21 and the boom cylinder 22. The excavator may also be provided with a swing pump 23 which supplies operating fluid to the hydraulic equipment for swinging the excavator boom laterally, the swing circuit being shown schematically at 24.
Each of the circuits 10 and 11 includes control valve means identified by the reference characters 25 and 26 respectively. A line 27 shown in broken lines in FIG. 1 provides for communication between the output or discharge of the pump circuit 11 and the unloading valve 25. The line 28 provides for communication between the output of pump circuit 10 and the unloading velve 26. The lines 27 and 28 are provided for purposes which will be explained in more detail hereinafter.
Reference is now made to FIGS. 2-4. FIG. 2 illustrates in schematic form the pumps for the circuit 10 together with a schematic representation of control valve means constructed in accordance with the present invention, whereas FIGS. 3 and 4 are detail views of the valve means. Although not necessary for accomplishing certain important objects of the invention, in the illustrative embodiment, the pumps and control valve means for the circuits 10 and 11 are identical.
In FIGS. 2 and 3, the pumps of the circuit 10 are shown at 12 and 13 as receiving fluid from reservoir 30 via passageways schematically shown at 31 and 32 respectively. Pump 12 discharges fluid under pressure through a passageway 33 which delivers fluid to the operating circuit which, as indicated in FIG. 1 includes the right track 18, stick 19 or bucket 20, depending upon the manipulation of the vehicle controls by means not shown. The two pumps are interconnected by a suitable drive connection represented by the reference character 34 in FIG. 2, so that they are rotated in unison by the prime mover 16.
Fluid discharged by pump 13 flows through a line 35, through control valve means schematically indicated by reference character 29, and a check valve 36 after which it is combined with flow from the pump 12.
The control valve means of the circuit 10 includes speed sensing means which preferably comprises a flow restricting orifice plate 37 mounted in the passageway 35 and secured by a snap ring 37a as shown in FIG. 3. Branch passages 38 and 39 lead from passageway 35 on opposite sides of the orifice plate 37, to opposite sides of a pressure responsive piston 40 mounted within a chamber 41 and biased by means of a spring 42 against an electrical probe 43. Probe 43 is mounted in a plug 44 within a sleeve of electrically non-conductive material 45. A lead 46 interconnects the probe with a solenoid 47. The circuit also includes an electrical power source such as battery 48 and a ground connection 49. When piston 40 rests against the probe 43, as occurs at low rates of flow of fluid discharged by pump 13 through passageway 35, an electrical circuit is completed through the piston and valve housing 50, both of which are electrically conductive, to ground so that the solenoid is energized and the valve 51 is open. When the differential pressure across the orifice plate 37 as measured on opposite sides of the piston 40 times the area of the piston exceeds the force of the spring 42, the piston lifts off the probe and the piston switch means comprising the probe 43 and the piston 40 are open and the solenoid 47 is de-energized and the valve 51 is closed. It can be seen therefore that a selection of the proper spring load and piston area can be used to cause the solenoid to be energized at flow rates and hence pump speeds below a predetermined value and de-energized at pump speeds above a predetermined value. Since the pumps are driven by the vehicle engine it will be appreciated that the flow rate of fluid in the passageway 35 is a function of engine speed.
The valve means further comprises a spool valve member 53 which acts in conjunction with the speed sensing means to effect unloading of pump 13. Spool member 53 is mounted within a bore 54 extending generally lengthwise of the valve housing as viewed in FIGS. 3 and 4. Spool member 53 is spring loaded by means of a spring 55 to a position in which it rests against a plug 56 which closes one end of the bore 54. In this position, fluid discharged from pump 13 is directed through passageway 35 to a passageway comprising annular groove 57, a portion of the bore 54 designated 54a, annular groove 58 and exits via a passageway 59 in which the check valve 36 is located. Flow from passageway 59 combines with the flow from pump 12 as previously noted.
Spool member 53 is adapted to move upwardly, compressing the spring 55 under conditions to be described presently. In the raised position, in which the spool 53 is moved to the opposite end of the bore 54 from that shown in FIGS. 3 and 4, flow entering the annular groove 57 is diverted by means of land 60 on the spool 53 into a passageway 61 which leads to a chamber 62 which returns the fluid discharged by pump 13 to the inlet of the pump indicated at 32 in FIG. 4. In this position of the valve spool 53, pump 13 is in what may be termed the unloaded condition in which it merely circulates fluid directly back to its inlet. The pump is virtually operating in a no load condition, consuming no vehicle horsepower except a minimal amount required to turn the gears and continuously circulate the operating fluid.
In order to move the spool 53 from the position shown in FIGS. 2-4 to the position in which pump 13 is unloaded, means are provided comprising a passageway 64 to establish communication of pressure between the passageway 59 at a point downstream from the check valve 36 and the lower end or face of spool member 53. Passageway 64 leads to annular groove 64a at the lower end of bore 54. A drilled passageway 65 having a restriction 66 extends lengthwise of the spool member 53. In the position of the valve spool 53 shown in FIGS. 3 and 4, the forces acting on the spool 53 are the pressure at the lower end or face of the spool as communicated by the line 64 times the area of the end spool, which force is opposed by the force of spring 55 and the pressure in the bore 54 above the spool 53 times the spool area at the opposite end of the spool. The spool is in the loaded position in which flow of pump 13 is combined with flow from pump 12 when the spring force plus the pressure above the spool times the spool area exceeds the pressure on the lower end of the spool times the spool area at the lower end.
A side passage 68 shown in FIGS. 2 and 4 leads from the chamber portion of the bore 54 designated 54b which is located on top of the spool 53, to the solenoid operated valve 51. As indicated above, the solenoid operated valve is normally (at speeds above the critical point) in the closed position blocking the passageway 68. When the valve 51 is opened, under conditions described hereinafter, there is communication from chamber portion 54a, through the passageway 68, through the valve 51, and a passageway 69 to the inlet 32 of the pump 13.
The pressure override means preferably comprises a poppet valve assembly 70 shown in FIGS. 2-4. The assembly includes a threaded housing 70a which is threaded into a counter bore at the upper end of the bore 54 as may be seen in FIGS. 3 and 4. Poppet valve housing 70a is provided with a central bore or chamber 73. A plug 71 having an orifice 72 provides communication between bore 73 and the bore 54. Side passageway 74 shown in FIG. 3 leads from the bore 73 through the housing 70a and communicates with a passage 75 which in turn communicates with the discharge passage 35 of pump 13 at a point just downstream from the orifice plate 37.
A poppet valve 76 is slidably fitted within the bore 73. The poppet valve 76 comprises a hollow spindle 77 and a conical element 78 which is adapted to contact a seat 79 in plug 71 and block off flow to bore 73 through the orifice 72. A spring 80 urges the conical element 78 into contact with the seat 79. In the illustrative embodiment, the upper end of the spindle portion of poppet valve 76 is stepped radially outwardly as shown at 81 to provide an annular surface 82 against which pressure communicated via a line 84 is brought to bear.
The poppet valve 76 is also provided with radial passages 85 which provide communication between the bore 73 and the hollow interior of the spindle portion 77. Pressure downstream of the orifice plate 37 is communicated to the bore 73 and to the interior of the poppet spindle via passages 75, 74 and cross passages 85.
The passageway 84 provides communication with a second circuit such as the circuit for the left track and boom shown in FIG. 1 via line 27. Pressure in the second circuit is thus communicated to the annular surface 82 and acts against spring 80 to lift the poppet off its seat. The force with which the poppet valve 76 is seated may be adjustably varied by means of a set screw 86 (FIG. 3) which is threaded in a plug 87 and bears against a plate or cap 88 which fits within the hollow interior of the spindle 77 and bears against the spring 80. A sealing cap 89 fits over the set screw 86.
Spindle 77 may be provided with additional annular surfaces, each of which is in communication with a separate circuit. In this event, the total of pressures in the separate circuits will act to lift the poppet off its seat.
In operation of the preferred embodiment, at pump speeds above the control point, which point represents a pump and hence a prime mover speed of desired setting, the differential pressure across the orifice plate 37, when transmitted through side passages 38 and 39, overcomes the spring force 42 and lifts the piston 40 away from probe 43. In this condition, the solenoid 47 is not energized and the valve 51 is closed. Assuming that poppet valve 76 is seated, as is the case when pump 13 is operated above the critical point, flow from the space above spool member 53 is blocked. In this condition, the pressures above and below the spool member 53 are equal and the spring force of spring 55 acts to keep the spool in lowermost position as shown in FIGS. 3 and 4 against plug 56. Flow from the pump 13 is directed through the passageway 57, 54a, 58 and 59 so that it joins the flow from pump 12.
In the event that pump speed drops below the control setting, as for example when the excavator bucket encounters a large rock or other obstruction, differential pressure across the orifice plate 37 drops and if it reaches the point at which piston 40 makes electrical contact with the probe 43, the solenoid 47 is energized to open the valve 51, venting the part of bore 54 which is above spool member 53. The pressure above the spool member is thereby dropped to reservoir pressure and the spool member shifts upwardly compressing spring 55 owing to the relatively higher pressure acting on the lower face of the spool member. It should be remembered that shifting of the spooling to the upper position as compared with the position viewed in FIGS. 3 and 4 causes the pump 13 to be unloaded.
As indicated from the above, poppet valve 77 is moved upwardly under certain conditions of operation to control the position of the spool 53. Because the poppet in the preferred embodiment is connected with at least one other circuit via the lines 84 and 27, the pressure in the other circuit acting against the annular step 80 will urge the poppet off seat 79. Also acting to urge the poppet off its seat is the pressure in the part 54b of bore 54 which is communicated to the conical tip of the poppet via the orifice 72. Acting to keep the poppet on its seat are the force exerted by the spring 80 and the pressure in the line 75 which acts interiorly of the hollow spindle portion 77 due to the cross passage 85. The pressure in line 75 prevents opening of the poppet when the pump 13 is loaded but is approximately zero when the pump 13 is unloaded since the discharge of pump 13 is communicating directly with suction.
At times when pump 13 is unloaded, and engine speed increases so as to cause the piston to lift off the probe, thereby de-energizing solenoid 47 to close valve 51, poppet valve 70 acts to prevent the reloading of the pump 13 if the pressures acting to open the poppet are high enough. In the preferred embodiment, these pressures are derived from the secondary circuit (e.g. pressure in circuit 11) and the space 54b above spool 53. When the pressures derived from these sources reach a predetermined valve, the poppet is lifted off its seat and communication is established between the space 54b and the line 75. Since pump 13 is unloaded, the pressure in line 75 is approximately zero. With the poppet open, the space above the spool 53 drops to a pressure which is low relatively to the pressure acting on the other end of the spool by an amount sufficient to overcome the spring load so that the spool 53 is kept in the raised position as viewed in FIGS. 3 and 4, even though the pump speed is above the critical point.
Since high pressure in line 75 is communicated to the poppet and causes the poppet to be held on its seat when the pump 13 is loaded, the system is in effect pressure responsive only in the unloaded mode. The significance of this is that the pump will not unload so long as the operator keeps pump speed above the set point. Thus the skilled operator can utilize flywheel energy of the prime mover in breaking through obstructions even though the rated horsepower of the vehicle is exceeded. If the operator is not so skilled, the system will operate to prevent overload conditions from developing.
As should be evident, whenever a pump is unloaded, the pressure responsive means acts to prevent reloading of that pump unless and until the pressures derived from the circuits sensed are low enough so that the rated horsepower will not be exceeded should the pump be reconnected to the system. This pressure responsive means is effective even though engine speed is high enough to cause the solenoid operated valve 51 to close so as to prevent repeated cycling which could occur should the sum of the horsepower requirements exceed rated horsepower.
As indicated above, opening of the poppet may be controlled in various ways. The pressures acting to prevent opening of the poppet may be derived from various sources. In equipment having a single hydraulic circuit, the load pressure in that circuit would be the pressure used to control opening of the poppet. In equipment having a plurality of hydraulic circuits the poppet may be made responsive to the sum of the pressures in some or all circuits or if desired may be made responsive to the highest pressure prevailing in any of the circuits.
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The disclosure relates to plural, motor driven hydraulic pump circuits, including circuits having the pumps in at least one circuit operated in pairs with all pumps being driven by a single prime mover. A speed responsive control device unloads one pump in one circuit when engine speed drops below a predetermined value without regard to the source of the condition causing the slowdown. Also included is a crossover means for sensing the pressure in aother circuit for preventing reloading of the unloaded pump when speed rises above the predetermined value unless and until the pressure including the pressure sensed in the other circuit is below a predetermined pressure.
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PRIOR APPLICATION
[0001] This application is a U.S. divisional application claiming priority from U.S. patent application Ser. No. 11/462,699, filed 5 Aug. 2006.
TECHNICAL AREA
[0002] The present invention concerns an improvement of the cooling, washing, and exchange of fluid in a continuous digester for the production of cellulose pulp.
THE PRIOR ART
[0003] FIG. 1 shows a typical design of the lower part of a continuous digester. A lower strainer section 2 is present in this digester from which consumed cooking fluid is withdrawn from the column of pulp in the digester. Dilution fluid or washing fluid WL is introduced into the bottom of the digester through vertical 4 V or horizontal 4 H dilution fluid nozzles or washing fluid nozzles. A certain amount of dilution fluid or washing fluid may also be added through nozzles 4 Sc in arms of the rotating bottom scraper and through a conventionally central pipe 4 C that opens out in the centre of the column of pulp in the digester.
[0004] In the prior art design shown in FIG. 1 , one or more rows of strainers 3 a / 3 b may form the actual strainer section, where each row of strainers comprises strainer surfaces 22 a / 22 b together with a withdrawal volume 20 arranged at each strainer surface, and a collection chamber 21 under the withdrawal volume from which consumed cooking fluid is led away to a recovery system, the flow labelled REC. The collection chamber 21 may be located also outside of the digester shell in what is known as an “external header”.
[0005] When it is desired to increase the production capacity of the digester, i.e. to increase the number of tonnes of digested pulp per day, the speed of the chips and the column of pulp down through the digester increases, while it is necessary at the same time to withdraw a greater amount of consumed cooking fluid and a greater volume of added dilution fluid or washing fluid from the strainer section.
[0006] This results in the lifting force from the upwards flow of fluid established at the bottom counteracting the tendency of the chips and column of pulp to sink, and this leads to the column of pulp easily becoming stuck such that output from the bottom of the digester is made more difficult, and sometimes even ceases completely.
[0007] Increasing the amount of dilution fluid or washing fluid added per unit of time at the nozzles 4 V/ 4 H/ 4 Sc/ 4 C arranged at the bottom proportionally to the increase of production, with the aim of maintaining a constant degree of dilution and washing per tonne of digested pulp, ensures that the upward lifting force on the chips and column of pulp increases proportionally with the increase in production.
[0008] There is thus an upper limit to the production capacity for each digester with a bottom of conventional design with a withdrawal section 2 and with the addition of dilution fluid or washing fluid.
[0009] Other types of strainer design for continuous digesters are known, but these have been implemented for particular reasons and they solve totally different problems.
[0010] U.S. Pat. No. 5,236,554 reveals a strainer design with which it is desired alternately to add new cooking fluid enriched with chemicals in one of four sections arranged at the periphery of the digester wall around the column of chips, and to withdraw cooking fluid from an opposite sector. The particular addition sector and the particular withdrawal sector of these four sectors are varied over time, such that it possible to reduce radial temperature gradients and obtain an even digestion of the chips over the complete cross-section of the column of chips. The addition sectors can be designed as wall sections lying next to strainer surfaces, with nozzles arranged in these wall sections.
[0011] The technology is most suitable at high locations in the digester where it is desired to have internal circulation and adjustment of the alkali profile, and it suffers from the disadvantage that only 25% of the strainer surface seen in the direction of the circumference of the digester is actively used as withdrawal strainer at any moment in time. The technology is not suitable for withdrawal sections in which there is instead a very high demand placed on the strainers (i.e. a large volume of withdrawn cooking fluid per unit of strainer area) around the complete digester, as is the case for the bottom strainer sections in, principally, overloaded digesters.
[0012] Thus U.S. Pat. No. 5,236,554 reveals something completely different than adding new cooking fluid enriched with chemicals through central pipes and only withdrawing consumed cooking fluid from the strainers in the wall of the digester, which technology ensures that only chips in the centre of the column of pulp are exposed to fresh cooking fluid and the chips in the column of pulp along the walls of the digester are exposed only to exposed cooking fluid. The technology with crossed or alternating addition and withdrawal around the wall of the digester is a technology that is revealed also in SE 145,257 (dated 1952).
[0013] U.S. Pat. No. 6,123,808 describes another variant of the addition of dilution fluid or washing fluid at the bottom of the digester. A dispersion and strainer area that runs around the circumference is used in this case as a distributor of the added dilution fluid or washing fluid, which dispersion and strainer area is arranged directly under the lowermost withdrawal strainer. The aim here is to obtain a more even distribution of dilution fluid or washing fluid around the complete circumference of the digester, in a manner that differs totally from the distribution that can be achieved with local dilution fluid or washing fluid nozzles. An important aspect of this solution is that the relevant dispersion and strainer area must cover a larger diameter than that of the strainer area of the withdrawal strainer positioned above it. The disadvantage of this design is that the injection pressure for fluid into the column of pulp from the dilution fluid or washing fluid that is added though the dispersion and strainer area will be very low. The added dilution fluid or washing fluid can risk also being drawn directly to the strainer that lies above the dispersion and strainer area without passing in practice through any significant volume of pulp or chips in the column of pulp.
THE AIM OF THE INVENTION
[0014] The primary aim of the invention is to improve the cooling, dilution and washing principally at the bottom of the digester in continuous digesters.
[0015] A second aim is that of being able to increase the production of existing digesters without experiencing problems with the flow of the column of chips in the digester when the volume of dilution fluid or washing fluid that is added at the bottom of the digester increases in proportion with the increase in production while essentially maintaining constant the dilution fluid or washing effect.
[0016] A further aim is to reduce the lifting force on the column of chips in the bottom wash, where the upwards flow from the fluid added at the bottom can be reduced by the establishment of several layers of upward flow on top of each other instead of these being formed at the same cross-section of the digester.
[0017] A further aim is to be able to establish a further washing zone at the lower part of the digester without needing to reconstruct the central pipe of the digester, which central pipe is always otherwise used in a conventional manner for the addition of digester circulations above the row of strainers located lowermost in the digester.
SUMMARY OF THE INVENTION
[0018] The arrangement concerns an improved design for at least one of the cooling, dilution and washing at the bottom of a continuous digester for the production of cellulose pulp. By arranging at least one extra strainer section above the lowermost strainer section, with the addition of washing fluid or dilution fluid between the extra strainer section and the lowermost strainer section, more washing fluid can be added at the bottom of the digester without counteracting the flow of the column of chips. This provides space for the increase of production, for improvement of the flow of the column of chips, or for combinations of these effects while retaining good cooling, washing and dilution at the bottom of the digester.
DESCRIPTION OF DRAWINGS
[0019] FIG. 1 shows a conventional design of a bottom strainer with the addition of dilution fluid at the bottom of a continuous digester;
[0020] FIG. 2 shows a first embodiment of the invention where an extra row of strainers has been arranged directly above the existing bottom strainer;
[0021] FIG. 3 shows an enlarged view of the design according to FIG. 2 ;
[0022] FIG. 4 shows a view seen in the section IV-IV in FIG. 3 ;
[0023] FIG. 5 shows an alternative embodiment of the invention with two extra rows of strainers arranged directly above the existing bottom strainer, where these extra rows of strainers are constituted by round strainers of the type known as “manhole strainers”.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 2 shows a first embodiment of the invention, where the bottom design comprises an arrangement for the addition and withdrawal of fluids to a digester that is used for the continuous cooking of cellulose pulp. Wood chips are continuously fed through an inlet at the top of the digester (not shown in the drawing) and cooked cellulose pulp is continuously output through an outlet 10 at the bottom of the digester. At least one strainer section 2 is arranged in the digester, in association with the bottom of the digester with strainer surfaces 22 c (or similarly 22 a , 22 b in FIG. 1 ) arranged in the strainer section arranged in the direction of the circumference of the wall of the digester for the withdrawal of consumed cooking fluid. Nozzles 4 V, 4 H, 4 Sc for the addition of dilution fluid or washing fluid are arranged under the lowermost strainer section 2 and between the lowermost strainer section 2 and the outlet 10 arranged in the bottom of the digester. A number of vertically directed nozzles 4 V are normally located in the curved bottom end wall of the digester evenly distributed around the circumference. These may typically constitute 10-30 nozzles, or more, in a digester with a diameter of 8 meters.
[0025] The vertical nozzles 4 V are supplemented with a number of dilution nozzles 4 H directed in a horizontal direction that open out into the wall of the digester just above the curved bottom wall but under the lowermost row of strainers. The number of these nozzles may constitute 10-30 in a digester with a diameter of 8 meters.
[0026] Addition of dilution fluid or washing fluid takes place in certain digesters also through the rotating bottom scraper through nozzles 4 Sc arranged in the bottom scraper. One outlet on each arm is shown in the drawing, but several of these outlets may be present across the arm of the bottom scraper, from the centre of the bottom scraper and out to the outer end of the arm of the bottom scraper.
[0027] In addition to these dilution nozzles in the bottom of the digester, there is also an outlet from a central pipe positioned at the level of the lowermost row of strainers 2 , often just above this row of strainers, but the flow from this central pipe contributes to the dilution or washing process at the bottom of the digester.
[0028] FIG. 2 shows that the strainer section is constituted by strainer surfaces 22 c that are located in the pattern of the squares of a chessboard, a pattern that is known as “staggered screens”, where these strainer surfaces in each row of strainers 3 a , 3 b has a blind plate 22 d between each strainer surface, which blind plate 22 d has a surface area that essentially corresponds to that of the surrounding strainer surfaces 2 c . These types of rows of strainer are normally located in strainer sections with several rows of strainers, in which rows of strainers that lie above or below a row of strainers have strainer surfaces that are displaced such that a chessboard pattern is formed. This design is often chosen if it is desired to keep the cost of the strainer section low, while at the same time having a high withdrawal capacity, since it is the case that each strainer surface 22 c has the capacity to drain the column of chips also in those parts that are located as neighbours to the blind plates, i.e. the strainer surfaces drain the column of chips in the direction of the circumference a good deal into half of the extent of the neighbouring blind plate in the direction of the circumference. The invention can, of course, be used also for strainer sections of the type that is shown in FIG. 1 , where each row of strainers is constituted by a continuous strainer surface that runs in the direction of the circumference. All strainer surfaces in this description may be constructed of what are known as “rod strainers” or they may be simpler plates with slits.
[0029] At least one extra strainer section 30 is arranged for the withdrawal of consumed cooking fluid according to the invention above the lowermost strainer section 2 at a distance between the uppermost part of the lowermost strainer section 2 and the lowermost part of the extra strainer section 30 . Furthermore, a number of extra nozzles 34 are arranged for the addition of dilution fluid or washing fluid distributed around the circumference of the digester between the uppermost part of the lowermost strainer section 2 and the lowermost part of the extra strainer section 30 , which extra nozzles are provided with fluid 33 with the aid of pumps, which fluid is continuously added into the column of pulp through the outlets of these nozzles 34 .
[0030] The distance between the uppermost part of the lowermost strainer section 2 and the lowermost part of the extra strainer section 30 is the distance 31 in FIG. 2 , which corresponds to a small section of blind plates where the extra nozzles 34 are arranged: this distance is less than the bottom diameter of the digester. This distance typically lies within the interval 0-8 metres. The variant in which this distance is zero means that the nozzles are located at the interface between the uppermost part of the lowermost strainer section 2 and the lowermost part of the extra strainer section 30 .
[0031] In one advantageous embodiment, the distance between the uppermost part of the lowermost strainer section 2 and the lowermost part of the extra strainer section 30 is considerably less than the height of the extra strainer section 30 , i.e. the distance is less than 2 meters, and preferably less than 1 meter. A normal row of strainers, which may establish the extra strainer section, conventionally has a height of between 1.5 and 2 meters in digesters with production capacities of 1,500-3,000 tonnes per day.
[0032] A compact reconstruction of the washing and dilution zone of the digester is obtained in this way that infringes to a minimal degree on the cooking zone that lies above it. The distance can, however, in certain cases be increased if changes to the cooking process are made at the same time, while even so retaining a sufficiently long cooking zone. This applies primarily to those digesters in which what is known as a long “Hi-heat” wash is used at the bottom of the digester, in which the process is changed such that parts of the original Hi-Heat zone are used as cooking zone. This zone may correspond to 30% or more of the total retention time of the chips in the digester, in older digesters with Hi-Heat wash.
[0033] FIG. 3 and FIG. 4 show in more detail the design with the extra nozzles 34 and the withdrawal volume 30 . The extra nozzles 34 are located arranged such that their openings have their outlet in the wall 40 of the digester between the uppermost part of the lowermost strainer section and the lowermost part of the extra strainer section. Each extra nozzle 34 is provided by the connecting pipes 37 with dilution fluid or washing fluid from a common distribution channel 38 that runs around the digester, and which is in its turn provided with dilution fluid or washing fluid by a pump shown schematically in FIG. 4 .
[0034] It is preferable that the strainer surface of the lowermost strainer section 2 , the strainer surface of the extra strainer section 30 and the openings of the extra nozzles 34 are all arranged at essentially the same diameter in the wall of the digester, something that is normally the case if manhole strainers are used that have been post-installed.
[0035] The extra strainers may otherwise be mounted in an inner digester wall that constitutes a wall section that is extended downwards from a superior strainer section, which means that the strainer surface of the lowermost strainer section 2 and the openings of the extra nozzles 34 are both arranged at essentially the same diameter in the wall of the digester, while the strainer surface of the extra strainer section 30 is located at a smaller diameter in this wall section that has been extended downwards.
[0036] The additional extra nozzles 34 are evenly distributed around the circumference of the digester and they are present in such a number that the distance around the circumference between neighbouring extra nozzles is less than 3 meters, preferably less than 2 meters.
[0037] It is appropriate that the nozzles have an opening that delivers a concentrated jet into the column of pulp, but they may have openings that are oval or slits in the direction around the circumference. Addition of fluid may, in one extreme variant in which it is desired to achieve greater volumes of added fluid between the extra strainer section and the lower strainer section, also take place through what is essentially one single continuous slit that runs around the circumference. It is advantageous for achieving the best penetration effect into the column of pulp that the slit of the openings of the nozzles are subject to a controlled drop in pressure for the establishment of a high injection velocity of fluid into the column of pulp.
[0038] The lower strainer section 2 is constituted by at least one row of strainers, preferably by at least two rows of strainers, as is shown in FIG. 2 , where each row of strainers 3 a , 3 b consists of strainer plates or rod strainers arranged in the direction of the circumference around the digester. A collecting channel 20 is arranged at each row of strainers 3 a , 3 b for the cooking fluid that has been withdrawn through the strainers in this row of strainers, where each collection channel has at least one emptying arrangement 21 for the removal of the withdrawn cooking fluid.
[0039] The extra strainer section 30 is constituted by at least one row of strainers 23 , where each row of strainers consists of strainer plates or rod strainers arranged in the direction of the circumference around the digester. A collecting channel 39 is arranged at each row of strainers for the cooking fluid that has been withdrawn through the strainers in this row of strainers, where each collection channel has at least one emptying arrangement 35 , 36 for the removal of the withdrawn cooking fluid.
[0040] Also the extra strainer section 23 may consist of at least one row of strainers with several strainer sections 23 b where the strainer sectors have wall sections between them in the form of blind plates 23 d that do not have strainer surfaces. A variant is shown in FIG. 5 in which the strainer sectors are round, of the type known as manhole strainers, and they are arranged in two rows 30 a , 30 b . The extra strainer section 23 may also consist of square strainer sectors of the type shown in FIG. 2 for the rows of strainers 3 a , 3 b , and arranged in a pattern that forms a chessboard around the circumference of the digester (an arrangement known as staggered screens).
[0041] The invention can be modified in a number of ways within the framework of the claims. Several copies of the extra strainer section 30 and the nozzle section 31 may, for example, be located one above the other, such that several positions for the addition of dilution fluid are obtained at several heights in the bottom of the digester.
[0042] An extra nozzle section can also be located above the extra row of strainers 30 in the variant that is shown in FIG. 2 .
[0043] While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims.
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The arrangement concerns an improved design for at least one of the cooling, dilution and washing at the bottom of a continuous digester for the production of cellulose pulp. By arranging at least one extra strainer section above the lowermost strainer section, with the addition of washing fluid or dilution fluid between the extra strainer section and the lowermost strainer section, more washing fluid can be added at the bottom of the digester without counteracting the flow of the column of chips. This provides space for the increase of production, for improvement of the flow of the column of chips, or for combinations of these effects while retaining good cooling, washing and dilution at the bottom of the digester.
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[0001] This application is a national stage entry of International Patent Application PCT/EP2013/058606, filed Apr. 25, 2013, entitled “REINFORCEMENT FOR A MATERIAL CONSISTING OF A MOULDABLE COMPOUND,” the entire contents of which are incorporated by reference, which in turn claims priority to German patent application 10 2012 206 954.2, filed Apr. 26, 2012, entitled “VERSTÄRKUNG FÜR EINEN WERKSTOFF AUS EINER FORMBAREN MASSE”, the entire contents of which are incorporated by reference.
BACKGROUND
[0002] The application relates to a reinforcement for a material made from a moldable composition. Reinforcements for materials made from moldable compositions can also be provided from renewable materials. For example, it is known from DE 40 00 162 C2 that parachutes from cattail seeds can be used for reinforcing a ceramic composition. It is also known from DE 40 00 162 C2 that various renewable raw materials can be used in a mixture. However, the materials here do not always attain the required strength. It is therefore an object of the present invention to provide a reinforcement by means of which the materials acquire the required strength. A further object of the invention is to provide a building material having such reinforcement and indicate a production process for the building material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Further details of the invention will be detailed with the aid of the following figures. In the figures,
[0004] FIG. 1 schematically shows three parachutes whose lateral fibers adjoin to fragments of barley awns.
[0005] FIG. 2 shows a parachute in more detail.
[0006] FIG. 3 shows a barley awn in more detail.
DETAILED DESCRIPTION
[0007] According to the invention, a reinforcement for a material made from a moldable composition is provided. The moldable composition can be, in particular, a building material. Barley awns and parachutes of seeds, in particular cattail seeds, are present as components in the reinforcement. Cattails are also frequently referred to by the scientific name Typha . A number of types of these are known. The types “narrowleaf cattail” having the scientific name “ Typha angustifolia ” and “broadleaf cattail” having the scientific name “ Typha latifolia ” are important in the present case. The parachutes here have stem fibers and lateral fibers branching off from the stem fibers. The lateral fibers are frequently also referred to as side arms. The lateral fibers of the parachutes are joined to one another by the barley awns. It is important that the proportion by weight of the barley awns and the parachutes are suitably matched to one another.
[0008] Empirical studies have found that the proportion by weight of the barley awns should be from about 0.1 time to about twice the proportion by weight of the parachutes. Particularly favorable conditions are obtained when the proportion by weight is from about 0.5 time to about one time that of the parachutes.
[0009] The mechanism of action of this reinforcement is worthy of further explanation here. The barley awns by nature have barbs into which the lateral fibers of the parachutes can be jammed. This results in joining of the lateral fibers to one another. A joining of lateral fibers of an individual parachute can occur here. However, in particular, joining of lateral fibers of different parachutes also occurs. This gives relatively large and joined-up structures which form a stable three-dimensional network. The material made from a moldable composition can be reinforced well in this way. However, not too many barley awns should be present since the stiffness of the barley awns would break up the structure of the compositions. If too many barley awns were to be present, the pieces of barley awns would project undesirably from the molding composition. It was necessary to understand these relationships and empirically determine a favorable proportion by weight of barley awns and parachutes.
[0010] In DE 4000162 C2, there column 8, example 6, an example in which both parachutes and barley awns are provided as reinforcement for a moldable composition, there a loam render composition, is given. However, 6.5 parts by weight of barley awns to 1.5 parts by weight of parachutes of cattail seeds are proposed. At such a high proportion of barley awns, the abovementioned problems occur, so that no optimal reinforcement is achieved. This is achieved only by means of the weight proportion range according to the invention.
[0011] It is not useful to indicate a precise optimal proportion by weight. The materials in question here are natural products which are always subject to certain fluctuations. For this reason, it is possible to indicate only ranges for optimal proportions by weight. In addition, it is also inconsequential whether the proportions by weight are adhered to exactly. Large deviations, for instance the value given in DE 4000162 C2, there column 8, example 6, are obviously to be avoided.
[0012] In an embodiment of the invention, the barley awns are present as fragments having a length of from about 2 mm to about 4 cm. It has been found to be particularly advantageous for the barley awns to be present as fragments having a length of about 4-8 mm. In the case of these relatively small fragments of the barley awns, the resulting network structure of barley awns and parachutes becomes three-dimensionally more effective. In addition, this fragmentation of the barley awns also makes mechanical handling of compositions reinforced in this way easier since the customary screw transport would fragment longer particles in an unacceptable way as a result of torsion.
[0013] In an embodiment, the stem fibers have a length of about 3 mm and/or the lateral fibers have a length of about 10 mm. It goes without saying that length fluctuations of about 50% from the indicated values are conceivable. In the case of the length of the stem fibers, it has to be taken into account that the length of the seed is added thereto.
[0014] In the case of the particularly suitable parachutes of cattail seeds of the species Typha latifolia , the stem fiber length is made up of a seed having a length of about 2 mm and the attached bundle of fibers having a length of 2.5 mm. Lateral fibers having a length of about 8.5 mm branch off therefrom. Good results have been achieved using these parachutes.
[0015] The invention provides a building material, for example a render mixture, having a reinforcement as described above. The requirement of building sustainably increases the demand for building materials having a high proportion of renewable raw materials. For this reason, there is also a demand for building materials, especially render mixtures, having reinforcement composed of biologically renewable raw materials, as presented above. In the case of render mixtures in particular, it has been found that reinforcement is of great importance. Render mixtures without reinforcements or with insufficient reinforcement have the problem that cracks can be formed in the render during drying of the render mixture after application of the moist render mixture. These cracks are visually undesirable and sometimes impair the protective function of the render. The usability and acceptability of a render mixture therefore depends critically on no crack formation occurring during drying. In order to avoid cracks, it is often proposed in the prior art that the render be applied in a plurality of layers and/or a woven mesh be introduced into the render. This makes a plurality of operations necessary, so that it is very advantageous to introduce a reinforcement into the render mixture in order to avoid crack formation. A particular aspect relates to buildings which are on the National Register of Historic Places, since sometimes only one layer of render is allowed to be applied here, so that the alternative of applying a plurality of render mixtures is ruled out.
[0016] In an embodiment of the invention, the building material is a render mixture containing clay. It can be, for example, a loam render. Loam is, as is known, a mixture of sand, silt and clay. However, there are also renders having a very high proportion of clay, so that it is normally no longer possible to speak of a loam render. Such render mixtures can also be reinforced well using the reinforcement described here.
[0017] In an embodiment of the invention, the building material is a mineral render and/or a synthetic resin render. Such renders are very widespread on the market and have positive properties in respect of long-term stability, thermal insulation and visual appearance.
[0018] In an embodiment of the invention, the building material contains leaf particles of cattail leaves. Predominant here are the leaves of Typha angustifolia. The addition of these leaves enables thermal insulation to be improved. In contrast to many other renewable raw materials, these leaves do not contain any silicon dioxide. This allows the leaves to be cut using sharp knives, so that clearly outlined particles having a small surface area can be provided. This leads to a reduced need for adhesives and thus to a reduced decrease in the strength. The building material of the invention which contains the reinforcement enables problems in respect of the strength to be reduced further. When parachutes of cattail seeds are used in the reinforcement, there are also no problems in respect of biological compatibility to be expected, even when the parachutes used are from Typha latifolia while the leaves are normally obtained from Typha angustifolia.
[0019] To produce a building material as indicated above, the following process is suitable. A building material firstly has to be selected. Barley awns then have to be provided. The barley awns are then mixed with parachutes of seeds, in particular cattail seeds. Here, as indicated above, the proportion by weight of the barley awns is from about 0.1 time to about twice the proportion by weight of the parachutes. Mixing with the selected building material is then carried out. In general, mixing with a dry mixture of the building material is carried out. It might normally be more advantageous firstly to mix the individual components on an effectively industrial scale using specifically designed mixing apparatuses and carry out mixing with water only on the building site. This leads to improved mixing results, reduced transport costs since the water does not also have to be transported and better durability since dry mixtures keep better. However, it should be emphasized that the order of the steps is not absolutely necessary. It would also be conceivable, for example, to add the parachutes to the dry mixture of the building material, mix this with water and then subsequently add barley awns.
[0020] In the harvesting of barley, the crop being harvested frequently goes directly into a combine harvester in the field. In many cases, fragments of barley awns are used instead of entire barley awns. Awn breakers are usually present in the combine harvesters. In these, the harvested barley awns are broken so that fragments of barley awns are obtained. In the above-described process, fragments of barley awns are then used instead of the entire barley awns. An advantage of fragments instead of entire barley awns is obtained, for example, in the case of render mixtures which have to be applied thinly. Here, entire barley awns would project in a visually undesirable manner.
[0021] In an embodiment of the production process, the proportion of fragments having the desired length is increased by sieving. Fragments of barley awns of differing lengths are formed, for example, in the abovementioned breaking up in awn breakers of combine harvesters. Appropriate sieving makes it possible to sort out those barley awns which do not have the desired length, so that the desired lengths remain.
[0022] In a further embodiment of the process, the parachutes are made unable to germinate. This can be effected by heating and/or irradiation of the parachutes, more precisely the seeds which are located on the parachute. A further possibility is to remove the seeds from the parachutes, for instance by means of a water jet or an air jet. It is advisable to make the parachutes unable to germinate. This ensures that no undesirable plant growth occurs in the moldable composition, i.e. usually in the building material.
[0023] FIG. 1 shows three parachutes 1 of cattail seeds. These each have a stem fiber bundle 2 . A plurality of lateral fibers 3 branch off from each stem fiber bundle 2 . It should be noted that FIG. 1 is very schematic and, for example, does not show that the lateral fibers 3 also point downward, i.e. in the direction of seeds 5 , as is clear from FIG. 2 . These lateral fibers 3 , also known as side arms, engage with the barbs of the fragments 4 of the barley awns. This effects joining of the various lateral fibers 3 . A stable three-dimensional network of different parachutes 1 is formed. This network is then able to strengthen lean mineral compositions to such an extent that they remain malleable and in the cured state withstand many stresses.
[0024] FIG. 2 shows a single parachute of a cattail seed in more detail. The seed 5 can be seen. This is adjoined by the stem fiber bundle 2 . Here, the seed 5 has a length of about 2 mm and the stem fiber bundle 2 itself has a length of about 2.5 mm. The individual lateral fibers 3 branch off therefrom. A typical length of the lateral fibers 3 is 8.5 mm.
[0025] FIG. 3 shows an individual fragment 4 of a barley awn. The fragments 4 of the barley awns are so suitable for joining of the lateral fibers 3 because their barbs have a shape on which the lateral fibers of the cattail seeds easily jam. At the jamming points 7 , the lateral fibers 3 are joined by jamming at the barbs 6 .
LIST OF REFERENCE NUMERALS
[0026] 1 Parachutes of cattail seeds
[0027] 2 Stem fiber bundle
[0028] 3 Lateral fibers
[0029] 4 Fragments of barley awns
[0030] 5 Seeds of the seed parachutes
[0031] 6 Barbs
[0032] 7 Jamming points
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Reinforcement for a material may be provided that includes a moldable composition, particularly for a building material, in which barley awns and seed parachutes, such as from bulrush seeds, are present as components in the reinforcement. The seed parachutes may comprise stem fibers and lateral fibers branching off therefrom, where the lateral fibers of the seed parachutes are connected to one another by the barley awns. The barley awns may have a weight proportion of approximately 0.1 to approximately 2 times, such as approximately 0.5 to approximately 1 time, higher than the weight proportion of the seed parachutes. A building material may be provided that includes the described reinforcement. A method for producing the building material may also be provided.
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BACKGROUND OF THE INVENTION
The present invention relates to an analog signal level detector.
The term level is here understood in its widest sense, because the applications envisaged for this detector essentially relate to knowing whether the expected signal is present or absent. The signal is expected, i.e. the range of its spectrum of frequencies is approximately known, together with its approximate amplitude, even if the range of possibilities is relatively wide. For example, a modem (modulator-demodulator) connected to a telephone line would recognise the presence of a call signal constituted by the carrier of known frequency.
Other similar or even relatively different applications can be envisaged. A voice activity detector in a speech analyzer could be useful for only initiating analysis operations in the presence of a signal manifesting the established existence of a voice activity with an adequate level.
Consequently the level detector in question can be a mean or average level detector of the rectified signal, without the mean or average word having to be taken in the strict mathematical sense. The object is to supply a signal recognizing the presence of an input signal if said mean value exceeds a predetermined threshold.
Such a detection requires a low-pass filtering, i.e. a certain signal integration with a time constant well above the variation period of the signal received. Without this there would be a risk of alternately detecting the presence and absence of the signal and each peak and each trough of the rectified alternating signal.
Thus, it is on the one hand necessary to rectify (preferably full-wave rectification) the signal to be detected and on the other make it undergo a certain integration.
Unfortunately, the integration of an analog signal with a relatively long time constant (e.g. 200 milliseconds for a 50 Hz signal) requires capacitors having relatively high values, which makes it difficult or even impossible to produce the signal detector in the form of an integrated circuit. For example for a modem, it is not only desirable for the detector to be in integrated form, but it is also desirable for it to form part of the same semiconductor chip as the actual modem.
SUMMARY OF THE INVENTION
The present invention proposes an analog signal level detector, which is particularly simple and requires no high value capacitor. This detector has the special feature of using as the integration element a digital reversible counter, which either carries out an up-count, or a down-count as a function of an analog-type comparison between the signal whose level is to be detected and the analog-type signal representing the counter content. Exceeding the level to be detected is determined on the basis of the counter content.
In the simplest case, the high order bit of the counter can be used to define whether a given mean level is exceeded.
The counting frequency is fixed and chosen in such a way that the counter content oscillates around a mean level with an oscillation amplitude which is low compared with this level. Thus, the counter content represents the mean level of the input signal.
The invention specifically relates to an analog signal level detector comprising a reversible counter, whose outputs supply a digital indication of the level of the analog input signal, an analog comparator, whose output is connected to one input of the counting direction of the counter, the counting direction being determined by the state of the comparator output, a means for establishing a difference or deviation signal, said means being connected to the outputs of the reversible counter and also receives the input signal to be detected, for establishing and applying to the comparator input a different signal representing the difference between the voltage level of the analog signal to be detected and a quantity proportional to the counter content, as well as a means for establishing a counting frequency for the counter, said frequency being such that the duration of the increase of the counter content from zero to its maximum value significantly exceeds the mean period of the signal to be detected.
In other words, a deviation or difference signal is established, whose positive or negative sign is detected by the comparator. If the sign is positive the counter will count up and if it is negative it will count down. In both cases, the counter content will vary slowly in one direction tending to reduce the amplitude of the difference signal. The counter acts as an integrator of the sign of the difference between its own content and the signal to be detected. As a result of this integration in the presence of a stable input signal, the counter content will undergo alternations of increase and decrease periods, in such a way that on average the sign of the difference signal will be positive just as often as it is negative. For an input signal constituted by a double alternation rectified sinusoid, it is possible to prove that the counter content then oscillates around a level representing the effective value of the input signal.
In the most general case, it is necessary to provide a rectifier (preferably a full wave rectifier) upstream of the detector input if the analog input signal to be detected is of an alternating type. However, it will be shown how, in a preferred embodiment of the invention, the rectifier can be eliminated, provided that account is taken of the sign of the input signal both for establishing the difference signal and for determining the counting direction.
In a simple embodiment, but requiring a rectifier upstream of the detector, the means for establishing the difference signal comprises a digital-analog converter, connected to the counter outputs. The counter output is applied to a comparator input, which also receives the rectified input signal on another input.
According to a preferred embodiment, the means for establishing the different signal comprises a system of switched capacitors having weighted respective values in accordance with the same binary weights as the outputs of the counter used for defining the different signal. A reference voltage source defines the ratio between the counter content and the quantity used for defining the different signals, i.e. the quantity compared with the analog input signal). A switching control circuit establishes the switching control signals, in accordance with a multiphase periodic cycle, and the counting frequency of the counter. Finally, a switching logic circuit controlled by the counter output and the switching control circuit, makes it possible to individually apply to each switched capacitor either the input signal, or the reference voltage, or an earth potential, as a function of conditions to be defined hereinafter.
The switched capacitors are connected to the comparator input and periodically establish thereon at the counting frequency of the counter, a potential which is the aforementioned difference signal. This potential is compared with zero by the comparator for defining the counting direction of the counter.
In principle, the switching cycle is as follows:
in a precharging phase, the capacitors are all charged with the input signal to be detected, then the store charges are isolated, a first plate of each capacitor is connected to the comparator input, whilst being maintained at a high impedence compared with any direct current supply;
in a comparison phase, the reference or earth potential is applied to the second plate of each capacitor, the choice of the potential applied to a given capacitor being fixed by the state of whichever of the counter inputs belongs to the same binary weight as the capacitor in question, the difference signal then appearing at the comparator output and is compared with zero.
In the preferred embodiment of the invention, there is no need for a rectifier upstream of the detector input, even for an alternating input signal as a result of introducing at each period a supplementary switching phase, which is a phase of determining the sign of the input signal. In this phase, which is in principle between the precharging phase and the leading phase, an earth potential is applied to the second plate of all the capacitors, so that during said phase the output of the comparator switches in one direction or the other as a function of the sign of the input voltage. This sign is stored in a flip-flop and is used, if negative, for modifying the establishment mode of the difference signal and the counting direction of the counter.
Thus, for example, if the detected and stored sign is negative, the reference voltage source (positive) is replaced by a negative reference source of the same value. At the same time, the counting direction determined by the comparator output following the reading phase is reversed compared with what it would be for a positive sign of the input signal (an EXCLUSIVE-OR gate controlled by the storage flip-flop of the sign is then inserted between the comparator output and the input of the counting direction of the counter).
In another embodiment, to obviate providing a negative reference voltage source, a supplementary capacitor is provided, whose value is equal to the sum of the values of the others. This capacitor is precharged to the reference voltage during the precharging phase. Then, during the reading phase, is applied thereto either the said reference voltage or the earth potential, depending on whether the stored sign is positive or negative. At the same time, if the stored sign is negative, there is a reversal of the choice between the reference potential of the earth potential applied to the switched capacitors during the reading phase. These two modifications amount to establishing a difference signal, which is not the difference between the input signal and the quantity proportional to the counter content, but is the difference between the inverse of the input signal and said quantity. Thus there is a full wave pseudo-rectification. It is then necessary to reverse the counting direction when the sign of the input signal is negative, as will be apparent from what is stated hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIG. 1 the basic circuit according to the invention.
FIG. 2 a time diagram useful for the understanding of the operation of the diagram of FIG. 1.
FIG. 3 a preferred embodiment of the invention.
FIG. 4 a time diagram of the switching control signals used in the circuit of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a simple embodiment of the detector according to the invention. In this embodiment, it is necessary to provide a preferably full wave rectifier 10, upstream of the detector input, if analog signal V1 whose level is to be detected is of an alternating type. Input A of rectifier 10 receives signal V1. Output B of the rectifier supplies a rectified signal V2. FIG. 2 shows for simplification purposes the input signal V1 in the form of a frequency sinusoid F, the signal V2 consequently having successive positive alternations.
Rectifier output B is connected to one input of a comparator 12 having another input C connected to the output of a digital-analog converter 14. The inputs of the latter are connected to the outputs of a reversible counter 16, whose counting up or down takes place at a frequency f defined by a clock signal H. The output of the converter 14 establishes on input C a voltage V3 representing the variations of the counter content. This voltage V3 varies in stepped manner in accordance with ramps which alternately increase, (when the counter counts up) and decrease (when the counter counts down), as can be seen in FIG. 2.
Thus, the circuit of FIG. 1 establishes the difference signal V4, which is the difference between voltages V2 and V3, and consequently between the rectified input signal and a quantity proportional to the counter content.
The output of comparator 12 is connected to a counting direction input of counter 16 and the state of this output determines the counting direction of the counter. If V2 exceeds V3, counter 16 will count up, whilst if V2 is below V3, the counter will count down. In both cases, the counting direction is such that the quantity V3 representing the content of the counter will tend to follow the rectified input signal V2.
However, the maximum increase slope of quantity V3 is voluntarily limited to the value such that in reality V3 cannot sufficiently rapidly follow signal V2.
For this purpose, the counting frequency f defined by clock H is such that the time taken by signal V3 for increasing from zero to its maximum (i.e. the time taken by the counter to pass from zero to its maximum) significantly exceeds the period 1/F of input signal V1. If the maximum content of the counter is Nmax, it is necessary for Nmax/f to be well above 1/F.
The amplitude of signal V3 is dependent on the digital/analog conversion scale in converter 14. A reference voltage Vref is used for defining this scale, Vref being the level reached by V3 when the counter content is at its maximum.
FIG. 1 also shows a second clock signal H' of the same frequency f as the signal H for periodically controlling the digital-analog conversion.
However, it must be ensured that the respective phases of the signals H and H' are such that the incrementation or decrementation of the counter does not take place at the time when the comparator 12 switches over.
In the presence of a sinusoidal alternating signal V1 of stable amplitude, it is found that the stepped signal V3 will weakly oscillate about a mean value. It is this mean value that the detector according to the present invention supplies to the user. For a full wave rectified sinusoidal input signal, said mean value represents the effective value of the input signal. For a random alternating signal, it can be simply stated that under stable operating conditions, the stepped signal oscillates triangularly (rising ramps and falling ramps) and the mean level of this triangular oscillation is established at a value such that on average the rectified signal V2 is just as frequently above as it is below the stepped signal V3.
This mean value can be obtained either in analog form at the output of converter 14, or in digital form at the output of counter 16 (output D). In a very simple case, only the high order bit of the counter will be used as the detector output. The value of voltage Vref is chosen as a function of a level threshold which it is wished to detect and it is ensured that the value of the high order bit of the counter defines the exceeding or non-exceeding of said threshold. A very simple case is that where the chosen threshold is Vref/2, whilst the maximum of the stepped signal V3 is Vref.
In connection with FIG. 1, it can also be stated that only a few high order bits of the counter can be used for application to the digital-analog converter, so that the stepped signal V3 will always have the same slope, but less steps.
FIG. 3 shows a preferred embodiment of the invention in which the difference signal is established by a group of switched capacitors (C1 to C n ). The circuit of FIG. 3 also comprises the reversible counter 16, having a counting direction input connected, via an EXCLUSIVE-OR gate 20, to the output of a comparator 12, whereof one input is connected to earth and whereof the other receives a difference signal (voltage V) representing the difference between the input signal and a quantity proportional to the counter content. It will be seen how the difference signal is periodically established by the group of switched capacitors. In this embodiment, voltage V is in reality the inverse of the aforementioned difference signal and it is applied to the inverting input of comparator 12.
The output of comparator 12 is also connected to the input of a flip-flop 22 for storing the sign of the input signal V1 to be detected. Thus, in this embodiment, input signal V1 can alternate about the earth potential, without it being necessary to provide a full wave rectifier. Comparator 12 periodically detects (at the counting frequency f) the sign of V1 and the outputs of flip-flop 22 store this sign. In this case output Q of flip-flop 22 is at 1 and output Q at O if the sign is positive and conversely if the sign is negative.
Output Q of flip-flop 22 is connected to an input of the EXCLUSIVE-OR gate 20 (whereof the other input receives the output of comparator 12), in such a way that if the sign detected during a counting period is positive, the counting direction input of the counter assumes a state which is that of the output of comparator 12 (counting up if voltage V is negative, counting down in the opposite case). If, on the other hand, the sign of V1 is negative, the EXCLUSIVE-OR gate 20 reverses the instruction given by the output of the comparator (counting down if voltage V is negative, counting up in the opposite case).
Capacitors C1 to C n all have a first plate connected to an inverting input (-) of the differential amplifier constituting comparator 12, whilst the other comparator input, which is non-inverting (+) is connected to earth.
The other plate of each capacitor C1 to C n is connected to a respective output of a logic switching circuit 24, which receives as signals to be switched on the one hand the input signal V1 and on the other an earth potential and finally a reference potential Vref.
The switching circuit is controlled:
on the one hand by the outputs of counter 16, more specifically by those used for establishing the conversion of the content of the counter into an analog quantity proportional to said content, whereby in actual fact use is only made of n high order bits of the counter;
on the other hand, by a not shown switching control circuit, which establishes periodic, signals at the counting frequency f of counter 16, in accordance with a multiphase cycle shown in FIG. 4--essentially, two periodic square wave signals .0.1 and .0.2 of the same frequency are established, .0.1 and .0.2 passing through logic level 1 substantially at the same time and .0.2 remaining at 1 longer than .0.1, a signal .0.'1 also being provided, which is identical to .0.1 but passes to zero again slightly before .0.1;
and finally by the output of the flip-flop 22 for storing the sign of V1, for modifying the switching operation as a function of the sign of V1.
Switching circuit 24 comprises a certain number of switching means and control gates (OR- and EXCLUSIVE-OR gates). Convention, in FIG. 3, the switches turn to the left of the drawing when the signal controlling them is at logic level 1 and towards the right when the signal controlling them is at level zero.
The various switches of the switching circuit are as follows:
A first switch I1, controlled by signal .0.'1, makes it possible to connect to earth the first plate of capacitors C1 to C n (.0.1=1), or to leave same at high impedence (.0.'1=0).
A switch I2, controlled by signal .0.1 makes it possible to apply to an intermediate point G of the circuit either input signal V1(.0.1=1), or the earth potential (.0.1=0).
A series of switches J1 to J n make it possible to individually connect the second plate of each capacitor (C1 to C n respectively) either to point G or to the reference potential Vref. Each switch J1 to J n is controlled by the output of a respective OR-gate K1 to K n , whereof one input receives the signal .0.2 and the other input receives the output of a respective EXCLUSIVE-OR gate L1 to L n . Said gate has an input connected to the output Q of flip-flop 22 and another input connected to a respective output taken from among the n high order outputs of the reversible counter 16.
Thus, each switched capacitor can be controlled by a respective output of the counter. The values of the capacitors are weighted in accordance with a binary progression corresponding to the weighting of the n highest order outputs of the counter, and capacitor of a given binary weight is controlled by the output of the counter of the same binary weight.
Capacitor C1 is controlled by the lowest order output of the counter. Capacitor C n , controlled by the highest order output of the counter has the value 2 n-1 C1; capacitor C n-1 has a value 2 n-2 C1 etc.
There is also a capacitor C'1 of the same value as C1, and directly connected, without switch, between the inverting input of comparator 12 and point G. Finally, a supplementary capacitor C n+1 of value equal to the sum of the capacitors C1 to C n , i.e. (2 n-1 ) C1 has a first plate connected like the other capacitors (C1 to C n and C'1) to the inverting input of comparator 12, has it second plate connected to a supplementary switch J n+1 making it possible to connect it either to the reference potential Vref or to point G. This switch is controlled by an OR-gate K n+1 , whereof one input receives signal .0.2 and the other receives the output Q from the storage flip-flop 22 of the sign of V1.
In order to complete the description of FIG. 3, it is pointed out that the clock signal applied to the reversible counter for incrementing or decrementing it is from an OR gate 25 receiving on one input the signal .0.1 and on the other input an over flow output CO from the counter. This overflow output CO passes to 1 if the counter content reaches its maximum on counting up or its minimum on counting down. The counter increments or decrements during the rising fronts of signal .0.1 with probibition of exceeding the maximum or minimum.
Finally, flip-flop 22 has a triggering input receiving the signal .0.2 inverted by an inverter, in such a way that the possible switching (according to the state of the comparator output) takes place on the falling fronts of the square wave pulses .0.2.
The detailed operation of the circuit of FIG. 3 will now be described.
For each period defined by the switching control circuit it is possible to distinguish three main phases, namely a precharging phase in which .0.2 and .0.1 are at 1, a phase determining the sign V1 during which .0.1 is at zero and .0.2 still at 1, and a comparison phase during which both .0.1 and .0.2 are at zero.
(a) precharging phase:
the second plates of capacitors C1 to C n are connected to point G by switches J1 to J n because .0.2=1;
point G receives the input voltage V1 by switch I2 because .0.1=1;
the second plate of the capacitor C n+1 is connected to Vref because .0.2=1;
finally, the first plate of all the capacitors C1 to C n , C'1 and C'n 1 is connected to earth by switch I1 because .0.1=.0.'1=1.
Capacitors C1 to C n and C'1 take the respective charges C1 V1, C2 V1, C n V1 and C'1 V1. Capacitors C n+1 takes a charge C n+1 Vref. In all the total charge present at the common point connecting the first plates of all the capacitors is
-C1V1-C2V1 . . . -C.sub.n V1-C'1V1-C.sub.n+1 Vref.
Just before the end of the precharging phase, i.e. just before .0.1 passes to zero, signal .0.'1 passes to zero opening switch I1 and isolating said overall charge on the input (high impedance) from comparator 12.
(b) phase of determining the sign of V1.
The switches are in the same position as in the precharging phase, except for I1 which is open and I2 which changes state and connects point G to earth.
As all the second plates of the capacitors are then at earth, except for C n+1 which remains at Vref, the first plates pass to a potential -V1 as a result of the charge stored and isolated on the first plates, said potential -V1 then appearing on the inverting input of comparator 12. Comparator 12 then supplies a logic state 1 if V1 is positive and 0 if V1 is negative.
This state remains until the falling front of .0.2, which defines the end of the sign determination phase. On this falling front, input Q of flip-flop 22 assumes the state imposed by the output of the comparator and output Q assumes the complementary state. The state of the flip-flop is then maintained for a complete period.
(c) comparison phase
In all cases, switch I1 keeps in high impedance (isolation with respect to any direct current of comparator 12 and the first plates of the capacitors connected thereto). Switch I2 keeps point G at earth. It is necessary to distinguish two cases, as a function of whether V1 is positive or negative during the switching cycle in question.
1. V1 is positive.
Switch J n+1 remains in its initial position because the OR gate K n+1 transmits to it the output Q=1 of flip-flop 22.
The EXCLUSIVE-OR gates L1 to L n receiving a state 1 from flip-flop 22 then invert the states of the n highest order outputs of the reversible counter 16. The single OR gates K1 to K n transmit these inverted states to use as a control for switches J1 to J n .
Thus, if the output of weight n is at 1, switch J n will switch over to connect the second plates of capacitor C n to Vref. Conversely, if said output is at zero, switch J n will not switch over and will leave the second plate of the capacitor C n connected to point G and consequently to earth. In the same way, the second plate of each capacitor C1 to C n is brought to Vref, if the output of corresponding weight is at 1 and is brought to zero if said output is at zero.
Thus, the common potential of the first plate of the switched capacitors will assume a value V, such that the sum of the charges of the different capacitors connected to the input of the comparator balances the initially stored charge, which is equal to:
-C1V1-C2V1- . . . -C.sub.n V1-C'1V1-C.sub.n+1 Vref (1)
In order to calculate the sum of the charges of the capacitors, when a potential V is present on the first plate, it must be borne in mind that the capacitors have values weighted in accordance with the weight of the outputs of the counter, which now control the individual application of Vref or O to these capacitors (C n =2 n-1 C1; C n+1 =2 n-2 C1, etc.).
If n is the content of the counter, the word "content" being understood to mean here the content present in the highest order outputs only, the sum of the charges is then:
(C1+ . . . +C.sub.n)V-N Vref C1+VC'1+(V-Vref)C.sub.n+1 (2)
The equality of terms (1) and (2) leads, whilst bearing in mind that
C.sub.n+1 =C1+ . . . +C.sub.n =(2.sup.n -1)C1
and that C'1=C1:
V(2.sup.n+1 -1)C1=(N Vref-V1·2.sup.n) C1
or ##EQU1##
Potential V which is established on the comparator input thus represents a difference signal as defined hereinbefore, namely a signal representing the difference between the input signal (V1) and a quantity proportional to the content N of the counter (N Vref/2 n ).
Comparator 12 supplies a logic state 1 if the difference signal V1(N Vref/2 n ) is positive and a state 0 if the signal is negative. This state defines the counter counting direction, which involves counting up if N Vref/2 n is below V1 and counting down in the opposite case.
The incrementation or decrementation of the counter with the thus defined direction occurs on the rising front of signal .0.1, the end of the comparison phase and at the start of the precharging phase of the following period.
2. V1 is negative during the considered period.
It is then necessary to compare the quantity N Vref/2 n representing the content of the counter with the absolute value of V1, i.e. with -V1.
It is therefore necessary to establish a difference signal -V1-N Vref/2 n , i.e. a potential V equal to ##EQU2## on the negative input of comparator 12. However, it is also possible to establish a potential ##EQU3## and then reverse the counting up or down instruction given by the output of the comparator. This is what is done here, as will be seen, the inversion of the instruction taking place by the EXCLUSIVE-OR gate 20 controlled by the output Q=1 of flip-flop 22.
On taking up again the operation carried out for the calculation of V with V1 positive, there is now a switching over of J n+1 towards the position in which capacitor C n+1 is connected to point G and consequently to earth.
The EXCLUSIVE-OR gates L1 to L n no longer invert the states of the N outputs of the counter. Thus, if the output of weight n is at 1, switch J n will switch over and will leave the second plate of capacitor C n connected to point G and consequently to earth. Conversely, if this output is at zero, the switch will switch over for connecting the capacitor C n to Vref. The same applies for the other capacitors C1 to C n-1 .
The common potential of the first plates will assume a value V, such that the sum of the charges of the different capacitors balances the initially stored charge, it being pointed out that it is equal to
-C1V1-C2V1-. . . --C.sub.n V1-C'1V1-C.sub.n+1 Vref (1)
Now, the sum of the charges of the capacitors is:
(C1+. . . +C.sub.n)V-(C1+. . . +C.sub.N)Vref +nVrefC1+VC'1+VC.sub.n+1 (4)
The equality of the terms 1 and 4 leads to:
V(2.sup.n+1 -1)C1=-N Vref C1-2.sup.n V1
or ##EQU4## which corresponds to what was sought, namely the establishment of a difference signal representing the difference between the rectified value (-V1) of the input signal V1 and the term N Vref/2 n proportional to the counter content.
Thus, at the time of the rising front of 1, there is an incrementation of the counter if -V1 exceeds N Vref/2 n and decrementation occurs in the opposite case.
As in the case of FIG. 1, the content of the counter will represent the mean level of the input signal V1. In the considered example, the highest order bit of the counter directly indicates whether the level is higher or lower then Vref/2, because N passes to 2 n-1 when the highest order bit passes to 1, the unswitched capacitor C'1 equal to C1 is provided here for permitting this simple use of the highest order output of the counter in a very accurate manner. Otherwise several outputs can be used for defining a different level threshold.
Obviously, the slower the increase rate of N Vref/2 n the lower the oscillation of the counter content around the mean detected value and the longer the time of establishing said mean value (in the same way as the zero return time in the case where the input signal disappears). It is therefore necessary to adopt a compromise on this point.
Reference is finally made to a pseudo-rectification of the input voltage in an embodiment with switched capacitors, like that of FIG. 3. If there is a negative reference voltage supply (-Vref), this can be used in place of Vref when flip-flop 22 indicates a negative sign of the input voltage. The capacitor C n+1 or the EXCLUSIVE-OR gates L1 to L n are then eliminated because they are no longer necessary. Then in the same way, there is a comparison on V1 with N Vref/2 n , when V1 is positive and a comparison of -V1 with NVref/2 n when V1 is negative.
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The invention relates to a detector of the mean level of a signal particularly intended to indicate whether an expected alternating signal is absent or present. This detector uses an analog comparator, a digital counter and a converter for establishing an analog signal to be compared with the expected rectified signal. The counter content oscillates round the mean value of the rectified signal. The counter serves as a digital integrator for the sign of the difference between the input signal and the content of the counter, in such a way that on average the input signal is just as often above as below the counter content. The digital - analog conversion can take place with the aid of switched capacitors.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of German Patent Application, Serial No. Serial No. 102015217521.9, filed Sep. 14, 2015, pursuant to 35 U.S.C. 119(a)-(d), the disclosure of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a propulsion device for a vehicle, especially an electric or hybrid vehicle.
[0003] The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
[0004] Vehicles that are embodied as electric or hybrid vehicles are known in the art. Such a vehicle includes at least one electric machine to propel the vehicle. In other words, the electric machine is embodied for driving the vehicle, so that the electric machine is also called a traction machine.
[0005] In order to drive the vehicle, the electric machine is supplied with electric current. For this purpose, the vehicle has at least one electric energy store, especially in the form of a battery, where electric current or electric energy can be stored in the electric energy store. In this case, the electric machine can be supplied with the electric current stored in the electric energy store, in order to drive the vehicle electrically, especially purely electrically. Purely electric drive is to be understood as the vehicle moving purely under electric power, such that the vehicle is driven exclusively with the aid of electric energy in the absence of a combustion engine.
[0006] Usually the vehicle also includes a gear unit that is driven by the electric machine, so that the vehicle can be driven via the gear unit by the electric machine. In this case, the vehicle has ground contact elements, especially in the form of wheels. While on the move, the vehicle rolls on a road via the ground contact elements. To drive the vehicle, the wheels are driven by the electric machine via the gear unit.
[0007] Such a vehicle, which includes an electric machine for driving the vehicle and a battery for supplying the electric machine with electric current, is also called a battery-electric vehicle (BEV). With battery-electric vehicles, the performance, and thus the size, meaning the outer dimensions, of the electric machine, as well as the gear ratio of the gear unit is usually determined by requirements for initial acceleration. The vehicle can be accelerated by virtue of the electric machine via the gear unit, especially as part of a process of the vehicle starting from rest. Usually the possible top speed of the vehicle, as well as the capability to accelerate at high speeds suffer as a rule from being restricted to a single-gear gear unit, which is to be understood as a gear unit with precisely one gear.
[0008] It would be desirable and advantageous to provide an improved propulsion device for a vehicle to obviate prior art shortcomings and to realize high initial acceleration and high top speed in a space-saving and cost-effective way.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention, a propulsion device includes an electric machine, a differential gear driven by the electric machine and operatively connected to an axle on the vehicle, with ground contact elements of the axle being driven by the electric machine via the differential gear, a planetary gear via which the differential gear is driven by the electric machine, the planetary gear comprising at least three gear elements that are rotatable about an axis of rotation, with one of the at least three gear elements being configured as a planet carrier, and at least one planet gearwheel which is different from the at least three gear elements, the planet gearwheel being rotatably supported on one of the at least three gear elements and in engagement with the other ones of the at least three gear elements via respective sets of teeth, a first one of the at least three gear elements being driven by the electric machine, and a second one of the at least three gear elements being driven by the electric machine via the first of the at least three gear elements and coupled to the differential gear, a switching device including at least one switching element and switchable between a first switch position, in which a third one of the at least three gear elements is secured against a rotation about the axis of rotation, and at least one second switch position in which the third one of the at least three gear elements is connected by the switching device to the first one of the at least three gear elements in a torsion-proof manner, an actuator configured to move the at least one switching element of the switching device between the first and second switch positions, and a parking brake including at least one parking brake element, the parking brake being movable by the actuator between a park position, in which the vehicle is prevented from rolling away, and at least one release position.
[0010] In accordance with the present invention, the propulsion device for a vehicle, especially an electric or hybrid vehicle, includes a differential gear, which is driven by an electric machine and connected to an axle on the vehicle. Ground contact elements of the axle are driven by the electric machine. The ground contact elements may comprise wheels, such that the vehicle, embodied for example as an automobile, rolls when traveling on a road. The vehicle is driven by the electric machine via the wheels.
[0011] The differential gear is also referred to as a differential transmission or differential, and allows the wheels to rotate at different speeds, when the vehicle is negotiating a curve, so that for example, the wheel on the outside of the curve can rotate faster than the wheel on the inside of the curve.
[0012] The planetary gear of the propulsion device has three gear elements that are rotated about an axis of rotation. One is embodied as the planet carrier of the planetary gear. The planetary gear further includes at least one planet gearwheel differing from the gear elements, which is supported rotationally on a one gear element, i.e. on the planet carrier, and is in engagement with the other gear elements via respective sets of teeth.
[0013] In this case, a first of the gear elements is driven by the electric machine. Furthermore, a second of the gear elements can be driven via the first gear element by the electric machine and is coupled to the differential gear, such that the differential gear is driven by the electric machine via the second gear element and the first gear element. Overall, the vehicle can thus be driven by the electric machine via the differential gear, the second gear element and the first gear element.
[0014] The switching device of the propulsion device is switched or adjusted between at least two switch positions. In a first switch position of the switching device, the third gear element is secured from rotating about the axis of rotation via the switching device. For example, the propulsion device, especially the planetary gear has a housing. The gear elements are rotated about the axis of rotation relative to the housing. In the first switch position of the switching device, the third gear element is fixed via the switching device on the housing, so that the third gear element cannot rotate about the axis of rotation relative to the housing.
[0015] In the second switch position of the switching device, the third gear element is connected in a torsion-proof manner to the first gear element via the switching device, so that when the first gear element is driven by the electric machine. The first gear element and the third gear element orbit together as a block, and in doing so, rotate about the axis of rotation relative to the housing.
[0016] The second gear element is thus a take-off of the planetary gear and the first gear element is a drive of the planetary gear. The planetary gear is driven via the drive from the electric machine and provides torques via the take-off, which are transmitted to the differential gear, so that the differential gear can be driven via the take-off, and thus by the torques provided via the take-off.
[0017] The fact that the switching device is provided, and can be switched between the switch positions, means that the planetary gear is switchable, so that both an especially high initial acceleration as well as an especially high top speed of the vehicle can be realized by means of the propulsion device. The initial acceleration is to be understood as an acceleration able to be brought about by means of the propulsion device, with which the vehicle can be accelerated from rest as part of a starting process. The top speed is the maximum realizable traveling speed of the vehicle. The high initial acceleration and the high top speed can be realized by means of the propulsion device in an especially space-saving and cost-effective way, since as a result of the fact that the planetary gear is switchable, so that for example at least two different gear ratios are able to be set, the external dimensions of the propulsion device and in particular of the electric machine can be kept especially small.
[0018] Advantageously, the number of parts and thus the weight, the installation space required and the costs of the propulsion device can be kept low, since only the switching device is provided and required in order to switch the planetary gear, and thus to obtain a high initial acceleration and a high top speed.
[0019] The electric machine of the propulsion device can be embodied as a traction machine for driving the vehicle. The electric machine can be operated, for example, in a motor mode, and thus as an electric motor. The vehicle can be driven via the planetary gear and the differential gear by the electric machine in the motor mode. It is further conceivable for the electric machine to be able to be operated in a generator mode and thus as a generator. In this generator mode the electric machine is driven for example via the differential gear and the planetary gear by the moving vehicle and thus by means of kinetic energy of the vehicle, wherein, in the generator mode, at least a part of the kinetic energy of the vehicle is converted into electric energy by means of the electric machine. Through this the vehicle is slowed down or braked for example. The electric machine provides the electric energy for example, so that at least one electric load can be supplied with the electric energy. As an alternative or in addition it is conceivable to store the electric energy in an electric storage device, in particular in a battery. In this case there can be provision for the propulsion device to include at least one such storage device.
[0020] According to another advantageous feature of the present invention, an actuator is provided, by means of which at least one switching element of the switching device is able to be moved between the switch positions. In the first switch position, the third gear element is secured by the switching element against a rotation about the axis of rotation, wherein the third gear element in the second switch position is connected to the first gear element in a torsion-proof manner. By means of the actuator automatic or automated or partly-automatic or partly-automated switching of the switching device, in particular of the switching element, can be realized, so that for example an especially advantageous transition from the first switch position into the second switch position and vice versa can be realized. In particular it is possible, after the startup process, to move the switching element by means of the actuator from the first switch position into the second switch position or vice versa, in order to realize an especially advantageous operation of the propulsion device and thus of the vehicle as a whole thereby.
[0021] According to another advantageous feature of the present invention, a parking brake with at least one parking brake element is provided, which is moved between a park position to prevent the vehicle rolling away and at least one released position. The propulsion device, in this case, includes at least one take-off shaft. The vehicle is driven by the electric machine. This take-off shaft, for example, involves one of the gear elements, but also a different shaft of the propulsion device from the gear elements. The take-off shaft is rotated about a second axis of rotation, in particular, relative to the housing. The second axis of rotation can be spaced away from the aforementioned first axis of rotation of the gear elements, or can coincide with the first axis of rotation. In the park position, the parking brake element acts to make a form fit together with the take-off shaft, such that the take-off shaft is secured via the brake element located in the park position from a rotation about the second axis of rotation. This advantageously enables the vehicle, when it is parked on an incline for example, not to roll away as a result of gravity, since the take-off shaft, and thus the ground contact elements, which are driven via the take-off shaft, cannot rotate.
[0022] In the release position, however, the parking brake element releases the take-off shaft, and thus the ground contact elements (wheels) of the vehicle, so that the take-off shaft and the ground contact elements can rotate. As a result, the vehicle is driven by the electric machine.
[0023] In order to keep the installation space required for the propulsion device small, there is provision for the parking brake element to be moved via the actuator. This means that the actuator is embodied to move the parking brake element from the park position into the release position and/or from the release position into the park position. This enables a separate actuator for actuating or moving the parking brake element. Consequently, the number of parts, the weight, the costs and the installation space required for the propulsion device can be kept low. In other words, there is provision for the parking brake element and the switching element to be adjusted or moved via the same actuator.
[0024] According to another advantageous feature of the present invention, the first one of the at least three gear elements can be configured as a hollow gearwheel, the second one of the at least three gear elements can be configured as a planet carrier, and the third one of the at least three gear elements can be configured as a sun gearwheel of the planetary gear. Thus the planet carrier represents the take-off of the planetary gear, wherein the hollow gearwheel represents the drive of the planetary gear. The sun gearwheel, as required, can be fixed to the housing by means of the switching device or can be secured against a rotation about the axis of rotation but also connected in a torsion-proof manner to the hollow gearwheel, so that both an especially high initial acceleration and also an especially high top speed are able to be realized in a cost-effective and space-saving manner.
[0025] According to another advantageous feature of the present invention, the actuator can be an electromechanical actuator, a hydraulic actuator, an electro-hydraulic actuator, or an electromagnetic actuator. As a result costs, weight and installation space required for the propulsion device can be kept low. This also enables short switching times of the switching device, in particular of the switching element, to be obtained.
[0026] According to another advantageous feature of the present invention, the planetary gear can have a stationary gear ratio ranging from 1.5 to 4. In other words the mathematical amount of the stationary gear ratio of the planetary gear lies in a range from 1.5 to 4, wherein the stationary gear ratio is usually designated i 0 . For example the stationary gear ratio or its value lies in a range of −4 to −1.5.
[0027] According to another advantageous feature of the present invention, the planetary gear in the second switch position can have a gear ratio which is smaller than a gear ratio in the first switch position. A rotational speed, at which, the first gear element rotates about the axis of rotation, when the first gear element is driven by the electric machine, is also referred to as the rotational drive speed, since the first gear element forms the drive of the planetary gear. Since the second gear element forms the take-off of the planetary gear, a rotational speed, at which, the second gear element rotates about the axis of rotation, when the second gear element is driven via the first gear element by the electric machine, is referred as the rotational take-off speed.
[0028] Since the planetary gear in the second switch position advantageously has now a smaller gear ratio than in the first switch position, the rotational take-off speed is smaller in the first switch position than in the second switch position when the rotational drive speed remains the same, so that the first switch position is embodied for example as a slow drive stage and the second switch position as a fast drive stage. Thus, by means of the first switch position an especially high initial acceleration can be realized, wherein the provision of the second switch position enables an especially high top speed of the vehicle can be realized.
[0029] According to another advantageous feature of the present invention, the planetary gear can have a gear step of at least 1.3, when the switching device switches from the first switch position to the second switch position. The gear step is to be understood in particular as the quotient of the gear ratio of the planetary gear in the first switch position and the gear ratio of the planetary gear in the second switch position. In the first switch position, the vehicle can thus be moved or driven in a so-called low speed range, wherein, in the second switch position, the vehicle can thus be moved or driven in a so-called high speed range, wherein the high speed range is greater than the low speed range. Thus, provision is made for the gear step to amount to at least 1.3 during switching from the low to the high speed range.
[0030] According to another advantageous feature of the present invention, the gear step can range from 1.3 to 1.6. As a result, a high initial acceleration and a high top speed are realized. This is especially advantageous for an electric vehicle, which can be propelled purely electrically, i.e. not by a combustion motor. With a hybrid vehicle the gear step can be greater than 1.6, wherein a hybrid vehicle differs from an electric vehicle in that the hybrid vehicle, by contrast with the hybrid vehicle, has an internal combustion engine for propelling the hybrid vehicle.
[0031] According to another advantageous feature of the present invention, at least one rotational speed sensor can be provided to detect a rotational speed of one of the at least three gear elements, in particular, of the second one of the gear elements. By detection of the rotational speed it is possible for example to move or to switch the switching element via the actuator depending on the rotational speed detected by means of the rotational speed sensor, so that especially advantageous switching processes of the propulsion device can be realized.
[0032] According to another advantageous feature of the present invention, the third one of the at least three gear elements can be secured via the switching device in the first switch position by a form fit against a rotation about the axis of rotation and can be connected in the second switch position by a form fit to the first one of the at least three gear elements in a torsion-proof manner. This enables an especially high efficiency of the propulsion device to be realized.
[0033] According to another advantageous feature of the present invention, the third one of the at least three gear elements can be secured via the switching device in the first switch position by a friction fit against a rotation about the axis of rotation and connected in the second switch position by a friction fit to the first one of the at least three gear elements in a torsion-proof manner This enables especially convenient switching processes to be realized.
[0034] According to another aspect of the present invention, a vehicle, in particular, an electric or hybrid vehicle, includes at least one electric machine embodied as a traction machine for driving the vehicle, and a propulsion device, as set forth above. Advantages and embodiments of the inventive propulsion device are to be seen as advantages and embodiments of the inventive vehicle, and vice versa.
BRIEF DESCRIPTION OF THE DRAWING
[0035] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0036] FIG. 1 is a schematic illustration of a first embodiment of a propulsion device according to the present invention;
[0037] FIG. 2 is a schematic illustration of a section of a second embodiment of a propulsion device according to the present invention;
[0038] FIG. 3 is a schematic illustration of a section of a third embodiment of a propulsion device according to the present invention;
[0039] FIG. 4 is a schematic illustration of a section of a fourth embodiment of a propulsion device according to the present invention;
[0040] FIG. 5 is a schematic illustration of a section of a fifth embodiment of a propulsion device according to the present invention; and
[0041] FIG. 6 is a schematic illustration of a section of a sixth embodiment of a propulsion device according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments may be illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
[0043] Turning now to the drawing, and in particular to FIG. 1 , there is shown a schematic illustration of a first embodiment of a propulsion device according to the present invention, generally designated by reference numeral 10 , for use in a vehicle, in particular, an electric vehicle. The propulsion device 10 includes an electric machine 12 shown in FIG. 1 schematically, wherein in particular the arrangement of the electric machine 12 is by way of example in FIG. 1 . The electric machine 12 includes a housing 14 , in which a stator 16 and a rotor 18 of the electric machine 12 are at least partly accommodated. The stator 16 is fixed to the housing 14 , wherein the rotor 18 is able to be rotated about a first axis of rotation relative to the housing 14 and relative to the stator 16 . For example the rotor 18 is able to be driven by the stator 16 , wherein the rotor 18 is connected to a shaft 20 in a torsion-proof manner. Thus the shaft 20 is able to be rotated about the said first axis of rotation relative to the housing 14 , wherein the electric machine 12 can provide torques via the rotor 18 and the shaft 20 to drive the vehicle.
[0044] The electric machine 12 is embodied as a traction machine, by means of which the vehicle is able to be driven. To this end the electric machine 12 is able to be operated in a motor mode and thus as a motor or electric motor. In the motor mode the electric machine 12 is supplied with electric energy or electric current respectively, through which the electric machine 12 provides torques to drive the vehicle via the shaft 20 .
[0045] In order to supply the electric machine 12 with electric current, the propulsion device 10 for example includes at least one electric energy store not shown in FIG. 1 , which is embodied as a battery for example. The electric machine 12 is connected via power electronics to the battery for example, so that the electric machine 12 can be supplied with electric current from the battery via the power electronics. Electric energy or electric current can namely be stored by means of the battery, wherein the electric current stored in the battery can be fed via the power electronics to the electric machine 12 .
[0046] It is further conceivable for the electric machine 12 to be able to be operated in a generator mode. In the generator mode the electric machine 12 functions as a generator and is driven by the moving vehicle and thus by means of kinetic energy of the vehicle. By means of the electric machine 12 at least a part of the kinetic energy of the vehicle is converted in generator mode into electric energy or electric current, wherein this electric current is provided by the electric machine 12 . The electric current provided by the electric machine 12 in the generator mode can be fed into the battery for example and stored there and/or fed to at least one electric load, which can be operated by means of the electric energy.
[0047] The propulsion device 10 further includes a differential gear 22 , which is assigned to an axle of the vehicle labeled overall by the number 24 . The axle 24 is for example a rear axle or a front axle and has ground contact elements in the form of wheels 26 . While driving along a road the vehicle rolls on the road via the wheels 26 rotating about an axis of rotation. The wheels 26 —as is explained in greater detail below—are able to be driven via the differential gear 22 by the electric machine 12 in its motor mode.
[0048] The differential gear 22 is also simply referred to as a differential and, when the vehicle is negotiating a curve for example, allows the wheels 26 to rotate at different speeds, so that for example the wheel on the outside of the curve can rotate faster than the wheel on the inside of the curve. This enables disproportionate stresses in the propulsion device 10 or in a drive train of the vehicle to be avoided.
[0049] The differential gear 22 includes a cage 28 , on which a bolt element 30 is held. Differential gearwheels 32 of the differential gear 22 are supported rotationally on the bolt element 30 , wherein the differential gearwheels 32 are embodied as toothed gearwheels and here as bevel gearwheels. The differential gear 22 also includes toothed gearwheels in the form of drive gearwheels 34 , which are embodied here as bevel gearwheels. The drive gearwheels 34 engage with the differential gearwheels 32 and are connected in a torsion-proof manner to shafts 36 . The shafts 36 are embodied for example as articulated shafts and are coupled to the wheels 26 , so that the wheels 26 are able to be driven via the shafts 36 by the electric machine 12 .
[0050] If the cage 28 is driven by means of the electric machine 12 and during this process is rotated about a second axis of rotation, the differential gearwheels 32 are driven via the bolt element 30 and are rotated during the process about the second axis of rotation, so that once again the drive gearwheels 34 and via these the shafts 36 and thus the wheels 26 are driven about the second axis of rotation. It can be seen from FIG. 1 here that the first axis of rotation, about which the rotor 18 and the shaft 20 are able to be rotated, is at a distance from the second axis of rotation and runs in parallel to the second axis of rotation.
[0051] The propulsion device 10 also includes a planetary gear labeled overall by the number 38 , which is embodied as a simple planetary gear and includes a first gear element in the form of a hollow gearwheel 40 , a second gear element in the form of a planet carrier 42 and a third gear element in the form of a sun gearwheel 44 . The planetary gear 38 further includes planet gearwheels 46 different from the gear elements (hollow gearwheel 40 , planet carrier 42 and sun gearwheel 44 ), which are each supported rotatably on the planet carrier 42 . The planet carrier 42 is also referred to as a web and is coupled here to the differential gear 22 , so that the differential gear 22 is able to be driven via the planetary gear 38 , in particular the planet carrier 42 , by the electric machine 12 in its motor mode. To this end the planet carrier 42 is connected to the cage 28 in a torsion-proof manner for example. In particular the planet carrier 42 can be embodied in one piece with the cage 28 .
[0052] The hollow gearwheel 40 has a first set of teeth in the form of inner teeth, wherein the sun gearwheel 44 has a second set of teeth in the form of outer teeth. Furthermore the respective planet gearwheel 46 has a third set of teeth in the form of outer teeth, so that the gear elements are embodied as toothed gearwheels. The planetary gear 38 is thus embodied as a toothed gearwheel gear, wherein the planet gearwheels 46 engage via the respective sets of teeth with the sun gearwheel 44 and the hollow gearwheel 40 . In other words the planet gearwheels 46 mesh both with the hollow gearwheel 40 and also with the sun gearwheel 44 .
[0053] It can be seen in this case from FIG. 1 that the hollow gearwheel 40 (first gear element) is able to be driven by the electric machine 12 , so that the planet carrier 42 is able to be driven by the hollow gearwheel 40 and via said gearwheel by the electric machine 12 . This means that the differential gear 22 , in particular the cage 28 , is able to be driven via the planet carrier 42 and the hollow gearwheel 40 by the electric machine 12 . To this end the hollow gearwheel 40 is connected in a torsion-proof manner to the toothed gearwheel 48 , wherein the toothed gearwheel 48 is embodied for example as a cylindrical gear or as a ring gear. For example the hollow gearwheel 40 is embodied in one piece with the toothed gearwheel 48 . In addition a toothed gearwheel 50 is connected to the shaft 20 in a torsion-proof manner, wherein the toothed gearwheel 50 is embodied as a cylindrical gear for example. The toothed gearwheel 50 is also referred to as the pinion or drive pinion and is able to be driven via the shaft 20 by the rotor 18 or by the electric machine 12 .
[0054] The toothed gearwheel 50 is in engagement with the toothed gearwheel 48 via the respective set of teeth, so that the toothed gearwheel 48 and via said gearwheel the hollow gearwheel 40 are able to be driven via the toothed gearwheel 50 and the shaft 20 by the electric machine 12 . The hollow gearwheel 40 thus represents a drive or a drive element of the planetary gear 38 , since the torques provided by the electric machine 12 in its motor mode for driving the vehicle via the toothed gearwheels 48 and 50 and thus via the hollow gearwheel 40 are introduced into the planetary gear 38 . The web (planet carrier 42 ) represents a take-off or a take-off element of the planetary gear 38 , since the planetary gear 38 provides the torques for driving the vehicle via the web and introduces them into the differential gear 22 . In other words the torques for driving the vehicle via the web are derived from the planetary gear 38 and transmitted to the differential gear 22 , in particular the cage 28 .
[0055] The propulsion device 10 further includes a switching device 52 with a first switching element 54 and a second switching element 56 . The second switching element 56 is connected to the sun gearwheel 44 in a torsion-proof manner. To this end a shaft 58 is provided, to which both the second switching element 56 and also the sun gearwheel 44 are connected in a torsion-proof manner. For example the sun gearwheel 44 is embodied in one piece with the shaft 58 . Thus the second switching element 56 is connected via the shaft 58 in a torsion-proof manner to the sun gearwheel 44 .
[0056] The first switching element 54 and thus the switching device 52 overall are able to be switched between a first switch position S 1 and a second switch position S 2 . To this end the first switching element 54 is able to be moved relative to the second switching element 56 between the switch positions S 1 and S 2 , wherein the first switching element 54 is able to be moved in an axial direction of the sun gearwheel 44 between the switch positions S 1 and S 2 and thus translationally.
[0057] The propulsion device 10 includes a housing 60 especially shown schematically in FIG. 1 , in which the switching device 52 and/or the planetary gear 38 and/or the differential gear 22 are each at least partly accommodated. In this case the gear elements (hollow gearwheel 40 , planet carrier 42 and sun gearwheel 44 ) are able to be rotated relative to the housing 60 about the said second axis of rotation, about which the cage 28 and the shafts 36 are also able to be rotated.
[0058] In the first switch position S 1 the sun gearwheel 44 is fixed by means of the first switching element 54 on the housing 60 , so that the sun gearwheel 44 is secured by means of the switching device 52 against a rotation about the second axis of rotation. In the first switch position S 1 the sun gearwheel 44 is supported via the shaft 58 , the second switching element 56 and the first switching element 54 on housing 60 , so that the sun gearwheel 44 cannot rotate about the second axis of rotation. A switching element 62 fixed to the housing 60 is provided for this purpose for example, with which the first switching element 54 interacts in the first switch position S 1 . As a result of this interaction the sun gearwheel 44 is fixed to the housing 60 and cannot rotate about the second axis of rotation relative to housing 60 .
[0059] In the second switch position the sun gearwheel 44 is connected via the shaft 58 , the second switching element 56 and the first switching element 54 in a torsion-proof manner to the hollow gearwheel 40 , so that the hollow gearwheel 40 and the sun gearwheel 44 —when the hollow gearwheel 40 is driven via the toothed gearwheels 48 and 50 by the electric machine 12 —orbit as a block and thus rotate together about the second axis of rotation relative to the housing 60 .
[0060] For example a fourth switching element 63 is connected in a torsion-proof manner to the hollow gearwheel 40 , wherein the first switching element 54 in the second switch position S 2 interacts with the fourth switching element 63 , so that through this the sun gearwheel 44 is connected in a torsion-proof manner via the shaft 58 , the second switching element 56 , the first switching element 54 and the fourth switching element 63 to the hollow gearwheel 40 .
[0061] Overall it can be seen that the sun gearwheel 44 , in the first switch position S 1 , is coupled to the housing 60 and in the second switch position S 2 to the hollow gearwheel 40 in a torsion-proof manner. It is further conceivable that the first switching element 54 is able to be moved into neutral position, in which the sun gearwheel 44 is decoupled both from the housing 60 and also from the hollow gearwheel 40 .
[0062] In the first switch position S 1 the planetary gear 38 has a first gear ratio i 1 , which essentially amounts to at least 1.5. In the second switch position S 2 the planetary gear 38 advantageously has a second gear ratio i 2 , which essentially at least amounts to 1. Thus the first switch position S 1 is a slow gear or a starting ratio, in which an especially high initial acceleration can be realized. This enables the vehicle to be accelerated especially strongly by means of the electric machine 12 . The second switch position S 2 is a fast gear, by means of which an especially high top speed of the vehicle can be realized by means of the electric machine 12 .
[0063] The propulsion device 10 advantageously includes an actuator 64 especially shown schematically in FIG. 1 and coupled to the switching device 52 , in particular to the first switching element 54 , in a way not shown in any greater detail, by means of which the switching element 54 is able to be switched or moved. The actuator 64 is embodied for example as an electromechanical actuator or hydraulic actuator, in particular an electrohydraulic actuator, or electromagnetic actuator, so that the first switching element 54 can be switched by means of the actuator 64 automatically or in an automated manner or semi-automatically or in a semi-automated manner.
[0064] As an especially simple solution the switching device 52 operates purely by making a form fit while interrupting the flow of power during the changing of switching stages S 1 and S 2 , wherein this change is also called a gear change. Thus, provision is advantageously made for the first switching element 54 to interact in the first switch position S 1 by a form fit with the third switching element 62 and in the second switch position S 2 to interact by a form fit with the fourth switching element 63 , so that a form-fit coupling of the sun gearwheels 44 with the housing 60 or the hollow gearwheel 40 respectively is provided. To this end the switching device 52 is embodied as a claw switch for example, so that the first switching element 54 is embodied as the switching claw. The switching claw in each case has teeth for example, wherein die switching elements 62 and 63 are embodied as respective sets of teeth. Through this the teeth act in the respective switch positions S 1 and S 2 in a form fit with one another.
[0065] In a comparatively more complex version the switch positions S 1 and S 2 , also referred to as gears, can be changed without interrupting the tractive power. This means for example that the first switching element 54 in the first switch position S 1 interacts by a friction fit with the third switching element 62 and in the second switch position S 2 by a friction fit with the fourth switching element 63 , so that then the sun gearwheel 44 is coupled in each case by a friction fit with the housing 60 or with the hollow gearwheel 40 respectively.
[0066] The design of the actuator 64 is oriented for example to the respective design of other actuators used in the propulsion device 10 , so that these actuators use the same operating principle. The switching element 54 is a separation element, which is used for coupling and decoupling or separating the sun gearwheel 44 . For this separating element for example an axial form fit in particular in the form of a claw coupling similar to a synchronizing unit, or a friction fit, in particular with flat or cone-shaped friction surfaces, is conceivable.
[0067] Through the first switch position S 1 a low speed range is able to be realized, in which the vehicle is moved or driven respectively, i.e. can be driven by the electric machine 12 . Through the second switching stage S 2 for example a so-called high speed range is able to be realized, in which the vehicle can be driven, wherein the high speed range is higher than the low speed range. Advantageously, provision is also made for the planetary gear 38 to have a stationary gear ratio i 0 , which lies for example in a range from −4 inclusive to −1.5 inclusive. Through the integration of the planetary gear 38 an additional gear ratio is realized for the low speed range, for example an effective gear ratio of i i =1−i 0 −1 , with retention of the direction of rotation. Advantageously, provision is made for a gear step when switching from a low speed range to a high speed range, wherein this gear step lies in a range from 1.3 inclusive to 1.6 inclusive, which has been shown to be advantageous for an electric vehicle, in particular a Battery-Electric Vehicle (BEV). For a Hybrid Vehicle (HEV) a greater gear step can be advantageous, wherein the limits of the concept are able to be expanded by using a kinematic equivalent planet set. This means that FIG. 1 shows a first form of embodiment of the propulsion device 10 , wherein FIGS. 2 to 7 illustrate further possible forms of embodiment of the propulsion device 10 .
[0068] In the low speed range, i.e. in the first switch position S 1 , the sun gearwheel 44 is firmly held via the switching device 52 , in particular in a form fit, wherein the drive takes place via the hollow gearwheel 40 with a ratio retaining the direction of rotation into the slow range. In the high speed range, i.e. in the second switch position S 2 , the sun gearwheel 44 is connected with the aid of the switching device 52 , in particular in a form fit, to the hollow gearwheel 40 , so that the planetary gear 38 or the planet set then orbits as a block.
[0069] Thus overall a two-gear stage is realized. For an especially simple way of realizing the two-gear stage the integration of a rotational speed sensor, in particular on housing 60 , is advantageous, in order for example either for the simple variant with tractive power interruption, to synchronize by rapid electric regulation or in order with the more complex variant capable of load switching, to enable the slip behavior of the friction-fit power-guiding components to be better regulated.
[0070] It is further advantageous that both the variant with and also the variant without tractive power interruption are able to be designed with just one active element as actuator 64 . It is further conceivable to dispose the differential gear 22 and the switching device 52 differently along the axis 24 in the vehicle, which in particular involves the axial location of the differential ring gearwheel, i.e. the toothed gearwheel 48 .
[0071] It might also be additionally possible to integrate a parking brake with at least one parking brake element into the propulsion device 10 and to actuate the parking brake element by means of the same actuator 64 as the first switching element 54 , i.e. to move it. Then a primary actuator of the parking brake can be dispensed with, wherein for reasons of functional safety only a significantly more simple secondary actuator is still provided for the parking brake element.
[0072] Also conceivable are other arrangements of the switching device 52 , in particular as a coaxial construction element directly on the electric machine 12 or as a parallel arrangement based on cylindrical gears. By means of the propulsion device 10 shown in FIG. 1 the installation space requirement can be kept especially low however. The advantage of the propulsion device 10 in accordance with FIG. 1 is that the two-gear stage as a constructional unit with the differential gear 22 provides the opportunity for compressing functions, since the differential gear 22 and the switching stage or switching device 52 respectively can form one unit. In addition it is possible in an especially simple manner to actuate the parking brake element by means of the actuator 64 , by means of which the first switching element 54 is also actuated.
[0073] FIG. 2 shows a schematic illustration of a second embodiment of a propulsion device 10 according to the present invention. Parts corresponding with those in FIG. 1 are denoted by identical reference numerals. The description below will center on the differences between the embodiments. In this embodiment, provision is made for planetary gear 38 of the planetary gear 38 , which has a stationary gear ratio i 0 in an advantageous range of i 0 =−0.54 . . . −53, with
[0000]
i
0
=
z
B
z
P
2
z
A
z
P
1
[0000] wherein z A designates the number of teeth of the hollow gearwheel 40 , and z B designates the number of teeth of the hollow gearwheel 40 . In addition, the respective planet gearwheel 46 is embodied as a double planet gearwheel, so that the planet gearwheel 46 has two planet gearwheel elements 66 and 68 , which are connected to one another in a torsion-proof manner. In this case z P1 designates the number of teeth of the planet gearwheel element 66 and z P2 number of teeth of the planet gearwheel element 68 . The planet gearwheel element 66 is in engagement with the hollow gearwheel 40 and the planet gearwheel element 68 is in engagement with the hollow gearwheel 40 .
[0074] FIG. 3 shows a schematic illustration of a third embodiment of a propulsion device 10 according to the present invention. In this embodiment, the stationary gear ratio i 0 ranges according to i 0 =−1.2 . . . −11, with
[0000]
i
0
=
z
B
z
A
[0075] FIG. 4 shows a schematic illustration of a fourth embodiment of a propulsion device 10 according to the present invention. In this embodiment, a second hollow gearwheel 41 is provided as the third gear element instead of a sun gearwheel in addition to hollow gearwheel 40 . The stationary gear ratio i 0 ranges according to i 0 =1 . . . 2.7, with
[0000]
i
0
=
z
B
z
P
1
z
A
z
P
2
[0000] wherein z B designates the number of teeth of the hollow gearwheel 40 and z A the number of teeth of the hollow gearwheel 41 .
[0076] FIG. 5 shows a schematic illustration of a firth embodiment of a propulsion device 10 according to the present invention. In this embodiment, a further planet gearwheel 70 is provided in addition to planet gearwheel 46 , wherein the planet gearwheels 46 and 70 are not connected to one another in a torsion-proof manner, but engage with one another via their respective teeth, so that the planet gearwheels 46 and 70 mesh with one another and can be rotatable relative to one another. In this case the planet gearwheel 46 is in engagement with the sun gearwheel 44 as well as being in engagement with the planet gearwheel 70 , which is in engagement with the planet gearwheel 46 and in engagement with the hollow gearwheel 40 . The stationary gear ratio i 0 ranges according to i 0 =1.2 . . . −17.6, with
[0000]
i
0
=
z
B
z
A
[0077] FIG. 6 shows a schematic illustration of a sixth embodiment of a propulsion device 10 according to the present invention. In this embodiment, both the third gear element and also the first gear element are embodied as sun gearwheels 44 and 45 , wherein the planet gearwheel 46 is embodied as a double planet gearwheel. In this case, the planet gearwheel elements 66 and 68 are connected to one another in a torsion-proof manner, wherein the planet gearwheel element 66 is in engagement with the sun gearwheel 44 and the planet gearwheel element 68 is in engagement with the sun gearwheel 45 . The stationary gear ratio i 0 ranges according to i 0 =1.2 . . . 41, with
[0000]
i
0
=
z
B
z
P
1
z
A
z
P
2
[0000] wherein z B designates the number of teeth of the sun gearwheel 45 and z A the number of teeth of the sun gearwheel 44 .
[0078] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. The embodiments were chosen and described in order to explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0079] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein:
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A propulsion device for a vehicle includes a differential gear, which is driven by the electric machine via a planetary gear and operatively connected to an axle on the vehicle, with the planetary gear including at least three rotatable gear elements. A switching device is switchable by an actuator between a first switch position, in which one gear element is secured against a rotation about the axis of rotation, and a second switch position, in which the one gear element is connected by the switching device to another gear element in a torsion-proof manner. A parking brake including at least one parking brake element is movable by the actuator between a park position, in which the vehicle is prevented from rolling away, and at least one release position.
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[0001] This application claims benefit under 35 USC 119(e) of U.S. provisional application No. 61/610,100, filed Mar. 3, 2012, the disclosure of which is incorporated by reference.
[0002] This invention provides a synergistic friction modifier composition for lubricants, said composition comprising a metal based friction modifier, such as a molybdenum dialkyldithiocarbamate, and certain esters of hydroxy carboxylic acids, for example, short chain alkyl esters of citric or tartaric acid such as tributyl citrate.
BACKGROUND OF THE INVENTION
[0003] Lubricants, such as lubricating oils and greases, are subject to deterioration at elevated temperatures, extreme contact pressures, or upon prolonged exposure to the elements. Such deterioration is evidenced in many instances by an increase in acidity and viscosity. It can cause metal parts to corrode and often leads to a loss of lubrication properties resulting in wear at the surfaces being lubricated, e.g. metal engine parts and the like.
[0004] A variety of additives have been developed to provide, antioxidant, antiwear, and deposit control properties etc, to these lubricants. Additives have also been developed to modify the lubricity and load bearing properties of the lubricant. For example, zinc dialkyldithiophosphates (ZDDP) have been used as antifatigue, antiwear, antioxidant, extreme pressure and friction modifying additives for lubricating oils for many years. However, ZDDPs are subject to several drawbacks due to the presence of zinc and phosphorus. For example, the presence of zinc contributes to emission of particulates in the exhaust.
[0005] Reducing friction between moving parts is of course a fundamental role of lubricants. This is especially significant in internal combustion engines and power transmission systems found in cars and trucks, for example, in part because a substantial amount of the theoretical mileage lost from a gallon of fuel is traceable directly to friction.
[0006] A variety of friction modifiers are widely known and used, including for example, fatty acid esters and amides, and organo molybdenum compounds, such as molybdenum dialkyldithiocarbamates, molybdenum dialkyl dithiophosphates, molybdenum disulfide, tri-molybdenum cluster dialkydithiocarbamates, non-sulfur molybdenum compounds and the like. Molybdenum friction modifiers are widely known and are effective over a broad temperature range, especially upon reaching temperatures of 120° C. or higher where chemical transformations form Mo-Sulfide glass coatings on surfaces. Molybdenum compounds however have some drawbacks, for example they can complex and interfere with dispersants and like other metal containing compounds, may suffer from particulate formation etc, as seen, for example, with the zinc anti-wear additive above. It is therefore desirable to reduce the amount of such friction modifiers in lubricants.
[0007] U.S. Pat. No. 5,333,470 discloses alkylated citric acid adducts, i.e., citrate esters, as antiwear and friction modifying additives for fuel and lubricants formed by reacting citric acid with 1, 2 or 3 equivalents of an alcohol. The anti-wear properties and friction reduction of compound mixtures derived from citric acid and oleyl alcohol are demonstrated.
[0008] U.S. Pat. No. 7,696,136 discloses lubricant compositions containing esters of hydroxy carboxylic acids, such as citrates and tartrates, which are useful as non-phosphorus-containing, anti-fatigue, anti-wear, extreme pressure additives for fuels and lubricating oils. The esters are used alone or in combination with a zinc dihydrocarbyldithiophosphate or an ashless phosphorus-containing additive, such as trilauryl phosphate or triphenylphosphorothionate. The addition of short chain esters, such as tri-ethyl citrate, borated tri-ethyl citrate and di butyl tartrate are shown to allow one to reduce the amount of ZDDP while maintaining good anti-wear properties.
[0009] It has now been found that while certain short chain esters of U.S. Pat. No. 7,696,136, e.g., tributyl citrate, can provide a modest decrease in friction coefficient of a lubricating oil, e.g., when added to a lubricant base stock or a commercial lubricant oil such as commercially available SAE 10-40, SAE 10-20, SAE 5-30 automotive oils etc, a much greater effect is seen when the citrate is combined with certain metal based friction modifiers, such as molybdenum friction modifiers. The surprisingly large synergy seen allows one to significantly reduce the amount of metal containing additives in lubricants, such as lubricants used in engines and power transmission systems.
SUMMARY OF THE INVENTION
[0010] A surprising reduction in the friction coefficient of lubricating oils is obtained by blending metal based friction modifiers, such as organo molybdenum friction modifiers, with short chain alkyl esters, e.g., C 1-8 alkyl, C 1-6 alkyl or C 1-4 alkyl esters, of hydroxy carboxylic acids, for example, esters of formula:
[0000]
[0000] wherein each R is an independently selected C 1-8 straight or branched chain alkyl;
G is COOR, (CH 2 ) 1-3 COOR or (CHOH) 1-3 COOR; and
G′ is H, (CH 2 ) 1-3 COOR or (CHOH) 1-3 COOR.
[0011] The esters of the invention can be substituted for at least a portion of a metal based friction modifiers generally encountered in lubricant compositions, while maintaining excellent performance, especially et higher temperatures, e.g., 100° C. or above, allowing one to use less metal in lubricating oils, oils such as those for automotive applications.
DESCRIPTION OF THE INVENTION
[0012] The invention provides a lubricant composition comprising:
[0000] A) a natural or synthetic lubricating oil, and
B) from about 0.01 to about 5 wt %, based on the weight of the lubricant composition, of a mixture of i) a metal based friction modifier such as a molybdenum friction modifier, and ii) a hydroxy carboxylic ester of formula I:
[0000]
[0000] wherein each R is an independently selected C 1-8 straight or branched chain alkyl:
G is COOR, (CH 2 ) 1-3 COOR or (CHOH) 1-3 COOR; and
[0013] G′ is H, (CH 2 ) 1-3 COOR of (CHOH) 1-3 COOR.
[0014] The weight ratio of component i) to ii) is typically from about 3:1 to about 1:9 based on the total weight of metal based friction modifier i) and hydroxy carboxylic ester ii). For example, the ratio by weight of i) to ii) is from about 2:1 to about 1:9, e.g., from about 2:1 to about 1:5 or 1:1 to 1:9. For example, component i) may be present in a greater amount than, or the same amount as, component ii), e.g., in a ratio of 3:1, 2:1 1.5:1 or 1:1. In many embodiments however, component i) is present in the same amount or less than the amount of component ii) for example, the ratio of i to ii is 1:1, 1:1.5, 1:2, 1:3, 1:4, 1:5 or up to 1:9. Generally the weight ratio of i to ii is from about 1.5:1 to about 1:9, or about 1.5:1 to about 1:5, such as about 1:1 to about 1:5, about 1:1 to about 1:4 or from about 1:1 to about 1:3.
[0015] Generally the mixture of metal based friction modifier 0 and hydroxy carboxylic ester ii) is present from about 0.01 to about 3 wt %, for example about 0.5 or 0.1 to about 2 wt %, or from about 0.1 or 0.5 to about 1.5 wt %, based on the weight of the lubricant composition.
[0016] In many embodiments, the hydroxy carboxyl ester comprises one or more esters of citric acid and/or tartaric acid, for example, compounds of the formulae II and/or III
[0000]
[0000] wherein R is selected from C 1-8 straight or branched chain alkyl. In many embodiments R is selected from C 1-6 straight or branched chain alkyl, for example R is selected from C 1-4 straight or branched chain alkyl or R is selected from C 2-6 or C 3-6 straight or branched chain alkyl. For example, the hydroxy carboxyl ester comprises at least one C 2-6 alkyl ester of citric acid.
[0017] C 1-8 straight or branched chain alkyl is, for example, selected from methyl, ethyl, propyl, iso-propyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, tert-pentyl, ethylpropyl, isomers of methyl butyl, hexyl, isomers of methylpentyl, isomers of ethylbutyl, heptyl, isomers of methylhexyl, isomers of ethylpentyl, isomers of propylbutyl, octyl, isomers of methylheptyl, isomers of ethylhexyl, isomers of propylpentyl, and tert-octyl.
[0018] C 1-6 straight or branched chain alkyl is, for example, selected from methyl, ethyl, propyl, iso-propyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, tert-pentyl, isomers of methyl butyl, ethylpropyl, hexyl, isomers of methylpentyl and isomers of ethylbutyl.
[0019] C 1-4 straight or branched chain alkyl is, for example, selected from methyl, ethyl, propyl, iso-propyl, butyl, isobutyl, sec-butyl and tert-butyl. For example, R is selected from methyl, ethyl, propyl and butyl.
[0020] In some particular embodiments R is C 3-6 straight or branched chain alkyl, and in certain embodiments R is C 3-6 straight chain alkyl, for example, linear butyl.
[0021] While each R in formula I, II, or III may be different, in many embodiments, each R is the same. For example, in many embodiments, the hydroxy carboxy ester is selected from trimethyl, triethyl, tri-propyl, and tri-butyl citrate or dimethyl, diethyl, di-propyl, and di-butyl tartrate, and alkyl isomers thereof, e.g., tri-isopropyl citrate or di-isopropyl tartrate etc.
[0022] Often, the hydroxy carboxy ester is selected from triethyl citrate, tri propyl citrate, tributyl citrate, tripentyl and trihexyl citrate, e.g., triethyl citrate, tri propyl citrate, and tributyl citrate.
[0023] The hydroxy carboxy esters of the invention are known compounds, and are either commercially available or readily prepared by known means.
[0024] Generally, the metal based friction modifier comprises one or more organo molybdenum compounds such as, for example, molybdenum dialkyldithiocarbamates, molybdenum dialkyl dithiophosphates, molybdenum disulfide, tri-molybdenum cluster dialkyldithiocarbamates, non-sulfur molybdenum compounds and the like; for example, a molybdenum dialkyldithiocarbamate friction modifier is often present. Many of these molybdenum compounds are well known and many are commercially available. Other friction modifiers may also be present, including organic fatty acids and derivatives of organic fatty acids, amides, imides, and other organo metallic species for example zinc and boron compounds, etc.
[0025] Commercial lubricant formulations typically contain a variety of other additives, for example, dispersants, detergents, corrosion/rust inhibitors, antioxidants, anti-wear agents, anti-foamants, friction modifiers, seal swell agents, demulsifiers, V.I. improvers, pour point depressants, and the like. A sampling of these additives can be found in, for example, U.S. Pat. No. 5,498,809 and U.S. Pat. No. 7,696,136, the relevant portions of each disclosure is incorporated herein by reference, although the practitioner is well aware that this comprises only a partial list of available lubricant additives. It is also well known that one additive may be capable of providing or improving more than one property, e.g., an anti-wear agent may also function as an anti-fatigue and/or an extreme pressure additive.
[0026] The lubricant compositions will often contain any number of these additives. Thus, final lubricant compositions of the invention will generally contain a combination of additives, including the inventive friction modifying additive combination along with other common additives, in a combined concentration ranging from about 0.1 to about 30 weight percent, e.g., from about from about 0.5 to about 10 weight percent based on the total weight of the oil composition. For example, the combined additives are present from about 1 to about 5 weight percent. Oil concentrates of the additives can contain from about 30 to about 75 weight percent additives.
[0027] Given the ubiquitous presence of additives in a lubricant formulation, the amount of lubricating oil present in the inventive composition is not specified above, but in most embodiments, except additive concentrates, the lubricating oil is a majority component, i.e., present in more than 50 wt % based on the weight of the composition, for example, 60 wt % or more, 70 wt % or more, 30 wt % or more, 90 wt % or more, or 95 wt % or more.
[0028] One embodiment of the invention is therefore a lubricant composition comprising
A) from about 70 to about 99.9 wt % of a natural or synthetic lubricating oil, B) from about 0.01 to about 5 wt % of the mixture of i) the metal based friction modifier and ii) hydroxy carboxylic ester described above, and C) one or more additional lubricant additive
wherein the combined amount of B) and C) present in the composition is from about 0.1 to about 30 weight percent based on the total weight of the lubricant composition.
[0032] In another embodiment the lubricating oil is present from about 90 to about 99.5 wt % and the combined amount of B) and C) is from about 0.5 to about 10 weight percent; and in another embodiment the lubricating oil is present from about 95 to about 99 wt % and the combined amount of B) and C) is from about 1 to about 5 weight percent based on the total weight of the lubricant composition.
[0033] In one particular embodiment, the lubricant composition comprises;
[0000] A) from about 70 to about 99.9 wt % of a natural or synthetic lubricating oil,
B) from about 0.01 to about 5 wt %, of a mixture comprising;
i) a metal based friction modifier selected from the group consisting of molybdenum dialkyldithiocarbamates, molybdenum dialkyl dithiophosphates, molybdenum disulfide, tri-molybdenum cluster dialkyldithiocarbamates, and ii) a hydroxy carboxylic ester selected from the group consisting of C 2-6 or C 3-6 straight or branched chain alkyl esters of citric acid; and
C) one or more additional lubricant additives selected from the group consisting of dispersants, detergents, corrosion/rust inhibitors, antioxidants, anti-wear agents, anti-foamants, friction modifiers, seal swell agents, demulsifiers, V.I. improvers and pour point depressants,
wherein the combined amount of B) and C) present in the composition is from about 0.1 to about 30 weight percent based on the total weight of the lubricant composition.
[0036] The natural or synthetic lubricating oil of the invention can be any suitable oil of lubricating viscosity. For example, a lubricating oil base stock is any natural or synthetic lubricating oil base stock fraction having a kinematic viscosity at 100° C. of about 2 to about 200 cSt, about 3 to about 150 cSt, and often about 3 to about 100 cSt. The lubricating oil base stock can be derived from natural lubricating oils, synthetic lubricating oils, or mixtures thereof. Suitable lubricating oil base stocks include, for example, petroleum oils, mineral oils, and oils derived from coal or shale petroleum based oils, animal oils, such as lard oil, vegetable oils (e.g., canola oils, castor oils, sunflower oils) and synthetic oils.
[0037] Synthetic oils include hydrocarbon oils and halo-substituted hydrocarbon oils, such as polymerized and interpolymerized olefins, gas-to-liquids prepared by Fischer-Tropsch technology, alkylbenzenes, polyphenyls, alkylated diphenyl ethers, alkylated diphenyl sulfides, as well as their derivatives, analogs, homologs, and the like. Synthetic lubricating oils also include alkylene oxide polymers, interpolymers, copolymers, and derivatives thereof, wherein the terminal hydroxyl groups have been modified by esterification, etherification, etc. Another suitable class of synthetic lubricating oils comprises the esters of dicarboxylic acids with a variety of alcohols. Esters useful as synthetic oils also include those made from monocarboxylic acids or diacids and polyols and polyol ethers. Other esters useful as synthetic oils include those made from copolymers of alphaolefins and dicarboxylic acids which are esterified with short or medium chain length alcohols.
[0038] Silicon-based oils, such as the polyalkyl-, polyaryl-, polyalkoxy-, or polyaryloxy-siloxane oils and silicate oils, comprise another useful class of synthetic lubricating oils. Other synthetic lubricating oils include liquid esters of phosphorus-containing acids, polymeric tetrahydrofurans, poly alphaolefins, and the like.
[0039] The lubricating oil may be derived from unrefined, refined, re-refined oils, or mixtures thereof. Unrefined oils are obtained directly from a natural source or synthetic source (e.g. coal, shale, or tar and bitumen) without further purification or treatment. Examples of unrefined oils include a shale oil obtained directly from a retorting operation, a petroleum oil obtained directly from distillation, or an ester oil obtained directly from an esterification process, each of which is then used without further treatment. Refined oils are similar to unrefined oils, except that refined oils have been treated in one or more purification steps to improve one or more properties. Suitable purification techniques include distillation, hydrotreating, dewaxing, solvent extraction, acid or base extraction, filtration, percolation, and the like, all of which are well-known to those skilled in the art. Re-refined oils are obtained by treating refined oils in processes similar to those used to obtain the refined oils. These re-refined oils are also known as reclaimed or reprocessed oils and often are additionally processed by techniques for removal of spent additives and oil breakdown products.
[0040] Lubricating oil base stocks derived from the hydroisomerization of wax may also be used, either alone or in combination with the aforesaid natural and/or synthetic base stocks. Such wax isomerate oil is produced by the hydroisomerization of natural or synthetic waxes or mixtures thereof over a hydroisomerization catalyst. Natural waxes are typically the slack waxes recovered by the solvent dewaxing of mineral oils; synthetic waxes are typically the waxes produced by the Fischer-Tropsch process. The resulting isomerate product is typically subjected to solvent dewaxing and fractionation to recover various fractions having a specific viscosity range. Wax isomerate is also characterized by possessing very high viscosity indices, generally having a V.I. of at least 130, preferably at least 135 or higher and, following dewaxing, a pour point of about −20° C., or lower.
[0041] The friction modifying mixture of metal based friction modifier and hydroxy carboxylic ester of the invention can be added to the lubricating oil directly as a combination or as individual components. The mixture can be added by itself or along with other common additives. A concentrate containing the mixture may also be prepared and added to the lubricating oil. It is also possible to add the friction modifying mixture to a preformulated lubricating oil which already contains all or most of the other formulation components.
[0042] The lubricating oil compositions of the invention can be used in a variety of applications, for example, crankcase lubricating oils for spark-ignited and compression-ignited internal combustion engines, gas engine lubricants, turbine lubricants, automatic transmission fluids, gear lubricants, compressor lubricants, metal-working lubricants, hydraulic fluids, and other lubricating oil and grease compositions.
[0043] For example, the friction modifying combination of the invention can be used in petroleum, polyester, polyolefin, alkylated aryl, silicon and similar oils commonly encountered in engines used in automobiles, trucks, airplanes, boats, ships and rail transport.
[0044] The friction modifying combination of the invention has been found to improve friction reduction over a wide temperature range, e.g., from 40-200° C. in various lubricants, for example, commercially available engine lubricants. The effectiveness of the combination allows for the reduction of metal components in these lubricants. The inventive combination is particularly effective in lubricating oils which may be used at temperatures above, e.g., 90° C., for example, lubricant applications wherein the temperatures may reach 100° C. or higher, such as 130° C., or 160° C. or higher.
EXAMPLES
[0045] In the following examples, the friction coefficient over a temperature range of 60-162° C. was determined from Cameron Plint testing of formulated motor oils to which mixtures of molybdenum friction modifiers and citrate esters according to the invention were added. Comparisons were made to the formulated oils without the inventive additive mixture (referred to as standard in the data tables) and/or to formulated motor oils to which only the molybdenum friction modifier or citrate ester was added. The commercial source of molybdenum dialkyldithiocarbamate and tributyl citrate was the same for each example. Ratios are by weight.
Example 1
[0046] A formulated, petroleum based 10W-40 motor oil obtained from a commercial supplier was blended with 1% by weight based on the weight of the motor oil, of a mixture of a commercially available molybdenum dialkyldithiocarbamate and tributyl citrate in a weight ratio of 1:1.
Example 2
[0047] A formulated, petroleum based 20W-40 motor oil obtained from a commercial supplier was blended with 1% by weight based on the weight of the motor oil, of the 1:1 mixture of molybdenum dialkyldithiocarbamate and tributyl citrate of Example 1.
[0048] Results from Examples 1 and 2, and the untreated standards are shown in Table 1.
[0000]
TABLE 1
Friction
coefficient (—)
132° C.
162° C.
10W-40 Standard
0.103
0.100
20W-40 Standard
0.104
0.108
Example 1, 10W-40
0.030
0.029
Example 2, 20W-40
0.040
0.020
Example 3
[0049] A commercially obtained, fully formulated, petroleum based 5W-30 motor oil was blended with 1% by weight based on the weight of the motor oil, of the 1:1 mixture of molybdenum dialkyldithiocarbamate and tributyl citrate.
Example 4
[0050] The commercially obtained 5W-30 motor oil used in Example 3 was blended with 1% by weight based on the weight of the motor oil, of a 1:3 mixture of the molybdenum dialkyldithiocarbamate and tributyl citrate.
Example 5
[0051] The commercially obtained 5W-30 motor oil used in Example 3 was blended with 1% by weight based on the weight of the motor oil, of a 19 mixture of the molybdenum dialkyldithiocarbamate and tributyl citrate.
[0052] Results from Examples 3-5 and the untreated standard are shown in Table 2.
[0000]
TABLE 2
Friction
coefficient (—)
132° C.
162° C.
5W-30 Standard formulation
0.108
0.094
Example 3, 1:1 MoFM:citrate
0.083
0.069
Example 4, 1:3 MoFM:citrate
0.068
0.057
Example 5, 1:9 MoFM:citrate
0.070
0.064
Example 6
[0053] The impact of the combination of the individual components vs the mixture of components was tested. A formulated, commercially available, fully synthetic 5 W 30 oil was treated with 1 wt % molybdenum dialkyldithiocarbamate, with 1 wt % tributyl citrate, and with 1 wt % of a 1:1 mixture of molybdenum dialkyldithiocarbamate and tributyl citrate. Friction coefficients were again measured over a range of temperatures.
[0054] Results from Example 6 are shown in Table 3
[0000]
TABLE 3
Friction
coefficient (—)
132° C.
162° C.
Standard
0.105
0.105
Standard plus tributyl citrate
0.100
0.105
Standard plus MoFM
0.031
0.030
Standard plus MoFM and tributyl citrate
0.035
0.028
[0055] Tributyl citrate alone was ineffective. However, the 1:1 blend of molybdenum friction modifier and tributyl citrate is as good or better in lowering the friction coefficient at higher temperatures than the molybdenum compound alone, even at half the amount of molybdenum.
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Combining a metal based friction modifier, such as a molybdenum dialkyldithiocarbamate, and certain esters of hydroxy carboxylic acids, such as short chain alkyl esters of citric or tartaric acid, e.g., tributyl citrate, has a synergistic effect on lowering the friction coefficient of lubricating oils allowing one to reduce the amount of metal based friction modifier needed to adequately formulate a lubricant with low friction characteristics.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of prior application Ser. No. 13/735,545, filed Jan. 7, 2013, now U.S. Pat. No. 8,516,321, issued Aug. 20, 2013;
Which was a divisional of prior application Ser. No. 13/396,017, filed Feb. 14, 2012, now U.S. Pat. No. 8,375,264, issued Feb. 12, 2013;
Which was a divisional of prior application Ser. No. 13/102,742, filed May 6, 2011, now U.S. Pat. No. 8,145,962, issued Mar. 27, 2012;
Which was a divisional of prior application Ser. No. 12/985,876, filed Jan. 6, 2011, now U.S. Pat. No. 7,962,818, issued Jun. 14, 2011;
Which was a divisional of prior application Ser. No. 12/840,928, filed Jul. 21, 2010, now U.S. Pat. No. 7,890,829, issued Feb. 15, 2011;
Which was a divisional of prior application Ser. No. 12/563,775, filed Sep. 21, 2009, now U.S. Pat. No. 7,793,182, issued Sep. 7, 2010;
Which was a divisional of prior application Ser. No. 11/954,403, filed Dec. 12, 2007, now U.S. Pat. No. 7,613,970, issued Nov. 3, 2009;
Which was a divisional of prior application Ser. No. 11/293,061, filed Dec. 2, 2005, now U.S. Pat. No. 7,328,387, issued Feb. 5, 2008.
Which claims priority from Provisional Application No. 60/634,842, filed Dec. 10, 2004.
This application is related to U.S. patent application Ser. No. 10/983,256, filed Nov. 4, 2004, titled “Removable and Replaceable Tap Domain Selection Circuitry,” and U.S. patent application Ser. No. 11/258,315, filed Oct. 25, 2005, titled “2 Pin Bus.”
BACKGROUND OF THE DISCLOSURE
This disclosure relates in general to IC or core signal interfaces and particularly to IC or core signal interfaces related to test, emulation, debug, trace, and function operations.
DESCRIPTION OF THE RELATED ART
FIG. 1 illustrates an IC or embedded core circuit 100 containing functional circuits 102 , IEEE 1149.1 (JTAG) circuit 104 , and emulation, debug, and/or trace circuit 106 . The functional circuit 102 communicates externally of the IC or core via bus terminals 103 . The 1149.1 circuit communicates externally of the IC or core via bus terminals 108 and internally to the functional circuit 102 via bus 114 . The emulation, debug, and/or trace circuit communicates externally of the IC or core via bus terminals 110 and internally to the functional circuit 102 via bus 112 . As seen, the 1149.1 circuit 104 comprises data registers 116 , instruction register 118 , mux 122 , falling clock edge FF 124 , tristate buffer 128 , and test access port (TAP) controller 120 . The 1149.1 circuit 104 has external terminals on bus 108 for a test data input (TDI) 132 , a test mode select (TMS) 134 , a test clock (TCK) 136 , a test reset (TRST) 138 , and test data output (TDO) 140 signals. The data registers 116 comprise a set of serially accessible registers, some providing input and output to functional circuit 102 via bus 114 . The registers can be used for performing boundary scan test operations on functional bus terminals 103 , performing internal scan testing of the functional circuit 102 , and/or supporting debug, trace, and/or emulation operations on the functional circuit 102 . As indicated, a power up clear (PUC) circuit 130 , which is a circuit for resetting or initializing a given circuit upon application of power, may be used instead of or in combination with the TRST terminal to set the state of the Tap 120 in the 1149.1 circuit 104 .
FIG. 2 illustrates an IC 200 containing four JTAG circuits 104 . One JTAG circuit 104 is associated with non-core circuitry in the chip and is referred to as the Chip Tap Domain 202 . The other JTAG circuits 104 are each associated with circuitry of an embedded core and are referred to as Core Tap Domains 204 - 208 . The Tap domains 202 - 208 are shown in Tap domain region 201 . The JTAG circuit 104 bus terminals 108 of each Tap domain 202 - 208 may be coupled to chip terminals 212 - 220 via a Tap Domain Selection circuit 210 . Once coupled, the JTAG circuit 104 of a selected Tap domain 202 - 208 may be accessed via chip terminals 212 - 220 for test, debug, trace, and/or emulation operations by an external controller. A variety of Tap domain selection circuits 210 that could be used in this example are described in a referenced paper entitled “An IEEE 1149.1 Based Test Access Architecture for ICs with Embedded Cores” authored by Whetsel and presented at the IEEE International Test Conference in November of 1997.
When using a Tap Domain Selection circuit as shown in FIG. 2 it is best to remove the TDO tristate buffer 128 of JTAG circuits 104 , if possible, to allow the flip flop 124 of the JTAG circuit 104 to directly drive the TDO signal on the interface 108 between the JTAG circuit 104 and the Tap Domain Selection circuit. This practice prevents floating (i.e. tristate) TDO signal lines inside the IC/core.
FIG. 3 illustrates an IC or embedded core circuit 300 containing functional circuits 102 , JTAG circuit 302 , and emulation, debug, and/or trace circuit 106 . The IC 300 is identical to IC 100 of FIG. 1 with the exception that JTAG circuit 302 is different from JTAG circuit 104 . The difference is that the JTAG circuit 302 includes a flip flop (FF) in the TCK path to the Tap 120 . The D input of the FF is coupled to the TCK signal 136 , the Q output of the FF is coupled to the TCK input of the Tap 120 , and the clock input of the FF is coupled to a functional clock (FCK) output 306 from function circuit 102 . The Q output of the FF is also output as a return clock (RCK) output on terminal 308 of bus 310 . The difference between bus 108 of FIG. 1 and bus 310 of FIG. 3 is the additional RCK signal 308 . The use of FF 304 in JTAG circuit 302 forces the TCK signal from an external controller to be sampled by the FCK 306 before it is allowed to be input to the Tap 120 . The RCK output 308 to the external controller indicates to the external controller when the TCK signal has been sampled by the FCK. For example, if the external controller sets TCK 136 high, the RCK signal 308 output will go high when the FCK 306 clocks the TCK into FF 304 . When the controller sees a high on RCK, it can set TCK low and again wait for the RCK to indicate when the low on TCK has been clocked into the FF 304 by the FCK 306 . This method of operating the JTAG circuit 302 allows the external controller to synchronize the operation of the TCK signal to the frequency of the FCK signal, using the handshaking operation provided by the RCK signal. This TCK handshaking technique, while not compliant to the IEEE 1149.1 standard, is being designed into embeddable cores provided by ARM Ltd. Thus the technique must be adopted in ICs that use embedded cores from ARM Ltd.
FIG. 4 illustrates an IC 400 containing four JTAG circuits 302 . One JTAG circuit 302 is associated with non-core circuitry in the chip and is referred to as the Chip Tap Domain 402 . The other JTAG circuits 302 are each associated with circuitry of an embedded core and are referred to as Core Tap Domains 404 - 408 . The Tap domains 402 - 408 are shown in Tap domain region 401 . The JTAG circuit 302 bus terminals 310 of each Tap domain 402 - 408 may be coupled to chip terminals 412 - 422 via a Tap Domain Selection circuit 410 . Once coupled, the JTAG circuit 302 of a selected Tap domain 402 - 408 may be accessed via chip terminals 412 - 422 for test, debug, trace, and/or emulation operations by an external controller. The Tap domain selection circuit 410 is similar to the Tap domain selection circuit 210 of FIG. 2 with the exception that it includes additional circuitry for coupling the RCK 308 output of a selected Tap domain 402 - 408 to the RCK chip terminal 422 .
SUMMARY OF THE DISCLOSURE
In a first aspect of the present disclosure, a method and apparatus is described in FIGS. 5-30 for addressing, instructing, and accessing Tap Domains in ICs or core circuits using a reduced number of signal terminals. In a second aspect of the present disclosure, a method and apparatus is described in FIGS. 31-34 for accessing a target Tap domain in an IC or core circuit using a reduced number of signal terminals. In a third aspect of the present disclosure, a method and apparatus is described in FIGS. 35-36 for reducing the number of IC or core signal terminals involved with emulation, debug, and trace operations. In a fourth aspect of the present disclosure, a method and apparatus is described in FIGS. 37-40 for reducing the number of IC or core signal terminals involved in function I/O operations. In a fifth aspect of the present disclosure, a method and apparatus is described in FIGS. 41-49 for selectively using either the 5 signal interface of FIG. 41 or the 3 signal interface of FIG. 8 .
DESCRIPTION OF THE VIEWS OF THE DRAWINGS
FIG. 1 illustrates an IC or core with a standard JTAG circuit Tap Domain.
FIG. 2 illustrates an IC or core having plural standard JTAG circuit Tap Domains and Tap Domain selection circuitry.
FIG. 3 illustrates an IC or core with a non-standard JTAG circuit Tap Domain.
FIG. 4 illustrates an IC or core having plural non-standard JTAG circuit Tap Domains and Tap Domain selection circuitry.
FIG. 5 illustrates an IC or core including the addressable Tap Domain Selection circuit of the present disclosure.
FIG. 6 illustrates more detail view of the addressable Tap Domain Selection circuit of the present disclosure.
FIG. 7A illustrates the operation of the Tap Domain Selection Circuit of the present disclosure in response to first, second, and third protocols.
FIG. 7B illustrates sequences of first, second, and third protocols of the present disclosure.
FIG. 8 illustrates a detail view of the Addressable Tap Domain Selection Circuit interfaced to plural Tap Domains.
FIG. 9 illustrates a detail view of the Address circuit of the present disclosure.
FIG. 10 illustrates a detail view of the Instruction circuit of the present disclosure.
FIG. 11 illustrates a detail view of the Tap Linking circuit of the present disclosure.
FIG. 12 illustrates the Reset, Address, and Instruction Controllers of the present disclosure.
FIG. 13 illustrates a detail view of the Hard and Soft reset controllers and sequences of the present disclosure.
FIG. 14 illustrates the state diagram of the Address and Instruction controller of the present disclosure.
FIGS. 15A and 15B illustrate detail views of the Address and Instruction controller of the present disclosure.
FIG. 16 illustrates the state diagram of the standard IEEE 1149.1 Tap controller.
FIG. 17 illustrates the connection between an external controller and the circuitry of the present disclosure existing in ICs or core circuits.
FIG. 17A illustrates the connection between an external controller and the circuitry of the present disclosure existing in stacked die circuits.
FIG. 18 illustrates the connection between an external controller and a circuit containing the present disclosure that is interfaced to standard legacy JTAG circuits in ICs or cores.
FIG. 19 illustrates the connection between an external controller and a circuit containing the present disclosure that is interfaced to standard legacy JTAG circuits in ICs or cores, and to ICs or cores that include the circuitry of the present disclosure.
FIG. 20 illustrates the TDI/TDO connection between I/O buffers of the present disclosure existing in an external controller and in target ICs or cores.
FIG. 21 illustrates the TMS/RCK connection between I/O buffers of the present disclosure existing in an external controller and in target ICs or cores.
FIG. 22 illustrates the data input circuit of I/O buffers of the present disclosure.
FIG. 23A-23D illustrates the operation of the output buffer of the I/O circuits of the present disclosure existing in an external controller and a target IC or core.
FIG. 24 illustrates the four cases of signal flow between the I/O buffer of an external controller and the I/O buffer of a target IC or core.
FIGS. 25-28 illustrate different sequences of performing first and second protocols of the present disclosure.
FIG. 29 illustrates the sequence of performing a second protocol, then a third protocol, then a first protocol according to the present disclosure.
FIG. 30 illustrates the sequence of performing a second protocol, then a first protocol according to the present disclosure.
FIG. 31 illustrates an interface between an external controller and a standard JTAG circuit within an IC or core.
FIG. 32 illustrates a reduced interface between an external controller and a standard JTAG circuit within an IC or core according to the present disclosure.
FIG. 33 illustrates an interface between an external controller and a non-standard JTAG circuit within an IC or core.
FIG. 34 illustrates a reduced interface between an external controller and a non-standard JTAG circuit within an IC or core according to the present disclosure.
FIG. 35 illustrates an interface between an external controller and emulation, debug, and trace circuits within an IC or core.
FIG. 36 illustrates a reduced interface between an external controller and emulation, debug, and trace circuits within an IC or core according to the present disclosure.
FIG. 37 illustrates a functional interface between first and second functional circuits of an IC or core.
FIG. 38 illustrates a reduced functional interface between first and second functional circuits of an IC or core according to the present disclosure.
FIG. 39 illustrates a functional interface between a master functional circuit in a first IC or core and slave functional circuits in second and third ICs or cores.
FIG. 40 illustrates a reduced functional interface between a master functional circuit in a first IC or core and slave functional circuits in second and third ICs or cores according to the present disclosure.
FIG. 41 illustrates an Addressable Tap Domain Selection circuit similar to that of FIG. 8 with the TDI, TDO, TMS, and RCK signals coupled via buffers to externally accessible signal terminals.
FIG. 42 illustrates a group of target devices on a board or other substrate, each target device including the Addressable Tap Domain Selection Circuit and its associated 5 pin TCK, TDI, TDO, TMS, and RCK interface, as well as Tap Domain Region.
FIG. 43 illustrates the legacy target devices of FIG. 18 , each including the standard IEEE 1149.1 TRST, TCK, TMS, TDI, and TDO terminals, and optionally the non-standard RCK terminal.
FIG. 44 illustrates an Addressable Tap Domain Selection circuit that has been designed in an IC or core to selectively use either the 5 signal interface of FIG. 41 or the 3 signal interface of FIG. 8 .
FIG. 45 illustrates an example design of the Interface Select Circuit of FIG. 44 .
FIG. 46 illustrates an example of the configuration of the Interface Select Circuit when it is in the 3 signal interface mode.
FIG. 47 illustrates an example of the configuration of the Interface Select Circuit when it is in the 5 signal interface mode.
FIG. 48 illustrates a group of target devices on a board or other substrate, each target device including the Addressable Tap Domain Selection Circuit of FIG. 44 and its selectable 3 or 5 pin interface.
FIG. 49 illustrates the legacy target devices of FIG. 18 , each including the standard IEEE 1149.1 TRST, TCK, TMS, TDI, and TDO terminals, and optionally the non-standard RCK terminal and the Addressable Tap Domain Selection Circuit of FIG. 44 operating in either the 3 or 5 signal interface mode.
DETAILED DESCRIPTION
FIG. 5 illustrates an IC 500 including the test, debug, trace, and/or emulation architecture of the present disclosure. The architecture includes a Tap domain region 522 comprising individual Tap domains 502 - 508 . Each Tap domain 502 - 508 includes a JTAG circuit 510 , which can be either the conventional JTAG circuit 104 or the modified JTAG circuit 302 . Each JTAG circuit 510 is coupled to an Addressable Tap Domain Selection circuit 514 via buses 512 . If a JTAG circuit 510 is a conventional JTAG circuit 104 , its bus 512 will be the same as bus 104 . If JTAG circuit 510 is a modified JTAG circuit 302 , its bus 512 will be the same as bus 310 .
Addressable Tap domain selection circuit 514 is coupled to external IC terminal signals TCK 516 , TMS/RCK 518 , and TDI/TDO 520 . The TCK 516 signal is the same as the TCK 214 signal shown in FIGS. 2 and 4 , with the exception that, in addition to operating as a clock input to the IC 500 from an external controller, the TCK 516 of FIG. 5 can also be operated as a data input and a control input from the external controller, according to a first protocol defined by the present disclosure. The TMS/RCK 518 signal is a signal defined by the present disclosure to operate as a signal that can serve as either an input signal to the IC 500 from an external controller or as a simultaneous input/output between the IC 500 and the external controller. Similarly, the TDI/TDO 520 signal is a signal defined by the present disclosure to operate as a signal that can serve as either an input signal to the IC from an external controller or as a simultaneous input/output between the IC and the external controller.
FIG. 6 illustrates in more detail the connections between the Addressable Tap Domain Selection circuit 514 and the Tap Domains 510 in Tap domain region 522 . Selection Circuit 514 is coupled externally of the IC via signal terminals TCK 516 , TMS/RCK 518 , and TDI/TDO 520 . As seen, pull up elements, pull down elements, or other state holding elements 602 such as bus holders are preferably connected to these terminals to allow them to be set to a known state when they are not externally driven. Selection circuit 514 is coupled to the Tap domains 1-4 in Tap region 522 via TDI 1-4 signals 132 , TDO 1-4 signals 140 , TMS 1-4 signals 134 , RCK 1-4 signals 308 , TCK signal 136 , and TRST signal 138 .
In this example, the Tap region 522 is assumed to contain four Tap domains 510 with all four Tap domains 510 being modified Tap domain 302 types. Thus each of the four Tap domains 510 will have a RCK 308 output (1-4) to the Selection circuit 514 . In another example, the Tap region 522 may contain four Tap domains 510 , each being conventional Tap domain 104 types, which would eliminate the need for the RCK signal connections to the Selection circuit 514 . In still another example, the Tap region 522 may contain mixtures of modified Tap domains 302 requiring RCK signal connections and conventional Tap domains 104 not requiring RCK signal connections. Also while this example shows four Tap domains 510 in Tap region 522 , a lesser or greater number of Tap domains 510 (104 or 302 types) may exist in Tap region 522 .
The purpose of the Addressable Tap Domain Selection circuit 514 is to allow for an external controller coupled to terminals 516 - 520 to input an address to the Selection circuit 514 of the IC then load an instruction into the Selection circuit 514 of the IC. The loaded instruction may provide a plurality of control functions within the IC, at least one control function being to control which one or more Tap domains 510 in Tap region 522 is selected for access by the external controller.
In applications of the present disclosure, a plurality of ICs may be coupled, at some point, to an external controller via terminals 516 - 520 , as depicted in FIG. 17 . Each Selection circuit 514 of each IC will have a local and a global address that enables it to input an instruction. The local address, as defined by the present disclosure, is an address capable of uniquely identifying one Selection circuit 514 within a given IC from any other Selection circuit 514 within the same or different IC. The global address is defined as an address that commonly identifies all Selection circuits 514 within any number of ICs. All the Selection circuits 514 of ICs will input the address from the external controller, but only the Selection circuit 514 having an address that matches either the local or global address input will be enabled to further input the instruction. Thus Selection circuits 514 not matching the address input will not input the instruction. These non-addressed Selection circuit 514 will be placed in an idle condition until the next address and instruction input sequence occurs.
FIG. 7A illustrates the high level operation of the Addressable Tap Domain Selection circuit 514 in response to first, second, and third protocols applied to the Selection circuit 514 via terminals TCK 516 , TMS/RCK 518 , and TDI/TDO 520 . The first protocol uses terminals TCK 516 and TMS/RCK 518 to; (1) move the Selection circuit 514 from the Tap Domain Access state 708 to either the Hard Reset state 702 or Soft Reset state 704 , (2) move between the Hard Reset state 702 and the Soft Reset state 704 , (3) move from the Address & Instruction input state 706 to either the Hard 702 or Soft 704 Reset states, or (4) remain in either the Hard 702 or Soft 704 Reset state. The second protocol uses terminals TCK 516 , TMS/RCK 518 , and TDI/TDO 520 to move the Selection circuit 514 from the Hard or Soft reset states into the Address & Instruction input state 706 or, if in the Address & Instruction input state 706 , to remain in the Address & Input state 706 . The third protocol uses terminals TCK 516 , TMS/RCK 518 , and TDI/TDO 520 to move the Selection circuit 514 from the Address & Instruction Input state 706 into the Tap Domain Access state 708 or, if in the Tap Domain Access state 708 , to remain in the Tap Domain Access state 708 .
Entry into the Hard reset state 702 fully resets all circuits in both the Selection circuit 514 and the Tap domains 510 in Tap region 522 . Entry into the Soft reset state 704 does not fully reset the Selection circuit 514 or Tap domains 510 . The Hard and Soft reset states 702 - 704 serve as starting points for communication sessions using the second protocol in state 706 . The Hard and Soft reset states 702 - 704 also serve as ending points for communication sessions using the second protocol in state 706 and using the third protocol in state 708 . Entry into the Address & Instruction input state 706 starts a communication session using the second protocol for inputting the above mentioned address and instruction. Entry into the Tap Domain Access state 708 starts a communication session using the third protocol for accessing the selected Tap Domain(s) 510 .
FIG. 7B illustrates examples of “starting and stopping” sequences of first, second, and third, and sequences of first and second protocols.
Protocol sequence A 712 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Hard Reset state 702 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, the instruction in this case selecting one or more Tap Domain(s) 510 for access, (3) switching from performing the second protocol to performing the third protocol to enter the Access Tap Domain state 708 , for accessing the Tap domain(s) 510 selected by the loaded instruction, and (4) switching from performing the third protocol, after the Tap domain access has been completed, to performing the first protocol to enter the Hard Reset state 702 , which terminates the protocol sequence and resets the Selection circuit 514 and the Tap Domains 510 .
Protocol sequence B 714 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Hard Reset state 702 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, the instruction in this case selecting one or more Tap Domain(s) 510 for access, (3) switching from performing the second protocol to performing the third protocol to enter the Tap Domain Access state 708 , for accessing the Tap domain(s) 510 selected by the loaded instruction, and (4) switching from performing the third protocol, after the Tap domain access has been completed, to performing the first protocol to enter the Soft Reset state 704 , which terminates the protocol sequence.
Protocol sequence C 716 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Soft Reset state 704 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, the instruction in this case selecting one or more Tap Domain(s) 510 for access, (3) switching from performing the second protocol to performing the third protocol to enter the Tap Domain Access state 708 , for accessing the Tap domain(s) 510 selected by the loaded instruction, and (4) switching from performing the third protocol, after the Tap domain access has been completed, to performing the first protocol to enter the Soft Reset state 704 , which terminates the protocol sequence.
Protocol sequence D 718 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Soft Reset state 704 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, the instruction in this case selecting one or more Tap Domain(s) 510 for access, (3) switching from performing the second protocol to performing the third protocol to enter the Tap Domain Access state 708 , for accessing the Tap domain(s) 510 selected by the loaded instruction, and (4) switching from performing the third protocol, after the Tap domain access has been completed, to performing the first protocol to enter the Hard Reset state 702 , which terminates the protocol sequence and resets the Selection circuit 514 and the Tap Domains 510 .
Protocol sequence E 720 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Hard Reset state 702 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, and (3) switching from performing the second protocol to performing the first protocol to enter the Hard Reset state 702 , which terminates the protocol sequence and resets the Selection circuit 514 and Tap Domains 510 .
Protocol sequence F 722 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Hard Reset state 702 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, and (3) switching from performing the second protocol to performing the first protocol to enter the Soft Reset state 704 , which terminates the protocol sequence.
Protocol sequence G 724 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Soft Reset state 704 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, and (3) switching from performing the second protocol to performing the first protocol to enter the Soft Reset state 704 , which terminates the protocol sequence.
Protocol sequence H 726 illustrates the sequence of; (1) initially performing a first protocol to enter into or remain in the Soft Reset state 704 , (2) switching from performing the first protocol to performing the second protocol to cause entry into the Address & Instruction input state 706 to input an address and instruction, and (3) switching from performing the second protocol to performing the first protocol to enter the Hard Reset state 702 , which terminates the protocol sequence and resets the Selection circuit 514 and Tap Domains 510 .
FIG. 8 illustrates the Addressable Tap Domain Selection circuit 514 in more detail. The Selection circuit 514 includes a TDI/TDO I/O circuit 802 , a TMS/RCK I/O circuit 804 , Reset, Address & Instruction controllers 806 , an address circuit 808 , an instruction circuit 810 , and a Tap Linking circuit 812 . The I/O circuits 802 and 804 each include an output buffer 814 , a resistor 816 , and a data input circuit 818 .
The output buffer 814 of I/O circuit 802 has an input coupled to the TDO output signal 820 from Linking circuit 812 , an output coupled to one lead of resistor 816 , and a 3-state control input coupled to the output enable 1 (OE1) signal 822 from Linking circuit 812 . The other lead of resistor 816 is coupled to the TDI/TDO terminal 520 . The data input circuit 818 has a first input coupled to the TDI/TDO terminal 520 , a second input coupled to the TDO signal 820 , and an TDI output signal 824 coupled to inputs of the Address circuit 808 , Instruction circuit 810 , and Linking circuit 812 .
The output buffer 814 of I/O circuit 804 has an input coupled to the RCK output signal 826 from Linking circuit 812 , an output coupled to one lead of resistor 816 , and a 3-state control input coupled to the output enable 2 (OE2) signal 822 from And gate 846 . The other lead of resistor 816 is coupled to the TMS/RCK terminal 518 . The data input circuit 818 has a first input coupled to the TMS/RCK terminal 518 , a second input coupled to the RCK signal 826 , and an TMS output signal 830 coupled to inputs of the Linking circuit 812 and Controllers 806 .
The Reset, Address, and Instruction Controllers 806 has inputs coupled to TCK terminal 516 , TMS signal 830 , an Address Match (AM) signal 838 output from Address circuit 808 , and to a function reset and/or power up clear signal 844 . The Controller 806 outputs instruction control (IC) signals 832 to Instruction Circuit 810 , an address clock (AC) signal 834 to Address Circuit 808 , a hard reset (HR) signal 836 to Instruction Circuit 810 and to the TRST input of Tap Domains 510 in Tap Region 522 , and an Enable signal 842 to And gates 848 and 850 .
And gate 850 inputs the Enable signal 842 and the TCK 516 signal and outputs a TCK 136 signal to Tap Domains 510 in Tap Region 522 . When Enable signal 842 is high, And gate 850 couples TCK signal 516 to TCK signal 136 . When Enable is low, TCK signal 136 is forced low.
And gate 848 inputs the Enable signal 842 and a signal 846 from instruction output bus 840 and outputs the OE2 signal 828 to output buffer 814 of I/O circuit 804 . When Enable signal 842 is high, And gate 848 couples instruction output signal 846 to the OE2 signal 828 . When Enable is low, OE2 828 is forced low, disabling output buffer 814 of I/O circuit 804 . If the Tap Domain 510 selected for access is a conventional Tap Domain, i.e. no RCK, the loaded instruction will output a low on instruction signal 846 to disable output buffer 814 from outputting RCK signals 826 onto TMS/RCK 518 when Enable signal 842 is set high. If the Tap Domain 510 selected for access is a Tap Domain that uses the RCK signal, the loaded instruction will output a high on instruction signal 846 to enable output buffer 814 for outputting RCK signals 826 onto TMS/RCK 518 when Enable signal 842 is set high.
The Linking Circuit 812 is coupled to the I/O circuits 802 - 804 and to the Controllers 806 as mentioned above. The Linking Circuit is further coupled to instruction output bus 840 of Instruction Circuit 810 to input instruction control, and to the Tap Domains 510 of Tap Region 522 , via signals TDI1-4 132 output, TDO1-4 140 input, TMS1-4 134 output, and RCK1-4 308 input signals.
FIG. 9 illustrates an example of how the Address Circuit 808 may be designed. The address circuit consists of an address shift register 902 , an address compare circuit 904 , and a local and global address circuit 906 . The shift register 902 responds to the address clock signal 834 to shift in an address from the TDI 824 . The compare circuit 904 operates to compare the address shifted into the shift register 902 to the local and global addresses output from local and global address circuit 906 . The compare circuit outputs the result of the compare on the address match signal 838 . Since the global address will be the same for all Selection circuits 514 , it will be fixed by design. The unique local address may be provided by the blowing of electronic fuses, an address programmed into a programmable memory, an address functionally written into a memory, an address shifted into a shift register, an address established on externally accessible device (IC/core) terminals, or by any other suitable address supplying means. A local address may not share the same address as the global address. The compare circuit is capable of comparing the data shifted into the address register 902 against both the local address and the global address output from address circuit 906 . If a match occurs between the data in the address register 902 and the local or global address, the address match signal 838 will be set high. If desired, two address match outputs, one for indicating a local address match and another for indicating a global address match, could be used instead of the single address match signal 838 .
FIG. 10 illustrates an example of how the instruction circuit 810 may be designed. The instruction circuit consist of an instruction shift register 1002 , instruction decode logic 1004 , and an instruction update register 1006 . The shift register 1002 responds to an instruction clock (I-Clock) signal from IC bus 832 to shift in an instruction from the TDI 824 input. The decode logic 1004 operates to decode the instruction shifted into the shift register 1002 and to output the decode to the update register 1006 . The update register 1006 stores the instruction decode in response to an instruction update (I-Update) signal from IC bus 832 . The stored instruction decode is output from the update register 1006 on instruction output bus 840 . The hard reset (HR) signal 836 is input to both the shift register 1002 and update register 1006 to reset the registers to known states when the hard reset signal from Controller 806 is active low.
FIG. 11 illustrates an example of how the Linking Circuit 812 is interfaced to the Tap Domains 510 of Tap Region 522 . The Linking Circuit 812 comprises TDI multiplexer circuitry 1102 , TDO multiplexer 1104 , TMS gating circuit 1110 , RCK selection circuit 1106 , and a Tap Tracker circuit 1114 .
The TDI multiplexer circuitry 1102 comprises four individual multiplexers for TDI1, TDI2, TDI3, and TDI4 as shown in the dotted line box. Each individual multiplexer is coupled to TDISEL signals from instruction output bus 840 . The TDI output of each multiplexers (TDI1-TDI4) is coupled to a respective TDI input of Tap domains 1-4 510 . In response to the TDISEL input, the TDI multiplexers allow any of the Tap domains to be coupled to the TDI signal 824 , or to the TDO outputs (1-4) of any other Tap Domain 1-4 510 . The TDO multiplexer 1104 is a single multiplexer that can select any of the TDO outputs (TDO1-4) from a Tap Domains 1-4 510 to be coupled to the TDO signal 820 in response to TDOSEL signals from the instruction output bus 840 . As can be seen, using the above described TDI and TDO multiplexer circuits, the Tap Domains 1-4 510 may be individually selected between TDI 824 and TDO 820 , or selectively linked serially together between TDI 824 and TDO 820 .
TMS gating circuit 1110 receives TMSSEL1-4 signals from instruction output bus 840 to allow any of the TMS1-4 inputs of Tap Domain 1-4 510 to be coupled to the TMS signal 830 . A high on a TMSSEL signal will couple TMS 830 to a respective TMS input of a Tap Domain 510 . A low on a TMSSEL signal will force a respective TMS input of a Tap Domain 510 low.
The TCK signal 136 is coupled to all TCK inputs of Tap Domains 510 . When the Enable signal 842 from Reset, Address, and Instruction Controllers 806 is high, TCK 136 is coupled to the TCK terminal 516 via And gate 850 of FIG. 8 .
The HR input 836 from Reset, Address, and Instruction Controllers 806 is input to the TRST input of the Tap Domains 510 of Tap Region 522 .
RCK selection circuit 1106 receives RCKSEL signals from instruction output bus 840 to allow any one or a combination of RCK 1-4 outputs of Tap Domains 1-4 510 to be coupled to the RCK signal 826 . In response to the RCKSEL signals, an RCK 1-4 from any Tap Domain 1-4 510 may be coupled to RCK 826 , a combination of RCK signals may be coupled to RCK 826 from voting circuit 1116 , or the RCK signal 826 may be coupled to a static logic level (a HI in this example) when no RCK is used by a Tap Domain 510 . The absence of an RCK signal from a Tap Domain is indicated by dotted line. The voting circuit 1116 is used whenever two or more Tap Domains each having an RCK are linked together for serial access. In this example, the AND gate of the voting circuit 1116 detects the condition where both RCKs are high and the OR gate of the voting circuit 1116 detects the condition where both RCKs are low. As mentioned previously, RCKs are handshaking signals fed back to the external controller to indicate when a Tap Domain of a core have synchronized the TCK signal level input from the external controller with a functional clock of the core.
The Tap Tracker circuit 1114 is an IEEE 1149.1 Tap state machine that is used in Linking Circuit 812 to track the states of the Tap Domain(s) being accessed in the Tap Region 522 . The main function of the Tap Tracker 1114 is to control the output enable 1 (OE1) signal to the output buffer 814 of I/O circuit 802 . The Tap Tracker will output a signal on OE1 to enable the output buffer to output onto terminal TDI/TDO 520 whenever the Tap Tracker (and selected Tap Domain(s)) are in the Shift-DR or Shift-IR states (see Tap Diagram of FIG. 16 ). In these states, the selected Tap Domains will be shifting data from TDI 824 to TDO 820 and the I/O circuit 802 will be in its mode of simultaneously inputting and outputting this shift data on TDI/TDO terminal 520 . When not in the Shift-DR or Shift-IR states, the Tap Domains will not be shifting data and the OE1 signal will be set to disable output buffer 814 of I/O circuit 802 from operating in the simultaneous input and output mode on TDI/TDO terminal 520 . While output buffer 814 is disabled, I/O circuit 802 operates in an input only mode to input data appearing of the TDI/TDO terminal 520 . As seen in FIG. 11 , the Tap Tracker inputs the TCK signal 136 , the HR signal 836 (as its TRST input), and TMS1-4 signals via OR gate 1112 .
FIG. 12 illustrates a block diagram of the Hard and Soft Reset controller 1202 and the Address and Instruction Controller 1204 within the Reset, Address, and Instruction Controllers Circuit 806 . The Hard and Soft Reset controller 1202 inputs the TCK signal 516 , the TMS signal 830 , and the functional reset and/or power up clear signal 844 , and outputs the Hard Reset (HR) 836 signal and a Soft Reset signal 1206 . The Hard Reset (HR) 836 signal is input to the Instruction Circuit 810 of FIG. 8 and the Tap Domains 510 of Tap Region 522 . The Address and Instruction Controller 1204 inputs the TCK signal 516 , the TMS signal 830 , the Address Match (AM) signal 838 , and the Soft Reset signal 1206 from controller 1202 , and outputs the instruction control (IC) signals 832 to instruction circuits 810 , address clock (AC) signal 834 to address circuit 808 , and the Enable signal 842 to And gates 848 and 850 . As indicated by dotted line, the Hard and Soft Reset controllers 1202 respond to the TCK 516 and TMS 830 inputs according to the previously mentioned first protocol, and the Address and Instruction controller 1204 responds to the TCK 516 and TMS 830 inputs according to the previously mentioned second protocol.
FIG. 13 illustrates an example of how the Hard and Soft Reset controller 1202 may be designed. The Hard and Soft Reset controller 1202 consists of two separate controllers, a hard reset controller 1302 and a soft reset controller 1304 . The hard reset controller 1302 consists of inverters 1306 and 1308 , Or gate 1310 , and flip flop pairs 1312 and 1314 connected as shown. Flip flop pairs 1312 and 1314 each include a rising edge clock flip flop feeding data to a falling edge flip flop, so it takes both a rising and falling clock edge to propagate an input to the output of the pair. The soft reset controller 1304 consists of inverters 1316 and 1318 , flip flop pairs 1320 and 1322 , and And gate 1324 connected as shown. Again the flip flop pairs 1320 and 1322 include a rising edge clock flip flop feeding data to a falling edge clock flip flop. In response to a low input on the function reset and/or power up clear input 844 , flip flop pairs 1312 and 1314 are reset, which sets the Hard Reset output 836 low and the Soft Reset output 1206 low, via And gate 1324 . In response to the function reset/power up clear 844 returning high, the Hard Reset controller 1302 will remain in the reset state (Hard Reset 836 output low) if the TCK 516 input is high and the TMS 830 input is in a stable low or high state. The Soft Reset controller flip flop pairs 1320 and 1322 are set while the TCK 516 input is high.
During the operation of a second or third protocol, the TCK 516 input is active, forcing the flip flop pairs of the Hard and Soft Reset controllers to be continuously forced to their set state due to the TCK 516 signal being coupled to the set (S) input of the pair's flip flops. In the set state, the Hard and Soft Reset controllers output highs on the Hard 836 and Soft 1206 Reset outputs, respectively. At the end of a second or third protocol operation, the Hard and Soft Reset controllers may be reset by a first protocol sequence applied on the TCK 516 and TMS 830 inputs. The Soft Reset controller 1304 is always reset following a second or third protocol operation so that a new second protocol operation may be initiated. The Soft Reset output 1206 of the Soft Reset controller 1206 is used to force the Address and Instruction controller 1204 to a Home state (see FIG. 14 ). From the Home state, another address and instruction input operation can be performed using the second protocol. The Hard Reset controller 1302 is reset (Hard Reset output 836 goes low) using the first protocol whenever all required second and third protocol operations have been performed. A low on the Hard Reset output 836 resets the instruction circuit 810 to a known state, forces the Address and Instruction Controller 1204 to the Home state, and resets the Tap Domains 510 via their TRST input.
Timing diagram 1326 of FIG. 13 illustrates a first protocol sequence on TCK and TMS that will reset the Hard Reset controller 1302 and output a low on the Hard Reset signal 836 and Soft Reset signal 1206 . The sequence includes the steps of holding the TCK signal 516 high while inputting a clock pulse or pulses on the TMS signal 830 . This Hard Reset controller design example requires two clock pulses on the TMS signal due to the choice of using two serially connected flip flop pairs 1312 and 1314 . With the TCK signal high, the rising and falling edges of the first TMS clock pulse sets the output of flip flop pair 1312 low and the rising and falling edges of the second TMS clock pulse sets the output of flip flop pair 1314 low, which forces the Hard Reset and Soft Reset outputs low. The low on the Hard and Soft Reset outputs will be maintained until the TCK signal goes low, which will set the outputs of flip flop pairs 1312 and 1314 high and the Hard and Soft Reset outputs 836 and 1206 high. As indicated in dotted line, if desired, additional TMS clock signals can occur after the Hard Reset controller 1302 has received the two TMS clock pulses required to set the Hard Reset output 836 low.
Timing diagram 1326 of FIG. 13 illustrates a first protocol sequence on TCK and TMS that will reset the Soft Reset controller 1304 and output a low on the Soft Reset output 1206 . The sequence includes the steps of holding the TCK signal low and inputting two clock pulses on the TMS signal. Like the Hard Reset controller 1302 design example above, the Soft Reset controller 1304 design example uses two serially connected flip flop pairs 1320 and 1322 for use with two TMS clock pulses. With TCK low, the rising and falling edges of the first TMS clock pulse sets the output of flip flop pair 1320 low and the rising and falling edges of the second TMS clock pulse sets the output of flip flop pair 1322 low, which forces the Soft Reset output 1206 low. The low on the Soft Reset output 1206 will be maintained until the TCK signal goes high, which sets the outputs flip flop pairs 1320 and 1322 high and the Soft Reset output 1206 high. As indicated in dotted line, if desired, additional TMS clock signals can occur after the Soft Reset controller 1304 has received the two TMS clock pulses required to set the Soft Reset output low.
While two TMS clock pulses were used in the Hard and Soft Reset controller design examples, a lesser or greater number of TMS clock pulses, and corresponding number flip flop pairs, may be used as well. Two TMS clock pulses were used in these examples because it reduces the probability that noise or signal skew problems might accidentally produce the hard and soft first protocol sequences on TCK and TMS, causing the Hard and Soft controllers to inadvertently enter their reset states. The first protocol sequence of TCK and TMS shown in the timing diagrams 1326 - 1328 are TCK and TMS sequences that are never produced during second and third protocol operations. The first protocol sequences are only detectable by the Hard and Soft Reset controllers.
FIG. 14 illustrates the state diagram of the Address and Instruction Controller 1204 . In response to a Soft Reset output 1206 from the Hard and Soft Reset controller 1202 the Address and Instruction controller 1204 will enter the Home state 1402 . The Home state is maintained while TMS is high. The controller transitions to the Input Address state 1404 when TMS goes low and remains there while TMS is low. During the Input Address state, the A-Clock 834 is active to shift in an address from TDI into the Address circuit 808 . When TMS goes high, the controller 1204 transitions to the Address match state 1406 to test for a match between the address shifted in and the local or global address. If the address does not match the local or global address, the controller will transition into the Idle state 1414 and remain there until a hard or soft first protocol sequence sets the Soft Reset output 1206 low, forcing the controller to return to the Home state. If the address matches the local or global address, the controller 1204 transitions into the Input Instruction state 1408 and remains there while TMS is low. In the Input Instruction state, the I-Clock signal on IC bus 832 will become active to shift in an instruction from TDI to the Instruction Circuit 810 . When TMS goes high, the controller will transition to the Update Instruction state 1410 an output the I-Update signal on IC bus 832 to update and output the instruction from the Instruction Circuit. When TMS goes low, the controller transitions to the Enable state 1412 . The Enable output 842 is set high during the Enable state to enable TCKs to be applied to the selected Tap Domains 510 . The controller will remain in the Enable state independent of logic levels on TMS. The TMS sequences shown in FIG. 14 that move the controller through its states define the second protocol. While the controller 1204 is in the Enable state 1412 , the TMS signal is operable to perform the third protocol operations to access the Tap Domains 510 without effecting the Enable state 1412 of controller 1204 . The controller returns to the Home state 1402 only when the Soft Reset signal 1206 goes low.
FIG. 15A illustrates an example of how the Address and Instruction controller 1204 of FIG. 12 may be designed. The controller 1204 consists of; (1) a state machine 1502 having inputs for TCK 516 , TMS 830 , Address Match 838 , and Soft Reset 1206 , and outputs for indicating when the state machine is in the input address state 1404 , input instruction state 1408 , update instruction state 1410 , and Enable state 1412 , and (2) flip flops 1504 - 1510 , and And gates 1512 - 1516 . The state machine 1502 responds to the TMS and Address Match inputs on the rising edge of TCK 516 to move though its states. The flip flops 1512 - 1516 respond to the falling edge of TCK 516 to gate the A-Clock, I-Clock, I-Update output signals on an off, and to set the Enable output signal.
In response to a low on the Soft Reset input 1206 , the state machine is forced to the Home state 1402 . While the state machine is in the Input Address state 1404 , the A-Clock signal 834 will be gated on to clock an address into the Address Circuit 808 . While the state machine is in the Input Instruction state 1408 , the I-Clock signal 832 will be gated on to clock an instruction into the Instruction Circuit 810 . While the state machine is in the Update Instruction state 1410 , the I-Update signal 832 will be gated on to update the instruction from the Instruction Circuit's output bus 840 . While the state machine is in the Enable state 1412 , the Enable output will be set high to enable Tap Domain access.
FIG. 15B illustrates an example of how the state machine 1502 may be designed. The state machine consists of next state decode logic 1518 , state flip flops A, B, C, and output state decode logic 1520 . The ABC state assignments are shown in the FIG. 14 state diagram. If the Soft Reset 1206 input is low, the state machine 1502 is reset to the Home state (ABC=000). If the Soft Reset 1206 input is high, the state machine responds to the rising edge of TCK to transition through its states according to the state diagram of FIG. 14 . The output state decode logic 1520 indicates when the state machine is in the input address state 1404 (ABC=001), the input instruction state 1408 (ABC=011), the update instruction state 1410 (ABC=100), and Enable state 1412 (ABC=101).
FIG. 16 illustrates the state diagram of the standard IEEE 1149.1 Tap controller. This state diagram and the design of the controller that uses it is well known and documented in IEEE Std 1149.1 and therefore does not require further teaching. Each Tap Domain 510 in Tap Region 522 will have a Tap controller that operates according to this standard state diagram. The TCK and TMS operation of the standard Tap controller shown in FIG. 16 defines the third protocol of the present disclosure.
FIG. 17 illustrates a group of target devices 1702 - 1706 on a board or other substrate 1700 , each target device including the Addressable Tap Domain Selection Circuit 514 and its associated 3 pin TCK, TDI/TDO, and TMS/RCK interface, as well as Tap Domain Region 522 . The target devices could be packaged ICs or unpacked IC die. The 3 pin interface of each target device is coupled to an external controller 1708 via cable connector 1710 to provide access for test, debug, emulation, and trace operations. Each target device 1702 - 1706 may contain embedded core target circuits 1712 - 1716 which also are interfaced to the external controller 1708 via the 3 pin interface. Further, each core 1712 - 1716 may contain embedded core targets circuits 1718 - 1722 also interfaced to the external controller 1708 via the 3 pin interface. As indicated, the external controller 1708 may be realized by using an interface card 1724 in a personal computer 1726 to control the 3 pin interface communication with the targets 1702 - 1706 , 1712 - 1716 , 1718 - 1722 via a cable connection 1728 . The 3 pin interface communicates to target circuits using the previously mentioned first, second, and third protocols.
Each target 1702 - 1706 , 1712 - 1716 , 1718 - 1722 of FIG. 17 has the previously mentioned local address to allow it to be individually addressed and instructed by the controller 1708 using the second protocol. Following the individual addressing and instructing of a target using the second protocol, the Tap Domains 510 within the target may be access by the controller 1708 using the third protocol to perform test, debug, emulation, and/or trace operations. Additionally, each target has the previously mentioned global address to allow all targets to be simultaneously addressed and instructed using the second protocol. The purpose of the global addressing is to allow all target devices to receive a global instruction. The global instruction may be an instruction that; (1) causes all targets to enter into a particular mode suitable for a test, emulation, debug, and/or trace operation, (2) causes all targets to enter into a mode to perform a global self test operation, (3) causes all targets to suspend functional operation, or (4) causes all targets to resume functional operation. Other types of global instructions may be conceived as well.
FIG. 17A illustrates an alternate configuration of FIG. 17 whereby a group of stacked die targets devices 1732 - 1736 exist on a board or other substrate 1730 . Each die in the stacks 1732 - 1736 includes the Addressable Tap Domain Selection Circuit 514 and its associated 3 terminal TCK, TDI/TDO, and TMS/RCK interface, as well as Tap Domain Region 522 . The TCK, TDI/TDO, and TCM/RCK terminals of each die in a stack are commonly connected to the TCK 1738 , TMS/RCK 1740 , and TDI/TDO 1742 signal interface to the external controller 1708 , via cable connector 1710 to provide access for test, debug, emulation, and trace operations. Each die in the stacks may contain embedded core target circuits 1712 - 1716 and 1718 - 1722 as described in FIG. 17 . The controller 1708 communicates to the stacked die targets using the previously mentioned first, second, and third protocols.
Each die in a stack 1732 - 1736 has the previously mentioned local address to allow it to be individually addressed and instructed by the controller 1708 using the second protocol. Following the individual die addressing and instructing, the Tap Domain 510 within the selected die may be accessed by the controller 1708 using the third protocol to perform test, debug, emulation, and/or trace operations. Additionally, each die in stacks 1732 - 1736 has the previously mentioned global address to allow all die in stacks 1732 - 1736 to be simultaneously addressed and instructed using the second protocol, for the reasons mentioned in regard to FIG. 17 .
FIG. 18 illustrates a group of legacy target devices 1802 - 1806 , each including the standard IEEE 1149.1 5 signal interface comprising TRST, TCK, TMS, TDI, and TDO terminals, but not the Addressable Tap Domain Selection Circuit 514 . The term legacy means that the devices are pre-existing devices whose design is fixed and cannot be altered. As shown, each legacy target device may also include the RCK terminal. The legacy target devices could be ICs 1802 - 1806 on a board or other substrate 1800 , embedded core circuits 1802 - 1806 within an IC 1800 , or embedded core circuits 1802 - 1806 within a core circuit 1800 .
As seen, a separate device 1808 exists between the legacy target devices 1802 - 1806 and the external controller 1708 . This separate device 1808 implements the Addressable Tap Domain Selection Circuit 514 as shown and described in regard to FIG. 8 and operates according the previously described first, second, and third protocols. It also includes the previously described local and global addressing modes. The local address 1810 is shown, in this example, as being input to the separate device 1808 on externally accessible terminals of device 1808 , which is one of the previously mentioned means for supplying the local address. The separate device 1808 serves to provide the interface between the 5 signal IEEE 1149.1 terminals, and optional RCK terminal, of each legacy target device and the 3 pin interface to the external controller 1708 . The operation of the separate device 1808 in accessing the legacy device Tap Domains is the same as described in FIG. 8 where the Addressable Tap Domain Selection Circuit 514 was described accessing the Tap Domains 510 of Tap Region 522 .
The arrangement shown in FIG. 18 could represent the legacy target devices 1802 - 1806 and separate device 1808 as being; (1) ICs/die on a board or substrate 1800 , embedded core circuits within an IC 1800 , or (3) embedded core circuits within a core circuit 1800 . FIG. 18 advantageously illustrates how legacy devices designed using the IEEE 1149.1 interface, and optional RCK, can be interfaced to the 3 pin controller 1708 by providing the Addressable Tap Selection Circuit 514 as a separate circuit to serve as the interface between the legacy devices 1802 - 1806 and external controller 1708 . The separate circuit 1808 could contain only the Addressable Tap Domain Selection Circuit 514 or it could contain the Addressable Tap Domain Selection Circuit 514 along with other circuits. Indeed, the separate circuit 1808 could be a larger functional IC/die or embeddable core circuit that includes the Addressable Tap Domain Selection Circuit 514 and its external terminal interfaces as a sub-circuit within the larger functional circuit.
FIG. 19 illustrates a group 1902 of IEEE 1149.1 legacy target devices 1802 - 1806 as described in FIG. 18 , and a group 1904 of target devices 1702 - 1706 as described in FIG. 17 . Each legacy target device 1803 - 1806 of group 1902 is interfaced to the external controller 1708 via the separate device 1808 as described in FIG. 18 whereas each target device 1702 - 1706 of group 1904 is interfaced to the external controller directly. This example is provided to illustrate how legacy devices 1802 - 1806 that are not designed according to the present disclosure and other devices 1702 - 1704 that are designed according to the present disclosure can both be accessed by an external controller 1708 by using separate device 1808 as the interface between the legacy devices and external controller.
FIG. 20 illustrates the TDI/TDO signal wire connection 2002 between the TDI/TDO terminal of an I/O circuit 802 of a controller 1708 and a TDI/TDO terminal of the I/O circuits 802 of the Addressable Tap Domain Selection Circuits 514 of target circuits 1-N. The controller will have to have the I/O circuit 802 in order to interface to and communicate with I/O circuits 802 of the target circuits 1-N via the TDI/TDO signal wire. Preferably, the output buffer 814 of the controller 1708 and the output buffers 814 of the target circuits will have approximately the same current sink/source drive strength. Also preferably the resistors 816 of the controller 1708 and target circuit I/O circuits 802 will have approximately the same resistance.
As seen in this example, the output buffer 814 of the controller's I/O circuit 802 is always enabled to output TDO data to the target circuits, while the output buffers 814 of the target circuit I/O circuits 802 are selectively enabled to and disabled from outputting TDO data to the controller 1708 by the output enable 1 (OE1) signal 822 from Tap Linking Circuit 812 . As previously described, the TDI 824 signal of the target I/O circuit 802 is coupled to the Address Circuit 808 , the Instruction Circuit 810 , and the Tap Linking Circuit 812 of Addressable Tap Domain Selection Circuit 514 , and the TDO 820 signal of the target I/O circuit 802 is coupled to the Tap Linking Circuit 812 of Addressable Tap Domain Selection Circuit 514 . The TDI 824 signal of the controller's I/O circuit 802 is coupled to a circuit within the controller designed to receive serial data input signals from TDI/TDO signal wire 2002 , and the TDO 820 signal of the controller's I/O circuit 802 is coupled to a circuit within the controller designed to transmit serial data output signals to TDI/TDI signal wire 2002 .
During first protocol operations the TDI/TDO signal wire is not used and the output buffers of the target circuits are disabled by the OE1 signals 822 .
During second protocol operations when the controller 1708 is inputting address and instruction signals to the target circuits 1-N, the output buffers 814 of the target circuits 1-N are disabled by OE1 822 , allowing the output buffer 814 of the controller to be the sole driver of the TDI/TDO signal wire 2002 . Thus during second protocols the I/O circuit 802 of target circuits 1-N operates as an input buffer on the TDI/TDO signal wire 2002 .
During third protocol operations when the controller 1708 is not inputting and outputting data to a selected one or more Tap Domain in the Shift-DR or Shift-IR states, the output buffer 814 of the addressed and all other target circuits will be disabled by the OE1 signal 822 . In this mode, the output buffer 814 of the controller is the sole driver of the TDI/TDO signal wire 2002 .
During third protocol operations when the controller 1708 is inputting and outputting data to a selected one or more Tap Domain in the Shift-DR or Shift-IR states, the output buffer 814 of the addressed target circuit will be enabled by the OE1 signal 822 . In this mode, both the output buffers 814 of the controller and addressed target circuit will be driving the TDI/TDO signal wire 2002 . This mode of operation allows data to flow simultaneously between the controller 1708 and the addressed target circuit via the TDI/TDO signal wire during each TCK period.
If, during this simultaneous data flow mode, the output buffer 814 of the controller 1708 and the output buffer 814 of the addressed target circuit are both outputting the same logic level, the voltage on the TDI/TDO signal wire 2002 will driven to that full logic level. The data input circuits 818 of the controller 1708 and addressed target circuit will detect that full logic level and input that logic level to the controller 1708 and to the addressed target circuit via their respective TDI signals 824 .
If, during this simultaneous data flow mode, the output buffer 814 of the controller 1708 and the output buffer 814 of the addressed target circuit are outputting opposite logic levels, the TDI/TDO signal wire 2002 will be driven to a mid point voltage level between the two opposite logic levels. The data input circuits 818 of the controller 1708 and addressed target circuit will detect that mid level voltage and, based on the logic level each was attempting to output, will input a logic level to the controller 1708 and to the addressed target circuit on their respective TDI signal 824 that is the opposite of logic level each was outputting.
When the output buffers 814 of the controller and addressed target circuit are driving opposite logic levels on TDI/TDO wire 2002 , the resistors 816 serve to limit the current flow between the two output buffers 814 and to serve as voltage droppers to allow the mid point voltage level on TDI/TDO signal wire 2002 to be more easily detected by the data input circuit 818 as a voltage level that is distinctly different from the normal full high or low logic level voltages output from the output buffers 816 . The operation of data input circuit 818 will be described later in regard to FIG. 22 .
FIG. 21 illustrates the TMS/RCK signal wire connection 2102 between the TMS/RCK terminal of an I/O circuit 804 of a controller 1708 and the TMS/RCK terminal of the I/O circuits 804 of the Addressable Tap Domain Selection Circuits 514 of target circuits 1-N. When target circuits use Tap domains with RCKs, the controller will have to have the I/O circuit 804 in order to interface to and communicate with I/O circuits 804 of the target circuits 1-N via the TMS/RCK signal wire. As with the TDI/TDO I/O circuits 802 above, the output buffers 814 of the controller and target circuits will preferably have approximately the same current sink/source drive strength and the resistors 816 will have approximately the same resistance.
As seen in this example, the output buffer 814 of the controller is always enabled to output TMS signals to the target circuits, while the output buffers 814 of the target circuits are selectively enabled to and disabled from outputting RCK signals 826 to controller 1708 by the output enable 2 (OE2) signal 828 . As previously described, the TMS 830 signal of the target I/O circuit 804 is coupled to the Tap Linking Circuit 812 and to the Reset, Address, & Instruction Controllers 806 , and the RCK 826 signal of the target I/O circuit 804 is coupled to the Tap Linking Circuit 812 of Addressable Tap Domain Selection Circuit 514 . The RCK 826 signal of the controller's I/O circuit 804 is coupled to a circuit within the controller designed to receive RCK input signals from the TMS/RCK signal wire 2102 , and the TMS 830 signal of the controller's I/O circuit 804 is coupled to a circuit within the controller designed to transmit TMS output signals to the TMS/RCK signal wire 2102 .
During first protocol operations when the controller 1708 is inputting soft or hard reset sequences to Hard and Soft Controller 1202 , the TMS/RCK signal wire will be driven by the output buffer 814 of controller 1708 and may or may not be driven by the output buffer 814 of a target circuit 1-N. If the first protocol is performed following a power up or function reset of target circuits 1-N, the output buffers 814 of the target circuits will not be enabled by OE2 and therefore only output buffer 814 of controller 1708 drives the TMS/RCK signal wire 2102 . Also, if a first protocol is performed following a second or third protocol where the OE2 signal is set low by instruction control signal 846 , only the output buffer 814 of controller 1708 will be driving the TMS/RCK signal wire 2102 . However, if a first protocol is performed following a second or third protocol where the OE2 signal is set high by an instruction, via instruction control signal 846 , both the output buffer 814 of controller 1708 and the output buffer of the address target circuit will be driving the TMS/RCK signal wire 2102 .
Following the input of a soft reset first protocol sequence, the OE2 will be forced low by the Soft Reset signal 1206 from the Hard and Soft Reset Controller 1202 going low. As previously mentioned, the Soft Reset signal 1206 , when low, forces the Address and Instruction controller 1204 into the Home state 1402 . In the Home state 1402 , the Enable signal output 842 of the Address and Instruction controller 1204 is low, which forces the OE2 signal 828 low via And gate 848 . Thus if the output buffer 814 of a target circuit was enabled prior to the input of a soft reset first protocol sequence, it will be disabled at the end of the soft reset protocol sequence.
Following the input of a hard reset first protocol sequence, the OE2 will be forced low by the Hard Reset signal 836 from the Hard and Soft Reset Controller 1202 going low. When Hard Reset signal 836 goes low, the instruction circuit 810 is reset to an instruction that sets the instruction control output signal 846 low which forces the OE2 output 828 of And gate 848 low. Also the Hard Reset signal going low will set the Soft Reset signal 1206 low, via And gate 1324 of FIG. 13 , which sets the Enable signal 842 low and the OE2 output of And gate 848 low. Thus if the output buffer 814 of a target circuit was enabled prior to the input of a hard reset first protocol sequence, it will be disabled at the end of the soft reset protocol sequence.
During second protocol operations when the controller 1708 is inputting address and instruction signals to the target circuits 1-N, the output buffers 814 of the target circuits 1-N are disabled by OE2 828 being low, allowing the output buffer 814 of the controller to be the sole driver of the TMS/RCK signal wire 2102 . Thus during second protocols the I/O circuits 804 of target circuits 1-N operate as an input buffers on the TMS/RCK signal wire 2102 .
During third protocol operations when the controller 1708 is communicating to a selected one of more Tap Domains of target circuits that do not use RCKs, the output buffer 814 of the addressed and all other target circuits will be disabled by the OE2 signal 828 being low. In this mode, the output buffer 814 of the controller is the sole driver of the TMS/RCK signal wire 2102 .
During third protocol operations when the controller 1708 is communicating to a selected one of more Tap Domains of target circuits that use RCKs, the output buffer 814 of the addressed target circuit will be enabled by its OE2 signal 828 being high and the output buffer 814 of all other target circuits will be disabled by their OE2 signals 828 being low. In this mode, the output buffer 814 of the controller and the output buffer 814 of the addressed target circuit will both be driving the TMS/RCK signal wire 2102 . In this mode of operation, a TMS signal can flow from the controller 1708 to the addressed target circuit and an RCK signal can flow from the addressed target circuit to the controller 1708 simultaneously via TMS/RCK signal wire 2102 during each TCK period.
If, during this simultaneous TMS and RCK signal flow mode, the output buffer 814 of the controller 1708 and the output buffer 814 of the addressed target circuit are both outputting the same logic level, the voltage on the TMS/RCK signal wire 2102 will driven to that full logic level. The data input circuits 818 of the controller 1708 and addressed target circuit will detect that full logic level and input that logic level to the controller 1708 via its RCK 826 and to the addressed target circuit via its TMS signal 830 . If, during this simultaneous data flow mode, the output buffer 814 of the controller 1708 and the output buffer 814 of the addressed target circuit are outputting opposite logic levels, the TMS/RCK signal wire 2102 will be driven to a mid point voltage level between the two opposite logic levels. The data input circuits 818 of the controller 1708 and addressed target circuit will detect that mid level voltage and, based on the logic level each was attempting to output, will input a logic level to the controller 1708 on its RCK 826 and to the addressed target circuit on its TMS 830 that is the opposite of logic level each was outputting.
When the output buffers 814 of the controller and addressed target circuit are driving opposite logic levels on TMS/RCK wire 2102 , the resistors 816 serve to limit the current flow between the two output buffers 814 and to serve as voltage droppers to allow the mid point voltage level on TMS/RCK signal wire 2102 to be more easily detected by the data input circuit 818 as a voltage level that is distinctly different from the normal full high or low logic level voltages output from the output buffers 814 .
FIG. 22 illustrates one example of how to design the data input circuit 818 of the I/O circuit 802 and 804 . The data input circuit 818 includes a voltage comparator circuit 2202 , a multiplexers 2204 , an inverter 2206 , and a buffer 2208 . The voltage comparator circuit 2202 inputs voltages from its wire input 2210 and outputs digital control signals S 0 and S 1 to multiplexer 2204 . The wire input 2210 for I/O circuit 802 is coupled to the TDI/TDO signal wire 2002 of FIG. 20 via TDI/TDO terminals of the controller 1708 and target circuits 1-N. The wire input 2210 for I/O circuit 804 is coupled to the TMS/RCK signal wire 2102 of FIG. 21 via TMS/RCK terminals of controller 1708 and target circuits 1-N.
As seen, the first voltage (V) to ground (G) leg 2218 of voltage comparator circuit 2202 comprises a series P-channel transistor and current source and the second voltage to ground leg 2220 comprises a series N-channel transistor and current source. As seen, S 1 is connected at a point between the P-channel transistor and current source of the first leg 2218 and S 0 is connected at a point between the N-channel transistor and current source of the second leg 2220 . The gates of the transistors are connected to wire input 2210 to allow voltages on the wire signal 2210 to turn the transistors on and off.
The operation of the voltage comparator circuit 2202 and multiplexer 2204 is shown in table 2222 and described herein. If the voltage on wire input 2210 is at a low level (logic zero), the S 0 and S 1 outputs are set high, which causes the multiplexer 2204 to select its low input 2224 and output the low input to In signal 2212 via buffer 2208 . If the voltage on wire input 2210 is at a mid level (mid point voltage), the S 0 is set low and the S 1 is set high, which causes the multiplexer 2204 to select its Out* input 2226 (inverted Out signal 2214 ) and output the Out* input to In 2212 via and buffer 2208 . If the voltage on wire connection 2210 is high (logic one), the S 0 and S 1 outputs are set low, which causes the multiplexer 2204 to select its high input 2228 and output the high input to In 2212 via and buffer 2208 .
For I/O circuits 802 , the In signal 2212 is connected to the TDI signal 824 of the controller 1708 and Addressable Tap Domain Selection Circuits 514 of target circuits 1-N of FIG. 20 , and the Out signal 2214 is connected to the TDO signal 820 of the controller 1708 and Addressable Tap Domain Selection Circuits 514 of target circuits 1-N of FIG. 20 .
For I/O circuits 804 , the In signal 2212 is connected to the RCK signal 826 of the controller 1708 and to the TMS signal 830 of the Addressable Tap Domain Selection Circuits 514 of target circuits 1-N of FIG. 21 . The Out signal 2214 is connected to the TMS signal 830 of the controller 1708 and to the RCK signal 826 of the Addressable Tap Domain Selection Circuits 514 of target circuits 1-N of FIG. 21 .
FIG. 23A illustrates the case where the output buffers 814 of the controller 1708 and an addressed target circuit are both outputting logic lows on TDI/TDO 2002 or TMS/RCK 2102 signal wires. In this case the signal wire 2002 / 2102 is low and the wire input 2210 to the data input circuits 818 is low. This causes the data input circuit 818 of the controller 1708 to input a low to the controller on In signal 2212 and the data input circuit 818 of the addressed target circuit to input a low to the target circuit on In signal 2212 .
FIG. 23B illustrates the case where the output buffer 814 of the controller 1708 is outputting a low on signal wire 2002 / 2102 and the output buffer 814 of an addressed target circuit is outputting a high on signal wire 2002 / 2102 . In this case a current path exists from the high voltage output (V) from the target circuit to the low voltage output (G) from the controller. The resistors 816 limit the current flow and the voltage drops across them produce a distinctly detectable mid point voltage level on the signal wire 2002 / 2102 . The mid point voltage level on the signal wire 2002 / 2102 is input to the data input circuits 818 of the controller and target circuit via wire inputs 2210 .
Since the data input circuit 818 of the controller 1708 knows the controller was outputting a logic low, it responds to the mid point voltage by inputting a logic high to the controller on In signal 2212 , which is the only logic level that can be output from the target circuit to cause the mid point voltage on signal wire 2002 / 2102 . Also since the data input circuit 818 of the target circuit knows the target circuit was outputting a logic high, it responds to the mid point voltage by inputting a logic low to the target circuit on In signal 2212 , which is the only logic level that can be output from the controller to cause the mid point voltage on signal wire 2002 / 2102 .
FIG. 23C illustrates the case where the output buffer 814 of the controller 1708 is outputting a high on signal wire 2002 / 2102 and the output buffer 814 of an addressed target circuit is outputting a low on signal wire 2002 / 2102 . In this case a current path exists from the high voltage output (V) from the controller to the low voltage output (G) from the addressed target circuit. Again the resistors 816 limit the current flow and the voltage drops across them produce a distinctly detectable mid point voltage level on the signal wire 2002 / 2102 . The mid point voltage level on the signal wire 2002 / 2102 is input to the data input circuits 818 of the controller and target circuit via wire inputs 2210 .
Since the data input circuit 818 of the controller 1708 knows the controller was outputting a logic high, it responds to the mid point voltage by inputting a logic low to the controller on In signal 2212 , which is the only logic level that can be output from the target circuit to cause the mid point voltage on signal wire 2002 / 2102 . Also since the data input circuit 818 of the target circuit knows the target circuit was outputting a logic low, it responds to the mid point voltage by inputting a logic high to the target circuit on In signal 2212 , which is the only logic level that can be output from the controller to cause the mid point voltage on signal wire 2002 / 2102 .
FIG. 23D illustrates the case where the output buffers 814 of the controller 1708 and an addressed target circuit are both outputting logic high on signal wire 2002 / 2102 . In this case the signal wire 2002 / 2102 is high and the wire input 2210 to the data input circuits 818 is high. This causes the data input circuit 818 of the controller 1708 to input a high to the controller on In signal 2212 and the data input circuit 818 of the addressed target circuit to input a high to the target circuit on In signal 2212 .
FIG. 24 illustrates timing waveforms 2402 for the four cases (A,B,C,D) in which simultaneous data communication occurs between the I/O circuit 802 / 804 of controller 1708 and the I/O circuit 802 / 804 of an Addressable Tap Domain Selection Circuit 514 of an addressed target circuit via a TDI/TDO or TMS/RCK signal wire 2002 / 2102 . In this example, the output enable 1 or 2 (OE1/OE2) signal 822 / 828 of the target circuit is set to enable output buffer 814 . Each case A-D is indicated in the timing diagram by vertical dotted line boxes.
Case A shows the controller and the target circuit outputting lows from their buffers 814 . In response, the wire 2002 / 2102 is low and both the controller and target circuit input lows via the In signal 2212 from their data input circuits 818 .
Case B shows the controller outputting a low from its buffer 814 and the target circuit outputting a high from its buffer 814 . In response, the wire 2002 / 2102 is at a mid voltage level causing the controller to input a high from the In signal 2212 of its data input circuit 818 , while the target circuit inputs a low from the In signal 2212 of its data input circuit 818 .
Case C shows the controller outputting a high from its buffer 814 and the target circuit outputting a low from its buffer 814 . In response, the wire 2002 / 2102 is at a mid voltage level causing the controller to input a low from the In signal 2212 of its data input circuit 818 , while the target circuit inputs a high from the In signal 2212 of its data input circuit 818 .
Case D shows the controller and the target circuit outputting high from their buffers 814 . In response, the wire 2002 / 2102 is high and both the controller and target circuit input highs via the In signal 2212 from their data input circuits 818 .
FIG. 25 illustrates a timing diagram of the operation of the present disclosure performing a first protocol Soft Reset Sequence 1328 followed by a second protocol showing entry into the Home state 1402 followed by entry into the Input Address state 1404 .
FIG. 26 illustrates a timing diagram of the operation of the present disclosure performing a first protocol Soft Reset Sequence 1328 followed by a second protocol that immediately enters the Input Address state 1404 .
FIG. 27 illustrates a timing diagram of the operation of the present disclosure performing a first protocol Hard Reset Sequence 1326 followed by a second protocol showing entry into the Home state 1402 followed by entry into the Input Address state 1404 .
FIG. 26 illustrates a timing diagram of the operation of the present disclosure performing a first protocol Hard Reset Sequence 1326 followed by a second protocol that immediately enters the Input Address state 1404 .
FIG. 29 illustrates a timing diagram of the operation of the present disclosure performing a full second protocol sequence 2902 of inputting an address 1404 , matching the address 1406 , inputting an instruction 1408 , updating the instruction 1410 , and entering the enable state 1412 , followed by performing a third protocol sequence 2904 to access the Tap domain(s) 510 selected by the instruction using the standard IEEE 1149.1 TMS protocol, followed by performing a first protocol sequence 2906 to input either a Soft Reset sequence 1328 or a Hard reset sequence 1326 to terminate the operation.
As seen, the second protocol 2902 uses the TCK 516 , TMS 830 , and TDI 824 signals, but not the TDO 820 signal. The third protocol 2904 uses the TCK 516 , TMS 830 , TDI 824 , and TDO 820 signals according to the Tap protocol defined in standard IEEE 1149.1. The first protocols 2906 (1328 and 1326) use only the TCK 516 and TMS 830 signals. The timing diagram of FIG. 29 illustrates in detail the present disclosure performing the previously described protocols A-D 712 - 718 sequences discussed early in regard to FIG. 7B .
FIG. 30 illustrates a timing diagram of the operation of the present disclosure performing a full second protocol sequence 2902 of inputting an address 1404 , matching the address 1406 , inputting an instruction 1408 , updating the instruction 1410 , and entering the enable state 1412 , followed by performing a first protocol sequence 2906 to input either a Soft Reset sequence 1328 or a Hard reset sequence 1326 to terminate the operation.
As seen, the second protocol 2902 uses the TCK 516 , TMS 830 , and TDI 824 signals, but not the TDO 820 signal. The first protocols 2906 (1328 and 1326) use only the TCK 516 and TMS 830 signals. The timing diagram of FIG. 30 illustrates in detail the present disclosure performing the previously described protocols E-H 720 - 726 sequences discussed early in regard to FIG. 7B .
While the description of the disclosure to this point has shown that the disclosure includes an Addressable Tap Domain Selection Circuit 514 capable of selecting one or more of a plurality of Tap Domains 510 within a Tap Region 522 ( FIGS. 6 and 8 ) using a reduced number of interface signals, it is possible to simplify the disclosure when access to only one JTAG circuit Tap Domain is required. A reduction of interface signals is achieved in the simplified version of the disclosure.
FIG. 31 illustrates a connected controller 3102 accessing the conventional JTAG circuit 104 of FIG. 1 using the 5 IEEE 1149.1 standard signals TDI, TDO, TMS, TCK, and TRST. The JTAG circuit 104 could be used in an IC or core for controlling test, debug, emulation, trace, boundary scan, or other operations of the IC or core.
FIG. 32 illustrates I/O circuits 802 of the present disclosure being used to reduce the signal interface between the connected controller 3102 and JTAG circuit 104 from 5 to 4 signals. One I/O circuit 802 is connected to the controller's TDO output via Out signal 2214 , to the controllers TDI input via In signal 2212 , and to the TDI/TDO signal wire 3202 via Wire signal 2210 . The other I/O circuit 802 is connected to the JTAG circuit's TDO output via Out signal 2214 , to the JTAG circuit's TDI input via In signal 2212 , and to the TDI/TDO signal wire 3202 via Wire signal 2210 .
As seen in FIG. 32 , the I/O circuit 802 associated with the controller can exist as a separate circuit from the controller 3102 or the I/O circuit 802 may be integrated with the controller 3102 to form a new controller 3204 . Preferably, but not necessarily, the output buffer 814 of the I/O buffer associated with the controller 3102 will be enabled all the time by setting its output enable signal 822 high, which allows the TDI/TDO wire 3202 to a always be driven to a valid signal level.
Also as seen in FIG. 32 , the I/O circuit 802 associated with the JTAG circuit 104 can exist as a separate circuit from the JTAG circuit 104 or the I/O circuit 802 may be integrated with the JTAG circuit 104 to form a new JTAG circuit 3206 . If the I/O circuit 802 associated with the JTAG circuit is a separate circuit, its output buffer 814 will be enabled, via output enable signal 822 , all the time since their is no signal available from the JTAG circuit 104 to act as an enable or disable signal to the output buffer 814 . If the I/O circuit 802 associated with the JTAG circuit 104 is integrated with the JTAG circuit 104 to form new JTAG circuit 3206 , the output enable 822 of the I/O circuit 802 will be connected to the JTAG's Enable signal 126 so that the output buffer 814 can be enabled during TDI and TDO shift operations and disabled during non shift operations.
The Enable signal 126 is a standard signal output from Tap controller 120 during data and instruction shift operations. The Enable signal 126 controls the enable and disable state of the JTAG circuit's TDO tristate output buffer 128 . If the I/O circuit 802 is integrated with JTAG circuit 104 to form new JTAG circuit 3206 it is preferred that the TDO tristate buffer 128 be removed, as indicated by crossed dashed lines, so that the TDO signal path formed between flip flop 124 and Out signal 2214 of I/O circuit 802 does not enter into a tristate (floating) state when shift operations are not being performed.
FIG. 33 illustrates a connected controller 3302 accessing the JTAG circuit 302 of FIG. 3 using the 5 IEEE 1149.1 standard signals TDI, TDO, TMS, TCK, and TRST plus the non-standard RCK signal. The JTAG circuit 302 could be used in an IC or core for controlling test, debug, emulation, trace, boundary scan, or other operations of the IC or core.
FIG. 34 illustrates I/O circuits 802 and 804 of the present disclosure being used to reduce the signal interface between the connected controller 3302 and JTAG circuit 302 from 6 to 4 signals. The connection and operation of I/O circuits 802 associated with controller 3302 and JTAG circuit 302 are the same as described previously in FIG. 32 in the following separate and integrated implementation descriptions of I/O circuit 804 . One I/O circuit 804 is connected to the controller's TMS output via Out signal 2214 , to the controllers RCK input via In signal 2212 , and to the TMS/RCK signal wire 3402 via Wire signal 2210 . The other I/O circuit 804 is connected to the JTAG circuit's RCK output via Out signal 2214 , to the JTAG circuit's TMS input via In signal 2212 , and to the TMS/RCK signal wire 3402 via Wire signal 2210 .
As seen in FIG. 34 , the I/O circuit 804 associated with the controller can exist as a separate circuit from the controller 3302 or the I/O circuit 804 may be integrated with the controller 3302 to form a new controller 3404 . Preferably, but not necessarily, the output buffer 814 of the I/O buffer associated with the controller 3302 will be enabled all the time by setting its output enable signal 822 high, which allows the TMS/RCK wire 3402 to a always be driven to a valid signal level.
Also as seen in FIG. 34 , the I/O circuit 804 associated with the JTAG circuit 302 can exist as a separate circuit from the JTAG circuit 302 or the I/O circuit 804 may be integrated with the JTAG circuit 302 to form a new JTAG circuit 3406 . Regardless of whether I/O circuit 804 is a separate circuit or integrated with JTAG circuit 302 , its output buffer 814 will be enabled, by setting its output enable signal 822 high, all the time since the RCK signal of JTAG circuit 302 must always be output to the controller 3302 during test, debug, emulation, trace, and/or other operations.
From the above examples shown in FIG. 31-34 , it is clear that the I/O circuits 802 - 804 of the present disclosure can be used to provide a method of reducing the interface signals between a controller 3102 , 3204 , 3302 , and 3404 and a JTAG circuit 104 , 3206 , 302 , and 3406 . While the access approach described in FIGS. 31-34 is a point-to-point access between a controller and a connected JTAG circuit, i.e. it does not provide the multiple JTAG circuit Tap Domain selecting features as described earlier in the present disclosure, it does offer a reduced signal interfacing approach which is simple and can be realized with a minimum of additional circuitry.
FIG. 35 illustrates an IC or core 3504 containing the emulation, trace, and/or debug circuit 106 of FIG. 1 coupled internally to a functional circuit 102 of the IC or core via bus 112 and externally to an emulation, trace, and/or debug interface 3506 of a controller 3502 via bus 110 . The bus 110 consists of input and output connections for allowing signals to flow between circuit 3506 and 106 during an emulation, trace, and/or debug operation. In this example, 8 connections are used on bus 110 .
The signals could be control signals, data signals, triggering signals, protocol signals used in message communications, and/or other signals used during an I/O operation of an emulation, trace, and/or debug operation. To increase the bandwidth of signal flow between the IC/core 3504 and controller 3502 it is advantageous to have as many input and output signals on bus 110 as possible. However, only so many IC terminals may be used on bus 110 , since the IC's functional input and output terminals 103 take priority and therefore will consume most of the available IC input and output terminals.
FIG. 36 illustrates how the controller 3502 and IC/core 3504 of FIG. 35 can be adapted with I/O circuits 802 of the present disclosure to reduce the number of signal connections between the controller and IC/core by one half without reducing the signaling bandwidth.
As seen in FIG. 36 , controller circuit 3602 differs from controller circuit 3502 of FIG. 35 in that the input and output signals of bus 110 to emulation, trace, and debug circuit 3506 are interfaced to I/O circuits 802 , via the I/O circuit's input 2214 and output 2212 . If desired, circuit 3506 may optionally be modified, as seen in dotted line, to allow inputting control to the 802 I/O circuit's output enable signal 822 , otherwise the output enable 822 input of I/O circuit 802 will be fixed to always enable the output buffer 814 of I/O circuit 802 .
Similarly, the IC/core circuit 3604 differs from IC/core circuit 3504 in that the input and output signals of bus 110 to emulation, trace, and debug circuit 106 are interfaced to I/O circuits 802 , via the I/O circuit's input 2214 and output 2212 . If desired, circuit 106 may optionally be modified, as seen in dotted line, to allow inputting control to the 802 I/O circuit's output enable signal 822 , otherwise the output enable 822 input of I/O circuit 802 will be fixed to always enable the output buffer 814 of I/O circuit 802 .
As seen in FIG. 36 , the number of bus 3606 connections, via wire terminals 2210 of the I/O circuits 802 of circuits 3602 and 3604 , is reduced by one half of that shown in bus 110 of FIG. 35 . Thus, the present disclosure provides a way of reducing the number of required emulation, debug, and/or trace signal connections between circuits 3602 and circuits 3604 of FIG. 36 on bus 3606 by one half that used in the prior art of FIG. 35 .
The following FIGS. 37-40 are provided to illustrate how the I/O circuits 802 (or 804 ) can be used to reduce the functional signal connections between functional circuits of an IC or core circuit.
FIG. 37 illustrates ICs or cores 3702 and 3704 each containing the functional circuit 102 of FIG. 1 . At least some of the functional circuits 102 inputs and outputs are coupled to each other via functional bus 103 of FIG. 1 . The bus 103 consists of input and output connections for allowing signals to flow between functional circuits 102 during functional operation. In this example, 8 connections are used on bus 103 . The signals could be data bus signals, address bus signals, or control bus signals used during functional communicating between functional circuits 102 .
FIG. 38 illustrates how the functional circuits 102 of ICs or cores 3702 and 3704 can be adapted with I/O circuits 802 of the present disclosure to reduce the number of signal connections on functional bus 103 between the functional circuits 102 . As seen, the functional bus 3806 between the adapted ICs or cores 3802 and 3804 require only one half the connections required by functional bus 103 of FIG. 37 . Also functional bus 3806 maintains the signaling bandwidth of functional bus 103 of FIG. 37 .
As seen in FIG. 38 , IC or core circuits 3802 and 3804 differ from IC or core circuits 3702 and 3704 of FIG. 37 in that the input and output signals of bus 103 to functional circuits 102 are interfaced to I/O circuits 802 , via the I/O circuit's input 2214 and output 2212 . Also as seen, functional circuits 102 in IC or core circuits 3802 and 3804 may optionally be modified, as seen in dotted line, to allow inputting control to the 802 I/O circuit's output enable signal 822 , otherwise the output enable 822 input of I/O circuit 802 will be fixed to always enable the output buffer 814 of I/O circuit 802 .
As seen in FIG. 38 , the number of bus 3806 connections, via wire terminals 2210 of the I/O circuits 802 of circuits 3802 and 3804 , is reduced by one half of that shown in bus 103 of FIG. 37 . Thus, the present disclosure provides a way of reducing the number of required functional signal connections between IC or core circuits 3802 and 3804 of FIG. 38 on bus 3806 by one half that used in the prior art functional bus 103 of FIG. 37 .
FIG. 39 illustrates conventional ICs 3902 , 3908 , 3912 on a board/substrate or core circuits 3902 , 3908 , 3912 within an IC being connected functionally together via functional bus 103 and select and control bus 3906 . IC/core 3902 contains a master functional circuit 3904 , such as a processor or DSP, that controls communication to slave functional circuits 3910 and 3914 , such as memories or other types of input and output circuits, in IC/cores 3908 and 3912 via buses 103 and 3906 . In this example, the select and control bus 3906 from the master functional circuit functions as a bus that selects a functional slave circuit 3910 or 3914 then inputs control to cause the selected slave circuit to input data from the master circuit or to output data to the master circuit via bus 103 . The functional bus 103 in this example is 8 signals wide.
FIG. 40 illustrates how the functional circuits 3904 , 3910 , 3914 can be adapted with I/O circuits 802 of the present disclosure to reduce the number of signal connections on functional bus 103 between the functional circuits. As seen, the functional bus 4008 between the adapted ICs or cores 4002 , 4004 , 4006 require only one half the connections required by functional bus 103 of FIG. 39 . Also functional bus 4008 maintains the signaling bandwidth of functional bus 103 of FIG. 39 .
As seen in FIG. 40 , IC or core circuits 4002 - 4006 differ from IC or core circuits 3902 , 3908 , and 3912 of FIG. 39 in that the input and output signals of bus 103 to functional circuits 3904 , 3910 , 3914 are interfaced to I/O circuits 802 , via the I/O circuit's input 2214 and output 2212 . Also as seen, the master functional circuit 3904 of IC/core circuit 4002 may optionally be modified, as seen in dotted line, to allow inputting control to the 802 I/O circuit's output enable signal 822 , otherwise the output enable 822 input of I/O circuit 802 will be fixed to always enable the output buffer 814 of I/O circuit 802 . Providing the ability to disable the output buffer 814 of I/O circuits 802 connected to master functional circuit 2904 in IC/core circuit 4002 allows for the output buffers 814 of a selected slave functional circuit's I/O circuits 802 , say slave circuit 3910 , to be enabled to drive the bus 4008 to communicate data to another one or more of the slave functional circuits, say slave circuit 3914 .
As seen in FIG. 40 , the number of bus 4008 connections, via wire terminals 2210 of the I/O circuits 802 of circuits 4002 , 4004 , 4008 , is reduced by one half of that shown in bus 103 of FIG. 39 . Thus, the present disclosure provides a way of reducing the number of required functional signal connections between IC or core circuits 4004 - 4006 of FIG. 40 on bus 4008 by one half that used in the prior art functional bus 103 of FIG. 39 .
While the preceding description has shown and described the Addressable Tap Domain Selection Circuit 514 as having a 3 pin interface consisting of TCK, TMS/RCK, and TDI/TDO signals, the Addressable Tap Domain Selection Circuit 514 may be designed to use the standard IEEE 1149.1 TDI, TDO, TMS, and TCK signals, plus the non-standard RCK signal.
FIG. 41 illustrates an Addressable Tap Domain Selection circuit 4102 that has been designed in an IC or core to use the standard IEEE 1149.1 interface signals TDI, TDO, TMS, TCK, and non-standard RCK signal. The only difference between the Addressable Tap Domain Selection circuit 4102 and the Addressable Tap Domain Selection circuit 514 of FIG. 8 is that the I/O circuits 802 and 804 have been removed and the TDI 824 , TDO 820 , TMS 830 , and RCK 826 signals have been coupled, via buffers 4104 - 4110 , to externally accessible signal terminals TDI 4112 , TDO 4114 , TMS 4116 , and RCK 4118 , respectively.
The operation of Addressable Tap Domain Selection circuit 4102 , in response to the first, second, and third protocols, is identical to that previously described with Addressable Tap Domain Selection circuit 514 . For example, the first protocol uses TCK and TMS 830 as previously described for Hard and Soft resets, the second protocol uses TCK, TMS 830 , and TDI 824 as previously described for loading address and instruction, and the third protocol uses TCK, TMS 830 , TDI 824 , and TDO 820 as previously described to access Tap domains. The only difference is that is that TDI 824 is coupled to a TDI input terminal 4112 instead of I/O circuit 802 , TDO 820 is coupled to a TDO output terminal 4114 instead of I/O circuit 802 , and TMS 830 is coupled to a TMS input terminal 4116 instead of I/O circuit 804 . Also the RCK 826 is coupled to RCK output terminal 4118 instead of I/O circuit 804 .
As seen, the control input of output buffer 4106 is coupled to OE1 822 to enable TDO output during shift operations and to disable TDO output during non-shift operations during third protocol (JTAG) operations. Also, the control input of output buffer 4110 is coupled to OE2 enable or disable RCK outputs during third protocol (JTAG) operations.
FIG. 42 illustrates a group of target devices 4202 - 4206 on a board or other substrate 4200 , each target device including the Addressable Tap Domain Selection Circuit 4102 and its associated 5 pin TCK, TDI, TDO, TMS, and RCK interface, as well as Tap Domain Region 522 . The target devices could be packaged ICs or unpackaged IC die. The 5 pin interface of each target device is coupled to an external controller 4208 via cable connector 4210 to provide access for test, debug, emulation, and trace operations. Each target device 4202 - 4206 may contain embedded core target circuits as described in FIG. 17 , which also are interfaced to the external controller 4208 via the 5 pin interface. As indicated, the external controller 4208 may be realized by using an interface card 4212 in a personal computer 1726 to control the 5 pin interface communication with the targets 4202 - 4206 via a cable connection 4214 . The 5 pin interface communicates to target circuits using the previously mentioned first, second, and third protocols.
Each target 4202 - 4206 has the previously mentioned local address to allow it to be individually addressed and instructed by the controller 4208 using the second protocol. Following the individual addressing and instructing of a target using the second protocol, the Tap Domains 510 within the target may be accessed by the controller 4208 using the third protocol to perform test, debug, emulation, and/or trace operations. Additionally, each target has the previously mentioned global address to allow all targets to be simultaneously addressed and instructed using the second protocol for the purposes previously mentioned in regard to FIG. 17 .
When a target is selected for a third protocol (JTAG) communication to one or more of its Tap Domains, its TDO 4114 terminal will be enabled by OE1 to output TDO 820 data from the Tap Domain(s) during the 1149.1 Shift-IR and Shift-DR states as previously mentioned. During third protocol (JTAG) operations to Tap Domains with RCK signals, the RCK 4118 terminal will be enabled by OE2 to output RCK 826 signals to the controller 4208 . During third protocol (JTAG) operations to Tap Domains without RCK signals, the RCK 4118 terminal will be disabled by OE2 to not output RCK 826 signals to the controller 4208 .
Only the addressed target circuit will be enabled to output on its TDO 4114 and RCK 4118 terminals. The TDO 4114 and RCK 4118 terminals of non-addressed target circuits will be disabled, via control signals OE1 and OE2 to buffers 4106 and 4110 , so that only the addressed target device is enabled to drive the TDO and RCK signal connections to the controller 4208 .
FIG. 43 illustrates the legacy target devices 1802 - 1806 of FIG. 18 , each including the standard IEEE 1149.1 TRST, TCK, TMS, TDI, and TDO terminals, and optionally the non-standard RCK terminal. The legacy target devices could be ICs 1802 - 1806 on a board or other substrate 4300 , embedded core circuits 1802 - 1806 within an IC 4300 , or embedded core circuits 1802 - 1806 within a core circuit 4300 .
As seen, a separate device 4302 exists between the legacy target devices 1802 - 1806 and the external controller 4208 . This separate device 4302 implements the Addressable Tap Domain Selection Circuit 4102 of FIG. 41 and operates according the previously described first, second, and third protocols. It also includes the previously described local and global addressing modes. The local address is shown, in this example, as being input to the separate device 4302 on externally accessible terminals of device 4302 . The separate device 4302 serves to provide the interface between the JTAG plus RCK interface of each legacy target device and the 5 signal interface to the external controller 4208 . The operation of the separate device 4302 in accessing the legacy device Tap Domains is the same as described in FIG. 41 where the Addressable Tap Domain Selection Circuit 4102 was described accessing the Tap Domains 510 of Tap Region 522 .
The arrangement shown in FIG. 43 could represent the legacy target devices 1802 - 1806 and separate device 4302 as being; (1) ICs/die on a board or substrate 4300 , embedded core circuits within an IC 4300 , or (3) embedded core circuits within a core circuit 4300 . FIG. 43 advantageously illustrates how legacy devices designed using the conventional IEEE 1149.1 interface and optional RCK can be interfaced to the 5 signal controller 4208 by providing the Addressable Tap Selection Circuit 4102 as a separate circuit to serve as the interface between the legacy devices 1802 - 1806 and external controller 4208 . As described for separate circuit 1808 of FIG. 18 , the separate circuit 4302 could contain only the Addressable Tap Domain Selection Circuit 4102 or it could contain the Addressable Tap Domain Selection Circuit 4102 along with other circuits.
There may be instances where it may be desirable to select between using a 5 signal interface to an Addressable Tap Domain Selection circuit as shown FIG. 41 and a 3 signal interface to an Addressable Tap Domain Selection circuit as shown in FIG. 8 . For example, for test operations it may be advantageous to use the 5 signal interface to enable standard JTAG communication from pre-existing JTAG controllers and testers designed to operate according to the standard JTAG interface and optional non-standard RCK signal. On the other hand, it may be advantageous to use the 3 signal interface during debug, emulation, and trace operations so that unused signals of the 5 signal interface may be used for other purposes.
FIG. 44 illustrates an Addressable Tap Domain Selection circuit 4402 that has been designed in an IC or core to selectively use either the 5 signal interface of FIG. 41 or the 3 signal interface of FIG. 8 . The Addressable Tap Domain Selection circuit 4402 is the same as that described in FIGS. 8 and 41 with the exception that an Interface Select Circuit 4404 has been substituted for the I/O circuits 802 and 804 of FIG. 8 and the input and output buffers 4104 - 4110 of FIG. 41 . The Interface Select Circuit 4404 has input terminals for receiving control 4416 from the instruction output bus, TDO signal 820 , OE1 signal 822 , RCK signal 826 , and OE2 signal 828 . The Interface Select Circuit 4404 has output terminals for outputting TDI signal 824 and TMS signal 830 . The Interface Select Circuit 4404 has input and output terminals for an auxiliary I/O bus (AUXI/O) 4406. The interface Select circuit 4404 has I/O terminals for an “AUXI/O1 or TDI” signal 4408 , “TDI/TDO or TDO” signal 4410 , “AUXI/O2 or TMS” signal 4412 , and “TMS/RCK or RCK” signal 4414 .
The function of the Interface Select Circuit 4402 is to respond to control inputs 4416 from the instruction register output bus to operate as either a 5 signal interface or as a 3 signal interface to the Addressable Tap Domain Selection Circuit 4402 .
If 5 signal interface operation is selected, the “AUXI/O1 or TDI” signal 4408 will operate as TDI 4112 of FIG. 41 , the “TDI/TDO or TDO” signal 4410 will operate as TDO signal 4114 of FIG. 41 , the “AUXI/O2 or TMS” signal 4412 will operate as TMS signal 4116 of FIG. 41 , and the “TMS/RCK or RCK” signal 4414 will operate as RCK signal 4118 of FIG. 41 .
If 3 signal interface operation is selected, the “AUXI/O1 or TDI” signal 4408 will operate as an auxiliary input or output signal, the “TDI/TDO or TDO” signal 4410 will operate as TDI/TDO signal 520 of FIG. 8 , the “AUXI/O2 or TMS” signal 4412 will operate as an auxiliary input or output signal, and the “TMS/RCK or RCK” signal 4414 will operate as TMS/RCK signal 518 of FIG. 8 .
When the instruction register 810 is reset, at power up or following a hard reset first protocol, it will output control 4416 to select either the 3 or 5 signal interface to the Addressable Tap Domain Selection circuit 4402 . Since the IEEE 1149.1 standard requires that its interface be enabled to operate following a reset or power up event, the 5 signal interface is preferably the interface selected by the instruction register 810 following reset or power up. However, while the 5 signal interface is preferred for consistency to the IEEE 1149.1 standard, users of the present disclosure may select the 3 signal interface at reset/power up as well.
FIG. 45 illustrates an example of how the Interface Select Circuit 4404 may be designed. The Interface Select Circuit includes I/O circuits 802 and 804 of FIG. 8 , TDO output buffer 4106 and TMS output buffer 4110 of FIG. 41 , multiplexers 4516 - 4526 , I/O buffers 4528 and 4104 , and I/O buffers 4532 and 4108 .
TDO 820 is coupled to an input of I/O circuit 802 and to the input of buffer 4106 . “TDI/TDO or TDO” 4410 is coupled to an output of I/O circuit 802 and to the output of buffer 4106 . TDI 824 is coupled, via multiplexer 4516 , to either an output of I/O circuit 802 or to the output of buffer 4104 . “AUXI/O1 or TDI” 4408 is coupled to the input of buffer 4104 and to the output of buffer 4528 . OE1 822 is coupled to the control input of buffer 814 of I/O circuit 802 via multiplexer 4518 and to the control input of buffer 4106 via multiplexer 4520 .
RCK 826 is coupled to an input of I/O circuit 804 and to the input of buffer 4110 . “TMS/RCK or RCK” 4414 is coupled to an output of I/O circuit 804 and to the output of buffer 4110 . TMS 830 is coupled, via multiplexer 4522 , to either an output of I/O circuit 804 or buffer 4108 . “AUXI/O2 or TMS” 4412 is coupled to the input of buffer 4108 and to the output of buffer 4532 . OE2 828 is coupled to the control input of buffer 814 of I/O circuit 804 via multiplexer 4524 and to the control input of buffer 4110 via multiplexer 4526 .
The output of buffer 4104 is coupled to an auxiliary input 1 (AUXIN1) signal 4504 . The input of buffer 4528 is coupled to an auxiliary output 1 (AUXOUT1) signal 4502 . The output of buffer 4528 is coupled to “AUXI/O1 or TDI” 4408 . The control input of buffer 4528 is coupled to control signal 4512 from instruction control bus 4416 .
The output of buffer 4532 is coupled to an auxiliary input 2 (AUXIN2) signal 4508 . The input of buffer 4532 is coupled to an auxiliary output 2 (AUXOUT2) signal 4506 . The output of buffer 4532 is coupled to “AUXI/O2 or TMS” 4412 . The control input of buffer 4532 is coupled to control signal 4514 from instruction control bus 4416 .
The select input of multiplexers 4516 - 4526 is coupled to control signal 4510 from instruction control bus 4416 . A low on control signal 4510 enables the 3 signal interface mode of Interface Select Circuit 4404 , and a high on control signal 4510 enables the 5 signal interface mode of Interface Select Circuit 4404 .
While control signal 4510 is high, multiplexer 4516 couples TDO 824 to the output of buffer 4104 , multiplexer 4518 couples OE1 822 to the control input of buffer 4106 , multiplexer 4520 couples a low (disable) signal to the control input of I/O circuit 802 , multiplexer 4522 couples TMS 830 to the output of buffer 4108 , multiplexer 4524 couples OE2 828 to the control input of buffer 4110 , and multiplexer 4526 couples a low (disable) signal to the control input of I/O circuit 804 . In this mode, the Interface Select Circuit 4404 enables the 5 signal interface to operate the Addressable Tap Domain Selection Circuit 4402 as described in FIG. 41 . That is to say the “AUXI/O1 or TDI” 4408 signal operates as the TDI signal 4112 of FIG. 41 , the “TDI/TDO or TDO” 4410 signal operates as the TDO 4114 signal of FIG. 41 , the “AUXI/O2 or TMS” signal 4412 operates as the TMS signal 4116 of FIG. 41 , and the “TMS/RCK or RCK” 4414 signal operates as the RCK 4118 signal of FIG. 41 .
While control signal 4510 is low, multiplexer 4516 couples TDO 824 to the output of I/O circuit 802 , multiplexer 4518 couples OE1 822 to the control input of I/O circuit 802 , multiplexer 4520 couples a low (disable) signal to the control input of buffer 4106 , multiplexer 4522 couples TMS 830 to the output of I/O circuit 804 , multiplexer 4524 couples OE2 828 to the control input of I/O circuit 804 , and multiplexer 4526 couples a low (disable) signal to the control input of buffer 4110 . In this mode, the Interface Select Circuit 4404 enables the 3 signal interface to operate the Addressable Tap Domain Selection Circuit 4402 as described in FIG. 8 . That is to say the “TDI/TDO or TDO” 4410 signal operates as the TDI/TDO 520 signal of FIG. 8 and the “TMS/RCK or RCK” 4414 signal operates as the TMS/RCK 518 signal of FIG. 8 .
While control signal 4510 is low, selecting the 3 signal interface mode of operation, the “AUXI/O1 or TDI” signal 4408 can be used as an input, if control signal 4512 is set to disable buffer 4528 , to transmit a signal to the AUXIN1 signal 4504 output. Alternately, if control signal 4512 is set to enable buffer 4528 , the “AUXI/O1 or TDI” signal 4408 can be used as an output to transmit a signal from the AUXOUT1 signal 4502 input.
While control signal 4510 is low, selecting the 3 signal interface mode of operation, the “AUXI/O2 or TMS” signal 4412 can be used as an input, if control signal 4514 is set to disable buffer 4532 , to transmit a signal to the AUXIN2 signal 4508 output. Alternately, if control signal 4514 is set to enable buffer 4532 , the “AUXI/O2 or TMS” signal 4412 can be used as an output to transmit a signal from the AUXOUT2 signal 4506 input.
FIG. 46 illustrates an example of the configuration of the Interface Select Circuit 4404 when it is in the 3 signal interface mode. In this mode, the Interface Select Circuit 4404 is configured to access the Addressable Tap Domain Selection Circuit 4402 using the 3 signals “TDI/TDO or TDO” 4410 (named simply TDI/TDO), “TMS/RCK or RCK” 4414 (named simply TMS/RCK), and TCK 516 as described in FIG. 8 . Since “AUXI/O1 or TDI” 4408 (named simply AUXI/O1) and “AUXI/O2 or TMS” 4412 (named simply AUXI/O2) are not used as interface signals, they are shown being used for auxiliary input or output signals to AUXI/O bus 4406 . As seen in FIGS. 45 and 46 , AUXI/O1 4408 can be programmed by instruction control input 4512 of control bus 4416 to be an output for AUXOUT1 4502 or an input for AUXIN1 4504 . Likewise, AUXI/O2 4412 can be programmed by instruction control input 4514 of control bus 4416 to be an output for AUXOUT2 4506 or an input for AUXIN2 4508 . The AUXIN1 4504 , AUXOUT1 4502 , AUXIN2 4508 , and AUXOUT2 4506 signals may be data signals, control signals, interrupt signals, triggering signals, or other types of signals that may be necessary to during test, debug, emulation, and/or trace operations using the 3 signal interface.
FIG. 47 illustrates an example of the configuration of the Interface Select Circuit 4404 when it is in the 5 signal interface mode. In this mode, the Interface Select Circuit 4404 is configured to access the Addressable Tap Domain Selection Circuit 4402 using the 5 signals “AUXI/O1 or TDI” 4408 (named simply TDI), “TDI/TDO or TDO” 4410 (named simply TDO), “AUXI/O2 or TMS” 4412 (named simply TMS), “TMS/RCK or RCK” 4414 (named simply RCK), and TCK as described in FIG. 41 . As seen, since “AUXI/O1 or TDI” 4408 (named simply TDI) and “AUXI/O2 or TMS” 4412 (named simply TMS) are used as interface signals, they cannot be used for auxiliary I/O signals as they were in FIG. 45 .
FIG. 48 illustrates a group of target devices 4204 - 4208 on a board or other substrate 4800 , each target device including the Addressable Tap Domain Selection Circuit 4402 of FIG. 44 and its selectable 3 or 5 pin interface, as well as Tap Domain Region 522 . The selectable 3/5 pin interface of each target device is coupled to an external controller 4808 via cable connector 4810 to provide access for test, debug, emulation, trace, and/or auxiliary I/O operations. Each target device 4802 - 4806 may contain embedded core target circuits as described in FIG. 17 , which also are interfaced to the external controller 4808 via the selectable 3/5 pin interface. As indicated, the external controller 4808 may be realized by using an interface card 4812 in a personal computer 1726 to control the selectable 3/5 pin interface communication with the targets 4802 - 4806 via a cable connection 4814 . The interface card 4812 is designed to communicate to the targets using either the 3 or 5 pin interface. The PC 1726 contains software for controlling the card 4812 to access the targets using either the 3 and 5 pin interface, and to switch the targets from operating in the 3 pin interface mode to the 5 pin interface mode, and from operating in the 5 pin interface mode to the 3 pin interface mode. The card 4814 is designed to interface with the auxiliary I/O signals of target circuits when the 3 pin interface mode is selected, and the PC 1726 contains software for comprehending auxiliary I/O signaling from the targets.
Each target 4802 - 4806 has the previously mentioned local address to allow it to be individually addressed and instructed by the controller 4808 using the second protocol in either the 3 or 5 pin interface modes. Following the individual addressing and instructing of a target using the second protocol, the Tap Domains 510 within the target may be accessed by the controller 4808 using the third protocol in either the 3 or 5 pin interface mode to perform test, debug, emulation, trace, and/or auxiliary I/O operations. Additionally, each target has the previously mentioned global address to allow all targets to be simultaneously addressed and instructed using the second protocol in either the 3 or 5 pin interface mode for the purposes previously mentioned in regard to FIG. 17 .
The controller 4808 may selectively switch the target circuits 4802 - 4806 from operating in either the 3 or 5 pin interface mode by issuing a global address to all targets, then loading an instruction into all targets that cause all targets to switch from their current interface mode to the other interface mode. For example, if all targets are operating in the 5 pin interface mode they can be switched to the 3 pin interface mode by the controller issuing a global address followed by an instruction that selects the 3 pin interface mode of the targets. Likewise, if all targets are operating in the 3 pin interface mode they can be switched to the 5 pin interface mode by the controller issuing a global address followed by an instruction that selects the 5 pin interface mode of the targets.
FIG. 49 illustrates the legacy target devices 1802 - 1806 of FIG. 18 , each including the standard IEEE 1149.1 TRST, TCK, TMS, TDI, and TDO terminals, and optionally the non-standard RCK terminal. The legacy target devices could be ICs 1802 - 1806 on a board or other substrate 4900 , embedded core circuits 1802 - 1806 within an IC 4900 , or embedded core circuits 1802 - 1806 within a core circuit 4900 .
As seen, a separate device 4902 exists between the legacy target devices 1802 - 1806 and the external controller 4808 . This separate device 4902 implements the Addressable Tap Domain Selection Circuit 4402 of FIG. 44 and operates in either the 3 or 5 signal interface mode according the previously described first, second, and third protocols. It also includes the previously described local and global addressing modes. The local address is shown, in this example, as being input to the separate device 4902 on externally accessible terminals of device 4902 . The separate device 4902 serves to provide the interface between the standard IEEE 1149.1 (plus optional RCK) interface of each legacy target device and the selectable 3 or 5 signal interface to the external controller 4808 . The operation of the separate device 4902 in accessing the legacy device Tap Domains is the same as described in FIGS. 44-47 where the Addressable Tap Domain Selection Circuit 4402 was described accessing the Tap Domains 510 of Tap Region 522 .
The arrangement shown in FIG. 49 could represent the legacy target devices 1802 - 1806 and separate device 4902 as being; (1) ICs/die on a board or substrate 4900 , embedded core circuits within an IC 4900 , or (3) embedded core circuits within a core circuit 4900 . FIG. 49 advantageously illustrates how legacy devices designed using the conventional IEEE 1149.1 interface and optional RCK can be interfaced to the selectable 3 or 5 signal interface controller 4808 by providing the Addressable Tap Selection Circuit 4402 as a separate circuit to serve as the interface between the legacy devices 1802 - 1806 and external controller 4808 . As described for separate circuits 1808 and 4302 of FIGS. 18 and 432 , the separate circuit 4902 could contain only the Addressable Tap Domain Selection Circuit 4402 or it could contain the Addressable Tap Domain Selection Circuit 4402 along with other circuits.
As seen in FIG. 49 , the Addressable Tap Selection Circuit 4402 of separate circuit 4902 has terminals for connecting to auxiliary I/O signals 4502 - 4508 . Thus when separate circuit 4902 is set to operate in the 3 signal interface mode, the “AUXI/O1 or TDI” signal 4408 and the “AUXI/O2 or TMS” signal 4412 can be used for communicating auxiliary I/O signals between a further circuit on assembly 4900 and the controller 4808 . The further circuit could be one or more of the target circuits 1802 - 1806 , or a circuit separate from target circuits 1802 - 1806 . The further circuit could also be a circuit contained within separate circuit 4902 .
Although the present disclosure has been described in detail, it should be understood that various changes, substitutions and alterations may be made without departing from the spirit and scope of the disclosure as defined by the appended claims.
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This disclosure describes a reduced pin bus that can be used on integrated circuits or embedded cores within integrated circuits. The bus may be used for serial access to circuits where the availability of pins on ICs or terminals on cores is limited. The bus may be used for a variety of serial communication operations such as, but not limited to, serial communication related test, emulation, debug, and/or trace operations of an IC or core design. Other aspects of the disclosure include the use of reduced pin buses for emulation, debug, and trace operations and for functional operations. In a fifth aspect of the present disclosure, an interface select circuit, FIGS. 41 - 49 , provides for selectively using either the 5 signal interface of FIG. 41 or the 3 signal interface of FIG. 8.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. national phase of International Application No. PCT/EP02/08298 filed on 25 Jul. 2002, which designated the U.S. PCT/EP02/08298 claims priority to DE Application No. 101 41 256.8 filed 23 Aug. 2001. The entire contents of these applications are incorporated herein by reference.
FIELD
The technology herein relates to an antenna for DVB-T reception.
BACKGROUND AND SUMMARY
As is known, it is planned that the transmission of broadcast radio and television signals will be changed completely from the analogue standard to the digital standard by 2010 at the latest. Transmissions will then be based on the Digital Video Broadcasting (DVB) Standard, which is suitable for digital reception of video and audio data via satellite, via cable or via terrestrially transmitted programs. The expressions DVB-S (for satellite reception), DVB-C (for cable reception) and DVB-T when the signals are transmitted terrestrially are used in a corresponding manner.
Receivers for DVB-T reception generally have rod antennas which are provided at the receiver; are connected, for example, by means of plugs to an interface; and must have a specific length and a specific diameter to match the received frequency spectrum. Conventional rod antennas have a length of around 12 to 13 cm.
The object of technology herein is to provide an antenna which is better than such prior technology and which can be produced easily.
In contrast to rod omnidirectional antennas which are otherwise used, a flat antenna which is in the form of a plate is proposed according to an exemplary illustrative non-limiting implementation. In this case, the total area of the antenna is preferably of such a size that it corresponds to the surface area of a conventional rod antenna for the frequency transmission band under discussion for a corresponding DVB-T Standard.
In a development of the exemplary illustrative non-limiting implementation, the flat antenna which is in the form of a plate may be provided with edge sections which are in the form of flaps and which improve the matching.
It has been found to be advantageous for the flat antenna which is in the form of a plate to be designed as a type of printed circuit board which is provided, at least on one surface face, with a conductive layer which forms the antenna receiving surface. A corresponding interface in the form of a plug or of a socket can then be formed on this basic antenna material which is in the form of a printed circuit board, in order to connect the antenna formed in this way to a corresponding plug connection on the receiver itself.
The receiver itself or parts of the receiver housing may otherwise be used as an opposing surface.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages will be better and more completely understood by referring to the following detailed description of exemplary non-limiting illustrative implementations in conjunction with the drawings of which:
FIG. 1 shows an exemplary illustrative non-limiting schematic side view over the complete area of a DVB-T antenna;
FIG. 2 shows a corresponding an exemplary non-limiting illustration of a view of the front face of the antenna, as is plugged onto a rearward face of a receiver; and
FIG. 3 shows an exemplary illustrative non-limiting side view, offset through 90°, of the antenna plugged onto the receiver in FIG. 2 .
DETAILED DESCRIPTION
The drawings illustrate a flat antenna 1 which is in the form of a plate and may be composed of a conductive metal plate or metal sheet. It may also be produced from a dielectric mount, for example a mount material 11 which is in the form of a printed circuit board and on at least one face of which a metallically conductive layer 3 is formed. In the illustrated exemplary non-limiting arrangement, the flat antenna which is in the form of a plate is in principle rectangular. In the illustrated exemplary non-limiting arrangement, it has two coupling areas 7 to the left and to the right of a vertical axis of symmetry 5 in the left-hand and right-hand lower area adjacent to the rectangular shape 6 of the antenna 1 and, in the end, these lead to an enlargement of the total antenna area.
A plug arrangement 13 is formed in the non-conductive printed circuit board area, or other area, 10 of the mount material 11 , between this coupling surface 7 and the upper large antenna section 9 , and is electrically connected via an electrical connecting line 15 to the large antenna array section 9 .
The flat antenna 1 which is in the form of a plate and is formed in this way can be plugged by means of its plug device 13 to, for example, a corresponding plug or socket arrangement 21 on the rear face of the receiver 23 . The plug device not only holds the antenna 1 , which is in the form of a plate, mechanically, but also connects it electrically to the receiver 23 .
The antenna area is of such a size that it corresponds approximately to the surface area of a conventional rod antenna, for the frequency transmission band under discussion. A conventional rod antenna, for example, has a length of about 80 to 90 mm and a diameter of 8 to 9 mm, up to a length of 15 cm and a diameter of virtually 15 mm. Overall, in this case, the antenna area may then, for example, have values of 1000 mm 2 to 8000 mm 2 , particularly when the antenna is operated in the DVB-T transmission band from 470 MHz to 872 MHz. If it is also intended to extend the transmission band in the direction of the VHF band, then the dimensions could be even larger.
Apart from the exemplary non-limiting arrangement which is illustrated and has been explained, a modified form is also feasible, in which, for example, the antenna is not plugged directly into the receiver but is placed on and/or plugged to a separate stand foot. To this extent, the antenna may also be provided with a fixed stand foot. This stand foot may, for example, also contain an amplifier, which is connected to the receiver by an antenna connecting cable, and is supplied with power from the receiver. Thus, in an entirely general form, the antenna may be installed or fitted separately from the receiver, and is then connected to a receiver via an antenna cable or in the form of a repeater.
The antenna has been described for the situation in which the antenna element is completely flat and planar. However, if required, it is also possible for the antenna to have at least slight spherical curvature, for example slight cylindrical curvature about at least one axis, as well. However, the longitudinal and lateral extent of the antenna element, which is intrinsically kept flat and planar, in both extent directions of the planar or slightly curved antenna element is very much greater than its possible slight extent transversely with respect to this plane.
While the technology herein has been described in connection with exemplary illustrative non-limiting implementations, the invention is not to be limited by the disclosure. The invention is intended to be defined by the claims and to cover all corresponding and equivalent arrangements whether or not specifically disclosed herein.
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The invention relates to an improved antenna for DVB-T reception which is characterized in that the antenna consists of a plate-shaped flat antenna.
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BACKGROUND OF THE INVENTION
The present invention relates to design and construction of lightweight elevated suspended guideways whereon high-speed vehicles will experience virtually no guideway-induced oscillations. More specifically it relates to a method of arranging suspension cables to suspend guideways along multiple towers so that deflections under vehicle load are virtually constant along the way, and temperature fluctuations do not affect alignments. Furthermore, the method of arranging suspension cables is designed to facilitate installation of pre-assembled suspension towers and pre-assembled guideway spans by helicopter.
Present multiple-span suspension bridges require anchors in alternate spans to prevent wavy rocking motion of decks and towers, thus precluding constant resilient suspension, which is necessary for oscillation-free high-speed travel.
SUMMARY OF THE INVENTION
The present invention provides structural components for an elevated suspended guideway comprising:
(a) A-frame-shaped suspension towers at regular intervals;
(b) continuous structural truss supported guideway with expansion joints at towers;
(c) above each guideway span between towers, a first tier of 32 identical inwardly sloping and upwardly extending suspension cables attached evenly spaced with their lower ends, 16 each along left and right edges, to the structural truss supporting the guideway, attaching points beginning and ending one-half space from adjacent towers, and having their upper ends attached in pairs to each other;
(d) above each guideway span between towers, a second tier of 16 identical inwardly sloping and upwardly extending suspension cables attached one each with their lower ends to the upper joints of the paired first tier suspension cables, and centrally above the guideway having their upper ends attached in pairs to each other and to their counter-parts from the opposite edge of the guideway truss;
(e) above each guideway span between towers, a third tier of four identical in vertical plane upwardly extending suspension cables having their lower ends one each attached to the upper joints of the paired second tier suspension cables, and having their upper ends attached in pairs to each other;
(f) above each guideway span between towers, a fourth tier of two identical in vertical plane upwardly extending suspension cables having their lower ends one each attached to the upper joints of the paired third tier suspension cables, and having their upper ends flexibly attached to the top of their next adjacent towers;
(g) above each guideway span between towers, cables parallel to guideway connecting the top joints of paired first, second and third tier suspension cables located nearest mid-span on one side of mid-span to their counterparts on the other side of mid-span;
(h) above each guideway span between towers, cables parallel to guideway flexibly connecting the top joints of paired first and second tier suspension cables located nearest towers to their respective next adjacent towers;
(i) above each guideway span between towers, cables parallel to guideway connecting the top joints of paired first tier suspension cables located on either side of one-quarter and three-quarter of the distance between towers to each other;
(j) motion dampers flexibly connecting guideway truss to tower legs.
The present invention is specifically directed at providing that guideway sagging under moving load is constant and fully resilient. This physical sameness is achieved by having suspension cables arranged whereby the load, irrespective of where it is located along the guideway, is substantially carried by the same type, number, size, length and position angle of suspension cables. Furthermore, this design also provides that temperature expansion and contraction does not cause guideway bending or misalignment, yet allows incorporation of horizontal and vertical curves, curve transitions, banking in curves, ascends and descends.
When used for high-speed conveyor-type automated people movers or fast freight pipelines, for example Articulated Train Systems (U.S. Pat. No. 3,320,903, Re. 26,673) or Bulk Material Conveyors (U.S. Pat. No. 4,024,947), a lightweight design would allow whole spans with suspension cables attached to be assembled at remote locations, transported to the site by helicopter and inserted between towers using quick snap-on connectors.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of a section the suspended elevated guideway including two towers and one span.
FIG. 2 shows a cross-section of the guideway with a front view of an A-frame suspension tower.
FIG. 3 shows a cross-section as in FIG. 2, except it depicts the guideway banked in a horizontal turn.
FIG. 4 is a graphic presentation of how temperature expansion and contraction lowers and raises the guideway while maintaining its longitudinal alignment.
FIG. 5 shows a typical guideway expansion joint located at each tower.
FIG. 6 shows construction of towers and guideway by helicopter.
FIG. 7 is a plan view of a typical span containing a horizontal curve.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view of a section of the suspended elevated guideway. Shown are two A-frame suspension towers 1 , a structural truss supported guideway 2 , first tier suspension cables 3 , second tier suspension cables 4 , third tier suspension cables 5 , fourth tier flexibly connected suspension cables 6 , longitudinal cables 7 , 8 and 9 , and flexibly connected longitudinal cables 10 and 11 . Not visible are expansion joints in guideway 2 behind viewed side legs of towers 1 . The height of each tier is shown here to approximate ¼ of tower height above guideway.
FIG. 2 is a cross-sectional view of guideway 2 . Shown are motion dampers 12 holding guideway 2 centrally between legs of tower 1 , a silhouette of vehicle 13 on guideway 2 , attaching locations 14 for cables 11 on a cross bar of tower 1 , attaching location 15 for cables 10 on a cross bar of tower 1 , and attaching location 16 for fourth tier cables 6 at the top of tower 1 . All connection locations in FIG. 2 are shown for towers 1 along a straight guideway 2 . At locations along the way where guideway 2 is horizontally curved, attaching locations 15 and 16 are moved laterally along tower 1 cross bars in the direction away from the center of the curve in amounts depending on span length and radius of curve.
FIG. 3 is a cross-sectional view of guideway 2 similar to FIG. 2, showing tower 1 located in a banked horizontal turn. Cantilevered arms 17 are attached to guideway 2 for use by first tier suspension cables 3 to prevent them from making contact with vehicle 13 leaning into the banked turn. Fourth tier suspension cables 6 are attached to the top cross bar of tower 1 at attaching location 18 , which lies on the center line of the arc of guideway 2 between towers 1 . Depending on weight of vehicles travelling on guideway 2 , tiebacks 19 may be added to towers 1 in tight curves.
FIG. 4 is an exaggerated graphic presentation of how temperature change affects cables connected to tower 1 . Shown are cold temperature position in solid lines, and warm temperature position in dashed lines. With temperature change, fourth tier suspension cable 6 and longitudinal cable 7 combine to raise and lower guideway 2 . All other cables expand and contract with the guideway in unison. Thus, do not disturb the guideway's relative alignment.
As an example, assuming all components are made of steel with similar temperature expansion factors, spans are 160 feet (50 m) long and towers 80 feet (25 m) high. If the design temperature range is from −50 F. to +120 F. (−47 C. to +49 C.), then the coldest connection location 20 between fourth tier suspension cable 6 and lateral cable 7 would move to the hottest connection location 21 , which is a movement to the left by 0.67″ (1.70 cm) and a lowering by 3.67″ (9.3 cm). Guideway 2 would drop uniformly by the same amount, and lateral cables 10 and 11 would rotate around their tower attaching points, similarly to that of fourth tier suspension cable 6 . All other components of the span would expand directly proportional away from he center of the span, which remains in fixed location.
FIG 5 shows a typical expansion joint between adjacent truss supports of guideway 2 . Structural members 22 are held together by gussets 23 with lateral flanges to which machined bolt 24 is attached to one truss section and in sliding engagement with a bushing 25 attached to a counter-part of its adjacent truss section. Machined bolts 24 have sufficiently length to permit guideway 2 thermal expansions and contractions, which, with the assumption detailed for FIG. 4 above would come to 2.7″ (6.8 cm). Bolt heads 26 would prevent accidental disconnection of expansion joints. For cross-section of guideway 2 , as shown in FIGS. 2 & 3, there would be 5 expansion joints as shown in FIG. 5 at each tower 1 . Dampers may be added to limit motion in expansion joins to those caused by temperature change.
FIG. 6 depicts the general method of erecting the suspended elevated guideway using helicopters. After surveying and clearing the route, concrete tower footings 27 are poured and allowed to cure. A-frame towers 28 are secured to footings 27 by ground crews brought in by small helicopter 29 . Large helicopters 30 carry pre-assembled towers 1 and guideway 2 spans from assembly location to erection site. Suspended from helicopter 30 is a load spreader 31 with four hooked carrying straps 32 attached to the upper joints of second tier suspension cables 4 . Hooked hanging straps 33 are merely holding the loose cables 6 , 10 and 11 in readiness for hookup to their respective towers 1 . At the erection site, guideway 2 is lowered into place until spreader 31 , which is longer than the span between towers 1 , comes to rest with its front and rear end on top of towers 1 , at which time helicopter 30 disconnects and returns for its next load. The ground crew connects suspension cables 6 and lateral cables 10 and 11 to towers 1 , and guideway 2 to the previously installed guideway 34 using vertical adjusting means incorporated in carrying straps 32 to achieve proper alignment. To prevent newly connected towers 1 from bending under uneven load, spreaders 31 remain and support the weight of guideways 2 until the next following span is added.
High tension electric power line construction experience has shown that heavy lifting helicopters 30 can make about 60 trips per day when the assembly location is not more than 5 miles (8 Km) away. On that scale, the here-described methodology could achieve a construction rate of one-mile (1.6 Km) per day. Lifting capacity of these helicopters 30 is in excess of 10 tons. A 160 feet (50 m) long, 5 by 5 feet (1.5×1.5 m) cross-section aluminum spreader 31 would weigh about 3 tons, and an equally lightly constructed guideway 2 may weigh 4 tons, for a total of 7 tons.
FIG. 7 is a plan view of a guideway 2 span containing a horizontal curve. Fourth tier suspension cables 6 and longitudinal cable 7 are shown in heavy outline. They are located on the centerline of the arc of the span of guideway 2 . For curved spans with equal radii, attaching points 18 of fourth tier suspension cables 6 are located opposite each other on the top cross-bar of towers 1 , and their horizontal components of cable tension cancel each other out. However, in guideway 2 horizontal curvature transitions from straight-line to curved, between curves of different radii or S-curves, attaching points 18 of fourth tier suspension cables 6 are not located opposite each other on the top cross-bar of towers 1 . For high-speed guideways 2 , such transitions would take place over several spans and the opposite attaching point 18 discrepancy in each span would be minimal. A simple solution would be to have fourth tier suspension cables 6 split in two near the top of towers 1 and attached to the top cross bar at spaced apart locations.
The sameness of suspension achieved by this design can be demonstrated with a graphical force analysis at each junction point of the suspension cables. However in principle, since a horizontal cable cannot transmit a vertical force, an incremental increase in cable tensions due to a vehicle with weight W on guideway 2 must necessarily travel only upwards, from guideway 2 through first, second, third and fourth tier suspension cables to the top of towers 1 . Thus, incremental tension increase F x in each tier suspension cable due to weight W amounts to:
F x =W/ cos α x ,
where α is the angle between cable direction and vertical, and x the tier number.
Assuming FIG. 1 is drawn to scale, then approximate angles between cable directions and vertical are, first tier α 1 =38°, second tier α 2 =42°, third tier α 3 =63° and fourth tier α 4 =67°. If weight W is acting at the lower end of any first tier cable 3 , incremental tension increases in cables directly above due to weight W are, in first tier 1.27 W, in second tier 1.35 W, in third tier 2.20 W and in fourth tier 2.56 W. Force diagrams also show that incremental tension increases F horiz occur in horizontal cables 7 and 8 due to weight W. The magnitudes of F horiz depend on location of weight W as follows:
(a) In horizontal cable 7 when weight W is in span portion:
First and fourth quarter F horiz =W(tan α 3 +tan α 4 ),
Second and third quarter: F horiz =W(tan α 4 −tan α 3 )
(b) In horizontal cable 8 when weight W is in span portion:
First and fourth quarter: F horiz =0,
Third and sixth eighth: F horiz =W(tan α 2 +tan α 3 ),
Fourth and fifth eighth: F horiz =W(tanα 3 −tan α 2 ).
Using above measured angles, incremental tension increase in horizontal cable 7 ranges from 0.39 W to 4.32 W, and in horizontal cable 8 from zero to 2.86 W. Incremental tension increases F horiz due to vehicle weight W in one half of the span travel via horizontal cables 7 , 8 and 9 across mid-span to the other half of the span, redistributing themselves there in reverse order and causing lifting forces to act on guideway 2 . To prevent these lifting forces from inducing seesaw-rocking motions of guideway 2 spans in the wake of intermittently passing vehicles 13 , guideway 2 must be tied down at each tower 1 by cables attached with their lower ends to the legs of towers 1 . With a tension spring in parallel with a damper inserted in each tie-down cable at towers 1 , there would also be automatic length adjustment when guideway 2 spans rise and fall with temperature change.
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Suspension cables for an elevated lightweight guideway are arranged so that high-speed traffic along the guideway is not subjected to guideway-induced oscillation. Furthermore, suspension cables are interconnected so that pre-assembled towers and guideway spans can be transported and rapidly installed by helicopter.
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BACKGROUND OF THE INVENTION
Conventionally, so-called air-sol type atomizer has been widely used, in which a pressurized propellant gas is used. The gas has been found, however, harmful to human bodies. In addition, there is a danger that the wasted container may explode due to the residual propellant gas.
For these reasons, so-called manual type small sized atomizers are now under reconsideration.
However, in conventional atomizers of this type, it is difficult to obtain a sufficient atomizing pressure, especially at the beginning of the atomization, so that fine particles of atomized content are not available.
In order to overcome this problem, the present Applicant has proposed a so-called accumulator type atomizer, in U.S. Pat. No. 3,908,870. This type of atomizer has a discharge valve which is forced to be closed, even when a atomizing head is depressed, until a sufficient pressure is established within the cylinder chamber. In other words, the discharge valve is allowed to open only after a sufficient pressure has been established to allow the atomization.
Although this accumulator type atomizer provides a solution to the aforementioned problem, another problem is caused that a considerably large force is required for depressing the atomizer head, resisting the forcible closing force on the discharge valve.
Also, in the atomizer of the other type than the accumulator type, a large depressing force is required for depressing the atomizer head, when the amount of spray at one time is large.
The present invention is aiming at providing a cap which is most advantageously used for these atomizers which require a large depressing force on the atomizer head, especially for accumulator type ones.
SUMMARY OF THE INVENTION
The present invention is aimed at reducing the force required for depressing the atomizer head by a provision of a handle lever to a cap of the atomizer, and provides the greatest advantage when used in combination with an accumulator type atomizer or other type of atomizer in which the amount of spray at one time is relatively large.
Thus, it is one object of the invention to make it possible to depress the atomizer head for atomization with a reduced force.
It is another object of the invention to prevent the atomized content which may be a chemical substance from attaching to the skin of hands, by allowing the operation at a position remote from the nozzle, thereby to protect the hands from bad effect on one's health.
It is still another object of the invention to prevent dusts or other contaminants from sticking to the atomizing head, by disposing the head within a cap, and, at the same time, to make it possible to operate the atomizer with the cap fitted onto the atomizing head, i.e. without necessitating the removal of the cap.
It is a further object of the invention to provide an atomizer having a handle lever, in which the handle lever does never hinder the packing of the atomizer for transportation.
These and other objects, as well as advantageous features and effects of the invention will become clear from the following description of preferred embodiments taken in conjunction with the attached drawings in which:
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of an atomizer having a cap embodying the present invention fitted thereon.
FIG. 2 is a plan view of the atomizer of FIG. 1,
FIG. 3 is a vertical sectional view of a cap of another embodiment of the invention,
FIG. 4 is a vertical sectional view of still another embodiment of the present invention,
FIG. 5 is a vertical sectional view of a further embodiment of the present invention,
FIG. 6 is an exploded perspective view of a member for use in the cap of FIG. 5,
FIG. 7 is a vertical sectional view of a still further embodiment of the present invention,
FIG. 8 is a sectional view taken along the line A--A of FIG. 7,
FIG. 9 is an exploded perspective view of a member for use in the cap of FIG. 7,
FIG. 10 is a vertical sectional view of a still further embodiment of the present invention,
FIG. 11 is a vertical sectional view illustrating the manner of operation of the embodiment of FIG. 10, and
FIG. 12 is a plan view of the cap of FIG. 10.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring at first to FIGS. 1 and 2 showing a preferred embodiment of the present invention, a main container body 1 containing a liquid to be atomized has an opening or outlet 2 to which fitted is a plug 3. An atomizer assembly consisting of a cylinder 5, a communication pipe 6 and an atomizer head 7 is attached to the container body 1 by means of the plug 3 and a retainer sleeve 4 screwed into the plug 3.
The arrangement is such that the liquid having been sucked into the cylinder is atomized from nozzle ports 8 formed in the peripheral wall of the atomizer head, through the communication pipe, as the atomizer head is depressed, while the atomizer head is moved back upwardly by a spring, as it is released, to cause a vacuum within the cylinder to suck the liquid for next atomization by the subsequent depressing of the atomizer head.
A cap 11 in accordance with the invention has a top wall 12 and a vertical peripheral wall 13 extending downwardly from the peripheral edge of the top wall 12. The cap 11 is adapted to be fitted onto the plug 3 on the container body 1, at its vertical peripheral wall 13.
As will be seen from the drawings, the peripheral wall 13 is provided at its front portion with an inwardly curved recess 14 the inner wall of which is made to approach the nozzle port 8 and is opened at a portion in front of the nozzle port 8 to provide a window 15 for the atomization.
The window 15 is elongated in the direction of the cylinder to allow the atomized liquid to be spread outwardly therethrough.
Another opening or window 16 for operation is provided over the top wall 12 and the rear upper portion of the peripheral vertical wall connected to that portion.
Second shielding plates 17,17 are optionally provided to shield the interior of the cap when a later-mentioned handle lever is depressed. For this purpose, the plates 17,17 are suspended from the back surface of the top wall.
The handle lever 21 has supporting rods 23,24 projected from both sides of the front portion of a plate 22. In the illustrated embodiment, the rods are projected through vertically downwardly extending portions 24,24.
The supporting rods are pivoted at their ends to the inner surface of the cap at front portion of the latter, through pins 25,25.
The pins 25,25 may be provided on the supporting rods and received by recesses or bores in the cap, or may be vice versa.
A projection 26 may be provided for depressing the atomizer head, at the front lower edge of the plate. A shield plate 27 is suspended from the rear end of the plate 22. The arrangement is such that the top wall of the cap comes in contact with the plate when the cap is fitted, or with the lower surface of the projection 26 when it is provided.
The window 16 for operation is adapted to be closed by the rear portion of the plate and the shielding plate.
As the rear portion of the plate is depressed at this condition, the handle lever 21 is rotated around the pins 26,26, so that the atomizer head and the communication pipe 6 are depressed to allow the atomization from the nozzle port. The atomized liquid is then discharged outwardly through the window 15 for the atomized liquid.
As the plate is released from the depressing force exerted by a finger, a spring disposed with the cylinder moves the atomizer head back upwardly which returns the handle lever also up to the original position of FIG. 1.
In the embodiment of FIG. 3, the cap is modified to have the inwardly curved recessed portion 14 extending down to the lower portion of the peripheral wall.
In this embodiment, front portion of the peripheral wall of the plug 3, as well as the front portion of the sleeve 4 are notched so as not to hinder the inwardly projected wall of the recessed portion 14.
The sleeve 4 screwed to the plug has an outwardly exdtending flange 9 having a peripheral fitting wall extending upwardly from its peripheral portion excepting the front portion.
A number of engaging projections 9b are formed on the fitting wall for engagement with projections 13a . . . formed in the inner wall of the cap so as to fix the cap 11 to the sleeve 4 against a rotation.
In the embodiment of FIG. 4, the combination of the plug and the sleeve are substituted by a retainer member 10.
The retainer member 10 has a peripheral wall 10b having at its upper end an engaging projection 10a and at its lower end an outwardly extending flange 10c. A fitting wall 10d is suspended from the lower surface of the flange, excepting the front portion of the latter, for fitting around the opening of the container body. A projection formed on the outer peripheral surface of the atomizer head at the lower portion thereof is adapted for engagement with said engaging projection of the retainer member, thereby to prevent the atomizer head from being moved unintentionally.
In the embodiments of FIGS. 3 and 4, the handle lever is formed to extend rearwardly from the plate, and the shield plate 27 is suspended from the position slightly ahead of the rearmost portion of the later.
In the embodiment of FIG. 5, the handle lever 21 consists of a lever body 31 and a sliding member 32. The lever body 31 has a plate portion 33 equipped with stoppers 34,34 at both sides of the rear end of the later 33.
The sliding member 32 has a plate portion 35 and a pair of side walls 36,36 suspended from both sides of the front portion of the plate portion 35. Each side wall has an inwardly extending engaging projection 37. A shield plate 38 is suspended from the rear end of the plate portion. A finger retaining portion 39 is formed on the rear portion of the plate portion. The plate portion 35 is slidably received by the gaps formed between the side walls 36,36 and between the engaging portions 37,37.
Ends of supporting rods are pivoted to the inner peripheral wall of the cap body, as is the case of the foregoing embodiments.
The arrangement is such that the lower end surface 40 of the shield plate 38 can be mounted on the lower edge 16a of the window 16 for the operation, when the sliding member 32 is brought to its most forward position.
In operation, the depression is made until the rear ends of the side walls 36,36 come in contact with the stoppers 34,34, as shown in two-dots-and dash line in FIG. 5.
After use, the sliding member is forced into again, so that the depression of the sliding member is prevented by the engagement of the lower edge of the shielding plate with the upper surface of the lower edge of the operation window 16.
In the embodiment of FIG. 7, the handle lever 21 is composed of a lever body 51 and an operating member 52.
The lever body 51 has a frame-like receptacle 53 having both side edges bent to form forwardly extending supporting rods 54,54. Engaging projections 55,55 are provided on the upper edges of the ends of the supporting rods.
Engaging plates 19,19 having engaging recesses 18,18 are formed at both side portions of the peripheral wall of the cap body.
The arrangement is such that the fore rod 53a of the receptacle is in contact with the top wall of the atomizer head 7, when the engaging projections 55,55 are in engagement with the engaging recesses 18,18 and the upper surface of the fore rod is in contact with the lower surface of the top wall of the cap body, while the rear rod 53b of the receptacle projects into the operation window 16.
The operation member 52 has a pressing plate 56 having a sliding wall 57 suspended from the lower edge of the rear end of the later.
The pressing plate is capable of closing the portion of the window 16 in the top wall, while the sliding plate is adapted to close the rear portion of the window.
Both the side portions 57a, 57a of the sliding wall is received by engaging portions 58,58 of the reap portion of the window, so that the sliding wall may be moved only up and downward direction.
The pressing plate is adapted to be abut by its lower surface by the upper surface of the receptacle 53.
As shown in FIG. 7, the receptacle 53 is depressed to cause a rotary member to rotate around the end of the lever, depressing the actuator, as the pressing plate is depressed with the cap assembled and fitted on the container body. As the pressing plate is released, the upwardly biased actuator is moved to cause the returning motion of the rotary member and the operation member 52 the back surface of the end portion of which being in engagement with the upper surface of the rear portion of the receptacle of the rotary member.
Referring next to the embodiment of FIG. 10, a window 61 is formed bridging over the front and rear top portions of the cap body. At the front portion of the window 61, guiding grooves 63,63 are provided to extend in the direction of the cylinder, at both side of the opening 62 of the window.
The operation lever 21 is provided with a vertical wall 65 capable of closing the front opening of the window, and has at its upper to rear portions a horizontal wall 66 capable of closing the top opening 64 of the window.
Pins 67,67 are provided at both lateral side portions of the lower section of the vertical wall 65, so as to be received by the aforementioned guiding grooves 63,63.
The arrangement is such that the operation member can be tilted rearwardly, when the pins are at their uppermost positions within the guiding grooves, i.e. when the operation member has been lifted to its uppermost position.
As will be seen from FIG. 11, when the cap is fitted to the container body, the vertical wall keeps a horizontal posture maintaining a contact with the top wall of the atomizer head 7. As the horizontal wall section 66 is depressed from this state, pins 67, 67 are brought into engagement with the top ends of respective guiding grooves 63,63, so as to cause the rotation of the operation lever around the pins, resulting in a depression of the atomizer head to perform the atomization through the nozzle port 8.
By arranging such that the lower portion of the vertical wall comes inside of the lower portion of the forward peripheral wall, when the vertical wall closes the front opening 62 of the window, the forward inclination of the operating member is prevented by the abutment of the inner portion 13b of the lower edge of the front opening and the outer surface of mid portion of the vertical wall, as will be seen from FIG. 10.
The backward inclination is prevented by the atomizer head.
The rear opening 68 of the window is so designed as to be closed by the rear portion of the peripheral wall of the atomizer head.
When the operation member is kept upright, front and top openings of the window are closed by the vertical and horizontal walls, respectively, so that the actuator cannot be depressed, thus playing a role of a safety device, while, for use, the operation member is lifted up and tilted backwardly to play the role of a lever for depressing the actuator with a reduced force.
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The present invention relates to a cap for an atomizer and, more particularly, to a cap for an atomizer especially of a type having a manually operated accumulation type main body.
However, the cap of the invention is widely applicable to other types of atomizers than the above mentioned type, having an ejecting pipe extending upwardly from the top surface of the main body and provided at its upper end with an atomizing head having nozzle ports (This head may be called an "actuator," as well.), the ejecting pipe being adapted to be depressed for allowing the content of the pipe to be released through the pipe to be atomized by the atomizing head.
The cap of the invention can be effectively used especially for those atomizers having a large amount of spray at one time.
The cap of the invention is characterized by comprising a lever fitted thereto for depressing the atomizing head. Thanks to the provision of this lever, the atomizing head can be depressed with a reduced force, without substantial difficulty.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to rotatable bow string releases and is particularly directed to a bow string release having a stiff trigger element.
2. Description of the Prior Art
The subject application is related to my co-pending application Ser. No. 07/535,892 entitled Bow String Release and filed on Jun. 11, 1990 now U.S. Pat. No. 5,078,116.
Many archers involved in both hunting and/or target shooting prefer to use a bow string release in order to more accurately position and hold the string during cocking of the bow and for more precision release of the string. Since archers have various forms of techniques for holding the bow string and bow, it is desirable that the release be rotatable in order to accommodate a large variety of users. A good release provides uniform release of the bow string and increases accuracy. The release is either hand held or strapped to the wrist and has a trigger which permits the archer to release the string.
Typically, such devices employ a pivotal finger that engages the bow string, the finger being pivoted to a release position for releasing the string. Releases of this type are illustrated in U.S. Pat. Nos. 3,898,974, 3,954,095 and 4,066,060. Many of the releases of this type include a head for housing the sear elements and a separate body for the trigger mechanism. A trigger element is disposed between and communicates with both the head and the body for translating the motion of the trigger to the sear. In most devices of the prior art, the trigger is either a fixed rod or pin which is rigid and translates one-to-one motion of the trigger to the sear in both the forward and reverse direction. Other devices utilize a flexible trigger element such as a ball and chain or a cord which is only operable in one direction. A disadvantage to the flexible type of trigger element is that the trigger element is inoperative to re-engage the sear once the trigger has been released, requiring a second mechanism for re-engaging the sear after release. While the rigid trigger elements overcome this problem, they do not have the feel of the flexible trigger element which is desired by many archers.
SUMMARY OF THE INVENTION
The subject invention overcome disadvantages of the prior art by incorporating a trigger element which has both the feel of a flexible ball and chain type element when used to release the string and the desirable reloading capabilities of rigid elements.
In the preferred embodiment of the invention, the trigger element comprises a stiff filament such as nylon or the like which is somewhat flexible, giving the feel of a flexible element when using the trigger. However, the stiff filament retains its shape and has the reloading capabilities of a rigid trigger element.
By utilizing the stiff trigger element of the subject invention, the sear mechanism can be greatly simplified since the trigger element can be used to reload the string release without additional components being required. In this regard, the sear element comprises a pair of pivotal jaws, one of which is controlled directly by the trigger element and the second of which is a follower element which responds to movement of the first jaw and a cam operated action relative to the element.
The bow release of the subject invention is rotatable a full 360°, permitting use of the release and any desired rotational orientation. The trigger action is adjustable to the individual requirements of the user.
It is, therefore, an object and feature of the subject invention to provide a rotatable bow string release having the reload capabilities of a rigid trigger element while operating with a feel similar to that of a flexible trigger.
It is another object and feature of the subject invention to provide for a simple bow string release mechanism wherein the trigger element is used to both release the string and to reload the string.
Other objects and features of the invention will be readily apparent from the accompanying drawing and detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWING
The drawings illustrate the best mode presently contemplated for carrying out the invention, wherein:
FIG. 1 is a top plan view of the bow string release in accordance with the subject invention, with covers removed.
FIG. 2 is a view similar to FIG. 1, illustrating the bow string release in the released position.
FIG. 3 is a fragmentary view similar to FIG. 1, showing an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The bow string release of the subject invention includes a head 10 and body 12 each mounted on a shaft 14. The shaft includes a hollow cylindrical bore 16 for receiving the trigger element 18. The head 10 includes a pair of pivot posts 20 and 22, upon each of which is mounted a sear jaw 24 and 26, respectively. The sear jaws 24 and 26 are pivotable about the pivot posts 20 and 22 between the closed position shown in FIG. 1 and the open position shown in FIG. 2.
In the preferred embodiment of the invention, the sear jaws 24 and 26 have a notch 28 and 30, respectively, for securing the bow string 32, shown in phantom, when the sear jaws are in the loaded, locked position of FIG. 1. In the preferred embodiment, a ball or similar type bearing element 34 is provided and in the closed position of FIG. 1 is in axial alignment with the pivot posts 20 and 22. A compression spring 36 is disposed between the jaws 24 and 26 for normally biasing the jaws into the open position. The ball 34 provides stability to the assembly and rides forward to the position shown in FIG. 2 when the bow string release is released to permit the string 32 to escape.
In the preferred embodiment of the invention, the head comprises a lower half 40, as shown in FIGS. 1 and 2, with a recessed cavity 42 for housing the sear jaws and triggering mechanism. A plurality of mounting posts or other mounts, as shown at 44 and 48, are provided for receiving a complimentary cover (not shown). The cover is designed to encapsulate the sear mechanism within the head and to hold the head on the shaft 14. A central bore 46 is provided in the head and cover for receiving the shaft. In the preferred embodiment, the shaft 14 is rigidly secured to the head, whereby the shaft and head rotate in unison.
The body 12, shown with the cover removed, also includes a cavity 48 for housing the trigger mechanism 50 and a central bore 52 for receiving the shaft 14. An enlarged end 54 on the shaft 14 maintains the head on the shaft, the head being rotatable about the shaft a full 360° . A plurality of posts 56 are provided in the bottom portion 55 of the head and are adapted to receive and secure the cover (not shown) for encapsulating the trigger mechanism and the shaft 14 in the body 12. In the preferred embodiment, the trigger mechanism 50 comprises a base portion 60 which is pivotably mounted on the post 62 provided in the body.
An actuator lever 64 is provided in the head and is pivotably secured to the jaw 24 at pin or post 66. The opposite end of the actuating lever 64 terminates in a cam surface 68, as shown. A cam follower such as the disk or wheel 70 is mounted on the second jaw 26 for rotation about the pin or post 72. The trigger element 18 comprises a stiff nylon filament or the like which extends from the actuating lever 64 to the trigger base 60 and is secured thereto by suitable means such as the ball and socket arrangement shown at 74 and 76.
In operation, the string release is locked in the closed position by engagement of the cam surface 68 with the cam follower 70, providing a rigid lock between the pins 66 and 72, for overcoming the force of the compression spring 36 and holding the sear notches 28 and 30 in the closed position as shown in FIG. 1. When the trigger element 60 is pulled back as shown in FIG. 2, the cam follower 70 rides along the cam surface 68, permitting both jaws 24 and 26 to pivot outwardly, for releasing the bow string 32.
The compression spring 36 normally urges the sear jaws into the open position of FIG. 2. This maintains the jaws in the open position after release, facilitating reentry of the string 32 for reloading. Once the string is placed back into the notches 28 and 30, the trigger is pushed forward to the position shown in FIG. 1, and the filament 18 is stiff enough to push the actuator lever 64 forward, engaging cam follower 70 and pushing both jaws 24 and 26 back to the closed position, where they remain locked until the trigger is again released.
A set screw 80 is provided in the body 12 of the bow release and has an outer end 82 in communication with the notch 84 of the trigger base 60. In the preferred embodiment, the set screw is threaded and is contained in the tapped hole 96. The set screw may be adjusted to control the forward motion of the trigger 50 for calibrating the touch of the release mechanism to the individual desires of the user.
The notch 98 provided in the back end of the body 12 is adapted to receive and secure a standard wrist strap as commonly used with bow string releases, in the manner well known to those skilled in the art.
An alternative embodiment of the head 10 and sear mechanism is shown in FIG. 3. The lower end 168 of the actuator lever 64 includes horizontal surface adapted to engage the roller 70, as in the embodiment of FIGS. 1 and 2. However, a vertical extension 169 is provided on the actuator lever 64 and extends downwardly beyond the lower edge 43 of the head 10 for defining a reset lever. The front surface 170 of the lever 169 acts as a positive stop, limiting the forward motion of the actuator 64 relative to the roller. A set screw 171 may be provided in the lever 169 and may be used to adjust the forward motion of the lever 169 and actuator 64 relative to the roller 70. This permits the archer to adjust the feel of the trigger, in the same manner as the set screw 80 in the embodiment of FIGS. 1 and 2. The reset lever 169 may be used to advance the actuator 64 from the retracted position (see FIG. 2) to the position shown in FIG. 3, whereby the actuator surface 168 engages the roller 70 and moves the sear mechanism from the open position to the closed position for retaining the bow string 32. The actuator lever 169 will also advance the trigger 50 from the retracted position of FIG. 2 to the advanced position of FIG. 1 via the filament 18. It be noted that the configuration of FIG. 3 would permit the configuration shown to be used in combination with a flexible, collapsible actuator such as a chain or the like in addition to the stiff filament 18 shown and described.
While certain features and embodiments of the invention have been described in detail herein, it will be understood that the invention includes all enhancements and modifications within the scope and spirit of the following claims.
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A bow string release includes a head and body which may be rotated relative to one another, wherein the sear is contained in the head and the trigger is contained in the body. A stiff trigger element is used for translating trigger motion to the sear, the stiff trigger element having a feel similar to that of flexible trigger elements but functional in both the forward and reverse directions as with rigid trigger elements, facilitating reloading of the release.
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This application is a continuation of application Ser. No. 08/628,067, filed Apr. 8, 1996, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for uniquely identifying castings in serial production, for tracking operating parameters associated with a molding process, and for recording sensed values of such parameters for each individual casting produced by a casting process.
2. Background Information
High volume production of castings used, for example, in automotive engines, typically involves molding by means of sand core packages. According to common practice, each sand core package is assembled from pre-made cores which are filled with melt, cooled, and further processed. Additional processing may include, for example, thermal reclamation of the core sand. Although it is desirable to uniquely identify castings for quality control and other reasons, efforts to provide such identification have generally not been successful in the context of high volume casting operations. One common practice has been to apply a tag or date code to molds, such that the date and a particular work shift are provided in raised relief in the finished product. Unfortunately, in high-volume production, thousands of parts may be made in a single shift, and problems associated with the casting process could necessitate scrapage and/or recall of all the parts produced in a given shift, for that matter, a plurality of shifts. It is desirable, therefore, to have the capability of associating or recording data pertaining to a casting process with each particular cast workpiece. In this manner, if it is determined subsequently that one or more cast workpieces were molded at a time when process parameters were out of specification, the affected castings may be identified with specificity.
The inventors of the present invention have fortuitously devised a system and method for providing unique identification of each casting produced in a foundry, while at the same time providing a system and method for tying each casting to and recording with the casting a plurality of operating parameters associated with the casting process. Thus, as noted above, if imperfect parts or workpieces are produced by the casting process because one or more of the operating parameters drifts out of acceptable limits, the affected parts may be readily identified by doing a search of a memory storage device situated within a molding controller, which will have data sets corresponding to the unique identification for each particular casting, coupled with recorded values for various parameters associated with the molding process.
It is an advantage of the present invention that a system according to this invention may be used to control casting inventories and to provide field service for castings, because each casting will be uniquely identified and the characteristics of the casting process pertaining to each particular casting will be readily ascertainable.
Other advantages of the present invention will become apparent to the reader of this specification.
SUMMARY OF THE INVENTION
A system for identifying castings includes a writer for forming moldable identification indicia in a workpiece shaping surface of mold, and a data logger for recording a data set for each casting with the data set including both the moldable identification indicia and a value for at least one parameter associated with the molding process. A writer used in a system according to the present invention may comprise either a machine-driven scriber for engraving identification indicia in a mold such that the identification indicia appear in raised relief in a workpiece shaped by the mold. Alternatively, the writer may comprise a computer controlled surface working tool for forming identification indicia in relief in a mold. Thus, the letters, numbers, alphanumeric code, or other type of identification indicia could be formed in either raised or lowered relief in a finished workpiece.
According to yet another aspect of the present invention, a casting identification system comprises an external identification writer for applying outer surface identification indicia to an outer surface of a mold such that the previously described moldable identification indicia and the outer surface identification indicia are in correspondence. If desired, both sets of indicia may be identical. A point here is that the moldable identification indicia are generally not readable after the core package has been assembled, it being understood that the moldable identification indicia are necessarily inscribed in an inner surface of the core package which will be exposed to melt during the pouring of melt into the core package.
According to yet another aspect of the present invention, at the approximate time the mold is filled with melt, a data logger receives a signal transmitted from a camera trained upon the outer surface identification indicia located on an outer surface of the mold. In this manner, a molding controller which controls the filling of the mold will be able to enter into a memory storage device a unique set of identification indicia for each particular part produced by the molding process, and the unique identification indicia will be part of the data set for each individual casting. Each data set will include a signal derived from the outer surface identification indicia and a value of a least one parameter associated with the molding process.
Finally, according to another aspect of the present invention, a method for operating a molding system so as to uniquely identify each one of a plurality of castings and to record values of process parameters associated with each individual casting, comprises the steps of: (1) using a first controller to control a surface working tool so as to form moldable identification indicia in a workpiece shaping surface of a mold, with such first controller also controlling an external identification writer so as to apply outer surface identification indicia to an outer surface of the mold, with the moldable identification indicia and the outer surface identification indicia being in correspondence.
The present method further includes using a second controller to control the filling of the mold and for recording a data set for each individual casting, with each data set including a signal derived from the outer surface identification indicia and at least one parameter associated with the molding process, such that the recorded outer surface identification indicia and the recorded value of at least one parameter will be maintained within a memory storage device housed within the second controller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, is schematic representation of a mold preparation system according to the present invention.
FIG. 1A is a surface segment of a workpiece shaping surface of a mold containing indicia engraved in a mold.
FIG. 2, is schematic representation of a molding process according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a system for identifying castings and for recording process parameters begins in the core room of a foundry, where mold prep controller 10 operates a surface working tool, in this case scriber head 12 having a scriber stylus 14 attached thereto, to engrave identification indicia in workpiece shaping surface 18 which is on the inside of mold package 16.
The results of the scribing process are shown in FIG. 1A. Note that the alphanumeric code 15 is engraved into workpiece forming surface 18 of mold 16. Those skilled in the art will appreciate, in view of this disclosure, that the type of scriber head 12 and engraving point 14 used in a system according to the present invention may comprise any one of a variety of such scriber heads and styli. Moreover, the particular program used to operate the scriber and stylist could be drawn from a veritable plethora of such programs used in the machine tool industry and elsewhere for the purpose of providing three-dimensional engraving upon a surface. The precise aspects of such a program are known to those skilled in the arts to which this disclosure pertains and are beyond the scope of the present invention.
The work of mold prep controller 10, scriber head 12, and stylus 14 produces a series of moldable identification indicia in surface 18 of mold 16. The first set of identification indicia are said to be moldable because metal or other melt, upon entering the mold, will flow into the engraved areas, so as to produce raised relief indicia in a desired manner. These raised relief indicia, 34, are shown in FIG. 2, as being applied to the side of a workpiece, which in this case is engine block 20, which has been released from mold 16.
After mold prep controller 10 and scriber head 12 engrave identification indicia on surface 18, mold 16 passes to another station wherein an external identification writer, in this case inkjet printer 22, sprays a set of outer surface identification indicia 21 on the outside of core package 16, in a location such that the sprayed outer surface indicia may be read optically at a later time during the molding process.
The inventors of the present invention have applied the inventive method and system to serial production of high volume aluminum castings using a reclaimable sand core process. The present system has been successfully employed with engine castings such as cylinder blocks and cylinder heads. Those skilled in the art will appreciate in view of this disclosure, however, that the present method and system could be employed with other moldable materials, such as ferrous and nonferrous metals and nonmetallic compounds cast with sand molds and, for that matter, any other type of mold in which at least a portion of the mold is replaceable after each molding operation. For example, if used with a plastic molding process, the mold could be provided with a replaceable interior panel suitable for engraving by the present system; a replaceable or cleanable exterior panel suitable for marking with inkjet printer 22 according to the present invention could also be employed.
Following preparation of mold 16 according to the present invention, the finished core package 16 moves to a mold room, wherein molding controller 24 not only controls the filling of mold 16 with melt from melt handler 32, but also records a data set. A plurality of sensors 30 tracks such operating parameters associated with the casting process, and specifically with melt handler 32, such as the time required to fill the mold or core package with melts and other parameters such as the chemical composition of the melt, the level of molten metal or other type of melt in the feed furnace, the temperature of the melt, and other parameters known to those skilled in the casting art and suggested by this disclosure. The outputs of the various sensors 30 are recorded by a memory storage device within molding controller 24. For this purpose, molding controller 24 could comprise either a simple data logger or personal computer or another type of process computer known to those skilled in the art and suggested by this disclosure. In any event, the data set, including the output of sensors 30 and, if desired, the time and date that the melt is introduced by melt handler 32 into mold 16, comprises part of the data set, with a complete data set including a signal derived from outer surface identification indicia 21 by camera 28, which is trained upon indicia 21 and which feeds its output to optical character reader 26. For the purposes of this disclosure, the set of parameters associated with the molding process may include date and time of day data, and sensors 30 may include a clock time sensor.
Once the outputs of sensors 30 and indicia 21 are recorded by molding controller 24, the operators of a system according to the present invention will be able to search the resulting file to find the identification indicia of castings which have any particular casting variable which might, for example, cause undesirable characteristics such as excessive porosity, structural weakness, or other defects.
While the invention has been shown and described in its preferred embodiments, it will be clear to those skilled in the arts to which it pertains that many changes and modifications may be made thereto without departing from the scope of the invention. For example, melt handler 32 may comprise either a simple ladle pouring system, or a more sophisticated mold filling system such as those currently employed for aluminum casting and having electromagnetically driven molten metal pumps. Yet other changes may occur to those skilled in the art in view of this disclosure. For example, inkjet printer 22 may be replaced by a read-write memory chip, or by a magnetic or visual bar code device or other type of device suggested by this disclosure.
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A method and system for identifying casting includes writers for applying unique identification indicia to the inside and outside of a molding core package. The identification indicia and at least one operating parameter associated with the molding process, such as day, time, melt temperature, melt composition, or other operating variables are tracked and recorded by a molding controller such that castings having a particular characteristic may be identified after the molding process has been completed.
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BACKGROUND OF THE INVENTION
This invention relates in general to transport apparatus for transferring discrete objects from one location to another with a high degree of accuracy. More specifically, it relates to a high speed, vacuum pick and place mechanism suitable for shuttling a succession of integrated circuits (IC's) to a well-defined position in a test plane offset from a main device flow path.
In the manufacture of IC's and the like it is important to test each circuit reliably and at a high throughput rate. Typically modern IC testers operate at rates in excess of 5,000 IC's per hour with each IC being tested in an interval of approximately 100 milliseconds. The IC's are generally stored and move in an end-to-end linear array.
These devices must move the IC's from this columnar array, one at a time, to a test site where they can be momentarily placed into electrical connection with a test circuit through a contactor assembly which acts as an electrical interface. The alignment problems are critical since the quality of the test depends on each lead making a good electrical connection with a single associated contact of the contactor assembly. In the testing of IC devices having a surface mount configuration (typically a square plastic body with leads on four sides and termed herein "SMD"), the handling problems have been accentuated by the presence of soft, readily-deformed leads on all four sides of a device (as opposed to earlier dual-in-line (DIP) packaged IC's with only two parallel rows of leads). It is also essential to a successful test handler that the operation of this transport be reliable, exhibit good wear characteristics, and accommodate IC's of different dimensions and configurations.
Conventional SMD IC testers typically allow the IC to drop under the influence of gravity to a test site level. The device is then advanced by one or more plungers to a test plane where the IC connects to a contactor assembly. Final positioning of the device is accomplished by camming the device using tapered side walls.
With this arrangement the camming surfaces apply side forces to the device which for at least some products, e.g. PCC packaged devices, can cause the bending of leads. Side wall camming can also result in a transfer of conductive material from the leads to the cam surfaces which in turn can develop into leakage paths that degrade the testing. Another problem with a "closed" system established by the tapered side walls is that the side walls and the devices must meet close dimensional tolerances to produce the desired steering of the device while avoiding lead damage or a jamming of the device. Stated in other words, this approach is not tolerant of variations in the dimensions of the product. This system is also intolerant of error in positioning the device at the test site. An incorrectly positioned device can damage the device or the machine when it is driven by the plunger or plungers.
Horizontal pick and place systems are known, principally in Japan, for testing quad surface mount IC's. These test devices use a convention pick and place system where a picker raises a device, moves it horizontally to a position over a test site, lowers it, and then returns to pick up another device. In end result the device moves in a horizontal plane. At the test site four separately actuated mechanisms then clamp the leads to contacts. Another mechanism then removes the device from the test site after it is tested. This arrangement is comparatively mechanically complex, relatively slow, and it is not readily adapted to a variety of package configurations and dimensions.
It is therefore a principal object of this invention to provide a mechanism for reliably and rapidly transporting a succession of IC's, particularly SMD IC's, that provides a reliable alignment with a contractor and which substantially eliminates physical contact with the leads which could deform them.
Another principal object is to provide a transport mechanism with the foregoing advantages that readily accommodates IC's of varying dimensions and configurations.
A further object is to provide a transport mechanism with the foregoing advantages which does not require critical tolerances on steering surfaces and which is substantially less prone to jamming of the devices than prior art mechanisms.
Another object is to provide a transport mechanism which both shuttles devices to a test site and places them in electrical connection with a test circuit without additional clamping mechanisms.
A still further object is to provide a transport mechanism with the foregoing advantages which does not create current leakage paths near the test area through the transfer of conductive material from the leads to guide surfaces.
SUMMARY OF THE INVENTION
A mechanism for reliably transporting IC devices: first, along a product flow path from a staging area to a test site; second, from the test site to a test plane offset from the flow path; and third, returning them to the flow path at the test site for further movement, preferably under the influence of gravity. In a preferred form the mechanism is built around a guide plate which mounts a slide reciprocally movable between a pick position at the staging area and a place position at the test site. The slide, in turn, pivotally mounts a vacuum pick that has a free end adapted to grip the lead IC in a linear array.
The pick is balanced so that it pivots under the weight of a gripped IC to place the IC in the flow path. The guide also plate mounts a pair of lateral guide rails which are preferably mutually inclined so that, in combination with a light vacuum grip by the picker, the IC being transported is self-centering during transport to the test site without physical contact with the leads. The IC engaging surfaces of the lateral guides are also preferably tapered to accept IC's of varying dimensions and facilitate the proper orientation of the IC during its movement to the test site. Spring loaded stops locate and orient the IC when the slide is in its pick and place positions. The pick and slide also preferably carry an elevator stop that assists the pick in supporting the IC during its movement to the test site.
A linear actuator supports a multi-port vacuum manifold which grips the IC being tested securely when it is positioned at the test site. The actuator drives the IC to a test plane along a direction generally perpendicular to the flow path. The shuttle mechanism carrying the IC is spaced fully from the sides of the perimeter of the IC at the test site so that nothing constrains the movement of the IC to the test plane, such as the steering surfaces of prior art devices. The alignment of the IC being tested is set by the upper stop, the lateral guide rails, the guide plate, the action of the articulated pick, and then the lower stop. The vacuum manifold is sufficiently strong to maintain the alignment of the IC during its transport to the contactor. The vertical position of the IC under test is readily adjusted to accommodate different size IC's by adjusting the position of the lower stop. The linear actuator preferably includes annular springs to absorb the shock of the impact as the actuator reaches its limit position which is adjustable by nuts threaded on the actuator frame. A coil spring or the like returns the actuator rod, the vacuum manifold and the tested IC to the product flow path. On the return the IC strikes the guide plate to strip it from the manifold. The gravitational forces overcome the vacuum grip as the device is stabilized on the rails so that it falls in a stable orientation.
The staging area has a cover spaced from the guide rails a distance determined by the thickness of the IC being tested. The upper stop is preferably a spring clip mounted on a spring plate where the clip extends into the product flow path a sufficient distance to engage the body of the IC under test, not its leads. An adjustment screw varies the rail-to-cover spacing for IC's of different thicknesses. The upper stop is positioned so that the IC leads will not impact on the upper stop.
These and other features and objects of the invention will be more fully understood from the detailed description which should be read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in vertical section of a transport mechanism accordint to the present invention.
FIG. 2 is a perspective view of the transport mechanism shown in FIG. 1.
FIGS. 3A-3E are simplified views of the mechanisms for controlling the movement of an IC under control of the transport mechanism shown in FIGS. 1 and 2 through a progressive movement of the device from a staying area, through testing, to discharge back into a main product flow path.
FIG. 4 is a perspective view of an automated, high speed test handler according to the present invention; and
FIG. 5 is a perspective view of an SMD IC which is transported and tested by the apparatus shown in FIGS. 1-4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 4 shows a high speed test handler 10 for integrated circuits (IC'of the type sold by Daymarc Corporation as its Model 757. It can test IC's of the dual-in-line (DIP) or surface mount (SMD) configuration (FIG. 5). A flow of IC's in end-to-end linear array are directed from a storage and heat chamber 10a, along a product flow path 12, to a test site 10b. After testing, the IC's are directed to one of several bins 10c depending on the results of the test. A test circuit 14 is connected electrically to the contactor, and through the contactor to an IC device under test (DUT) which is located at the test site and then placed into a position where its leads are each in electrical connection with one contact of the contactor assembly.
FIGS. 1-3E show an IC transport mechanism 16 according to the present invention which receives a succession of IC's, particularly SMD IC's from a track section 18 which directs the devices from the chamber 10a toward the transport mechanism 16. In general, the IC's are stacked in line in the track 18 with a first IC (hereinafter the "IC" or "DUT") held on an upper stop 20 at a staging area 22. The DUT is carried by a vacuum pick 24 and an elevator stop 35 from the staging area to the test site 10b where a placer sub-assembly 26, also termed a probe drive, grips the DUT with a multi-port vacuum manifold 28 secured to one end of a linear actuator, as shown, an air bellows 26a which drives a multi-section shaft 26b and the manifold 28 against the action of a return coil spring 26c. These elements are supported by a frame 26d. The actuator drives the gripped DUT from the flow path 12 to a test plane 30 where the leads make electrical connection with associated contacts of a contactor assembly 29 shown schematically.
The transport mechanism is organized on a guide plate 32 having a central recess that receives and guides a generally H-shaped slide 34 which carries a highly wear resistant cam surfaces 34a and 34b at the upper and lower ends of the slide, respectively. The slide is mounted for a vertical reciprocating motion. A drive 36 for the slide includes a rotating wheel 36a with an eccentric coupling to a lever arm 36b whose free end is replaceably coupled to a mating recess 34c of the slide. Rotation of the disc 36a by a conventional electric motor or the like causes the lever arm, and hence the slide, to move in a vertical reciprocating motion.
The pick 24 is pivotally mounted on the slide 34 in a mount assembly 34d which also connects the pick to a port 34e that connects to a suitable, conventional vacuum source. The pick is positioned so that when the slide is in is upper or "pick" limit position, the free end 24a of the pick is positioned to couple and grip the top surface of the lead IC held on the stop 20. The articulation of the pick allows it to rotate under the influence of the vacuum to move to the gripping position without the maintenance of tight dimensional tolerances on clearances. At the same time, the "elevator" stop 35 also secured on the assembly 34 has a free end positioned to support and stabilize the IC after it bears most of the weight of the IC. The portion of the stop which projects into the product flow path is narrow so that it passes freely between the spaced apart free ends of a lower stop 38 when they are positioned in the flow path. In the lower or "place" limit position, the DUT engages and is located and oriented on the lower stop 38. Preferably the DUT body, not its leads, engage the stop 38 before the slide reaches its extreme limit position so that the pick, which is lightly coupled to the DUT, continues to urge the DUT onto the stop 38 to ensure the DUT is properly aligned with respect to the contact or assembly. The pick remains in a vacuum grip with the DUT, while the placer mechanism 26 and the vacuum manifold 28 also establish a grip to ensure a continuous positive control over the position of the DUT at the test site. The weight of the DUT coupled to the pick rotates the pick counterclockwise, as shown, to place the body of the DUT, not its leads, into contact with the beveled, outwardly facing surfaces 40a, 40a of a pair of lateral guide rails, 40, 40 mounted on the guide plate 32. The guide rails are also preferably mutually inclined to narrow slightly in a downward direction, as shown, towards the test site. As a result, as the pick moves toward the test site carrying the DUT, the guide rails, in cooperation with a light, single point grip of the pick on the DUT, allows the DUT to automatically center itself laterally.
A cover plate 42 is spaced from the rails 40, 40 at the staging area by the thickness of the IC's being processed. An adjustment screw 44 acts against the plate 42 to vary the rail to cover spacing to accommodate IC's of different thicknesses. A spring plate 41 is mounted on gibs secured to the guide plate with the upper stop 20 mounted at its free end. The spring plate is positioned with respect to the slide so that the cam surfaces 34a of of the slide 34 engage and displace the free end. This moves the stop out of the flow path so that the lead IC can move downwardly onto the elevator stop and under control of the pick 24 and the slide.
Similarly the lower stop 38 is formed as an angled end portion of a spring plate 46 secured at its lower end to the guide plate 32 by screws 47 received in elongated openings 46a in the plate to provide a vertical adjustment of the stop. In its relaxed state, the stop 38 is clear of the flow path 12. When the slide is in its lower limit position, the cam surfaces 34b drive the upper free end of the spring plate to a position where the stop is interposed in the flow path to receive the DUT. As noted above, the stop is formed with two spaced apart DUT-engaging portions to allow the elevator stop to pass through the clearance and to provide a more stable support for the DUT. When the slide 34 and the pick 24 move back toward the upper pick position to transport the next IC, the stop moves out of the flow path under the spring force of the plate 46.
The placer mechanism in its preferred form utilizes multiple vacuum ports, four as shown, distributed generally symmetrically with respect to the DUT top surface and generating a sufficient vacuum grip on the DUT to secure its spatial location through the movement to the test plane and the connection to the contactor assembly. The application of the vacuum grip to the DUT is coordinated with the movement of the pick 24 and the slide 34 so that the DUT is gripped by the manifold once it is reliably seated, and thereby located on the stop 38. The pick continues to grip the DUT to provide a continuity of gripping control. The path of movement of the manifold, is generally perpendicular to the direction of the movement of the DUT along the flow path under control of the pick. The placer mechanism also includes stiff annular springs 26e which absorb the shock generated by the actuator as it reaches its extreme travel limit coincident with the DUT being positioned at the test plane in electrical connection with the contactor assembly. A pair of nuts 26f threaded on a portion of the shaft 26b adjustably set the amount of travel of the placer mechanism.
It is significant that the transport mechanism 16 is constructed so that there is a clear perimeter around a DUT when it is at the test site and ready for movement to the test plane. This avoids lead contact with fixed surfaces which could distort them or otherwise degrade the test results. During vertical movement, the picker grips the DUT from its top surface with the leads projecting toward the test plane; guiding contact is made only at the surfaces 40a, 40a of guide rails 40, 40, acting on top edges of the body of the DUT, opposite the leads. Except for the cover 42, and a lower cover 48 below the test site, the device is therefore gripped and guided only from one side, leaving the leads totally unobstructed in the direction of the test plane.
In operation the IC in the track section 18 rests on stop 20 until it is cammed away by cam surface 34a to release the IC causing it to fall under the influence of gravity onto the elevator stop 35 with the vacuum pick lightly attached to its upper face opposite the leads. The pick then moves downwardly causing the stop 20 to re-enter the product flow path 12 to hold the next IC at the staging area. The stop elevator and pick carry the IC downwardly until it comes into contact with the lower stop 38. Continued downward movement of the pick and stop 35 ensure that the IC is aligned and located on the lower stop. The vertical position and the orientation of the IC at the test site are therefore set principally by the lower stop. The pick interacting with the beveled surfaces 40a of the mutually inclined guide rails 40 position the IC at the test site laterally. The placer mechanism 26 then grips the IC tightly and carries it in a lateral direction to a test plane where it is placed in electrical connection with the contactor assembly. There is no physical contact between the IC device or its leads with a steering surface during this lateral movement. After the test is completed, the placer mechanism returns to its initial position under the influence of the spring 26d. During this return movement, the device strikes the guide plate and is stripped from the vacuum manifold. It has been found that this stripping arrangement, whether due to the continued, albeit diminished, influence of the vacuum grip immediately after the stripping begins, stabilizes the IC on the rails so that it falls in a controlled manner down the flow path 12 after it is stripped.
There has been described a transport mechanism for discrete objects, particularly SMD IC's, which rapidly and reliably carried the IC's from a staging area to a test site and then a test plane without a mechanical steering or guiding of the leads, but with a very accurate control over the physical location of the IC, particularly at the test site and during the movement to the test plane. These advantages are also provided with a transport mechanism that readily adjusts to IC's of varying size or configuration. Other than the transport mechanism itself, no other activators are necessary to clamp or otherwise connect the leads to contacts at the test plane. The transport mechanism described above is also highly resistant to jamming of IC's in the mechanism which can damage the IC or the mechanism.
While this invention has been described with respect to its preferred embodiments, it will be understood that various alterations and modifications will occur to those skilled in the art from the foregoing detailed description and the drawings. For example, the picker could have multiple ports or a non-pivoting mounting, the placer mechanism could have any of a variety of drives, and the escapement mechanism provided by the stops and cams could be accomplished by a variety of other mechanical or electro-mechanical techniques. Also, while the invention has been described with respect to a vertical picking movement under control of the pick 24 in cooperation with the guide rails and stops, it will be understood that the invention is not limited to a vertical movement and could include, for example, movement along an inclined, or even a horizontal, direction. These and other variations and modifications are intended to fall under the scope of the accompanying claims.
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In an automated high speed test handler for integrated circuits (IC's) an articulated vacuum picker reciprocates to transfer IC's successively from a staging area to a test site. Movable stops position and locate the IC at a test site. A sliding plate mounts the picker and carries cam surfaces to control the stops. A reciprocating placer mechanism carrying a multi-port vacuum manifold carries an IC being tested from the test site to a test plane displaced laterally from the flow path of the device. The picker is balanced to rotate under the weight of the IC being carried against mutually inclined lateral guide rails so that the mechanism is self-centering. These guide and locating mechanisms accurately position the IC so that there is no need for a physical steering of the IC's as they approach the test plane or a separately actuated clamping of the device in the test plane. After testing, the device is stripped from the vacuum manifold as the device encounters a guide plate on the return stroke of the placer mechanism.
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FIELD OF THE INVENTION
This invention relates to a tool commonly used in construction and/or demolition, generically referred to as a pry bar, and more particularly it relates to an assembly of components that can be interchangeably assembled to customize the tool to a variety of tasks.
BACKGROUND OF INVENTION
A pry bar in accordance with the present invention includes a bar end portion, a fulcrum portion and a handle portion. The bar end portion typically (but not necessarily) has a flat leading edge that can be inserted under a member secured to a support, e.g. a to-be-removed floorboard fastened to an under-flooring. A heel or fulcrum portion is located rearward of the leading edge and a handle portion extends rearwardly and upwardly from the heel or fulcrum portion. The tool user forces the flat leading edge under, e.g. the floorboard and forces pivotal movement of the handle about the fulcrum to raise the leading edge. Typically, a first pry motion as described produces partial raising of the board edge to permit the user to further insert the leading edge and further raise the board. A user becomes proficient in the procedure and with a couple of repeats (insert and pry) will accomplish the task of detaching the board from the under-flooring.
The above explanation is one of many tasks suitable for the pry bar and the tasks range from a delicate removal task to a task demanding substantial brute force. To accommodate these tasks in the past, either the user carried a number of pry bars or made due with a pry bar of mid-range size.
BRIEF DESCRIPTIONS OF THE INVENTION
It is an objective of the present invention to provide an assembly of tool components that can be discriminately assembled together to selectively construct any of a variety of different pry bars to accommodate a variety of pry bar tasks.
In a preferred embodiment, the three individual components are the handle, the fulcrum and the bar end. The fulcrum may be a single item of, e.g. a half-moon configuration. The rounded bottom provides the abutment surface and the flat top is configured to receive a bar end. The bar end has a flat, straight body portion that engages a substantial length of the flat top and is secured to the flat top with multiple screws seated in threaded holes in the flat surface. The bar end protrudes beyond one end of the fulcrum with the protruded end shaped to provide e.g. a tapered/flared end tip for insertion under a member to be pried. In an alternate embodiment the threaded holes are extended along the flat top and the bar end can be adjusted to protrude different lengths beyond the end of the fulcrum.
At the end of the fulcrum opposite the bar end, an enlarged threaded opening is provided, the axis of which is angled relative to the flat top. The enlarged threaded opening removably receives e.g. a cylindrical handle. Further, as may be desired, the fulcrum may be provided with a flat rear end provided below the handle to enable the user to assist the initial insertion step by applying a hammering force. In this latter event, the structure of the fulcrum may require a stronger material.
As assembled, the three components make up a pry bar configuration that is designed with a wider range of prying motions and amplified prying forces due at least in part to the strategic size and location of the fulcrum. Where added leverage is desired, the handle can be replaced with a longer handle. Where a different bar end tip is desired, the bar end can be replaced with a substitute bar end of desired end tip configuration.
With e.g. three handle lengths and e.g. four or more bar end types, a great latitude in pry bar tasks can be accommodated. Still further, the use can be expanded with different sizes of fulcrums to enable the configuration of even a greater variety of pry bar configurations.
The invention will be more fully appreciated upon reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates in perspective a pry bar assembly in accordance with the invention;
FIG. 2 is a side view of the pry bar of FIG. 1 , partially in section, and shown in use for prying e.g. a board from a sub-flooring;
FIG. 2A illustrates a modification that enables hammering of the fulcrum;
FIG. 3 illustrates the tool of FIG. 2 in an alternate state of assembly;
FIG. 4 shows a variety of handles for use with the tool of FIGS. 1–3 ;
FIGS. 5 and 6 are top views of the tools as shown in FIGS. 2 and 3 ; and
FIGS. 7–9 illustrate different bar ends for the tools of FIGS. 1–3 .
DETAILED DESCRIPTION
FIGS. 1 and 2 illustrate a pry bar of the present invention which includes a fulcrum 10 , a bar end 12 and a handle 14 . As illustrated in FIG. 2 , the pry bar is being used to pry loose a board 16 secured as by nailing, gluing, etc. to a sub-flooring 18 . As is typical for such use, the tool user first places the sharpened end tip 20 of the bar end 12 at the juncture between board 16 and sub-flooring 18 . The tool is initially shoved under the edge of the board (arrow 22 ) as permitted by the tightness of the board to the sub-flooring. The handle is then forced down (arrow 24 ) which typically pries the board edge up enough to insert the bar further under the board (again, arrow 22 ) followed by substantial raising and loosening of the board 16 from the sub-flooring. It will be noted that the projected tip of the bar end is angled relative to the main body portion to present a flat orientation of the tip for this insertion procedure.
The above is an example only of but one type of use for the tool/pry bar. The tool is usable in many different ways and many different orientations. For example, it may be used to strip ceiling tiles from overhead, pry up heavy beams to permit a fork lift to slide under, or roll a large cylinder out of the way. The uses of such a pry bar are endless and the criteria is that the bar end, fulcrum and handle are arranged to enable the bar end tip to fit under the object to be pried, the fulcrum contact point positioned sufficiently close and in contact with a support, the bar end configured so as to enable the bar end tip to slide under the object, and with the handle sufficiently extended from the fulcrum to allow the user to apply a desired force to enable the user's leveraged force (arrow 24 ) to achieve raising of the object. Hereafter, such uses of such a pry bar is referred to as pry bar tasks.
As generally explained above, there are substantial variables depending on the use to be made of the tool. For “lighter” tasks, a lighter, more compact pry bar utilizing the shorter handle will be desired. For heavier tasks, a pry bar having a longer handle which provides greater leverage will be desired. When working overhead or prying off of the floor, i.e. removing tiles, a longer reach and thus longer handle may be desired, etc.
To accommodate these task variables, the present invention enables conversion from a short handle to a longer handle and/or conversion from a narrow bar end tip to a wider bar end tip and/or conversion to a different bar end type. Still further, the bar end can be shifted relative to the fulcrum, thus enabling deeper penetration under the object to be pryed.
FIGS. 2–9 illustrate a conversion process of a preferred embodiment of the invention. As shown in FIGS. 2 and 3 , the fulcrum component 10 has a curved bottom 26 that serves as the pivotal or engagement surface of the tool (see FIG. 2 where engagement with sub-flooring 18 is indicated). A rear end 28 has a threaded opening 30 for receiving a tubular handle 14 . The upper side of the fulcrum has a notch 32 that is configured to receive various ones of the bar ends 12 , 12 ′, 12 ″, 12 ′″ (see FIGS. 7–9 ).
It will be noted from FIG. 2 that the notch configuration allows a lesser thickness underlying the bar end 12 while providing a greater wall thickness surrounding the opening 30 . This accommodates the desire for lesser weight but without sacrificing strength where desired, e.g., surrounding the threaded opening 30 . With reference to the bar ends 12 , 12 ′, etc. of FIGS. 5–9 , they are provided with openings 34 that match up with the threaded holes 36 in the fulcrum 10 . As will be observed with reference to FIGS. 2 , 3 , 5 and 6 there may be more threaded holes 36 than the number of openings 34 provided in the bar end 12 , i.e. four holding screws 38 may be adequate for holding the bar end 12 but the greater number of threaded holes 36 allows the same bar end to be shifted outwardly as indicated in FIG. 3 , i.e. the openings 34 are matched up with the outer-most threaded openings 36 .
Whereas with all hand tools weight is a consideration, it is preferred that the fulcrum 10 be composed of a strong but light-weight metal e.g. aluminum, with further lightening of the weight provided by the openings 40 . Should the tool be intended for hammering, i.e., striking a flat surface 44 in the alternate fulcrum structure 10 ′ of FIG. 2A , it may be desired to thicken the web sections or make the fulcrum from a stronger material.
Many advantages are provided by a tool assembly as illustrated. A composite of handle, fulcrum and bar end is lighter than traditional pry bars and therefore easier to handle. It is more versatile in the tasks it can perform i.e. with rapid re-assembly options, and can adapt to many different uses. Among them is the ability to use a short handled pry bar when desirable and quickly connect to a longer handle when a longer reach for greater leverage is desirable.
The half moon shaped fulcrum provides a greater range of motion of the handle (arrow 24 ) which conveys a greater movement to the bar end 20 (compare FIGS. 2 and 3 .) The ability to swap out or move the bar end on the fulcrum enables the pry bar to be set up for close in, more rapid removal tasks e.g. for the lighter tasks, but also enabling a set up for greater applied force for the heavier tasks. The simplicity of the assembly and re-assembly enables the user to accommodate multiple tasks with greater efficiency.
The pry bar, when fully assembled with a smaller handle, can fit into the same tool loops as designed for hammers and the like. The tool is easier to maneuver when standing on a ladder and because the handles are rapidly interchangeable, a user can adapt a tool to accommodate many different situations, e.g. to avoid having to stoop over when one can stand with a longer handle, or use a shorter handle to fit into tight spaces, etc.
In general, the pry bar tool can be easily and quickly replaced with a different pry bar end/or handle, creating a multi-usable tool for such varied work tasks as removal of cement, roof tiles, linoleum, plywood, beams, etc. Again, the variables are endless. For example note the provision of the crevice 42 on the bar ends 12 for pulling nails, staples, etc.
Whereas the above explanation illustrates a number of variables, many additional variables will become apparent to those skilled in the art. Accordingly, the claims are intended to encompass all such variables and the terms used are to be given their common understanding and meaning.
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A pry bar tool having independent components, including a fulcrum, multiple and different handles, and multiple bar ends, said handles and bar ends selectively and releasably attachable to the fulcrum to accommodate different pry bar tasks.
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[0001] This application is a continuation of U.S. patent application Ser. No. 13/620,221, filed Sep. 14, 2012, now U.S. Pat. No. 9,060,037, which is a continuation of U.S. patent application Ser. No. 12/210,701, filed Sep. 15, 2008, now U.S. Pat. No. 8,305,890, all of which are herein incorporated by reference in their entirety.
[0002] The present invention relates generally to communication networks and, more particularly, to a method and apparatus for prioritizing signaling messages in communication networks, e.g., packet networks such as Voice over Internet Protocol (VoIP) networks.
BACKGROUND OF THE INVENTION
[0003] In a well engineered network, signaling servers will not be overloaded under the normal operation mode. However, overload will occur if there are failures in the network or if there are significant increases in traffic load beyond the engineered loads. This can be the results of a disaster or mass calling due to a popular event such as reality TV shows, etc. In the former scenario, if the failures affect some signaling servers, the surviving servers will have to handle extra calls attempts. In the latter scenario, call attempts are generated so that call volumes are significantly higher than under normal operating mode.
SUMMARY OF THE INVENTION
[0004] In one embodiment, the present invention enables prioritization of signaling messages in a communication network. For example, the method receives at least one signaling message, and classifies each of the at least one signaling message. The method schedules each of the at least one signaling message for processing, and discards selectively one or more signaling messages that have been scheduled under an overload condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The teaching of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0006] FIG. 1 illustrates an exemplary Voice over Internet Protocol (VoIP) network related to the present invention;
[0007] FIG. 2 illustrates an example signaling flow for a call setup using SIP signaling messages in a VoIP network of the present invention;
[0008] FIG. 3 illustrates an example two tier with three classes classification structure in a VoIP network of the present invention;
[0009] FIG. 4 illustrates a flowchart of a method for creating a call signaling message by a User Agent Client (UAC) in a packet network, e.g., a VoIP network, of the present invention;
[0010] FIG. 5 (shown as FIG. 5A and FIG. 5B ) illustrates a flowchart of a method for processing the arrival of a signaling message at a User Agent Server (UAS) in a packet network, e.g., a VoIP network, of the present invention;
[0011] FIG. 6 illustrates a flowchart of a method for serving signaling messages in signaling message queues at a User Agent Server (UAS) in a packet network, e.g., a VoIP network, of the present invention;
[0012] FIG. 7 illustrates an example message scheduler in a VoIP network of the present invention;
[0013] FIG. 8 illustrates a flowchart of a method for discarding signaling message from a non-provisional queue using head of queue drop trigger in a packet network, e.g., a VoIP network, of the present invention;
[0014] FIG. 9 illustrates a flowchart of a method for resetting the dropping counter parameter in a packet network, e.g., a VoIP network, of the present invention;
[0015] FIG. 10 illustrates a high level block diagram of a general purpose computer suitable for use in performing the functions described herein; and
[0016] FIG. 11 illustrates a flowchart of a method for discarding signaling message from a non-provisional queue using time expiration in a packet network, e.g., a VoIP network, of the present invention.
[0017] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
[0018] To better understand the present invention, FIG. 1 illustrates a communication architecture 100 having an example network, e.g., a packet network such as a VoIP network related to the present invention. Exemplary packet networks include internet protocol (IP) networks, asynchronous transfer mode (ATM) networks, frame-relay networks, and the like. An IP network is broadly defined as a network that uses Internet Protocol to exchange data packets. Thus, a VoIP network, a SoIP (Service over Internet Protocol) network, or an IMS (IP Multimedia Subsystem) network is built on an IP network.
[0019] In one embodiment, the VoIP network may comprise various types of customer endpoint devices connected via various types of access networks to a carrier (e.g., a service provider) VoIP core infrastructure over an Internet Protocol/Multi-Protocol Label Switching (IP/MPLS) based core backbone network. Broadly defined, a VoIP network is a network that is capable of carrying voice signals as packetized data over an IP network. The present invention is described below in the context of an illustrative VoIP network. However, the present invention should not be interpreted to be limited by this particular illustrative architecture.
[0020] The customer endpoint devices can be either Time Division Multiplexing (TDM) based or IP based. TDM based customer endpoint devices 122 , 123 , 134 , and 135 typically comprise of TDM phones or Private Branch Exchange (PBX). IP based customer endpoint devices 144 and 145 typically comprise IP phones or IP PBX. The Terminal Adaptors (TA)/VoIP Gateway (Gateway) 132 and 133 are used to provide necessary interworking functions between TDM customer endpoint devices, such as analog phones, and packet based access network technologies, such as Digital Subscriber Loop (DSL) or Cable broadband access networks. TDM based customer endpoint devices access VoIP services by using either a Public Switched Telephone Network (PSTN) 120 , 121 or a broadband access network via a TA/Gateway 132 or 133 . IP based customer endpoint devices access VoIP services by using a Local Area Network (LAN) 140 and 141 with a router 142 and 143 , respectively.
[0021] The access networks can be either TDM or packet based. A TDM PSTN 120 or 121 is used to support TDM customer endpoint devices connected via traditional phone lines. A packet based access network, such as Frame Relay, ATM, Ethernet or IP, is used to support IP based customer endpoint devices via a customer LAN, e.g., 140 with a router 142 . A packet based access network 130 or 131 , such as DSL or Cable, when used together with a TA/Gateway 132 or 133 , is used to support TDM based customer endpoint devices.
[0022] The core VoIP infrastructure comprises several VoIP components, such as the Border Element (BE) 112 and 113 , the Call Control Element (CCE) 111 , VoIP related Application Servers (AS) 114 , and Media Server (MS) 115 . The BE resides at the edge of the VoIP core infrastructure and interfaces with customers endpoints over various types of access networks. A BE is typically implemented as a Media Gateway or a Session Border Controller and performs signaling, media control, security, and call admission control and related functions. The CCE resides within the VoIP infrastructure and is connected to the BEs using the Session Initiation Protocol (SIP) over the underlying IP/MPLS based core backbone network 110 . The CCE is typically implemented as a Media Gateway Controller, a softswitch, or a Call Session Control Function in an IMS network and performs network wide call control related functions as well as interacts with the appropriate VoIP service related servers when necessary. The CCE functions is a signaling endpoint for all call legs between all BEs and the CCE. The CCE may need to interact with various VoIP related Application Servers (AS) in order to complete a call that require certain service specific features, e.g. call waiting, call forwarding, voice mail, etc.
[0023] Calls that originate or terminate in a different carrier can be handled through the PSTN 120 and 121 or the Partner IP Carrier 160 interconnections. Originating or terminating TDM calls can be handled via existing PSTN interconnections to the other carrier. Originating or terminating VoIP calls can be handled via the Partner IP carrier interface 160 to the other carrier.
[0024] In order to illustrate how the different components operate to support a VoIP call, the following call scenario is used to illustrate how a VoIP call is setup between two customer endpoints. A customer using IP device 144 at location A places a call to another customer at location Z using TDM device 135 . During the call setup, a setup signaling message is sent from IP device 144 , through the LAN 140 , the Router 142 , and the associated packet based access network, to BE 112 . BE 112 will then send a setup signaling message, such as a SIP-INVITE message if SIP is used, to CCE 111 . CCE 111 processes the called party information and queries the necessary VoIP service related application server 114 to obtain the information to complete this call. In one embodiment, the Application Server (AS) functions as a SIP back-to-back user agent. If BE 113 needs to be involved in completing the call, then the CCE 111 sends another call setup message, such as a SIP-INVITE message if SIP is used, to BE 113 . Upon receiving the call setup message, BE 113 forwards the call setup message, via broadband network 131 , to TA/Gateway 133 . TA/Gateway 133 then identifies the appropriate TDM device 135 and rings that device.
[0025] Once the call is accepted at location Z by the called party, a call acknowledgement signaling message, such as a SIP 200 OK response message if SIP is used, is sent in the reverse direction back to the CCE 111 . After the CCE 111 receives the call acknowledgement message, it will then send a call acknowledgement signaling message, such as a SIP 200 OK response message if SIP is used, towards the calling party. In addition, the CCE 111 also provides the necessary information of the call to both BE 112 and BE 113 so that the media exchange can proceed directly between BE 112 and BE 113 . The call signaling path 150 and the call media path 151 are illustratively shown in FIG. 1 . Note that the call signaling path and the call media path are different because once a call has been setup up between two endpoints, the CCE 111 does not need to be in the media path for actual direct media exchange.
[0026] Note that a customer in location A using any endpoint device type with its associated access network type can communicate with another customer in location Z using any endpoint device type with its associated network type as well. For instance, a customer at location A using IP customer endpoint device 144 with packet based access network 140 can call another customer at location Z using TDM endpoint device 123 with PSTN access network 121 . The BEs 112 and 113 are responsible for the necessary signaling protocol translation, e.g., SS7 to and from SIP, and media format conversion, such as TDM voice format to and from IP based packet voice format.
[0027] Media Servers (MS) 115 are special servers that typically handle and terminate media streams, and to provide services such as announcements, teleconference bridges, transcoding, and Interactive Voice Response (IVR) messages for VoIP service applications.
[0028] VoIP services have proliferated in recent years due to rapid advance in technology and market demands. Service providers are aggressively looking for ways to offer VoIP to customers via various Quality of Service (QoS) mechanisms. However, the existing discussions on providing QoS to VoIP traffic primarily focus on the VoIP call media path such as how to ensuring voice quality after calls are accepted. Little has been done on providing QoS treatment for VoIP signaling messages, such as SIP signaling messages, especially at SIP servers that are involved in setting up VoIP calls. In one embodiment of the present invention, CCE 111 shown in FIG. 1 is a SIP server.
[0029] Providing QoS treatment for VoIP signaling messages at SIP servers is beneficial when SIP servers are overloaded. In a well engineered network, SIP servers will not be overloaded under the normal operation mode. However, overload will occur if there are failures in the network or if there are significant increases in traffic load beyond the engineered loads.
[0030] When SIP servers are overloaded, signaling messages will be dropped at the SIP servers. The dropped signaling messages may be signaling messages that need to be treated with higher priority. For example, calls from callers such as government emergency control agents that manage or assist in the rescue efforts in a disaster, should be handled with priority. To prevent signaling message dropping of important calls, QoS features have to be implemented at SIP servers so that important messages will always be processed even under overload conditions.
[0031] The present invention enables differential QoS treatments of various signaling messages at signaling servers. In one embodiment, the present invention employs three components: classification of signaling messages, scheduling of signaling messages for processing, and selective discarding of signaling messages under overload conditions, to support differential QoS treatments of signaling messages. Signaling message are first classified to different priority levels and then scheduled to be processed and, if necessary, when memory space runs out, discarded by a signaling server according to their classified priority levels.
[0032] FIG. 2 provides an example signaling flow 200 for a call setup using SIP signaling messages. In FIG. 2 , endpoint 210 initiates a call setup request towards endpoint 220 via a proxy 230 and a proxy 240 as shown. In this example, endpoint 210 and endpoint 220 are User Agent Clients (UAC) and proxy 230 and proxy 240 are User Agent Server (UAS) for SIP signaling purposes. User Agent Client (UAC) is a logical entity that creates a new SIP request and then sends it to the network. User Agent Server (UAS) is a logical entity that generates a response to a SIP request. The response accepts, rejects, or redirects the request.
[0033] For instance, SIP INVITE message F1 is generated and sent by endpoint 210 to proxy 230 . Upon receiving INVITE message F1, proxy 230 , acting as both a UAC and a UAS, generates and forwards an INVITE message F2 to proxy 240 . In addition, proxy 230 , acting both as a UAC and a UAS, also responds to INVITE message F1 by generating and sending the SIP 100 TRYING message F3 to endpoint 210 .
[0034] Upon receiving INVITE message F2, proxy 240 generates and forwards INVITE message F4 to endpoint 220 in response to INVITE message F2. In addition, proxy 240 also generates a SIP 100 TRYING message F5 to proxy 230 in response to INVITE message F2. The rest of the signaling message flows can be similarly interpreted. Note that once a call is setup between the two endpoints, the endpoints can then signal each other directly without going through the proxies. For instance, SIP ACK message F12, BYE message F13, and 200 OK message F14 are such directly exchanged signaling message between endpoint 210 and endpoint 220 . The media session flow represents the call media path and flow between endpoint 210 and endpoint 220 .
[0035] In one embodiment, the classification component of the present invention decides which message gets higher priority than others. For example, a two-tier classification approach is introduced. In the first tier, calls are categorized into two classes, a high priority class and a low priority class. The high priority class comprises signaling messages that are more important than those of low priority class. The criteria of such categorization can be flexibly configured by individual service providers. For instance, calls originated from government emergency agents (e.g., government employees (federal, state, city, county, etc.), medical personnel, utility employees, and so on) can be classified as the high priority class. In the second tier, signaling messages from the low priority class of calls are further classified into two classes based upon the nature of the messages. For instance, the SIP call INVITE and BYE messages can be configured to have higher priority than other SIP signaling messages, such as 1xx messages comprising provisional responses. Again, the actual classification criteria within the lower priority class can be flexibly configured by individual service providers. SIP messages of different classes will then be queued separately so that they can be served in a differential manner.
[0036] This illustrative two tier classification structure is based upon both the call type and the SIP signaling message type. Though one can define as many classes as it is needed, in one embodiment, a three class structure using this two tier classification is used:
Class 1: all SIP messages associated with high priority calls; Class 2: important SIP signaling messages from low priority calls, also know as non-provisional signaling messages; and Class 3: non-important SIP signaling messages from lower priority calls, also know as provisional messages.
[0040] Note that the number of high priority calls should be restricted to a small percentage of all call types. Therefore, the amount of signaling message traffic of high priority calls shall be engineered to never overload any signaling servers in a VoIP network.
[0041] FIG. 3 illustrates an example 300 of the two tier with three classes signaling message classification scheme in a VoIP network of the present invention. In FIG. 3 , all incoming signaling messages arrive first into queue 310 . Then these messages are parsed and pre-processed by module 320 . The IP header Differentiated Service Code Point (DSCP) field is used to determine the classes to which incoming signaling message belong. Once the classification is performed, signaling message are then queued into the appropriate classes, e.g., queue 330 for storing high priority messages, queue 340 for storing non-provisional messages, and queue 350 for storing provisional messages. Queued signaling messages in these queues are then processed by module 360 according to the present invention described herein.
[0042] Since SIP is an application layer protocol employing IP networks for transmissions, the actual SIP messages are encapsulated within IP packets while traversing through IP networks. When IP packets carrying SIP messages arrive at a SIP server, the SIP server needs to determine what type of SIP message is carried within an arriving IP packet first before placing it into a service queue. Thus, IP packet header needs to carry a SIP message identity. In one embodiment, the present invention uses an existing IP header field for classification purpose, such as the Differentiated Service Code Point (DSCP) field in the IP packet header. The DSCP field is an 8 bit field within the IP packet that can be used to prioritize the importance of the IP packet.
[0043] The marking for IP packets with encapsulated SIP messages is performed whenever a new SIP message is composed. For instance, when a call request arrives at a User Agent Client (UAC), a new SIP INVITE message is composed and created and the resulting IP packet is appropriately marked by the UAC. Note that some SIP messages are generated at SIP servers as responses to INVITE messages and their resulting IP packets will need to be marked accordingly before transmission as well.
[0044] Moreover, for any given call setup flow initiated at a SIP User Agent Client (UAC), there could be multiple SIP User Agent Servers (UAS) along the signaling path. Therefore, some SIP response messages will need to be forwarded by SIP servers that are not the origin of the SIP response messages. Queuing only occurs for those SIP messages that arrive at a SIP server and must wait for processing.
[0045] FIG. 4 illustrates a flowchart of a method 400 for processing a call request by a SIP User Agent Client (UAC) in VoIP network, of the present invention. Method 400 starts in step 405 and proceeds to step 410 .
[0046] In step 410 , the method receives a call request at the UAC. In step 420 , the method inspects the received call request to determine the classification of the call request. In one embodiment, the call request will be classified using the two tier and three class classification structure based on the customer type and the signaling message type. For example, the SIP INVITE signaling message for a call associated with a particular customer can be assigned to the high priority class.
[0047] In step 430 , a SIP INVITE signaling message is composed and created. In step 440 , the method encapsulates the composed SIP INVITE message within an IP packet. In step 450 , the method marks the IP packet with the appropriate classification determined in step 420 . In one embodiment, the IP packet is marked using the DSCP field in the IP packet header. The method ends in step 460 .
[0048] The scheduling of signaling message for processing component of the present invention places SIP messages arriving at a SIP server into different signaling message service queues. When IP packets with SIP messages arrive at a SIP server, the packet headers are inspected and the packets are then placed into different queues. The SIP server then processes those SIP messages according to the defined service scheduling algorithm. In one embodiment, the present invention uses a service scheduling algorithm that takes into consideration the time sensitive nature of SIP messages.
[0049] In one embodiment, the scheduling algorithm is a hybrid scheduling algorithm that combines strict priority scheduling and First In First Out (FIFO) scheduling. The strict priority scheduling means that a SIP server will process SIP messages from low priority call queues only when the high priority call queue is empty. For all other low priority call queues, the SIP server will serve the SIP message that has the longest waiting time regardless of which low priority queue that the SIP message is in. Essentially, the SIP messages in the low priority queues are being served in FIFO fashion.
[0050] To ensure the proper order of services between two low priority queues, a message scheduler, is used to track the order of arrivals. Whenever a new message arrives, it will be time stamped. A record is entered into the message scheduler indicating the type of the message and its associated arrival time.
[0051] The reason for queuing low priority SIP messages into separate queues is to allow intelligent selective discarding of signaling messages under overload conditions.
[0052] For example, during a national disaster such as hurricane Katrina, calls from all over the world would be directed to the disaster sites, the number of call attempts will be overwhelmingly high even five or ten times higher than the normal load. Thus, the SIP servers may become the bottleneck. The existing SIP servers on the market will treat all the call attempts in a FIFO fashion. Under normal conditions, in a well engineered network, SIP messages can be handled in a timely fashion using FIFO serving discipline. However, under the overload conditions, the processing rate of a SIP server will become lower than the SIP message arrival rate, and will be accumulated in queues at the SIP server. Unfortunately, the arriving SIP messages will be discarded upon arrival when the queues reach their full capacity.
[0053] The issue associated with the FIFO treatment of all messages at SIP server is that the dropped messages can be the ones that trigger retransmission of SIP messages from originating UAC. Consequently, more messages are created to flood the already overloaded SIP servers. In a typical SIP call setup flow, it is essentially a three-way handshake session of involving SIP INVITE, SIP 200, and SIP ACK messages and a media session is terminated by a two-way handshake involving SIP BYE and SIP 200 messages. All other messages are provisional ones that will not trigger retransmission of messages toward a SIP server.
[0054] By putting different messages into different queues, one has the advantage of deciding whether to discard a low priority message already sitting in a queue so as to be able to accept the newly arrived high priority message.
[0055] Moreover, due to the time sensitive nature of non-provisional messages, serving a non-provisional message that has been sitting in the queue for too long is a waste of resources. Particularly when the volume of requests to high priority queue is unusually high, waiting time for the messages in the non-provisional queue can be significantly long. One way to overcome this problem is to discard the message from the head of the queue whenever it is necessary. It is sufficient to apply the head of queue dropping to the non-provisional queue only.
[0056] In the present invention, two mechanisms can be used to determine when a message should be dropped from the head of queue. One approach is the time expiration message discarding method, and another approach is the head drop trigger message discarding method.
[0057] In the time expiration message discarding method, a user configurable parameter, such as an expiration time, is introduced. The value of expiration time is the maximum allowable time that a non-provisional message can remain in the non-provisional queue. Whenever a message has to be deleted from the non-provisional queue, the waiting time of the head of queue will be checked first. If the waiting time is larger than the expiration time, the message will be deleted from the head of the queue rather than from the tail of the queue. Otherwise, the message form the tail of the queue will be discarded.
[0058] A detailed flowchart of the processing of an arrived signaling message is also provided in FIG. 5 . FIG. 5 illustrates a flowchart of a method 500 for processing the arrival of a signaling message at a UAS in a VoIP network of the present invention. Method 500 starts in step 505 and proceeds to step 510 .
[0059] In step 510 , the method receives a SIP signaling message via an IP network. In step 515 , the method inspects the IP header of the IP packet that is received. For example, the priority of the SIP message is extracted using information embedded in the IP packet header.
[0060] In step 520 , the method checks if the SIP server memory is completely utilized. If the SIP server memory is completely utilized, the method proceeds to step 523 ; otherwise, the method proceeds to step 563 .
[0061] In step 523 , the method checks if the SIP message is a provisional signaling message. If the SIP message is a provisional signaling message, the method proceeds to step 555 ; otherwise, the method proceeds to step 525 .
[0062] In step 525 , the method checks if the provisional message queue is empty. If the provisional message queue is empty, the method proceeds to step 528 ; otherwise, the method proceeds to step 560 .
[0063] In step 528 , the method checks if the non-provisional message queue is empty. If the non-provisional message queue is empty, the method proceeds to step 555 ; otherwise, the method proceeds to step 532 .
[0064] In step 532 , the method checks the type of discard method to be used to drop signaling messages. If the time expiration discard method is used, the method proceeds to step 534 . If the head of queue drop trigger discard method is used, the method proceeds to step 536 .
[0065] In step 534 , the method executes the time expiration discard method (as further described below in method 1100 ). After the execution of step 534 , the method proceeds to step 555 if the received message is a non-provisional message and there is no time expired non-provisional message in the non-provisional message queue, or to step 570 if the received message is a non-provisional message and there is an expired message in the non-provisional message queue, or to step 580 if the received message is high priority message.
[0066] In step 536 , the method executes the head of queue drop trigger discard method described in method 800 . After the execution of step 536 , the method proceeds to step 570 if the received message is a non-provisional message or to step 580 if the received message is a high priority message.
[0067] In step 555 , the method discards the received signaling message. The method then proceeds to step 590 .
[0068] In step 560 , the method discards a message from the tail of the provisional message queue. The method then proceeds to step 563 .
[0069] In step 563 , the method checks if the received message is a high priority message. If the received message is a high priority message, the method proceeds to step 580 ; otherwise, the method proceeds to step 565 .
[0070] In step 565 , the method checks if the received message is a provisional message. If the received message is a provisional message, the method proceeds to step 575 ; otherwise, the method proceeds to step 570 .
[0071] In step 570 , the method places the received message into the provisional message queue. The method then proceeds to step 585 .
[0072] In step 575 , the method places the received message into the non-provisional message queue. The method then proceeds to step 585 .
[0073] In step 580 , the method places the received message into the high priority message queue. The method then proceeds to step 585 .
[0074] In step 585 , the method updates the message scheduler accordingly. The method then ends in step 590 .
[0075] FIG. 11 illustrates a flowchart of a method 1100 for discarding signaling message from a non-provisional queue using time expiration in a VoIP network, of the present invention. Method 1100 starts when step 534 in method 500 is reached and the method proceeds to step 1110 .
[0076] In step 1110 , the method checks if the received message is a high priority message. If the received message is a high priority message, the method proceeds to step 1120 ; otherwise, the method proceeds to step 1150 .
[0077] In step 1120 , the method checks if the head of queue message in the non-provisional message queue has exceeded the expiration timer threshold. If the head of queue message in the non-provisional message queue has exceeded the expiration timer threshold, the method proceeds to step 1130 ; otherwise, the method proceeds to step 1140 .
[0078] In step 1130 , the method discards the head of queue message from the non-provisional message queue. The method then proceeds to step 580 in method 500 .
[0079] In step 1140 , the method discards the tail of queue message from the non-provisional message queue. The method then proceeds to step 580 in method 500 .
[0080] In step 1150 , the method checks if the head of queue message in the non-provisional message queue has exceeded the expiration timer threshold. If the head of queue message in the non-provisional message queue has exceeded the expiration timer threshold, the method proceeds to step 1160 ; otherwise, the method proceeds to step 555 in method 500 .
[0081] In step 1160 , the method discards the head of queue message from the non-provisional message queue. The method then proceeds to step 570 in method 500 .
[0082] In the head drop trigger message discarding method, a user configurable parameter, such as a head of queue drop trigger, is introduced. Whenever a signaling message in the non-provisional queue is deleted due to high priority message arrivals, the server is spending more time on the high priority queue. It indicates that the messages in the non-provisional queue have to wait longer to be served. If a significant number of messages are deleted from the non-provisional queue since the last non-provisional message was served, there is a very high likelihood that the signaling message waiting at the head of the non-provisional queue is too old to be meaningful. Thus, if the number of deleted messages from non-provisional queue exceeds the user configured parameter of the head of queue drop trigger, the head of queue discard will be performed if a non-provisional message has to be dropped.
[0083] To implement the head drop trigger message discarding method, the concept of dropping zone is introduced. There are two dropping zones, the tail of queue dropping zone and the head of queue dropping zone. Furthermore, a dropping counter to keep track of number of consecutive tail of queue drops from the non-provisional queue is introduced. Consecutive dropping is defined to be the number of discard for non-provisional signaling messages since the last non-provisional message was served. When the dropping counter exceeds the head of queue drop trigger, the dropping zone is the head of queue dropping zone, otherwise it is the tail of queue dropping zone. If the dropping zone is in the tail of queue dropping zone, the dropping counter is reset to zero whenever a non-provisional message is served or scheduled. If it is in the head of queue dropping zone, the dropping counter is decremented by one whenever a head of queue discard occurs until it is zero.
[0084] FIG. 8 illustrates a flowchart of a method 800 for discarding a signaling message from a non-provisional queue using head of queue drop trigger in a VoIP network of the present invention. Method 800 starts when step 536 in method 500 is reached and the method proceeds to step 807 .
[0085] In step 807 , the method checks to verify if the method has previously been initialized already. If the method has previously been initialized already, the method proceeds to step 813 ; otherwise, the method proceeds to step 810 .
[0086] In step 810 , the method initializes the dropping counter parameter to 0 and the dropping zone to tail of queue dropping when an initial signaling message arrives. The dropping counter parameter keeps track of the number of consecutive tail of queue drops from the non-provisional queue. The dropping zone parameter can either be the tail of queue dropping zone or the head of queue dropping zone, indicating signaling message shall be discarded from the tail of queue or the head of queue, respectively.
[0087] In step 813 , the method determines if the received signaling message is a high priority message. If the received signaling message is a high priority message, the method proceeds to step 815 ; otherwise, the method proceeds to step 860 .
[0088] In step 815 , the method checks if the dropping zone parameter is set to the tail of queue dropping zone. If the dropping zone parameter is set to the tail of queue dropping zone, the method proceeds to step 820 ; otherwise, the method proceeds to step 840 .
[0089] In step 820 , the method increments the dropping counter parameter by 1.
[0090] In step 825 , the method checks if the dropping counter value exceeds the head of queue drop trigger parameter. Note that the head of queue drop trigger parameter is a user configurable parameter set by the user. If the dropping counter value exceeds the head of queue drop trigger parameter, the method proceeds to step 830 ; otherwise, the method proceeds to step 835 .
[0091] In step 830 , the method sets the dropping zone parameter to the head of queue dropping zone.
[0092] In step 835 , the method discards a non-provisional signaling message from the tail of the non-provisional queue. The method then proceeds to step 580 in method 500 .
[0093] In step 840 , the method decrements the dropping counter parameter by 1.
[0094] In step 845 , the method checks if the dropping counter parameter value is 0. If the dropping counter parameter value is 0, the method proceeds to step 850 ; otherwise, the method proceeds to step 855 .
[0095] In step 850 , the method sets the dropping zone parameter to the tail of queue dropping zone. In step 855 , the method discards a non-provisional signaling message from the head of the non-provisional queue. The method then proceeds to step 580 in method 500 .
[0096] In step 860 , the method discards a non-provisional signaling message from the tail of the non-provisional queue. The method then proceeds to step 570 in method 500 .
[0097] FIG. 9 illustrates a flowchart of a method 900 for resetting the dropping counter parameter in a VoIP network of the present invention. Method 900 starts in step 905 and proceeds to step 907 .
[0098] In step 907 , a signaling message is served by a signaling server. In step 910 , the method checks if the next signaling message to be processed is a message from the non-provisional queue. If the next signaling message to be processed is a message from the non-provisional queue, the method proceeds to step 920 ; otherwise, the method proceeds to step 940 .
[0099] In step 920 , the method checks if the dropping zone parameter is set to the tail of queue dropping zone. If the dropping zone parameter is set to the tail of queue dropping zone, the method proceeds to step 930 ; otherwise, the method proceeds to step 940 .
[0100] In step 930 , the method resets the dropping counter parameter to a value of 0. The method ends in step 940 .
[0101] Compared to threshold based queue management schemes, another advantage of separate queues for SIP messages is to maximize utilization of the memory space in a SIP server. The four associated procedures that are performed by a SIP server will be described as follows.
[0102] In a first procedure, in order to facilitate the differential treatment of SIP messages in a SIP server, the classification rules are programmed into the SIP server. A user interface is used by service providers to define and configure rules within the server according to service needs.
[0103] In a second procedure, a message scheduler is used to track the order of arrival of SIP signaling messages, including both provisional and non-provisional signaling messages, which do not belong to high priority queue. Whenever such a new SIP signaling message arrives, the arrival order is recorded into the message scheduler. Whenever a message is processed, the associated record is eliminated from the message scheduler.
[0104] FIG. 7 illustrates an example message scheduler 700 in a VoIP network of the present invention. State 710 illustrates the initial state of the message scheduler before a signaling message, either provisional or non-provisional, is served by a SIP signaling server. State 720 illustrates the state of the message scheduler after the head of queue provisional signaling message is served. State 730 illustrates the state of the message scheduler after a provisional signaling message is received and inserted into the tail of queue.
[0105] In a third procedure, a SIP signaling message that arrives at a User Agent Server (UAS) is processed. The pseudo code of the processing of an arrived signaling message is given below.
[0106] If it is from a higher priority source,
If the memory space is not full
[0108] Put it into high priority queue
Else
Discard a SIP message from provisional queue Put the newly arrived message into high priority queue
[0112] Else
Update Message Scheduler—enter its record If it is not a provisional message (determined by rules)
If the memory space is not full
Put it into a non-provisional queue
Else
Discard a provisional message from provisional queue
[0119] Put the newly arrived message into non-provisional queue
Else
If the memory space is not full
[0122] Put it into a provisional queue
Else
Discard the newly arrived SIP message
[0125] In a fourth procedure, the signaling messages in the various message queues are served by the UAS. The pseudo code of this processing is given below.
[0126] If high priority queue is not empty
Process a SIP message from the high priority queue
[0128] Else
Check the Message Scheduler and select the SIP message accordingly Process the chosen SIP message Update the Message Scheduler—eliminate its record Ready to process next message
[0133] A detailed flowchart of the serving of signaling messages in various signaling message queues is provided in FIG. 6 . FIG. 6 illustrates a flowchart of a method 600 for serving signaling messages in signaling message queues at a UAS in a VoIP network of the present invention. Method 600 starts in step 605 and proceeds to step 610 .
[0134] In step 610 , the method awaits to serve the next SIP message in signaling message queues after a previous message has been served.
[0135] In step 615 , the method checks if the high priority message queue is empty. If the high priority message queue is empty, the method proceeds to step 620 ; otherwise, the method proceeds to step 645 .
[0136] In step 620 , the method checks if the message scheduler is empty. If the message scheduler is empty, the method proceeds back to step 610 ; otherwise, the method proceeds to step 625 .
[0137] In step 625 , the method checks if the next signaling message to be served is a message from the provisional message queue according to the message scheduler. If the next signaling message to be served is a message from the provisional message queue according to the message scheduler, the method proceeds to step 630 ; otherwise, the method proceeds to step 635 .
[0138] In step 630 , the method processes the signaling message from the head of queue of the provisional message queue. The method then proceeds to step 640 .
[0139] In step 635 , the method processes the signaling message from the head of queue of the non-provisional message queue. The method then proceeds to step 640 .
[0140] In step 640 , the method updates the message scheduler accordingly after a signaling message has been processed. The method then proceeds back to step 610 .
[0141] In step 645 , the method processes a signaling message from the head of queue of the high priority message queue. The method then proceeds to step 610 .
[0142] This fourth procedure guarantees call setup of high priority calls. While the third procedure effectively serves as an overload control mechanism to minimize the SIP message retransmissions due to loss of non-provisional messages so as to increase the resource utilization as well as the successful call setup rate.
[0143] It should be noted that although not specifically specified, one or more steps of methods 400 , 500 , 600 , 800 , 900 , and 1100 may include a storing, displaying and/or outputting step as required for a particular application. In other words, any data, records, fields, and/or intermediate results discussed in the method can be stored, displayed and/or outputted to another device as required for a particular application. Furthermore, steps or blocks in FIGS. 4 , 5 , 6 , 8 , 9 , and 11 that recite a determining operation or involve a decision, do not necessarily require that both branches of the determining operation be practiced. In other words, one of the branches of the determining operation can be deemed as an optional step.
[0144] FIG. 10 depicts a high level block diagram of a general purpose computer suitable for use in performing the functions described herein. As depicted in FIG. 10 , the system 1000 comprises a process serving signaling messages in signaling message queues at a UAS or element 1002 (e.g., a CPU), a memory 1004 , e.g., random access memory (RAM) and/or read only memory (ROM), a module 1005 for prioritizing VoIP signaling messages, and various input/output devices 1006 (e.g., storage devices, including but not limited to, a tape drive, a floppy drive, a hard disk drive or a compact disk drive, a receiver, a transmitter, a speaker, a display, a speech synthesizer, an output port, and a user input device (such as a keyboard, a keypad, a mouse, and the like)).
[0145] It should be noted that the present invention can be implemented in software and/or in a combination of software and hardware, e.g., using application specific integrated circuits (ASIC), a general purpose computer or any other hardware equivalents. In one embodiment, the present module or process 1005 for prioritizing VoIP signaling messages can be loaded into memory 1004 and executed by processor 1002 to implement the functions as discussed above. As such, the present process 1005 for prioritizing VoIP signaling messages (including associated data structures) of the present invention can be stored on a computer readable medium or carrier, e.g., RAM memory, magnetic or optical drive or diskette and the like.
[0146] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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A method and apparatus for enabling prioritization of signaling messages in a communication network are disclosed. For example, the method receives at least one signaling message, and classifies each of the at least one signaling message. The method schedules each of the at least one signaling message for processing, and discards selectively one or more signaling messages that have been scheduled under an overload condition.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a navigation apparatus suitably mounted on an automotive vehicle for displaying a road map or the like, a navigation method and an automotive vehicle having such a navigation apparatus mounted thereon.
2. Description of the Prior Art
Various types of navigation apparatuses for use on an automotive vehicle are under development. The navigation apparatus comprises, for example, a large-capacity storage means such as a CD-ROM storing road map data, means for detecting the present position, and a display unit for displaying the road map of the neighborhood of the detected present position on the basis of the data read from the data storage means. The present position detection means includes a positioning system using a positioning earth satellite called the GPS (Global Positioning System) or a device operated using a self-contained navigation method by tracking the change in the present position from the starting point on the basis of the information including the vehicle running speed and the direction in which the vehicle is running.
Also, the map of the desired position as well as the neighborhood of the present position can be displayed on the display unit by key operation as far as the associated map data are available.
In this navigation apparatus for use on automotive vehicles, for example, the display unit is generally mounted in the vicinity of the driver's seat so that the driver can check the map of the neighborhood of the present position while the vehicle is running or waiting for a traffic signal.
The above-mentioned navigation apparatus is required to be operated in a manner not to interfere with the operation of the vehicle on which the apparatus is mounted. While the vehicle is moving, for example, complex operations of the navigation apparatus are prohibited. In other words, this navigation apparatus, when installed on the vehicle, is connected with a running condition detector (such as a parking brake switch). In this way, the apparatus can be fully operated only when the detector finds that the vehicle is stationary, and a complicated key operation is prohibited while the vehicle is not stationary (i.e., when the vehicle is moving).
It is, however, inconvenient that the key operation is impossible for switching the display map while the vehicle is moving. Demand is high, therefore, for a navigation apparatus that can be manipulated in sophisticated manner without interfering with the vehicle operation.
SUMMARY OF THE INVENTION
In view of these points, the object of the present invention is to provide a navigation apparatus that facilitates a sophisticated operation of various devices including the navigation apparatus without interfering with the vehicle operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the apparatus according to an embodiment built in an automotive vehicle.
FIG. 2 is a perspective view showing the vicinity of the driver's seat of an automotive vehicle into which the apparatus according to an embodiment is built in.
FIG. 3 is a diagram showing a configuration according to an embodiment of the invention.
FIG. 4 is a diagram for explaining a storage area configuration of a voice recognition memory according to an embodiment.
FIG. 5 is a diagram for explaining a storage area configuration of a latitude/longitude conversion memory according to an embodiment.
FIG. 6 is a flowchart showing the process based on voice recognition according to an embodiment.
FIG. 7 is a flowchart showing the display process of the navigation apparatus according to an embodiment.
FIG. 8 is a flowchart showing the destination-setting process according to an embodiment.
FIG. 9 including FIGS. 9A and 9B is a diagram for explaining an example display of the destination according to an embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to the accompanying drawings.
This embodiment is applied to a navigation apparatus mounted on an automotive vehicle. The manner in which the apparatus according to this embodiment is mounted on the vehicle will be explained with reference to FIGS. 1 and 2. As shown in FIG. 2, an automotive vehicle 50 has a steering wheel 51 mounted on the front of a driver's seat 52. Basically, the driver seated in the seat 52 operates the navigation apparatus. Other occupants of the vehicle 50, however, may operate the navigation apparatus. A navigation apparatus body 20 and a voice recognition unit 10 connected to the navigation apparatus body 20 are installed in an arbitrary space (in the rear trunk, for example) in the vehicle 50, and a positioning signal-receiving antenna 21 is mounted outside of the vehicle body (or in the vehicle inside of the rear window) as described later.
As seen from FIG. 2, which shows the neighborhood of the driver's seat, a talk switch 18 and an operating key 27 for the navigation apparatus are arranged beside the steering wheel 51. The switch and keys are so arranged as not to interfere with the operation of the vehicle while running. Also, a display unit 40 connected with the navigation apparatus is arranged in such a position as not to interfere with the forward field of view of the driver. A speaker 32 for outputting a voice signal synthesized in the navigation apparatus 20 is mounted at such a position (beside the display unit 40, for example) that the output voice can reach the driver.
Further, the navigation apparatus according to this embodiment is so constructed as to accept a voice input. For this purpose, a microphone 11 is mounted on a sun visor 53 arranged in the upper part of the windshield in a way to pick up the speech of the driver seated in the driver's seat 52.
Also, the navigation apparatus body 20 according to this embodiment is connected with an engine control computer 54 of the automotive vehicle, which supplies a pulse signal proportional to the vehicle speed.
Now, the internal configuration of the navigation apparatus will be explained with reference to FIG. 3. In this embodiment, the voice recognition unit 10, which is connected with the navigation apparatus 20, is also connected with the microphone 11. This microphone 11 preferably has a comparatively narrow directivity to pick up only the speech of the person seated in the driver's seat.
The voice signal picked up by the microphone 11 is supplied to an analog/digital converter 12, where it is sampled with a signal of a predetermined sampling frequency and converted into a digital signal. The digital voice signal output from the analog/digital converter 12 is applied to a digital voice processing circuit 13 including an integrated circuit called a DSP (Digital Signal Processor). The digital voice processing circuit 13 supplies the digital voice signal as vector data to the voice recognition circuit 14 by such means as bandwidth division or filtering.
This voice recognition circuit 14 is connected with a voice recognition data storage ROM 15 and performs the recognition operation in accordance with a predetermined voice recognition algorithm (such as HMM or Hidden Markov Model). A plurality of candidates are thus selected from the voice recognition phonemic models stored in the ROM 15, and the character data corresponding to the most coincident phonemic model among the candidates is read out.
Explanation will now be made about the data storage condition of the voice recognition data storage ROM 15. According to this embodiment, only the place names and the words are recognized for giving instructions to operate the navigation apparatus. As shown by the setting of the storage area in FIG. 4, the place names registered include only the names of the prefectures and other municipalities (cities, wards, towns and villages) in Japan. In addition, character codes of the place names and phonemic models providing data for voice recognition of the place names are stored for each pair of prefecture and municipality.
In Japan, for example, there are about 3500 municipalities over the whole country, and therefore about 3500 place names are stored. In the case of a town which is pronounced one of two ways "Machi" and "Cho", however, two types of data including "xx Cho" and "xx Machi" are stored. In similar fashion, for the place name of a village which is also pronounced one of two ways "Son" and "Mura", two types of names, i.e., "xx Son" and "xx Mura", are stored for each of such villages.
Also, as regards the municipalities located adjacent to a boundary of a prefecture the name of which is liable to be called by the wrong name, the prefectural name often mistaken for it is additionally registered. The city of "Kawasaki, Kanagawa Prefecture", for example, is registered also as "Kawasaki, Tokyo" including the name of the adjacent prefecture.
Further, various character codes of words representing operating instructions to the navigation apparatus and corresponding phonemic models are stored. The words include those indicating a display position such as "destination", "starting point", "intermediate place", "residence", and those for giving various operating instructions such as "What time is it now?" (a command asking about the present time), "Where are we now?" (a command asking about the present position), "What is the next" (a command asking about the next intersection), "How long to go?" (a command asking about the remaining distance to the destination), "What is the speed" (a command asking about the current speed), "What is the altitude" (a command asking about the altitude), "Which direction should we take?" (a command asking about the direction in which to run), and "Command list" (a command for displaying a list of recognizable commands).
In the case where a character code corresponding to a phonemic model coinciding with the recognition obtained through a predetermined voice recognition algorithm from an input vector data through the voice recognition circuit 14 represents a place name, then the particular character code is read from the ROM 15. The character code thus read is applied to a converter circuit 16. The converter circuit 16 is connected with a conversion data storage ROM 17, so that the longitude/latitude data and incidental data associated with the character data supplied from the voice recognition circuit 14 are read out of the ROM 17.
Now, explanation will be made about the data storage condition of the conversion data storage ROM 17 according to this embodiment. In this embodiment, a storage area is set for each character code identical to that of the place name stored in the voice recognition data storage ROM 15. As shown in FIG. 5, the latitude/longitude data and display scale data as incidental data of each place name are stored for each character code representing a place name. Unlike the character code read from the voice recognition data storage ROM 15 that is expressed in katakana, the latitude/longitude conversion data storage ROM 17 has also stored therein character codes for display in kanji, hiragana and katakana, in addition to character codes of katakana.
According to the present embodiment, the latitude/longitude data of each place name represents the absolute position of a municipal office (such as city office, ward office, town office or village office) of the area indicated by the particular place name. Also, the incidental data which are output together with the latitude/longitude data include the display character code and the display scale. The display scale data are set in several levels, for example, according to the size of the area indicated by each place name.
The latitude/longitude data and the incidental data read from the latitude/longitude conversion data storage ROM 17 are applied to output terminals 10a, 10b as an output of the voice recognition unit 10. The data produced at the output terminals 10a, 10b are applied to the navigation apparatus 20. The voice recognition unit 10 according to this embodiment includes a talk switch 18 adapted to open and close in unlocked state (that is to say, turned on only as long as depressed). While this talk switch 18 is depressed, only the voice signal picked up by the microphone 11 is processed as described above by the circuits all the way from the analog/digital converter 12 to the latitude/longitude conversion circuit 16.
Now, explanation will be made about a configuration of the navigation apparatus 20 connected with the voice recognition unit 10. The navigation apparatus 20 comprises a GPS antenna 21. The positioning signal received from a GPS satellite by the antenna 21 is processed by a present position detecting circuit 22. The data thus received is analyzed to detect the present position. The present position data thus detected include the latitude/longitude data providing the prevailing absolute position.
The present position data thus detected are applied to an arithmetic circuit 23. The arithmetic circuit 23 functions as a system controller for controlling the operation of the navigation apparatus 20. The arithmetic circuit 23, in which a CD-ROM (optical disk) for storing the road map data is set, is connected with a CD-ROM driver 23 for reading the data stored in the CD-ROM, a RAM 25 for storing various data required for data processing, a vehicle speed sensor 26 for detecting the behavior of the vehicle on which the navigation apparatus is mounted, and an operating key 27. In the case where the latitude/longitude coordinate data including the present position is obtained, the CD-ROM drive 24 is controlled to read the road map data of the neighborhood of the position represented by the coordinate. The road map data read by the CD-ROM driver 24 is temporarily stored in the RAM 25. Display data for displaying the road map is produced by use of the road map data thus stored. In the process, the map is displayed from the display data in a scale set by the operation of the key 27 arranged at a predetermined position in the vehicle.
The display data produced by the arithmetic circuit 23 are applied to a video signal producing circuit 28, which generates a video signal of a predetermined format on the basis of the display data. The resulting video signal is applied to an output terminal 20c.
The video signal output from the output terminal 20c is applied to a display unit 40. The display unit 40 performs the receiving process on the basis of the video signal and causes the road map or the like to be displayed on the display panel of the display unit 40.
In addition to the road map of the neighborhood of the present position, the road map of an arbitrary position designated by the operation of the key 27 can also be displayed under the control of the arithmetic circuit 23. Also, specific coordinate positions representing "destination", "starting point", "intermediate place" and "residence" can be registered by the operation of the key 27. In the case where a specific coordinate position is registered, the coordinate position data thus registered (latitude/longitude data) are stored in the RAM 25.
Also, in the case where the vehicle speed sensor 26 detects that the vehicle is running, the arithmetic circuit 23 rejects the operation of the key 27 except for comparatively minor ones.
The navigation apparatus 20 also comprises a self-contained navigator 29 for computing the running speed of the vehicle accurately on the basis of a pulse signal corresponding to the vehicle speed supplied from an automotive engine control computer or the like, detecting the direction in which the vehicle is running on the basis of the output of a gyro sensor in the self-contained navigator 29, and measuring the present position autonomously from a position determined by the speed and the running direction. Under the circumstances where the present position is incapable of being detected by the present position detection circuit 22, for example, the present position is measured by the self-contained navigation method from the position last detected by the present position detection circuit 22.
The arithmetic circuit 23 is also connected with a voice synthesis circuit 31. In the case where the arithmetic circuit 23 is required to issue some instruction by voice, the voice synthesis circuit 31 is caused to synthesize the voice for the instruction and to produce the voice from a speaker 32 connected to the voice synthesis circuit 31. The voice instructions include, for example, "We are approaching the destination", "You should proceed to the right", etc. These and various other instructions are issued by voice as required as a navigation apparatus. Also, the voice synthesis circuit 31 synthesizes the voice recognized by the voice recognition unit 10 on the basis of the character data supplied thereto, and output the synthesized voice from the speaker 32. This process will be described later.
The navigation apparatus 20 comprises input terminals 20a, 20b supplied with the character code, latitude/longitude data and data incidental thereto output from the output terminals 10a, 10b of the voice recognition unit 10. These latitude/longitude data, data incidental thereto and the character code data produced from the input terminals 20a, 20b are applied to the arithmetic circuit 23. The arithmetic circuit 23, when supplied with the latitude/longitude and other data from the voice recognition unit 10, controls the CD-ROM driver 24 to read the road map data of the neighborhood of the particular latitude/longitude from the disk. The road map data read by the CD-ROM driver 24 are temporarily stored in the RAM 25. By use of the road map data thus stored, display data for displaying the road map are produced. The display data thus produced are used to display the map around the supplied latitude and longitude in the designated display scale incidental to the latitude/longitude data.
On the basis of this display data, the video signal producing circuit 28 generates a video signal, and the display unit 40 is caused to display the road map of the coordinate point designated by the voice recognition unit 10.
In the case where a character code representing a verbal instruction for operating the navigation apparatus is supplied from the output terminal 10b of the voice recognition unit 10, the arithmetic circuit 23 identifies the verbal character code and performs related control operations. Assume that the verbal character code specifies a display position such as "destination", "starting point", "intermediate place" or "residence". It is decided whether the coordinate of the display position is registered in the RAM 25 or not. If it is registered so, the road map data of the neighborhood of the particular position is read from the disk by the CD-ROM driver 24.
Also, when registering the display position of "destination", "starting point", "intermediate place" or "residence", the voice of, say, "register destination" can be recognized and set. When an instruction is given for registration of any of these display positions, the cursor position (indicated by a mark at an arbitrary position in the map by a predetermined operation of the key 27) on the map displayed on the display unit 40 is registered. The arithmetic circuit 23 according to this embodiment is adapted to automatically set the route up to the position of a destination or an intermediate place which may be registered. More specifically, what is considered the most appropriate route from the position registered as the residence or the present position detected by the present position detecting circuit 22 up to the destination or the intermediate place is determined automatically by arithmetic operations. In the case where information on traffic jam or other road conditions is available from an external source, however, the route can be set taking such information into account.
On the other hand, assume that a character code data indicating the pronunciation of a recognized voice is supplied to the arithmetic circuit 23 from the voice recognition unit 10. The words represented by the character code are synthesized by the voice synthesis circuit 31 and output as a voice from the speaker 32 connected with the voice synthesis circuit 31. Suppose the voice recognition unit 10 recognizes the voice as "Bunkyo Ward, Tokyo", for example, the voice synthesis circuit 31 performs synthesis in a manner to generate a voice signal pronounced "Bunkyo Ward, Tokyo" on the basis of the character string data of the pronunciation recognized. The voice signal thus generated is output by way of the speaker 32.
In such a case, according to the present embodiment, whenever a voice is recognized by the voice recognition unit 10, the latitude/longitude data are supplied to the terminal 20a of the navigation apparatus 20 substantially at the same time as the character code data representing the recognized pronunciation is applied to the terminal 20b. The arithmetic circuit 23, however, first causes the voice synthesis circuit 31 to synthesize the recognized voice, and then causes the road map display data to be produced on the basis of the latitude/longitude data.
Now, explanation will be made about displaying the road map using the voice recognition unit 10 and the navigation apparatus 20. First, the voice recognition operation of the voice recognition unit 10 will be described with reference to the flowchart of FIG. 6. The first step decides whether the talk switch 18 is on or not (step 101). In the case where the decision is that the talk switch 18 is on, the voice signal picked up by the microphone 11 during the on-time of the talk switch 18 is sampled by the analog/digital converter 12 and processed by the digital voice processing circuit 13 into vector data (step 102). On the basis of this vector data, the voice recognition circuit 14 performs the voice recognition process (step 103).
It is decided whether the voice of a place name stored in the voice recognition data storage ROM 15 (i.e., a place name registered in advance) has been recognized (step 104). In the case where the voice of a registered place name has been recognized, the character data for pronouncing the recognized place name is read out of the ROM 15 and output from the output terminal 10b (step 105). At the same time, the latitude/longitude data of the recognized place name are read from the latitude/longitude conversion data storage ROM 17 connected to the latitude/longitude conversion circuit 16 (step 106). The place names registered in the ROM 15 represent domestic prefectures and municipalities, and therefore the voices of a place name are recognized in the form of "xx City, xx Prefecture", "xx Ward, xx City" or the like (in the case under consideration, the ward name can be recognized even if the prefectural name is omitted).
The latitude/longitude data and incidental data read out on the basis of the recognized voice are output from the output terminal 10a (step 107).
In the case where step 104 is unable to recognize the voice of a registered place name, it is decided whether a registered specific voice other than the place name has been recognized or not (step 108). In the case where a registered specific voice other than the place name has been recognized, a character code corresponding to the recognized voice is determined (step 109), and the character code thus identified is output from the output terminal 10b (step 110).
In the case where even a specific registered voice other than a place name could not be recognized in step 108, the process is terminated. In such a case, an alternative is to notify the navigation apparatus 20 that the voice could not be recognized and to issue a warning by means of the voice synthesized on the voice synthesis circuit 31 or the characters displayed on the display unit 40.
Now, the operation of the navigation apparatus 20 will be explained with reference to the flowchart of FIG. 7. First, the arithmetic circuit 23 decides whether the present position display mode is set or not (step 201). In the case where the decision is that the present position display mode is set, the present position detecting circuit 22 is caused to execute the measurement of the present position (step 202). The road map data of the neighborhood of the present position thus measured is read from the CD-ROM (step 203). On the basis of the road map data thus read out, the process is performed for displaying the road map of the corresponding coordinate point on the display unit 40 (step 204).
In the case where the decision in step 201 is that the present position display mode is not set, or in the case where the process for display of the road map of the present position has been completed in step 204 and the road map is on display, then it is decided whether the latitude/longitude data, etc. are supplied from the voice recognition unit 10 through the input terminals 20a, 20b (step 205). In the case where the decision is that the latitude/longitude data and incidental character data or the like are supplied, the pronunciation character code supplied through the terminal 20b is supplied to the voice synthesis circuit 31, so that the voice recognized by the voice recognition unit 10 is synthesized and output from the speaker 32 (step 206). The road map data of the neighborhood of the position indicated by the latitude/longitude data is then read out of the CD-ROM (step 207). On the basis of the road map data thus read out, the road map display process is performed thereby to display the road map of the corresponding coordinate point on the display unit 40 (step 208).
In the case where the decision in step 205 is that the latitude/longitude data are not supplied from the voice recognition unit 10, or in the case where the process for displaying the road map of a designated place name is complete in step 208, and the road map is on display, on the other hand, it is decided whether the character code directly specifying a display position is supplied from the voice recognition unit 10 through the input terminal 20b (step 209). In the case where the decision is that the character code is supplied from the terminal 20b, the particular character code is supplied to the voice synthesis circuit 31, and the voice recognized by the voice recognition unit 10 is output from the speaker 32 (step 210). In the case where step 209 identifies a character code directly specifying the display position (i.e., such words as "destination", "starting point", "intermediate place", "residence" or the like), it is decided whether the coordinate point specified by these characters is registered in the RAM 25 or not (step 211). In the case where such coordinate point is registered, the road map data of the neighborhood of the position indicated by the latitude/longitude data representing the registered coordinate point is read from the CD-ROM (step 212). The process for displaying the road map is performed on the road map data thus read out, and the road map of the corresponding coordinate point is displayed on the display unit 40 (step 213). The process returns to step 201 while the same road map is on display.
In the case where step 209 decides that the character code directly specifying the display position is not supplied from the voice recognition unit 10, the arithmetic circuit 23 decides whether the operation is performed for specifying the display position by the operating key 27 (step 214). In the case where the operation is performed for specifying the display position, it is decided whether the vehicle is moving or not on the basis of the data detected by the vehicle speed sensor 26 (step 215). In the case where the arithmetic circuit 23 decides that the vehicle is moving, the operation performed at that time is invalidated and the process returns to step 201 (in which case some alarm may be issued).
In the case where the decision is that the vehicle is not moving, on the other hand, the process proceeds to step 211 for deciding whether a coordinate point is registered or not. In the case where a coordinate point is registered, the process is performed for displaying the road map of the coordinate point (steps 212, 213), after which the process returns to step 201.
In the case where step 211 decides that the coordinate point of the corresponding position such as "destination", "starting point", "intermediate place" or "residence" is not registered, an alarm is issued against the lack of registration by voice synthesis through the voice synthesis circuit 31 or by character display on the display unit 40 (step 216), and the process returns to the decision in step 201.
The foregoing explanation with reference to the flowchart of FIG. 7 refers to the process relating to map display. In the case where a character code is supplied from the voice recognition unit 10 based on the result of recognizing a voice specifying an operation other than map display, however, the corresponding process is performed under the control of the arithmetic circuit 23. When the character code is supplied upon recognition of a voice meaning "What time is it now?", for example, a voice announcing the present time is synthesized by the voice synthesis circuit 31 and output from the speaker 32 under the control of the arithmetic circuit 23. Other commands are also processed similarly as a verbal reply synthesized by the voice synthesis circuit 31 and output from the speaker 32, or by a corresponding display on the display unit 40.
The process in which a destination is set on the road map on display by means of the voice recognition unit 10 and the navigation apparatus 20 according to this embodiment will be explained with reference to the flowchart of FIG. 8.
First, an input voice is recognized, and the road map of the place name recognized is displayed on the display unit 40 (step 401). When this map display is started, the cursor display position is set at the center of the map. As shown in FIG. 9A, for example, the cross indicating the cursor position is displayed at the center of the map.
It is decided whether the key is operated to move the cursor position from this state (step 402). When the operation for moving the cursor position is performed, the cursor display position is moved in the direction designated by the operation (step 403).
The next decision is whether the operation is performed for setting a destination (or whether a verbal instruction is issued for setting a destination) (step 404). In the case where the operation is performed for setting a destination, it is decided whether the route setting mode is for setting the route from the present position (present position mode) or from a position registered as the residence (residence mode) (step 405). In the present position mode, the present position measured by the positioning operation is determined, so that the arithmetic operation is performed for setting the route from this present position to the cursor position (step 406). In the residence mode, on the other hand, a position registered as a private residence is determined, and the arithmetic operation is performed for setting the route from the position thus determined to the cursor position (step 407).
In either mode, a mark indicating a destination is displayed at a position set as the destination in the map on display. At the same time, in the case where the map contains the road selected as the route, the particular route is displayed (step 408). As shown in FIG. 9B, for example, a flag is displayed at the position set as the destination, and the road set as the route to the destination is displayed by a thick dashed line. This display process terminates the destination-setting process.
The display process performed as described above can freely set by voice input a display position in any part of the country, thereby making it possible to display the road map of the desired position easily. More specifically, the operator can simply speak "xx City, xx Prefecture" or "xx Ward, xx City" by way of the microphone 11 while depressing the talk switch 18. Then, the particular voice is recognized and the road map of the area is displayed. The position designation by key operation, therefore, is eliminated. Even under the circumstances where the complex key operation is difficult, the navigation apparatus can be operated smoothly. According to this embodiment, the verbal expressions indicating place names recognizable by the voice recognition unit 10 are limited to the names of domestic prefectures and municipalities. Therefore, only a comparatively small number (about 3500) of voices can be recognized. As a result, the voice recognition circuit 14 in the voice recognition unit 10 can recognize a place name by a voice recognition process comparatively small in capacity and in time. The time before a verbally designated map is displayed can be reduced. At the same time, the recognition rate is improved by limiting the number of recognizable place names in this way.
According to this embodiment, a destination is set by the cursor position on the map on display, and therefore the route to a destination can be set by simple operation. More specifically, the conventional route-setting method in the route setting mode requires a complicated operation for setting the coordinate points of the starting point and the destination. In this embodiment, by contrast, a destination can be set on the displayed map simply by the key operation or the voice recognition operation. In this case, the starting point is determined either at the present position or at the private residence or the like registered in advance. The route can thus be set automatically from the present position or the registered position simply by setting the destination in either mode.
In this way, a desired destination can be set by an instruction according to voice recognition on the map selectively displayed by voice recognition. Therefore, the route can be set very easily by verbal instructions alone.
According to this embodiment, the coordinate point data corresponding to the place names stored in the ROM 17 of the voice recognition unit 10 include the latitude/longitude data indicating the absolute position of each municipal office (city office, ward office, town office or village office) of a particular area. Therefore, the map centered around the municipal office of a particular area is displayed conveniently. This is the most desirable mode of display since the municipal office of each area is often located at the center of the area.
In the above-mentioned embodiment, the place names recognized by the voice recognition unit are limited to those of the prefectures and other municipalities in Japan. The voice can be recognized, however, specifying more detailed place names or positions. In other words, the name of a building which is likely to provide a target and an address by which the exact position can be specified may also be recognized directly by voice, so that the destination may be specified as a position designated by the recognized voice. Examples are "Tokyo Station", "Tokyo Tower" and other station or facility names.
Further, instead of setting the latitude/longitude data indicating the absolute position of a municipal office (city office, ward office, town office or village office) of a particular area as the central coordinate point for each place name, the latitude/longitude data indicating other positions may be used alternatively. A simple example is the latitude/longitude data of the geological center of a particular area (city, ward, town or village).
Furthermore, the latitude/longitude data of the geographical center of an area may be replaced by the coordinate point data of the eastern, western, northern and southern ends of the particular area. In such a case, four data including the longitudes of the eastern and western ends and the latitudes of the northern and southern ends are stored to serve the purpose.
In the above-mentioned embodiment, the recognized voice is converted into a character code and then this character code is converted into the latitude/longitude data by the latitude/longitude conversion circuit 16. Instead, the recognized voice may be directly converted into the latitude/longitude data. Even in the case where the recognized voice is not directly converted into the latitude/longitude data, the ROM 15 and the ROM 17 for storing the conversion data may be integrated as a single memory to share a place name storage area.
The above-mentioned embodiment, which is applied to the navigation apparatus using a positioning system called the GPS, can of course be applied to the navigation apparatus using other positioning systems with equal effect.
The navigation apparatus according to this invention can set a destination in simple fashion on the map on display.
In view of the fact that a destination is set on the road map displayed under the control of a voice recognized by the voice processing means, the mere voice makes a search possible for a destination map to be displayed, thereby greatly facilitating the destination-setting work of the user.
Also, since the route up to a set destination is determined from the present position measured by the positioning means as the origin, the work for setting the route from the present position to the destination is greatly facilitated.
Alternatively, the route to a destination is set from a specified position as the origin. This simplifies the setting of the route from a predetermined position such as a private residence.
Furthermore, a destination can be easily set on the displayed map by the navigation method according to the invention.
In this case, since a destination is set on the road map displayed under the control of a recognized voice, verbal search is possible for a destination map to be displayed, thereby greatly facilitating the destination-setting work.
In addition, a route from the present position to a destination can be easily set because the present position measured is used as the origin for setting the route to the destination.
What is more, in view of the fact that a route to a set destination is determined with a predetermined specific position as the origin, the route can be set easily from a predetermined position such as a private residence.
Furthermore, in an automotive vehicle according to this invention, a destination can be easily set in the map on display. Even in the circumstances where the complex key operation is difficult in a running vehicle, simple processes including voice recognition permit a destination to be set. The operation of the navigation apparatus in a running vehicle can thus be simplified while at the same time securing safety.
Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various changes and modifications could be effected therein by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
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A navigation apparatus and navigation method for an automobile in which a map is visually displayed and a desired destination can be set by speaking the name of such destination. A voice recognition section recognizes the destination and marks it on the map that is being displayed and the best route to the displayed destination is then shown on the map to be followed by the driver of the automobile.
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BACKGROUND OF THE INVENTION
The present invention relates to a waste oil delivery system and more particularly to a simplified system for delivering waste oil to a burner or heater which may be located a long distance from and elevated well above an oil reservoir.
Numerous varieties of heaters or burners are known, and these include heaters and burners which utilize the combustion of oil to produce heat. Typically, the oil is delivered from an oil source or reservoir, such as a tank, to an orifice in a nozzle located adjacent to or in a combustion chamber. The nozzle and the orifice may mechanically atomize the oil (a so-called "hydraulic combustion system") and/or admix air to aerate it (a so-called "air atomizing combustion system") to produce an aerosol thereof. In either event, the oil, now mechanically broken up into micro-globules, is directed into the combustion chamber, where it is burned to produce heat.
Oil burners and heaters are often capable of combusting fuel oils ranging from No. 1 fuel oil--a volatile, distillate oil--to No. 6 fuel oil--a high-viscosity fuel--to waste oils. Prior art fuel oil delivery systems have utilized a single pump, located physically near the burner or heater. The low side of the pump is connected to a line to which the pump applies a negative pressure (about 10-12 inches of mercury) to pull the fuel oil into the pump. Thereafter, the pump transmits the oil to its high side for subsequent delivery through a delivery line to the nozzle or its orifice. A practical limit on the maximum distance between the fuel reservoir and the low side of the pump is imposed by the physics of lifting liquids by negative pressure. This practical limit is a head lift of about fourteen feet. Thus, the use of single pump prior art fuel oil delivery systems is limited to residences and commerical buildings of moderate height (where the tank is at or near ground level) or to the ground level of a building (where the tank is buried). Higher buildings or deeper tank depths require multiple, or booster, pump systems, or multiple tanks and delivery systems periodically spaced throughout the levels of the building.
Thus, one hallmark of prior art oil delivery systems is a reliance on "pulling" fuel oil to the burner or heater.
The type pump most often found in prior art oil delivery systems typically regulates its output pressure to a selected value by means of an internal or adjunct pressure regulator. A relief valve or similar relief device, may also be provided to bypass excess oil, that is, oil in excess of that required to maintain the selected output pressure, back to the reservoir. The output pressure at the high side of the pump is usually with the range of 75-300 pounds per square inch where the oil is non-waste oil which is burned in a hydraulic combustion system. Where the fuel oil is waste oil or other oil burned in an air atomizing combustion system, the pressure of the oil at the high side of the pump is maintained by the pump at about 10 pounds per square inch.
The high side of the pump in a prior art fuel oil delivery system moves pressure-regulated fuel oil through the line connected thereto to the nozzle. The amount of pressure regulation or bypassing which occurs at the pump varies at the viscosity of the oil. Viscosity, in turn, is dependent on the inherent characteristics of the fuel oil (e.g., its chemical make-up) and the temperature thereof. Because of these variables, the flow rate of the fuel oils to the nozzle is difficult to control by pressure regulation.
The range of pressures which may be experienced at the high side of the pump and the difficulty in controlling the flow rate of the fuel oil to the nozzle has led to the use of pressure regulators in the high side line between the pump and the nozzle. Such regulators maintain the pressure of the fuel oil delivered to the nozzle within a range of about 3 to 5 pounds per square inch. Typically, the regulator is "automatic" and regulates the upstream pressure of the fuel oil as the pressure of the oil delivered to the nozzle varies.
In order to "match" the amount of oil delivered to the nozzle and the requirements of the particular combustion zone with which the nozzle is used, the size of the orifice in the nozzle may be appropriately selected.
Thus, another hallmark of prior art fuel oil delivery systems is the reliance on pressure regulation and orifice size to control and regulate the flow rate of fuel oil to the nozzle.
The above-described limitation on the distance from which, and the height to which, fuel oil may be delivered, the difficulty in controlling flow rate of fuel oil to a nozzle, and the need to rely on pressure regulation and orifice site to achieve desired oil flow are factors adversely affecting the applicability and economy of present fuel oil burner and heater systems. An object of the present invention is to eliminate or ameliorate these factors by the use of a simple, economical fuel oil delivery system.
SUMMARY OF THE INVENTION
With the above and other objects in view, the present invention contemplates a simple heating oil delivery system for delivering waste oil from a source of oil to a burner or heater. The burner or heater may be located a long distance from and/or may be elevated well above the reservoir, which may be a storage tank, which is located above ground or is buried. The oil delivery system is similar only in a general way to prior art systems: it delivers fuel oil from the reservoir to a combustion zone of a heater or burner, and the fuel oil is introduced into the combustion zone following atomization thereof upon exiting an orifice of a nozzle. However, in prior systems: (1) the oil is received in the orifice at a predetermined pressure due to the action of pressure regulation upstream of the nozzle and (2) the predetermined pressure and the size of the orifice control the flow rate of the oil out of the orifice and into the combustion zone. Neither of the two foregoing characteristics apply to the present invention.
The delivery system of the present invention is particularly adapted for use with an air-atomizing combustion system which burns waste oil, although other oils may be used. A positive displacement metering pump, which includes no pressure-regulating or by-pass facilities, is usually located physically close to the oil reservoir and remote from the nozzle. The pump removes the oil from the source and thereafter pushes the oil to deliver it to the nozzle. The oil is delivered to the nozzle at a constant flow rate regardless of its pressure in the orifice or the size of the orifice. No pressure-regulating facilities between the pump and the nozzle are utilized.
The distance between the pump and the nozzle may exceed fourteen feet and may be about one-hundred feet or more. Heating pads adjacent the delivery line between the pump and the nozzle may heat the oil. Preferably, the pads are located proximate to the nozzle.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a fuel oil delivery system according to the prior art; and
FIG. 2 is a schematic view of a fuel oil delivery system according to the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is schematically depicted a fuel oil delivery system 10 according to the prior art. The delivery system 10 delivers fuel oil 12 from source or reservoir 14 thereof, such as a tank, to a combustion zone 16 of a burner, heater or similar heat-producing system 17. The fuel oil 12 is introduced into the combustion zone 16 in atomized form 18.
Atomization 18 of the oil 12 is effected by a nozzle 20 having an orifice 22 therein through which the oil 12 passes. If the system 10 is a so-called "hydraulic" system, atomization 18 of the oil 12 is achieved by its passage through and out of the orifice 22. If the system 10 is a so-called air-atomizing system, air is admixed with the oil 12 in the orifice 22, as depicted at 24, to aerate it. In either event, the atomized oil 18, now broken up into micro-globules, is burned within the combustion zone 16 to produce heat.
Typically, the oil 12 is removed from the reservoir 14 by the action of a pump 30. In standard arrangements, the pump 30, the nozzle 20 and other related elements of the burner 17 are physically proximate and are included in a common "package" comprising the burner system 17. More specifically, the distance 32 between the pump 30 and the nozzle 20 is relatively short, while the distance 34 between the pump 30 and the reservoir 14 is relatively substantially longer. The oil 12 is drawn from the reservoir 14 by the pump 30 applying a negative pressure via its low side 30L to a line 36, an inlet 38 of which is immersed in the oil 12. As is well known, this type of pumping, termed herein as "pulling" is limited by physical considerations to lifting the oil 12 to a height H no greater than about fourteen feet. The oil 12 pulled into the pump 30 is then forced from the high side 30H thereof, through a line 38 to the proximate nozzle 20.
The pump 30 is usually pressure-self-regulated. That is, a pressure regulator 40, which may be internal to the pump 30 or which may be an external adjunct to the pump 30, regulates, as shown by the arrows 42, the pressure of the oil 12 at the high side 30H of the pump 30 and in the line 38 to a selected value. Pump 30, as used in prior art systems 10, may also utilize pressure-relief facilities 44, which by-pass the oil internally or feed back excess oil 12 to the reservoir 14 through a line 46. Often, due to factors related to the characteristics of the pump 30 (e.g., pulsing), the oil (e.g., viscosity) or other elements of the system 10 additional pressure regulation is utilized. To that end, the line 38 may include a pressure regulator 48, which controls the pressure of the oil 12 delivered to the nozzle 20, in accordance with regulation input, diagrammatically shown at 50, sent from a sensor 52, associated with the nozzle 20 and its orifice 22, to the regulator 48.
Where the system 10 is used with hydraulic combustion and the oil 12 is non-waste oil, the pressure of the oil 12 at the high side 30H of the pump 30 is typically within a range of 75-300 lb/in 2 . If the system 10 is used with air-atomizing combustion and delivers waste oil, this pressure is about 10 lb/in 2 . The regulator maintains the pressure of the oil 12 delivered to the nozzle 20 to between about 3-8 lb/in 2 .
If required, as may be the case where the oil 12 is waste oil, the oil in the line 38 is heated, as shown by the arrow 54, in any convenient manner.
Prior art oil delivery systems 10 are, therefore, characterized by:
(1) Delivering fuel oil 12 by pulling it from the reservoir 14--this limits the height H to which the oil 12 can be lifted; and
(2) Reliance on pressure regulation, in the pump 30 and/or via pressure regulation facilities 48, 50, 52, and the size of the orifice 22 to control the flow rate of the oil 12 into the combustion zone 16--This renders the system 10 expensive and complicated, and, nevertheless, often results in poor or improper flow rates of the oil 12.
A system 100 according to the present invention is shown in FIG. 2, wherein like reference numerals denote similar elements to those in FIG. 1. The system 100 achieves improved delivery of oil 12 to the combustion zone 16 by virtue of the simplification and rearrangement of the system 10 of FIG. 1.
A pump 102 is used to move oil 12 from the reservoir 14 to the nozzle 20 for burning in the combustion zone 16. The pump 102 is preferably a positive displacement, metering pump and may be a gear pump, such as a ring gear pump of the type available from Sun Tec Industries under the designation fuel pump. The pump 102 may be basically similar to the pump 30, but it includes no pressure-regulation facilities 40, 42. The pump 102 draws the oil 12 from the reservoir 14 via a line 104 having an inlet 106 and delivers the oil 12 to the nozzle 20 via a line 108. The pump 102 is located proximate to the reservoir 14 and is not usually proximate to the nozzle 20. This locational change from the prior art system 10 of FIG. 1 permits oil 12 to be delivered to great heights H and/or to nozzles 20 located substantial distances away therefrom. Thus, in contrast to FIG. 1, the pump-to-reservoir distance 34 has been shortened to 34' and nearly eliminated, while the pump-to-nozzle distance 32 has been lengthened to 32' with oil lifts H' far greater than H being achieveable.
The metering pump 102 of the system 100 "pushes" the oil 12 to the nozzle 20. Because of this and the foregoing considerations, the flow rate of the oil 12 to the nozzle 20 is a function of the design and operating parameters of the pump 102 and not of pressure. Accordingly, the pressure-regulating facilities 48, 50, 52 as well as those 40, 42 associated with the pump 30 are eliminated. The size of the orifice 22 also does not, within practical limits, i.e., excluding orifices of zero (or extremely small) or infinite (or extremely large) diameter, determine the flow rate of the oil 12 into the combustion zone 16.
The foregoing improved system 100 is particularly adapted to deliver waste oil 12 to the nozzle 20. Where required for reasons of viscosity, low volatility or otherwise, the waste oil may be heated to a selected temperature by heating pads 110, located proximate to the nozzle 20, as shown by arrows 112.
A pressure relief valve 113 is installed on the push side of the pump 102 to provide pressure relief in the event of blockage in the supply line 108 or nozzle 20.
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The distance between the combustion nozzle and the pump of a waste oil heater can be significantly increased by using a positive displacement pump which is proximate to the reservoir and remote from the nozzle, contary to the usual positioning of oil delivery pumps. The pump, which is not pressure regulated, thus pushes oil to the nozzle at a constant flow rate regardless of oil pressure at the nozzle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Application No. CN201520065126.7, entitled “ABOVE GROUND POOL,” filed on Jan. 29, 2015, the disclosure of which is incorporated by reference herein in its entirety. This application is a continuation application of U.S. patent application Ser. No. 14/671,845, filed on Mar. 27, 2015.
BACKGROUND INFORMATION
[0002] 1. Technical Field
[0003] The present invention relates to pools, and more specifically, to an above ground pool.
[0004] 2. Background
[0005] An above ground pool is a facility installed on a piece of vacant land for recreational usage. For example, it can be installed on the yard of a house or a piece of vacant land elsewhere for adults and children to play together. Due to its ease of installation and usage, above ground pools have become very popular.
[0006] Currently, above ground pools can be mainly categorized into two types: frame pools and inflatable pools. There are a variety of structures and forms for frame pools. A round frame pool is the most typical above ground pool, which mainly includes a series of horizontal support members, vertical support members and a pool liner. In these types of above ground pools, the horizontal support members are connected in sequence via connecting members to form a circular structure. The vertical support members support the circular structure so as to form a support frame, and then the pool liner is affixed to support frame to form a pool body. The pool body forms an above ground pool or basin for holding water. When a frame pool of this structure is fully filled with water, the water can exert a significant amount of pressure on the pool body, thus the support frame must be sturdy enough to withstand extremely high pressure forces.
[0007] However, most horizontal support members, vertical support members, and connecting members used in the support frames of traditional round frame pools comprise tubes having a D-shaped cross-section. In practical applications, these “D-shaped tubes” have a number of disadvantages. For example, such tubes are difficult to manufacture and control their manufacturing process due to the asymmetric shape of the tubes' cross-section. These D-shaped tubes typically have a structure without a narrowed mouth at a tube end, so the clearance fit between the tube end and a corresponding connector is relatively large, resulting in poor overall stability. Since the shape of the D-shaped tube is asymmetric, it is more difficult to cut to form arcuate corners. Also, the manufacturing cost is fairly costly. All of these factors result in great difficulty in the machining of connector elbows.
[0008] In addition, the connection between corresponding D-shaped tubes is achieved by engagement at single point, such that the connection has a relatively poor firmness and strength. Therefore, support frames formed by the use of D-shaped tubes mentioned above have a lower bearing capacity, thus compromising the safety and performance of the above ground pool.
[0009] Overall, the bearing performance of the support frame of an above ground pool may have a direct impact on the stability of the entire above ground pool. Due to the factors discussed above, conventional above ground pools are prone to collapse and cause injury accidents. Thus, a need therefore exists for an above ground pool having a sturdy support frame that is easy to assemble.
SUMMARY
[0010] An above ground pool according to the present invention is provided in order to solve the technical problems present in support frames of conventional above ground pools, namely, the poor bearing capacity of existing above ground pool support frames.
[0011] One example of an above ground pool of the present invention includes a support frame and a pool liner. The support frame includes a series of horizontal support members and vertical support members. The horizontal support members and the vertical support members each include an elongated tube with an elliptical cross-section.
[0012] The pool liner is affixed to the support frame. The pool liner is supported by the support frame to form a body for holding water within the pool.
[0013] In some implementations, the support frame further includes a plurality of T-shaped connectors for coupling the horizontal support members and the vertical support members together. Each T-shaped connector includes a horizontal tubular member and a vertical tubular member transverse to the horizontal tubular member. The horizontal tubular member and the vertical tubular member each has an elliptical cross-section.
[0014] In some implementations, the T-shaped connectors couple two corresponding horizontal support members together in sequence to form a substantially circular ring-shaped structure. In some implementations, the ring-shaped structure may be oval in shape. In some implementations, the vertical tubular member is coupled to a corresponding vertical support member.
[0015] In some implementations, a first end of the horizontal tubular member is detachably connected to an end of a first corresponding horizontal support member and a second end of the horizontal tubular member is detachably connected to an end of a second corresponding horizontal support member. The first corresponding horizontal support member and the second corresponding horizontal support member may be connected to the first end of the horizontal tubular member and the second end of the horizontal tubular member by a retainer located proximal the respective points of attachment.
[0016] In some implementations, the retainer is a retaining pin configured to pass through a first set of positioning holes and a corresponding second set of positioning holes. The first set of positioning holes is formed at the first end of the horizontal tubular member and the second end of the horizontal tubular member. The corresponding second set of positioning holes is formed at ends of the corresponding horizontal support members. The retaining pin is configured to lock the horizontal tubular member and the corresponding horizontal support members together.
[0017] In some implementations, the vertical tubular member is detachably connected to a corresponding vertical support member by a spring-loaded latch coupled to an end of the vertical support member. The latch is configured to engage an aperture formed at an open end of the vertical tubular member.
[0018] In some implementations, the spring-loaded latch includes a pin boss that houses a spring element and detent pin. The pin boss is mounted inside one end of the vertical support member and configured such that the detent pin is outwardly biased by the spring element to engage the aperture. The detent pin is configured to lock the vertical tubular member and the vertical support member together.
[0019] In some implementations, the above ground pool further includes a plurality of tensioning devices coupled to an outer surface of the body of the pool and a tensioning belt. Each tensioning device is coupled to the outer surface of the body in-between two neighboring vertical support members. The tensioning belt may be alternately weaved about the outer surface of the body through the tensioning devices and over the vertical support members to retain the vertical support members close to the body. In some implementations, the tensioning belt is arranged about the body of the pool at a height equal to approximately one-third of the height of the body of the pool. In some implementations, the above ground pool further includes a plurality of support bases coupled to a bottom end of the vertical support members.
[0020] A second example of an above ground pool of the present invention is further provided. The above ground pool includes a support frame and a pool liner. According to this example, the support frame includes a series of horizontal support members, connectors, and U-shaped support members. The horizontal support members and connectors may each have a circular cross-section. The U-shaped support members may have an elliptical cross-section.
[0021] The pool liner is affixed to the support frame. The pool liner is supported by the support frame to form a body for holding water within the pool.
[0022] In some implementations, the horizontal support members are coupled together in series by the connectors to form a ring-shaped structure. In some implementations, the ring-shaped structure forms a rectangle, square, or other polygon shape. In some implementations, the connectors are each L-shaped.
[0023] In some implementations, the above ground pool further includes couplings coupled to free ends of the U-shaped support members. The couplings detachably connect the U-shaped support members to the ring-shaped structure to support the ring-shaped structure in an oblique fashion.
[0024] In some implementations, each free end of the U-shaped support member includes a reduced diameter portion. The reduced diameter portion includes a first set of latching holes spaced apart from a second set of latching holes.
[0025] In some implementations, the coupling further includes a flexible V-shaped pin and a hollow casing. The flexible V-shaped pin includes a first pair of studs spaced apart from a second pair of studs. The hollow casing includes a pair of orifices. The flexible pinis disposed within the reduced diameter portion of U-shaped support members such that the first pair of studs extends through the second set of latching holes to engage the pair of orifices, and the second pair of studs extends through the first set of latching holes.
[0026] In some implementations, the casing is a tube having an oval cross-section corresponding with the cross-section of the U-shaped support members.
[0027] In some implementations, the above ground pool further includes a plurality of support belts coupled to and arranged about a bottom portion of the body of the pool. Each support belt is coupled between the bottom portion of the body of the pool and a horizontal portion of a corresponding U-shaped support member.
[0028] In some implementations, each support belt includes a sleeve for passing the horizontal portion of the U-shaped support member therethrough.
[0029] A first example of a support frame for an above ground pool of the present invention is provided. The support frame includes a plurality of horizontal support members and a plurality of vertical support members, where a pool liner may be affixed to and supported by the support frame to form a body for holding water within the pool.
[0030] The horizontal support members may include an elongated tube with an elliptical cross-section. The vertical support members may be coupled to the horizontal support members. The vertical support members may include an elongated tube with an elliptical cross-section.
[0031] In some implementations, the support frame further includes a plurality of T-shaped connectors for coupling the horizontal support members and the vertical support members together. The T-shaped connector includes a horizontal tubular member and a vertical tubular member transverse to the horizontal tubular member. The horizontal tubular member and the vertical tubular member each has an elliptical cross-section.
[0032] In some implementations, the T-shaped connectors couple two corresponding horizontal support members together in sequence to form a substantially circular ring-shaped structure. In some implementations, the ring-shaped structure may be oval in shape.
[0033] In some implementations, the vertical tubular member is coupled to a corresponding vertical support member. In some implementations, a first end of the horizontal tubular member is detachably connected to an end of a first corresponding horizontal support member and a second end of the horizontal tubular member is detachably connected to an end of a second corresponding horizontal support member. The first corresponding horizontal support member and the second corresponding horizontal support member are connected to the first end of the horizontal tubular member and the second end of the horizontal tubular member by a retainer located proximal the respective points of attachment.
[0034] In some implementations, the retainer is a retaining pin configured to pass through a first set of positioning holes formed at the first end of the horizontal tubular member and the second end of the horizontal tubular member, and a corresponding second set of positioning holes formed at ends of the corresponding horizontal support members. The retaining pin is configured to lock the horizontal tubular member and the corresponding horizontal support members together.
[0035] In some implementations, the vertical tubular member is detachably connected to a corresponding vertical support member by a spring-loaded latch coupled to an end of the vertical support member. The latch is configured to engage an aperture formed at an open end of the vertical tubular member.
[0036] In some implementations, the spring-loaded latch includes a pin boss that houses a spring element and detent pin. The pin boss is mounted inside one end of the vertical support member and configured such that the detent pin is outwardly biased by the spring element to engage the aperture. The detent pin is configured to lock the vertical tubular member and the vertical support member together.
[0037] In some implementations, the support frame further includes a plurality of tensioning devices coupled to an outer surface of the body of the pool and a tensioning belt. Each tensioning device may be coupled to the outer surface of the body in-between two neighboring vertical support members The tensioning belt may be alternately weaved about the outer surface of the body through the tensioning devices and over the vertical support members to retain the vertical support members close to the body.
[0038] In some implementations, the tensioning belt is arranged about the body of the pool at a height equal to approximately one-third of the height of the body of the pool. In some implementations, the above ground pool further includes a plurality of support bases coupled to a bottom end of the vertical support members.
[0039] A second example of a support frame for an above ground pool of the present invention is further provided. The support frame includes a plurality of horizontal support members, a plurality of connectors, and a plurality of U-shaped support members, where a pool liner may be affixed to and supported by the support frame to form a body for holding water within the pool.
[0040] The plurality horizontal support members each include an elongated tube with a circular cross-section. Each of the connectors that couple corresponding horizontal support members together comprise an L-shapes tube with a circular cross-section.
[0041] Each of U-shaped support members comprise a U-shaped tube with an elliptical cross-section. In some implementations, the horizontal support members are coupled together in series by the connectors to form a ring-shaped structure. In some implementations, the ring-shaped structure forms a rectangle, square or other polygon shape.
[0042] In some implementations, the above ground pool further includes couplings coupled to free ends of the U-shaped support members. The couplings detachably connect the U-shaped support members to the ring-shaped structure to support the ring structure in an oblique fashion. In some implementations, each free end of the U-shaped support member has a reduced diameter portion, the reduced diameter portion having a first set of latching holes spaced apart from a second set of latching holes.
[0043] In some implementations, the coupling further includes a flexible V-shaped pin including a first pair of studs spaced apart from a second pair of studs and a hollow casing. The hollow casing includes a pair of orifices. The flexible pin is disposed within the reduced diameter portion of U-shaped support members such that the first pair of studs extends through the second set of latching holes to engage the pair of orifices, and the second pair of studs extends through the first set of latching holes. In some implementations, the casing includes a tube with an oval cross-section corresponding with the cross-section of the U-shaped support members.
[0044] In some implementations, the support frame further includes a plurality of support belts coupled to and arranged about a bottom portion of the body of the pool. Each support belt may be coupled between the bottom portion of the body of the pool and a horizontal portion of a corresponding U-shaped support member. In some implementations, each support belt includes a sleeve for passing the horizontal portion of the U-shaped support member therethrough.
[0045] Advantageously, support frames of above ground pools according to the present invention are at least partially composed of tubes with an elliptical cross-section. The symmetric shape of the cross-section reduces the difficulty in machining a tube bend, lowers the complexity in manufacturing the tubes, effectively improves the stability, and facilitates quality control. Meanwhile, a slight clearance fit between the tube end of the elliptical tubes and the connector may be achieved. This enables the support frame to withstand large mechanical stresses and provide stability and enhanced structural support. In addition, a bolt connection is utilized between the tube end of the elliptical tubes and the connector. Such bolt connection is secure and provides greater strength. Therefore, support frames formed by elliptical tubes provide better bearing performance, thereby improving the stability of the entire above ground pool and providing an excellent safety performance.
[0046] Other devices, apparatus, systems, methods, features and advantages of the disclosure will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The above-mentioned and other features, properties and advantages of the present invention will become more apparent from the following description of embodiments with reference to the accompany drawings, in which:
[0048] FIG. 1 is a perspective view illustrating one example of an implementation of a support frame of an above ground pool according to the teachings of the present invention.
[0049] FIG. 2 is a front view of the support frame illustrated in FIG. 1 .
[0050] FIG. 3 is a top view of the support frame illustrated in FIG. 1 .
[0051] FIG. 4 is a partial exploded view of the support frame of FIG. 1 , illustrating how corresponding horizontal support members are coupled with a vertical support member by a T-shaped connector.
[0052] FIG. 5 is another partial exploded view of the support frame of FIG. 1 , illustrating how corresponding horizontal support members are coupled with a vertical support member by a T-shaped connector.
[0053] FIG. 6 is a partial cross-sectional view of the support frame of FIG. 1 , illustrating how a horizontal support member is coupled to the T-shaped connector.
[0054] FIG. 7 is a perspective view of a spring-loaded latch for connecting a vertical support member and a T-shaped connector in the support frame of FIG. 1 .
[0055] FIG. 8 is a bottom view of the spring-loaded latch illustrated in in FIG. 7 .
[0056] FIG. 9 is a side view of the spring-loaded latch illustrated in FIG. 7 .
[0057] FIG. 10 is a front view of the spring-loaded latch illustrated in FIG. 7 .
[0058] FIG. 11 is an exploded perspective view of the spring-loaded latch illustrated in FIG. 7 .
[0059] FIG. 12 is a perspective view illustrating an above ground pool incorporating the support frame illustrated in FIG. 1 .
[0060] FIG. 13 is a perspective view illustrating a second example of an implementation of a support frame of an above ground pool according to the teachings of the present invention.
[0061] FIG. 14 is a top view of the support frame illustrated in FIG. 13 .
[0062] FIG. 15 is a front view of the support frame illustrated in FIG. 13 .
[0063] FIG. 16 is a side view of the support frame illustrated in FIG. 13 .
[0064] FIG. 17 is a partial exploded view of the support frame of FIG. 13 , illustrating how corresponding horizontal support members are coupled with the U-shaped support members.
[0065] FIG. 18 is a perspective view of a horizontal support member of the support frame illustrated in FIG. 13 .
[0066] FIG. 19 is a side view of the horizontal support member illustrated in FIG. 18 .
[0067] FIG. 20 is a perspective view of a U-shaped support member of the support frame illustrated in FIG. 13 .
[0068] FIG. 21 is a front view of the U-Shaped support member illustrated in FIG. 20 .
[0069] FIG. 22 is a partial cross-sectional view of the support frame of FIG. 13 illustrating how the U-shaped support members are coupled to the horizontal support members.
[0070] FIG. 23 is a partial cross-sectional view of the support frame of FIG. 13 illustrating how the neighboring horizontal support members are coupled together.
[0071] FIG. 24 is a perspective view of a positioning member of the support frame illustrated in FIG. 13 .
[0072] FIG. 25 is a front view of the positioning member illustrated in FIG. 24 .
[0073] FIG. 26 is a top view of the positioning member illustrated in FIG. 24 .
[0074] FIG. 27 is a side view of the positioning member illustrated in FIG. 24 .
[0075] FIG. 28 is a perspective view illustrating an above ground pool incorporating the support frame illustrated in FIG. 13 .
[0076] FIG. 29 is a perspective view illustrating a third example of an implementation of a support frame of an above ground pool according to the teachings of the present invention.
[0077] FIG. 30 is an enlarged view of the portion A in FIG. 29 .
[0078] FIG. 31 is a front view of the support frame illustrated in FIG. 29 .
[0079] FIG. 32 is a side view of the support frame illustrated in FIG. 29 .
[0080] FIG. 33 is a top view of the support frame illustrated in FIG. 29 .
[0081] FIG. 34 is a perspective view illustrating an above ground pool incorporating the support frame illustrated in FIG. 29 .
[0082] FIG. 35 is a top view illustrating a fourth example of an implementation of a support frame of an above ground pool according to the teachings of the present invention.
DETAILED DESCRIPTION
[0083] The present invention will be further described below in conjunction with particular example implementations and the accompanying drawings. Further details are provided in the following description in order for the present invention to be fully understood. However, the present invention can be implemented in various ways other than those described herein. A person skilled in the art can make similar analogies and modifications according to practical applications without departing from the spirit of the present invention, and therefore the contents of the particular examples herein should not be construed as limiting to the scope of the present invention.
[0084] FIGS. 1-30 illustrate various implementations of a support frame for an above ground pool according to the teachings of the present invention. Referring now to FIGS. 1-3 , FIG. 1 is a perspective view illustrating one example of an implementation of a support frame 10 of an above ground pool according to the teachings of the present invention. FIG. 2 is a front view of the support frame 10 . FIG. 3 is a top view of the support frame 10 .
[0085] As shown, the support frame 10 includes a plurality of horizontal support members 11 and a plurality of vertical support members 12 . The horizontal support members 11 and the vertical support members 12 each include an elongated tubular member with an elliptical cross-section. The vertical support members 12 are coupled to the horizontal support members 11 . The support frame 10 may further include a plurality of T-shaped connectors 13 that are mainly used to couple the horizontal support members 11 and the vertical support members 12 together.
[0086] Referring now to FIGS. 4-6 , FIG. 4 is a partial exploded view of the support frame 10 illustrating how corresponding horizontal support members 11 are coupled with a vertical support member 12 by the T-shaped connector 13 . FIG. 5 is another partial exploded view of the support frame 10 illustrating how corresponding horizontal support members 11 are coupled with a vertical support member 12 by a T-shaped connector 13 . FIG. 6 is a partial cross-sectional view of the support frame 10 illustrating how a horizontal support member 11 is coupled to the T-shaped connector 13 .
[0087] As shown, the T-shaped connector 13 includes a horizontal tubular member 130 and a vertical tubular member 131 . The vertical tubular member 131 is transversely arranged on the horizontal tubular member 130 . In particular, the vertical tubular member 131 is transversely perpendicular to the horizontal tubular member 130 . The horizontal tubular member 130 and the vertical tubular member 131 each have an elliptical cross-section.
[0088] The T-shaped connectors 13 couple two neighboring horizontal support members 11 together in sequence by means of the horizontal tubular member 130 . In this way, the horizontal support members 11 may be coupled together to form a substantially circular ring structure (as best shown in FIG. 3 ).
[0089] Turning back to FIGS. 4 and 5 , a first end 132 of the horizontal tubular member 130 of each T-shaped connector 13 may be detachably coupled to an end 112 of a first corresponding horizontal support member 110 . A second end 133 of the horizontal tubular member 130 may, likewise, be detachably coupled to an end 113 of a second corresponding horizontal support member 111 . The first corresponding horizontal support member 110 and the second corresponding horizontal support member 111 may respectively be coupled to the first end 132 and the second end 133 of the horizontal tubular member 130 by a retainer, as discussed in further detail below. In order to ensure the stability and firmness of the coupling, the retainer should be located proximal the respective points of attachment between the horizontal support members 110 , 111 and the horizontal tube member 130 .
[0090] In some implementations, the retainer may include a retaining pin 14 . In other implementations, the retainer may include claps, threaded fasteners, or other suitable attachment means. As shown in FIG. 4-6 , a first set of positioning holes 134 is provided on the first end 132 and the second end 133 of the horizontal tubular member 130 . A corresponding second set of positioning holes 114 is provided on the end 112 of the first horizontal support member 110 and the end 113 of the second horizontal support member 111 . When the first end 132 and the second end 133 of the horizontal tubular member 130 of the T-shaped connector 13 are respectively butt-jointed to the end 112 of the first horizontal support member 110 and the end 113 of the second horizontal support member 111 , the first set of positioning holes 134 is correspondingly aligned with the second set of positioning holes 114 . In this alignment, the retaining pin 14 may be passed through the first set of positioning holes 134 and the corresponding second set of positioning holes 114 (as shown in FIG. 6 ), so that the horizontal tubular member 130 of the T-shaped connector 13 and the corresponding horizontal support members (i.e., the first horizontal support member 110 and the second horizontal support member 111 ) are, for example, snap-locked together. In some implementations, a bearing pad 140 may be provided between the retaining pin 14 and the horizontal tubular member 130 to reduce the wear between the retaining pin 14 and the horizontal tubular member 130 and increase robustness therebetween.
[0091] Similarly, the vertical tubular member 131 of the T-shaped connector 13 may be coupled to a corresponding vertical support member 12 . As shown in FIGS. 4 and 5 , the vertical tubular member 131 of each T-shaped connector 13 may be detachably connected to the corresponding vertical support member 12 by a spring-loaded latch 15 . During connection, the spring-loaded latch 15 is coupled to an end 121 of the vertical support member 12 . An aperture 122 is provided at an open end of the end 121 . The spring-loaded latch 15 is disposed in the end 121 of the vertical tubular member 131 and engages and is locked with the aperture 122 .
[0092] Referring to FIGS. 7-11 , FIG. 7 is a perspective view of one example of a spring-loaded latch 15 for coupling the vertical support member 12 with a T-shaped connector 13 . FIG. 8 is a bottom view of the spring-loaded latch 15 . FIG. 9 is a side view of the spring-loaded latch 15 . FIG. 10 is a front view of the spring-loaded latch 15 . FIG. 11 is exploded perspective view of the spring-loaded latch 15 .
[0093] As shown, the spring-loaded latch 15 includes a pin boss 150 . The pin boss 150 houses a spring element 151 and a detent pin 152 . The pin boss 150 includes a hollow circular annular outer wall 153 with an outwardly protruding, semi-circular accommodating cavity 154 coupled to an open end of the annular outer wall 153 . The spring element 151 may be mounted within the accommodating cavity 154 such that one end of the detent pin 152 passes through the interior of the accommodating cavity 154 and bears against the spring element 151 , while the other end is outwardly biased, such that a portion of the detent pin may extend out from the accommodating cavity 154 (as best shown in FIGS. 7 and 8 ).
[0094] The annular outer wall 153 may be shaped to match or otherwise complement the cross-section of the end 121 of the vertical support member 12 (as shown in FIGS. 4 and 5 ). When the spring-loaded latch 15 is fitted into the end 121 of the vertical support member 12 , the annular outer wall 153 of the pin boss 150 is embedded in the interior of the end 121 of the vertical support member 12 such that the detent pin 152 snap-fitted into the aperture 122 on the end 121 of the vertical support member 12 under the elastic force of the spring element 151 .
[0095] Turning back to FIG. 5 , an aperture 135 may be formed at an open end of the vertical tubular member 131 of the T-shaped connector 13 . The vertical tubular member 131 is butt-jointed to the end 121 of the vertical support member 12 . The aperture 135 on the vertical tubular member 131 may be aligned with the aperture 122 on the vertical support member 12 , so that the detent pin 152 passes through the apertures 122 and 135 to, for example, snap-lock the T-shaped connector 13 to the vertical support member 12 .
[0096] FIG. 12 is a perspective view of one example of an above ground pool 100 incorporating the support frame 10 . As shown in FIG. 12 , the above ground pool 100 includes the support frame 10 and a pool liner 16 . The pool liner 16 may be affixed to and supported by the support frame 10 to form a pool body for holding water. In some implementations, the upper part of the pool liner 16 may be sheathed on the horizontal support members 11 , and the periphery of the pool liner 16 may lie against the vertical support members 12 .
[0097] In order to further secure the poor liner 16 to the above ground pool 100 , the above ground pool 100 may further include a plurality of tensioning devices 17 and a tensioning belt 18 . The tensioning devices 17 include one or more straps or loops coupled to an outer surface of the pool body. Each tensioning device 17 may be coupled to the outer surface of the body in-between two neighboring vertical support members 12 . The tensioning belt 18 may be alternately weaved about the outer surface of the body through the tensioning devices 17 and over the vertical support members 12 to retain the vertical support members 12 close to the pool body, thereby increasing the tensioning force of the pool body. In some implementations, the tensioning belt 18 may be arranged about the pool body at a height equal to approximately one-third of the height of the pool body. The tensioning belt 18 serves to reinforce the lower structure of the pool body to impart a greater bearing capacity. In some implementations, the above ground pool 100 may further include a plurality of support bases 120 coupled to a bottom end of the vertical support members 12 for improving the overall robustness of the above ground pool 100 .
[0098] Referring to FIGS. 13-16 , FIG. 13 is a perspective view of a second example of a support frame 20 of an above ground pool according to the teachings of the present invention. FIG. 14 is a top view of the support frame 20 . FIG. 15 is a front view of the support frame 20 . FIG. 16 is a side view of the support frame 20 .
[0099] As shown, the support frame 20 includes a plurality of horizontal support members 21 , a plurality of connectors 22 , and a plurality of U-shaped support members 23 . Each horizontal support member 21 has a circular cross-section. The connectors 22 are used to couple corresponding horizontal support members 21 together, and each connector 22 has a circular cross-section. Free ends of the U-shaped support members 23 are connected to the horizontal support members 21 and each U-shaped support member 23 has an elliptical cross-section. The horizontal support members 21 are coupled together in series by the plurality of connectors 22 to form a ring structure. In the present implementation, the connectors 22 may be L-shaped such that the ring structure forms a rectangle. In other implementations, the connectors 22 may have other shapes, such as V-shape, such that the ring structure may for a polygon or other geometric shape.
[0100] FIG. 17 is a partial exploded view of the support frame 20 , illustrating how corresponding horizontal support members 21 are coupled with the U-shaped support members 23 and L-shaped connectors 22 . As shown, when the ring structure forms a rectangle or polygon, the sides of the rectangle or polygon are formed by the horizontal support members 21 . Every two or corresponding horizontal support members 21 are connected in series successively. The corner parts of the sides of the rectangle are formed by the L-shaped connectors 22 connected between corresponding horizontal support members 21 .
[0101] Each horizontal support member 21 is further connected to a corresponding U-shaped support member 23 . The horizontal support members 21 may be affixed to each other via a positioning member 25 . The horizontal support member 21 and the connector 22 may likewise be affixed to each other via a positioning member 25 . However, a coupling 24 may be required to fixedly connect the U-shaped support member 23 and the horizontal support member 21 to each other.
[0102] FIG. 18 is a perspective view of the horizontal support member 21 , and FIG. 19 is a front view of the horizontal support member 21 . As shown in these figures, one end 211 of the horizontal support member 21 includes a reduced diametrical portion and a first aperture 212 in the reduced portion. A second aperture 215 is formed at an opposite end 213 of the horizontal support member 21 . One or more connection opening 214 are formed along a rod surface of the horizontal support member 21 for receiving free ends of a corresponding U-shaped support member 23 .
[0103] Referring now to FIGS. 20-22 , FIG. 20 is a perspective view of the U-shaped support member 23 . FIG. 21 is a front view of the U-shaped support member 23 . As shown in FIGS. 20 and 21 , the free end of the U-shaped support members 23 include a reduced diameter portion 231 having a first set of latching holes 232 spaced apart from a second set of latching holes 233 .
[0104] FIG. 22 is a partial cross-sectional view of the support frame 20 , illustrating how the free ends of U-shaped support members 23 are connected to the horizontal support members 21 . As shown in FIG. 22 , in conjunction with FIG. 17 , the coupling 24 is coupled in the reduced diameter portion 231 of the free ends of the U-shaped support members 23 , such that the U-shaped support member 23 is detachably connected to the ring structure via the coupling 24 . The U-shaped support members 23 support the ring structure in an oblique fashion; for example, the U-shaped support member 23 may be inclined outwardly along the ring structure by 30° or any other suitable angle.
[0105] The coupling 24 may include a flexible V-shaped pin 241 and a hollow casing 242 . The flexible V-shaped pin 241 may include a first pair of studs 243 spaced apart from a second pair of studs 244 .
[0106] The hollow casing 242 includes a pair of orifices 245 and the hollow casing 242 is sheathed outside the reduced diameter portion 231 of the U-shaped support member 23 such that the first set of latching holes 232 and the second set of latching holes 233 are respectively aligned with the orifices 245 . The flexible V-shaped pin 241 is positioned within the reduced diameter portion 231 of the U-shaped support member 23 such that the first pair of studs 243 extends through the second set of latching holes 233 to engage the corresponding orifices 245 . Likewise, the second pair of studs 244 extends through the first set of latching holes 232 . In this way, the U-shaped support member 23 and the horizontal support member 21 may be, for example, snap-locked together via the couplings 24 .
[0107] The hollow casing 242 includes a tube having an oval cross-section corresponding with the cross-section of the U-shaped support members 23 . As such, the connection between the U-shaped support members 23 and the horizontal support members 21 may be more robust.
[0108] FIG. 23 is a partial cross-sectional view of the support frame 20 , illustrating how neighboring horizontal support members 21 are coupled together a positioning member 25 . As shown in FIG. 23 , in conjunction with FIGS. 17-19 , the sides of the rectangle or polygon ring structure are formed by the horizontal support members 21 . Every two or corresponding horizontal support members 21 are connected in series successively via the positioning members 25 . The positioning member 25 is sheathed on the reduced diameter portion of end 211 of one of the horizontal support members 21 , and the other end 213 of the other neighboring horizontal support member 21 is sheathed outside the positioning member 25 , such that the two neighboring horizontal support members 21 are affixed to each other.
[0109] Turing now to the positioning member 25 , FIG. 24 is a bottom perspective view of the positioning member 25 . FIG. 25 is a front view of the positioning member 25 . FIG. 26 is a top view of the positioning member 25 . FIG. 27 is a side view of the positioning member 25 .
[0110] As shown in FIGS. 24-27 , in conjunction with FIG. 17-19 , the positioning member 25 includes a hollow sheathing member 251 comprising a tube with an oval cross-section corresponding to the cross-section of the reduced diameter portion of the horizontal support member 21 . One end of the positioning member 25 is provided with an annular stud 252 . The cross-section of the annular stud 252 corresponds to the cross-section of the horizontal support members 21 . The opposite end of the positioning member 25 is provided with a locking buckle 253 . When two neighboring horizontal support members 21 are connected, one end of the positioning member 25 is sheathed on the reduced diameter portion of one end 211 of one of the horizontal support members 21 , with the other end 213 of the other neighboring horizontal support member 21 is sheathed outside the positioning member 25 . In this way, the locking buckle 253 passes through the second aperture 215 of the other end 213 of the horizontal support member 21 so that the locking of two neighboring horizontal support members 21 can be achieved.
[0111] Likewise, the L-shaped connector 22 and corresponding horizontal support members 21 may also be fixedly locked with each other via the positioning member 25 . For example, one end of the positioning member 25 may be sheathed at one end of the L-shaped connector 22 , while the opposite end 213 of the horizontal support member 21 may be sheathed on the positioning member 25 , such that the locking buckle 253 passes through the second aperture 215 of the opposite end 213 of the horizontal support member 21 and the locking of the horizontal support member 21 and the L-shaped connector 22 can be achieved (not shown in the Figures).
[0112] FIG. 28 is a perspective view illustrating one example of an above ground pool 200 incorporating the support frame 20 . As shown, the above ground pool 200 includes the support frame 20 (as shown in FIG. 13 ) and a pool liner 26 . The pool liner 26 may be affixed to and supported by the support frame 20 to form a pool body for holding water. In some implementations, the upper part of the pool liner 26 may be sheathed on the horizontal support members 21 such that the periphery of the pool liner 26 lies against the U-shaped support members 23 .
[0113] In order to further secure the poor liner 26 , the above ground pool 200 may further include a plurality of support belts 27 . The support belts 27 may be coupled to and arranged about a bottom portion of the body of the pool. Each support belt 27 may be coupled between the bottom portion of the body of the pool and a horizontal portion of a corresponding U-shaped support member 23 . In particular, in order to increase the strength of support of the support belts 27 , each support belt 27 may include a sleeve 271 where the horizontal portion of the U-shaped support member 23 passes through the sleeve 271 of the support belt 27 to tension the support belt 27 .
[0114] Turning to FIGS. 29-34 , FIG. 29 is a perspective view illustrating a third example of an implementation of a support frame 30 an above ground pool according to the teachings of the present invention. FIG. 30 is an enlarged view of the portion A in FIG. 29 . FIG. 31 is a front view of the support frame 30 . FIG. 32 is a side view of the support frame 30 . FIG. 33 is a top view of the support frame 30 .
[0115] As shown in FIG.s 29 - 33 , the support frame 30 may include a plurality of horizontal support members 31 , a plurality of vertical support members 32 , and a plurality of U-shaped support members 34 . The horizontal support members 31 and the vertical support members 32 may each have an elliptical cross-section, and the vertical support members 32 may be coupled to the horizontal support members 31 .
[0116] The support frame 30 may further include a plurality of T-shaped connectors 33 which are used to couple the horizontal support members 31 and the vertical support members 32 together. As best shown in FIG. 30 , the T-shaped connectors 33 may include a horizontal tubular member 330 and a vertical tubular member 331 , where the vertical tubular member 331 is transversely arranged on the horizontal tubular member 330 . In particular, the vertical tubular member 331 is transverse and perpendicular to the horizontal tubular member 330 . Moreover, the horizontal tubular member 330 and the vertical tubular member 331 may each have an elliptical cross-section.
[0117] The T-shaped connectors 33 may be used to couple two neighboring horizontal support members 31 together in sequence via the horizontal tubular members 330 . At the same time, at least some of the neighboring horizontal support members 31 may be connected in series via the positioning members 35 . In this way, the T-shaped connectors 33 and the positioning members 35 together couple the plurality of horizontal support members 31 with one another to form a substantially elliptical ring structure.
[0118] As further shown in FIG. 30 , opposite ends 332 of the horizontal tubular member 330 of each T-shaped connector 33 may be detachably connected to ends of the corresponding horizontal support members 31 . The corresponding horizontal support members 31 may be respectively connected to opposite ends 332 of the horizontal tubular member 330 by a retainer. To ensure the stability and firmness of the coupling, the retainer may be located proximal the respective points of attachment between the horizontal tubular member 330 and the T-shaped connector 33 .
[0119] In like manner, the vertical tubular member 331 of the T-shaped connector 33 may be coupled to a corresponding vertical support member 32 . The vertical tubular member 331 of each T-shaped connector 33 may be detachably connected to the corresponding vertical support member 32 by a spring-loaded latch.
[0120] It should be noted that the structure of the T-shaped connector 33 in the present example is the same as that of the T-shaped connector 13 in the example above. In particular, the manner in which the T-shaped connectors 33 are coupled to the horizontal support members 31 and the vertical support members 32 is the same as that described the examples above. The structure of the positioning member 35 in the present example is also the same as that of positioning member 25 in the example above, and the manner in which the positioning member 35 is connected to the horizontal support member 31 is the same as that of the first example above, the detailed description of which is omitted for brevity.
[0121] The U-shaped support members 34 may be detachably connected to the ring structure via the couplings. The U-shaped support members 34 support the ring structure in an oblique fashion. For example, a U-shaped support member 34 may be inclined outwardly along the ring structure by angle of 30°. It is further noted that free ends of the U-shaped support members 34 are coupled to the corresponding horizontal support members 31 , and each U-shaped support member 34 has an elliptical cross-section. The structure of the U-shaped support member 34 in the present example is the same as that of the U-shaped support member 23 in the second example, and the manner in which the U-shaped support member 34 is coupled to the horizontal support member 31 is the same as that described in the second example, the detailed description of which is omitted for brevity.
[0122] FIG. 34 is a perspective view of illustrating one example of an above ground pool 300 incorporating the support frame 30 . As shown, the above ground pool 300 includes the support frame 30 (as shown in FIG. 29 ) and a pool liner 36 , where the pool liner 36 may be affixed to and supported by the support frame 30 to form a pool body for holding water. In some implementations, the upper part of the pool liner 36 may be sheathed on the horizontal support members 31 such that the periphery of the pool liner 36 lies against the vertical support members 32 .
[0123] In order to further secure the poor liner 36 , the above ground pool 300 may further include a plurality of tensioning devices 37 and a tensioning belt 38 . The tensioning devices 37 may be coupled to an outer surface of the pool body. In some implementations, each tensioning device 37 may be coupled to the outer surface of the body in-between two neighboring vertical support members 32 . The tensioning belt 38 may be alternately weaved about the outer surface of the body through the tensioning devices 37 and over the vertical support members 32 to retain the vertical support members 32 close to the pool body, thereby increasing the tensioning force of the pool body. In some implementations, the tensioning belt 38 may be arranged about the pool body at a height equal to approximately one-third of the height of the pool body to effectively reinforce the lower structure of the pool body to impart a greater bearing capacity. In some implementations, the above ground pool 300 may further include a plurality of support bases 320 , where the support bases 320 are coupled to a bottom end of the vertical support members 32 for improving the overall robustness of the above ground pool 300 .
[0124] The above ground pool 300 may further include a plurality of support belts 39 that may be coupled to and arranged about a bottom portion of the body of the pool. Each support belt 39 may be coupled between the bottom portion of the body of the pool and a horizontal portion of a corresponding U-shaped support member 34 . In particular, in order to increase the strength of support of the support belts 39 , each support belt 39 may include a sleeve 391 adapted to allow the horizontal portion of the U-shaped support member 34 to pass through the sleeve 391 of the support belt 39 to tension the support belt 39 .
[0125] FIG. 35 is a top view illustrating a fourth example of an implementation of a support frame 40 of an above ground pool according to the teachings of the present invention. As shown, the support frame 40 is substantially the same as that of the support frame 30 of the previous example, except that support frame 40 includes a plurality of horizontal support members 41 , a plurality of arcuate support members 42 , a plurality of vertical support members (not shown), and a plurality of U-shaped support members 44 . The horizontal support members 41 , the arcuate support members 42 , the U-shaped support members 44 and the vertical support members may each have an elliptical cross-section. The vertical support members may be coupled to the plurality of arcuate support members 42 in an upright or vertical fashion. The U-shaped support members 44 may be coupled to the horizontal support members 41 in an oblique fashion.
[0126] The support frame 40 may further include a plurality of T-shaped connectors 43 , each comprising a horizontal tubular member and a vertical tubular member. The vertical tubular member is transversely arranged on the horizontal tubular member. In some implementations, the vertical tubular member is transversely perpendicular to the horizontal tubular member.
[0127] The horizontal tubular member and the vertical tubular member may each have an elliptical cross-section. The connectors 43 couple two neighboring arcuate support members 42 together in sequence via the horizontal tubular members. At the same time, the horizontal support members 41 are connected in series via the positioning members 45 . In this way, the T-shaped connectors 43 and positioning members 45 couple the horizontal support members 41 and the arcuate support members 42 with one another to form an elliptical ring structure.
[0128] It should be noted that the structure of the T-shaped connector 43 in the present example is the same as that of the T-shaped connectors described in the previous examples, and the T-shaped connector 43 is coupled to the arcuate support member 42 and the vertical support member in the same manner as that described in the first example above. The structure of the positioning member 45 in the present example is the same as that of the positioning member 25 in the second example above. The positioning member 45 is, further, connected to the horizontal support member 41 in the same manner as that described in the first example above.
[0129] Further, the structure of the U-shaped support member 44 in the present example is the same as that of the U-shaped support member 23 in the second example. The U-shaped support member 44 may be coupled to the horizontal support member 41 in the manner as that described in the second example above, the detailed description of which is omitted for brevity.
[0130] In summary, by improving the structure of the support frame, a more robust above ground pool structure with a high bearing capacity may be achieved according to the teachings the present invention. The support frame is at least partially composed of tubes having an elliptical cross-section. Due to the symmetric shape of the cross-section of the elliptical tubes, difficulties in the manufacture of the tubes are reduced, thus effectively improving the support frame's stability. A slight clearance fit between the ends of the elliptical tubes and each connector enables the support frame to withstand large mechanical stresses and contributes to its enhanced stability. In addition, a tailored bolt connection is provided between the ends of the elliptical tubes and each connector, which is more secure and provides greater structural strength. Therefore, above ground pools according to the teachings of the present invention provide better bearing performance and the overall stability and safety performance than existing above ground pool designs.
[0131] The various components of the support frame of the present invention may be constructed from molded or machined stainless steel, aluminum, metal, iron, plastic, fiberglass, composite, polycarbonate, alloy, or other suitable materials. The pool liner, tensioning devices, tensioning belt, and support belt of the present invention may be constructed of flexible reinforced polyvinyl chloride (PVC), polyurethane (PU) cloth, plastic, canvas, tactical nylon webbing, or any other durable material. Above ground pools of the present invention may further incorporate other components not shown or described herein, such as water pumps, valves, piping, motors, or other pool components and accessories known in the art.
[0132] In general, terms such as “coupled to,” and “configured for coupling to,” and “secured to,” and “configured for securing to” and “in communication with” (for example, a first component is “coupled to” or “is configured for coupling to” or is “configured for securing to” or is “in communication with” a second component) are used herein to indicate a structural, functional, mechanical, electrical, signal, optical, magnetic, electromagnetic, ionic or fluidic relationship between two or more components or elements. As such, the fact that one component is said to be in communication with a second component is not intended to exclude the possibility that additional components may be present between, and/or operatively associated or engaged with, the first and second components.
[0133] While the detailed embodiments of the present invention have been described, a person skilled in the art should understand that these are merely illustrative, and that the scope of the present invention is defined by the appended claims. Various alterations or modifications can be made by a person skilled in the art to these embodiments without departing from the spirit of the present invention. However, these alterations and modifications shall all fall within the scope of the present invention.
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An above ground pool is provided. The above ground pool includes a support frame and a pool liner. The pool liner is affixed to and supported by the support frame to form a body for holding water within the pool. The support frame includes a series of horizontal support members and vertical support members, each having an elliptical cross-section. The symmetric shape of the cross-section of the elliptical tubes reduces the difficulties inherent in machining tube bends, simplifies the manufacturing of the tubes, effectively improves the support frame's stability, and facilitates quality control. The horizontal support members and vertical support members are coupled together by one or more connectors to form an enclosed or ring structure.
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BACKGROUND
[0001] Recreational sports in the United States are extremely popular among people of almost all age groups. Peewee soccer, peewee baseball, and adult softball, baseball, and soccer leagues are just a few examples of organized recreational activities enjoyed by sports enthusiasts.
[0002] The popularity of these sports has driven growth in an industry that provides practice equipment and practice facilities to sports enthusiasts. A batting cage is an example of such a facility that allows players to practice hitting baseballs or softballs, which are mechanically thrown to the batter. These mechanical pitching machines usually include a rotating wheel or arm that throws the ball, a ball hopper, and a means to automatically collect the balls. A similar concept is employed to launch tennis balls and soccer balls to practicing players. The players receive feedback based on how far and what direction the ball travels once hit or kicked. This feedback is subjective and typically is not recorded for comparison to subsequent or previous performance.
[0003] Over the past 30 years or so, changes have been made to improve practice equipment. The main improvements have been more accurate pitching and rolling machines and the introduction of selectable pitching/rolling speeds. Although some changes have been made to the pitching/rolling equipment, an opportunity for improving the overall experience of simulated play still exists. This opportunity arises from the fact that some players who enjoy recreational sports cannot endure the physical stress or time commitments normally associated with participating in an organized league. Also, parents and children usually belong to separate leagues based on age. Thus, there is no known way for both age groups to compete against one another fairly while enjoying the scoring aspects of their chosen sport.
[0004] Accordingly, there is a need for equipment and facilities that can simulate a league experience with head-to-head competition without the commitment of time or the rigors of actual play. In addition, there is a need for a practice facility that can pit players of different skill levels or abilities against one another while accounting for their differences in ability to make for a competitive experience.
SUMMARY
[0005] Provided herein is an improvement for a practice facility that simulates a sport playing environment, wherein the facility has a projectile striking region and a target region for the projectile. The improvement is a computerized feedback system that includes an input device for receiving participant credentials sufficient to activate the computerized feedback system and an output device for displaying perceptible output to a participant. A target array including at least one target is removably mounted in the target region and operative, when stimulated by the projectile, to produce at least one feedback signal. A data processing device is included that is adapted to receive each feedback signal produced by the target array, process selected feedback signals according to rules for the sport in order to generate processed data, and selectively transmit the processed data to the output device.
[0006] The target array may include a plurality of targets correlated to the sport and be stimulated upon impact by the projectile. The input device, such as a card reader, and the output device may be included in a kiosk. The participant's credentials and selected processed data may be stored on a memory device readable by the kiosk. The data processing device may also be adapted to update the data stored on the memory device.
[0007] Also contemplated is a gaming system for simulating a competitive sport involving a projectile that includes a plurality of practice facilities each including a simulated playing environment correlated to the sport, wherein the playing environment has a projectile striking region and a target region for the projectile. Each practice facilities also includes a target array including at least one target removably mounted in the target region and operative, when stimulated by the projectile, to produce at least one feedback signal. A kiosk is included in each practice facility that includes an input device for receiving participant credentials and an output device for displaying perceptible output to the participant. The gaming system includes a data processing system including at least one data processing device associated with each facility. The data processing system is adapted to receive feedback signals produced by the target arrays, process selected ones of the feedback signals according to rules for the sport in order to generate processed data, and selectively transmit the processed data to the output devices. Each of the kiosks may include a data processing device.
[0008] The data processing system may be adapted to determine relative skill levels among participants in order to generate ranking data. Selected ranking data may be stored on a memory device readable by the kiosk. The data processing system is adapted to update data, such as ranking data, stored on the memory device. The sport may be selected from the group consisting of baseball, softball, soccer, tennis, hockey, and golf, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a batting cage according to the exemplary embodiment of the present invention showing the interconnection of the scoring targets, computer kiosk, server, database, and Internet;
[0010] FIG. 2 is a front view in elevation of the batting cage shown in FIG. 1 further illustrating the scoring targets;
[0011] FIG. 3 is a partial cross-section of a target showing the construction of the target and sensor mounting;
[0012] FIG. 4 is a perspective view of the kiosk introduced in FIG. 1 as viewed from the front of the kiosk;
[0013] FIG. 5 is a schematic representation of a network interconnecting a plurality of practice facilities with a database;
[0014] FIG. 6 is a perspective view of a soccer practice cage showing the interconnection of the scoring targets, computer kiosk, server, database, and Internet;
[0015] FIG. 7 is a front view in elevation of the soccer practice cage shown in FIG. 4 further illustrating the scoring targets; and
[0016] FIG. 8 is a perspective view of the kiosk shown in FIG. 4 as viewed from the front of the kiosk.
DETAILED DESCRIPTION
[0017] Provided herein is a real-time scoring feedback and long term statistical tracking system. The system includes scoring targets with sensors, computer hardware, software database technology, and display or point-of-sale kiosks. The targets can be adjusted and configured to simulate a multitude of different sports. In addition, the system can be configured for retrofit installation on existing practice facilities such as a batting cage facility. The exemplary embodiment of the present invention is described with respect to the games of baseball, softball, and soccer. It should be understood, however, that the invention may be applied to other games, such as tennis, hockey, and golf, where a projectile is directed by the actions of a player. The scoring system also allows players of all ages to compete against one another, regardless of skill or talent level. Players may also compete head-to-head or against a group of players by recording each player's scores and tracking them against other players either locally (at the same facility) or remotely (another town, state or nationwide) thru an Internet web site. As used herein the term score refers to a player successfully impacting a target with a projectile. For example, in the case of a batting cage, this may constitute impacting the home run target with a baseball. Similarly, in the case of a soccer practice facility, a score would constitute hitting a target within the simulated goal.
[0018] FIG. 1 illustrates a first exemplary embodiment of a practice facility 10 incorporating the real-time scoring, feedback, and long-term statistical tracking system, generally referred to as a feedback system. In general the figures diagrammatically represent various components of the system and are for explanation purposes only. In this case the practice facility 10 is a batting cage 20 configured for batting practice with softballs or baseballs. Batting cage 20 includes a cage frame 22 . In this case frame 22 is 12 feet wide, 15 feet high, and 65 feet long. Frame 22 is preferably covered with netting to form roof 21 , end-walls 24 and 25 , and sidewalls 26 and 28 . There is a door 23 for player entrance in the front of the cage 20 . Simulated playing surface 27 includes a standard home plate 32 and batter's box 33 located in the striking region, which is front and center of cage 20 . First and third base path lines 34 are also shown on the floor of the cage for aesthetic purposes. Batting cages as described above are available from suppliers, such as Athletic Training Equipment Company, Inc. of Sparks, Nev.
[0019] A point-of-sale and session display kiosk 40 is located in the front of the cage 20 in the right corner. Pitching and ball retrieval machine 30 is located in the center of the cage 20 . Suitable pitching and ball retrieval machinery 30 is available from suppliers, such as Athletic Training Equipment Company, Inc. of Sparks, Nev. Scoring area or target region 80 includes targets (single 86 , double 88 , triple 82 , and home run 84 ) that are securely mounted to the back wall 25 of cage 20 . Each target is connected to the computer server 60 located outside the cage 20 . Any suitable communication link 41 , such as wireless, Ethernet cables, or the like may be used to interconnect the computer server 60 , the kiosk 40 , and the targets. A database 50 for maintaining player statistics may be stored in server 60 . The server 60 may be located onsite or offsite and connected to kiosk 40 via a data network 70 , such as the Internet. In an alternative construction the server 60 may reside within the kiosk 40 .
[0020] Target region 80 is shown in more detail in FIG. 2 , which shows the practice facility 10 as viewed from the batter's perspective from the front of cage 20 looking towards the target area 80 and back wall 25 . Target area 80 includes two “SINGLE” targets 86 that are preferably mounted 8 feet from the floor of the cage. “SINGLE” targets 86 are preferably 10 feet long by 1 foot high. Target area 80 also includes two “DOUBLE” targets 88 , which are preferably located 6 inches above the “SINGLE” targets 86 . “DOUBLE” targets 88 are preferably 6 feet long by 1 foot high. “HOME RUN” targets 84 are preferably located 6 inches above the “DOUBLE” targets 88 . “HOME RUN” targets 84 are preferably 6 feet long by 2 feet high. Finally, there are two circular shaped “TRIPLE” targets 82 located in the upper left and right hand corners of the target area 80 . “TRIPLE” targets 82 are, in this case, approximately 3 feet in diameter.
[0021] With reference to FIG. 3 (showing “SINGLE” target 86 ) it can be seen that each target is constructed of ½ inch thick steel plate 81 . Each target also includes a durable padded cover to dampen the velocity of projectiles (in this case baseballs) in order to minimize rebounding of the projectiles. In this case the padded cover is constructed of foam 83 , which is covered by a vinyl cover 85 . The scoring indicia may be etched, embossed or otherwise formed or painted onto the cover 85 for easy visibility. Located on the back of each target is a sensor 87 that is stimulated when the target is struck or impacted by a projectile, thereby triggering a feedback signal indicative of the projectile impacting the target. Sensor 87 may be of the type known as a knock or vibration sensor to name a representative few. The sensor 87 electronically sends the impulse to connected computer hardware and software. Sensors, connections, and wiring are constructed to withstand inclement weather (rain, snow, sleet, hail, etc.) and temperature ranges (−10 to +120 degrees Fahrenheit).
[0022] As targets are hit and scores are registered the player's score is displayed in real time on the point-of-sale kiosk 40 next to the batter in the front of the cage. As illustrated in FIG. 4 the display kiosk 40 is comprised of a base portion 48 and a display portion 49 . The base portion 48 is constructed of a 3-foot by 3 foot, square steel box. Base portion 48 includes a bar-coded card reader 43 , a ball speed/difficulty selector 47 , a ball type (baseball or softball in this case) selector 45 and a game-processing computer 42 . The display portion 49 of the kiosk 40 is preferably a 24-inch display screen housed in ½ inch thick fiberglass secure casing for security and protection. Preferably, the kiosk is built to withstand inclement weather (rain, snow, sleet, hail, etc.) and temperature ranges (−10 to +120 degrees Fahrenheit).
[0023] The display kiosk 40 houses a computer 42 that tallies the player's scores and calculates simulated player movements and positions, which are then displayed on display 49 . Card reader 43 reads pre-registered bar-coded customer cards 44 , which are tracked to individual account numbers. Players may obtain a customer card 44 by filling out a preprinted registration form or registering online via the Internet. Players swipe their card 44 thru card reader 43 to start each game session. All targets hit are recorded and tracked to the player's account number. The customer's card 44 preferably holds characteristic information about the player such as name, age, height, skill level, preferred pitching speed, batting average, ranking, and the like. Based on the player's information the computer 42 can automatically adjust for ball speed and simulated player movements, for example. Thus the system compensates for players' differences allowing fair head to head play between players of disparate skill level or age. The kiosk 40 may accept prepaid payments for a session via the customer cards 44 and the card reader 43 . Alternatively, the kiosk may use point of sale payment options.
[0024] Hits, runs, and goals scored are tracked via server 60 with database software 50 that logs and tracks each successfully hit target. Preferably the statistics are uploaded in real time from the kiosks 40 to the database 50 . FIG. 5 illustrates a representative network where a plurality of practice facilities 10 and 10 ′ are connected to the central database 50 via a data network 70 , such as the Internet. Players can access their statistics (hits, runs, batting average, RBIs, goals scored, national rankings, etc.) and where they rank nationally within their age or skill group. Players may also join leagues on a web site using a secure login and password that is unique for each player. Players may view previous session statistics anytime via a standard Internet web site connection 75 .
[0025] FIGS. 6-8 show a soccer practice facility 210 . Soccer practice facility 210 is similar to the practice facility shown in FIGS. 1-5 except that the playing surface 227 , target area 280 , and machinery 230 are configured for practicing soccer. Soccer practice facility 210 includes a cage 220 , which is 12 feet wide and 65 feet long. A point-of-sale and session display kiosk 240 is located in the front of the cage in the right corner. A square box 232 is located near the front of the cage on playing surface 227 and is used as the player's starting point for kicking balls that are rolled to the player in regular intervals. Ball rolling and retrieval machinery 230 is located in the center of the cage near the back with a protective screen or fencing in front for protection. Game targets 282 , 284 , 286 , and 288 are located in the upper and lower corners of a simulated soccer goal at the back of the cage. Each target is connected to the computer kiosk 240 . The computer server 260 is connected either directly or via the Internet, to the point-of-sale and display kiosk 240 . The targets, kiosk, and server may all be interconnected with any suitable communication link 241 , such as wireless, Ethernet cables, or the like.
[0026] Accordingly, the present invention has been described with some degree of particularity directed to the exemplary embodiments of the present invention. It should be recognized, however, that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the exemplary embodiments of the present invention without departing from the inventive concepts contained herein.
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An improvement for a practice facility that simulates a sport playing environment, wherein the facility has a projectile striking region and a target region for the projectile. The improvement is a computerized feedback system that includes an input device for receiving participant credentials sufficient to activate the computerized feedback system and an output device for displaying perceptible output to a participant. A target array including at least one target is removably mounted in the target region and operative, when stimulated by the projectile, to produce at least one feedback signal. A data processing device is included that is adapted to receive each feedback signal produced by the target array, process selected feedback signals according to rules for the sport in order to generate processed data, and selectively transmit the processed data to the output device.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. Ser. No. 07/930,088, filed Aug. 14, 1992, now abandoned; which is a divisional of U.S. Ser. No. 07/543,655, filed Jun. 26, 1990, abandoned; which is a divisional of U.S. Ser. No. 07/202,758, filed Jun. 3, 1988, which issued as U.S. Pat. No. 4,956,184; which is a continuation-in-part of U.S. Ser. No. 07/190,798, filed May 6, 1988, abandoned.
TECHNICAL FIELD
This invention relates generally to topical formulations that are useful for treating various dermatologic disorders, including genital herpes lesions, facial and body acne, topical fungal infections, psoriasis, eczema, dandruff, skin ulcers (e.g., decabutus), and other dermatologic diseases associated with microbial proliferation. This invention also relates to the anti-inflammatory properties and uses of pharmaceutical compositions.
BACKGROUND OF THE INVENTION
There are a Large number of dermatologic diseases that are thought to be caused by microbial overgrowth somehow result in a dermatologic infection and/or inflammatory reaction. These diseases include acne vulgaris and other pilosebaceous inflammatory disorders, which are thought to be caused in part by an overgrowth of the anaerobic bacterium Propionibacterium acnes (P. acnes), which is normally present in the sebaceous follicles but proliferates in large numbers during acute acne. P. acnes generates a lipase, a protease, and other potentially damaging substances. Follicular contents are known to be chemo-attractive for leukocytes, and complement activation is probably also important in the inflammatory process. Although the precise mechanisms are not entirely clear, inflammation and edema in the follicular wall result in follicular rupture, leaking follicular contents into the surrounding dermis and creating further inflammation. The visible consequence of this series of dermal events is a deep inflammatory nodule, called a "cyst." An accumulation of neutrophils in the mouth of a follicle produces a pustule. Deep inflammatory or cystic lesions may arise from preexisting closed comedones in an area of normal-appearing skin.
Genital herpes is also called "Herpes Progenitalis" and is caused by the herpes simplex virus, usually type 2. Primary genital herpes follows an incubation period of 3 to 7 days. The disease can be found by localized burning or paresthesia and followed by eruption of grouped vesicles, often at multiple sites on the genitalia. The lesions generally heal in 2 to 4 weeks, but the virus remains in the nerve heads and can remain dormant or trigger secondary lesions by migrating down the nerve fiber to the nerve ending to reproduce into more lesions. Recurrent genital herpes is common after the primary infection. Secondary lesions heal within two weeks, and secondary attacks become less frequent with time. Treatments include drying agents to symptomatically lessen the discomfort of the lesion. Acyclovir, applied topically, tends to decrease pain of the primary lesions, but it has not proven very effective for decreasing vital shedding or lesion duration. Topical acyclovir has not been shown to be particularly effective for reducing or treating recurrent disease.
Acyclovir is a purine nucleoside analog that is selectively cidal to the herpes simplex virus because only the thymidine kinase enzyme of herpes simplex virus can convert acyclovir to its monophosphate form while host cell thymidine kinase cannot. The monophosphate form is converted to an acyclovir triphosphate, which can interfere with vital DNA replication. Topical acyclovir is applied as a 5% ointment every three hours, or up to eight times daily, for at least seven days. The up to eight-times-a-day dosing is a difficult procedure for patients and creates patient compliance problems for dosing in the genital areas throughout the day and throughout the night. A further problem of acyclovir has been the development resistant strains of herpes simplex, caused by a mutation of the thymidine kinase gene. Accordingly, no backup treatments are available for acyclovir-resistant herpes simplex infections. This problem exists with most antibiotic microbial treatments, but is generally not a problem non-antibiotic treatments.
Topical fungal or yeast diseases represent a large class of diseases. These can include tinea versi color, which is a superficial fungal infection caused by the lipophilic yeast Pityrosporum orbiculare. The infected areas do not pigment normally and produce a whitish, spotted appearance in dark-skinned or tanned persons. Treatments include the use of dandruff shampoos on the affected areas and typical antifungal agents, including the imidazole derivatives miconazole and clotrimazole. Fungal lesions on the skin surface are named "tinea" and the Latin name of the particular type of location. For example, "tinea capitis" is for scalp lesions, while "tinea cruris" is for groin lesions. Tinea cruris is often manifest as symmetrical scaly patches on the inner surfaces of the thighs. The infection spreads with a central clearing area and a sharply demarcated border. Itching is common and severe. The major causitive organisms are T. rubrum, T. mentagrophytes, and Epidermophyton floccsum.
Tinea pedis is commonly called "athlete's foot." It is often caused by Trichophyton rubrum or Trichophyton mentagrophytes. It often begins as a scaly lesion between the toes and spreads to produce an acute inflammatory vesicular disease, accompanied by itching, burning and pain. Tineas corpotis is also called "ringworm" and is a dermatophyte infection involving nonspecific areas of skin. The infection is an erythematous, scaly patch on the skin with sharp, acute borders and central clearing. Current treatments for topical fungal diseases include the imidazole derivatives, miconazole and clotrimazole. Griseofulvin is a systemic agent, and ketoconazole is also used systemically but is expensive and is associated with severe side effects. Side effects of griseofulvin include headaches and abdominal discomfort.
Eczema is a superficial inflammation of the skin characterized by an initial erythematous, papulovesicular process often accompanied by oozing and crusting and followed by a chronic phase of scaling, thickening and post-inflammatory pigment changes. Causes of eczema are largely uncertain but can include fungal infection. Treatments are largely symptomatic and can include topical corticosteroids for the inflammatory reaction.
Psoriasis is a papulosquamous disease characterized by chronic periodic remissions and exacerbations. Lesions usually consist of erythematous plaques with silvery scale, and possibly a pustular form. The causes of psoriasis include several theories. One theory advances that psoriasis is an inflammatory overreaction to a yeast infection, such as that caused by P. ovale. The disease is characterized histologically by accelerated cellular turnover. Psoriasis is a chronic condition and an affected individual can develop lesions at any time. Treatments vary, depending on what one believes is the cause of the disease. However, no single treatment has yet proven to be successful for a wide variety of cases.
Dandruff is a scaling condition of the scalp. It is thought to be caused by an overgrowth of P. ovale, a yeast. Treatment is usually an antimicrobial agent such a pyrithione zinc, a keratolytic agent such as salicylic acid, or by a cytostatic agent such as a coal tar.
Stasis dermatitis is a leg ulcer and is a form of eczema and often the result of venous insufficiency. It often develops in a patch just distal to where a vein was removed for a bypass procedure. Treatment is usually with a topical steroid or with an antibacterial and keratolytic agent, such as 20% benzoyl peroxide.
Acquired Immune Deficiency Syndrome (AIDS) is believed to be spread by sexual contact, and more specifically, through transmission of the HIV virus. The current preventive means for transmission by sexual contact with an individual suspected of harboring the HIV virus is a barrier, such as a condom. At present, there are no known virucidal chemical barrier preparations available that can be used alone or with a condom for prevention of the spread of HIV during sexual contact.
Anti-inflammatory agents are usually classified as steroid or non-steroidal agents. The non-steroidal anti-inflammatory agents most often function by inhibition of prostaglandin or leukotriene biosynthetic pathways. For example, non-steroidal anti-inflammatory drugs such as aspirin (acetylsalicylic acid), indomethacin, and ibuprofen are known to inhibit the fatty acid cyclooxygenase enzyme in the prostaglandin pathway from arachidonic acid. Steroid drugs have anti-inflammatory activity but also have numerous side effects, including sodium retention, hepatic deposition of glycogen, and dramatic redistribution of body fat. The steroid anti-inflammatory properties are mediated by inhibiting edema, fibrin deposition, capillary dilation, migration of leukocytes, and deposition of collagen. Steroid anti-inflammatory agents have immunosuppressant side effects.
While it is difficult to give an adequate description of the inflammatory phenomenon in terms of the underlying cellular events in the injured tissue, there are certain features of the process that are generally agreed to be characteristic. These include fenestration of the microvasculature, leakage of the elements of blood into the interstitial spaces, and migration of leukocytes into the inflamed tissue. On a macroscopic level, this is usually accompanied by the clinical signs erythema, edema, tenderness (hyperalgesia), and pain. During this complex response, chemical mediators such as histamine, 5-hydroxytryptamine (5-HT), slow-reacting substance of anaphylaxis (SRS-A) , various chemotactic factors, bradykinin, and prostaglandins are liberated locally. Phagocytic cells migrate into the area and cellular lysosomal membranes may be ruptured, releasing lytic enzymes. All these events may contribute to the inflammatory response. However, aspirin-like drugs have little or no effect upon the release or activity of histamine, 5-HT, SRS-A, or lysosomal enzymes; and similarly, potent antagonists of 5-HT or histamine have little or no therapeutic effect on inflammation.
The inhibition of prostaglandin biosynthesis by aspirin and other non-steroidal anti-inflammatory agents, such as ibuprofen, has been demonstrated in three different systems, cell-free homogenates of guinea pig lung, per fused dog spleen, and human platelets. There are now numerous systems in vitro and in vivo in which inhibition of prostaglandin biosynthesis by aspirin, ibuprofen, or similar compounds has been demonstrated, and it is evident that this effect is not restricted to any one species or tissue. The effect is dependent only on the drug reaching the enzyme, cyclooxygenase (prostaglandin synthetase); the distribution and pharmokinetics of each agent thus have an important bearing on the drug's activity.
The migration of leukocytes into inflamed areas is an important component of inflammation. Although the classical aspirin-like drugs (salicylates, pyrazolone derivatives, ibuprofen, indomethacin, etc.) block prostaglandin biosysthesis, they do not inhibit the formation of the major chemotactic metabolite of arachidonic acid, HETE, and may even increase concentrations of this compound in tissues.
Hypoxia and ischemia are inevitable fates of any kind of tissue injury. Oxygen tension in tissue wounds, when measured by implanted polarographic oxygen electrode, was found to be only 5 to 15 mm Hg, as compared to control tissue values of 40 to 50 mm Hg. ( Sheffield, "Tissue Oxygen Measurements with Respect to Soft Tissue Wound Healing with Normobaric and Hyperbaric Oxygen," Hyperbaric Oxygen Rev. 6:18-46, 1985.) Tissue ischemia is associated with an inflammatory response mediated by stimulated Hagemann factor arid complement cascades. (Weiss et al., "Phagocyte-Generated Oxygen Metabolites and Cellular Injury", Lab Invest. 47:5-18, 1982.) These factors activate polymorphonuclear leukocytes (PMNs) and result in a massive influx of phagocytic leukocytes into the wound. Paradoxically, the antimicromial properties of PMNs are greatly impaired in the ischemic wound region in vivo because of the lack of molecular oxygen. (Mandell, "Bactericidal Activity of Aerobic and Anaerobic Polymorphonuclear Neutrophils," Infect. Immunol. 9:337-41, 1974.) Oxygen therapy, including hyperbaric oxygen treatment, has been suggested to facilitate wound healing and is often used as adjunctive therapy in problem wounds and wound infections. However, the optimal times and mode of oxygen therapy still remain clouded. Oxygen radicals are involved in the phagocytic actions of PMNs, which, upon activation, generate superoxide and hydroxyl radicals as well as hydrogen peroxide and hypochlorous acids at the site phagocytosis.
Any wounding, whether surgical or traumatic causes disruption of blood vessels, tissue hemorrhage, activation of Hageman factor, and stimulation of complement pathways. These morphologic and biochemical events result in the massive influx of PMNs into the wound site and the production of superoxide radicals by PMNs as part of the phagocytic response [Reaction (i)]. The generated superoxide radicals undergo the Haber-Weiss reaction [Reaction (ii)] or iron-catalyzed Fenton type reactions [Reaction (iii)], producing cytotoxic OH radicals and H 2 O 2 , which ultimately form hypohalite radicals via the myeloperoxidase, system [Reaction (iv)]. ##STR1##
Although the presence of these oxygen-free radicals is necessary for the oxidative killing of microorganisms, excessive generation of these cytotoxic radicals may be extremely harmful to native tissues. Tissues are generally equipped with adequate antioxidative defense systems, consisting of such enzymes as superoxide dismutase, catalase, and glutathione peroxidase. However, these antioxidative enzymes are known to be reduced during ischemia and hypoxia.
Accordingly, there is a need in the pharmaceutical art for a therapeutic agent that has both strong and broad spectrum antimicrobial properties for a wide variety of bacterial, fungal, vital, and yeast infections, as well as anti-inflammatory activity, yet not be an antibiotic with the risk of developing resistant microbial strains. It is further desirable to develop a chemical agent that can be used as an antimicrobial sexual barrier and lubricating gel that has strong antiviral properties to kill active HIV virus and thereby help prevent the spread of AIDS. There is also a need in the pharmaceutical art for an anti-inflammatory therapeutic agent that does not possess the side effect problems of the aspirin-like nonsteroidal anti-inflammatory agents or the immunosuppressant properties of the corticosteroids.
SUMMARY OF THE INVENTION
The aforementioned therapeutic problems are treated by a strongly antimicrobial and anti-inflammatory formulation wherein the active antimicrobial and/or anti-inflammatory effects are provided by a composition which comprises a chlorine dioxide liberating compound and a protic acid. Preferably, the chlorine dioxide liberating compound is an alkaline metal chlorite. Most preferably, the chlorine dioxide generating compound is sodium chlorite or potassium chlorite. Topical formulations are useful for the topical treatment of dermatologic disorders thought to be caused by overgrowth of pathogenic microorganisms that possibly result in an inflammatory response, or for inflammatory conditions. These dermatologic disorders include topical fungal diseases, vital lesions such as from genital herpes, and inflammatory/bacterial disorders such as acne. Additionally, the formulations containing the active agents of the present invention are useful for the treatment of decubitus ulcers, psoriasis, eczema and as an antimicrobial sexual lubricant to prevent the transmission of sexually transmitted diseases, such as HIV (AIDS), chlamydia, genital herpes, warts, gonorrhea, and syphilis. Systemic formulations that are administered orally, or by injection into muscles, joint capsules, peritoneum, intralymphatically or directly into inflamed tissue. The inventive formulations have an added benefit of broad spectrum antimicrobial activity.
All of the formulations involve infusion, tissue, dermatologic or topical uses of a formulation containing chlorous acid in metastable balance, which provides chlorine dioxide as the active antimicrobial and anti-inflammatory agent. The formulations involve two solutions, gels, or creams adapted to be mixed and either infused or injected into the site of activity, taken orally, or topically applied so as to adhere to the epithelial surface and penetrate into the dermis. The first solution, gel, or cream contains an amount of metal chlorite, such that, when combined in equal parts with the first gel, the chlorite ion concentration in the form chlorous acid is no more than about 15% by weight of the total amount of chlorite ion concentration. The second solution, gel, or cream contains an aqueous solution containing suitable amounts of a protic acid. Preferably, the first gel contains a polysulfonic acid wherein the anion of the salt has the formula: ##STR2## wherein X has a value such that the molecular weight of the anionic portion of the polymer is from about 1,000,000 to about 5,000,000 daltons.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the in vitro chemotaxis of the inventive composition at the active concentration of Example 1 and the non-steroidal anti-inflammatory agent ibuprofen (0.5 mg/ml). The inventive composition is shown by and ibuprofen by . When there is a dotted Line, the inventive composition and ibuprofen were reacted with BSA (bovine serum albumin).
FIG. 2 shows the effect of the inventive composition (called "Alcide") and ibuprofen on the thiobarbituric acid-reactive material production at the wound site during the healing process.
FIG. 3 shows the effect of the inventive composition (called "Alcide") and ibuprofen on the conjugated dienes formation at the wound site during the healing process.
FIG. 4 is a scintigraphic comparison of Indium-111-radioactivity accumulation at the wound site during the healing process. The inventive composition is termed "Alcide." Gamma-scintigraphy was performed 4 hours following the Indium-111-labeled PMN injection. Images were digitized in a 128×128 matrix, and regions of interest in wound and nonwound areas were studied.
DETAILED DESCRIPTION OF THE INVENTION
The compositions described herein are useful as topical formulations to treat human skin disorders caused by microbial overgrowth or by inflammation. The skin disorders include facial or body acne, topical fungal infections, genital herpes, psoriasis, leg and decubitus ulcers, eczema, and dandruff. The composition can function as a lubricating barrier gel for the prevention of transmission of sexually transmitted diseases. Dandruff, psoriasis, and eczema are hyperproliferative or inflammatory disorders that are believed to be initiated by, or associated with fungal or yeast microbial overgrowth. Accordingly, the skin disorders are often caused by microorganisms, including bacterial, viral, yeast and fungal sources. The compositions or formulations are also useful as anti-inflammatories.
The therapeutic compositions are useful for the treatment of skin diseases that involve an inflammatory and/or a microbial proliferation component or both components. Thus, the topical application of the inventive compositions containing a chlorine dioxide liberating compound in one solution, cream, or gel and a protic acid in the other solution, cream, or gel, when mixed, yield chlorine dioxide that is the active antimicrobial or anti-inflammatory agent. A gel composition should have superior skin-adherence properties.
Topical application of the therapeutic compositions described herein relates to application to the surface of the skin and to certain body cavities such as the mouth, vagina, colon, bladder, nose, and ear.
Systemic application can be localized directly by injection into inflamed tissue, such as the joint for arthritis or encapsulated in an enteric-coated capsule that can release its contents in the intestine after passing through the stomach.
The therapeutic compositions and formulations described herein are useful for the treatment of inflammatory disorders. For example, inflammatory disorders caused by influx of PMNs into a wound site can be inhibited by the inventive compositions and formulations. Similarly, ibuprofen, a non-steroidal anti-inflammatory agent also has been found to inhibit PMN influx into inflammatory tissues. The inhibition of PMN influx into a wound site can simultaneously reduce the formation of malondialdehyde and conjugated dienes, suggesting that most of the free radicals generated during the early stage of wound healing are mediated by PMNs. The majority of PMNs have been found to reach the site of inflammation at the early stage of tissue injury. The compositions and formulations of the present invention comprising a chlorine dioxide liberating compound in a protic acid inhibited the rate of PMN influx into the wound site during the healing process. The decrease in PMN influx was accompanied by the reduced formation of malondialdahyde and conjugated dienes, implying a simultaneous reduction in free radical formation. Accordingly, the ability of the inventive compositions and formulations to inhibit PMN influx into a wound site is evidence of anti-inflammatory activity.
One aspect of the inventive process is for the treatment of skin disorders caused by microbial overgrowth or inflammation, such as acne, psoriasis, eczema, genital herpes simplex lesions, topical fungal infections, decubitus and leg ulcers and dandruff, with a formulation comprising two solutions, creams, or gels. The first solution, cream, or gel contains a pharmaceutically effective amount of a chlorine dioxide generating compound. The second solution, cream, or gel contains an effective amount of a protic acid to maximally and controllably release chlorine dioxide from the chlorine dioxide generating compound, chlorous acid, formed when the two solutions, creams, or gels are mixed. Preferably, the first and second solutions are aqueous solutions.
The inventive process applies a composition formed by the combination of the first gel, cream, or solution and the second gel, cream, or solution. Preferably, the dermatalogic composition is formed by the combining of the first and second gels. More preferably, the first gel, containing the chlorine dioxide releasing compound, has a metal chlorite and a polysulfonic acid salt. The final concentrations of chlorite and acid are relatively low. The final concentration range of chlorite concentration from about 100 ppm to about 5000 ppm. Preferably, the final range of chlorite concentration is from about 800 ppm to about 1600 ppm. The final concentration range of acid is from about 0.1% w/w to about 5% w/w. Preferably, the final concentration range of acid is from about 0.5% w/w to about 1.3% w/w.
A second aspect of the inventive process is for the treatment of inflammatory disorders such as arthritis, interstitial cystitis, and inflamed bowel by specifically localizing the inventive composition to the inflamed tissue. This can be accomplished, for example, by injecting the mixed solutions directly into the joint capsule or by simultaneously injecting both the first and second solutions with a double syringe and needle of the type disclosed in U.S. Pat. No. 4,330,531. Thus the first and second solutions will mix at the site of injection and locally form chlorous acid for modulated release of chlorine dioxide. Alternatively, the solutions can be mixed prior to administration and delivered by G-I tube infusion (orally or rectally) to the inflammed section of the G-I tract. A further delivery mode is by encapsulation in a specially coated pharmaceutical matrix that is designed to release its contents in the small intestine upon oral administration.
The composition provides a metastable chlorous acid composition formed from small amounts of chlorite, preferably from a metal chlorite, and acid, preferably an organic acid with a pK from about 2.8 to about 4.2. The composition is capable of generating chlorine dioxide over an extended time up to about 24 hours, at continuing levels of effectiveness. As chlorine dioxide forms, more of the chloride converts to chlorous acid by interacting with hydrogen ions further generated by ionization of the organic acid.
Weak organic acids which may be used in the second solution or gel to form the composition of the inventive process include citric, malic, tartaric, glycolic, mandelic and other structurally similar acids as described in Formula I hereinbelow: ##STR3##
R 1 and R 2 may be the same or different and may be selected from the group consisting of hydrogen, methyl, --CH 2 COOH, --CH 2 OH, --CHOHCOOH, and --CH 2 C 6 H 5 . Compositions of a metal chlorite and the weak organic acids of Formula I are disclosed in copending U.S. patent application Ser. No. 850,009, filed on Apr. 10, 1986. The entire disclosure of that application is hereby incorporated by reference.
The second gel, containing the protic acid, also contains a gelling agent or thickener which is well known to those skilled in the art. Any gelling agent or thickener which is nontoxic and nonreactive with the other ingredients of the composition may be used, such as cellulose gels, typically methyl cellulose, or preferably, hydroxy ethyl cellulose. Furthermore, that gel may also contain a preservative, such as benzyl alcohol or sodium benzoate. Other additives, such as buffers to adjust the pH of the composition to become more compatible with the skin, may be used.
The amount of thickener in the second, protic acid-containing gel may be generally from about 0.5% to about 5%, typically from about 0.8% to about 4%, and preferably from about 1% to about 3% of the gel, by weight, of the total composition. The amount of preservative in the gel may be generally from about 0.1% to about 0.05%, typically from about 0.01% to about 0.04%, and preferably from about 0.02% to about 0.03% by weight of the total composition. The chlorine dioxide liberating compound or metal chlorite and the protic acid are present in separate gels, and the amount of the preservative is present in only that gel containing the protic acid.
The first gel, containing a metal chlorite, is preferably thickened with a polysulfonic acid salt. The amount of polysulfonic acid salt added will depend on the desired use of the resulting composition. The amount of polysulfonic acid salt is generally from about 5% to about 15%, typically from about 5% to about 10%, and preferably from about 6% to about 8% by weight of the total composition. The polysulfonic acid is prepared from: ##STR4## or a salt thereof. The polymerization reaction may be accomplished by a solution, emulsion, or suspension polymerization process. The medium for the polymerization is water, an alcohol, or a mixture thereof. The polymerization reaction is described in copending U.S. patent application Ser. No. 038,016, filed Apr. 14, 1987 and incorporated by reference herein.
The treatment of certain skin diseases or certain body cavity and joint inflammatory conditions can be additionally accomplished by the synergistic combination of the chlorous acid/chlorine dioxide formed upon admixture of the two gels, creams or solutions and from the protic acid itself. For example, the composition for acne contains salicylic acid as the protic acid in the second gel. It is known that salicylic acid is a keratolytic agent useful for its desquamatory properties in the treatment of acne. Further, another protic acid useful for topical treatments is lactic acid, which also functions to form chlorous acid from the metal chlorite, from which chlorine dioxide is formed.
The gel, cream, or solution containing the protic acid (second gel, cream, or solution) and the gel, cream, or solution containing the metal chlorite (first gel, cream, or solution) are mixed either before application to the affected skin area or in situ. After the gels, creams, or solutions are mixed, the pH of the final mixture composition is generally less than about 7, typically from about 2 to about 5, and preferably from about 2.5 to about 4. In the treatment process, the mixture composition is ordinarily applied to the affected skin area at a level of about 0.00.1 gram to about 0.1 gram per square centimeter of the affected substrate.
The present invention also encompasses a method of treatment of certain skin diseases, wherein the mixture composition of two creams, solutions or gels is applied topically to affected skin at least once daily. Preferably, the mixture composition is applied topically to affected skin twice daily (e.g., b.i.d.). The mixture composition should not be applied to affected skin more than eight times a day.
The present invention is illustrated by the following examples. Unless otherwise noted, all parts and percentages in the examples as well as the specification and claims are by weight.
EXAMPLE 1
This example illustrates a formulation useful for the topical treatment of genital herpes according to the methods of the present invention. This formulation also can be used for hemorrhoids and has anti-inflammatory activity, as shown in Examples 7-9. There is prepared a two-part topical composition according to the invention, having a first gel with sodium chlorite as the chlorine dioxide liberating agent and a second gel with lactic acid as the activator protic acid. The formulations on a percent weight basis are as follows:
______________________________________ %______________________________________First GelPoly (sulfonic acid) 45.0(16% solution ± 1%)Sodium hydroxide 1 N 45.0Sodium chlorite (80% ± 5%) 0.32Tetrasodium EDTA 0.19Water q.s.Second GelLactic Acid (88% ± 5%) 2.64Natrosoi 250 MR 1.75Isopropyl alcohol U.S.P. 5.0Poloxamer 188 0.4Sodium Benzoate 0.04Water q.s.______________________________________
EXAMPLE 2
The composition of Example 1 was prepared for a clinical trial in a pair of unit dose sachets. A 2-gram quantity of gel containing 0.16% of active chlorite was prepared by mixing the contents of both sachets immediately prior to application. Thirty-five patients (30 males and 5 females) were enrolled. Thirty-four were diagnosed as having active genital herpes. Thirty-one patients complied with the treatment of twice daily dosing for seven days. Three patients received the compositions of Example 1 t.d.s., and one patient defaulted. Patients were examined daily until the lesions were healed (defined as re-epithelialization of the original lesions). The results of the study were compared to a similar study conducted with topical acyclovir and placebo (Fiddian et al, J. Antimicrob. Chem. 12:Suppl. B:67-77, 1983) and are presented together in Table 1 below:
______________________________________ Median Median Duration of Viral Median Recurrence Symptoms Shedding Healing Rate (d) Time (d) Time (d) %______________________________________Example 1 3* 1** 8 (1-17) 19.4(32)Acyclovir 5 3 7-8 35Placebo 8 6-9 10-13 55______________________________________ *Twenty-one of twentyfour patients had a duration of symptoms of 5 or les days. **Sixteen of twentytwo patients had viral shedding times of 1 day or less
Clinically, 34/35 patients were suffering from first episode (primary) herpes. One patient had a typical lesion (ulcer) which was infected with Haemophyllis ducryiae which crusted over and failed to respond to treatment with the composition of Example 1. The treatment was virologically effective and patient compliance was good. Positive factors mentioned by the patients influencing compliance were:
twice daily dosing (compared with 5 times daily with some treatments such as Acyclovir)
the formation of a dry protective film over the lesions; reduction of odor; and sanitizing effect.
EXAMPLE 3
The following formulation can be used as a dermatologic gel for psoriasis treatment:
______________________________________ %______________________________________BaseSodium chlorite (80% ± 5%) 0.32Tetrasodium EDTA 0.19Poly (sulfonic acid) 45.0(16% solution ± 1%)Sodium hydroxide 1 N 40.0Nacconol 90F 1.8Water q.s.ActivatorPropylene glycol U.S.P. 40.0Salicylic acid U.S.P. 2.0Poloxamer 188 0.4Sodium Benzoate 0.04Natrosol 250 MR 2.1Isopropyl alcohol U.S.P. 5.0Water q.s.______________________________________
EXAMPLE 4
The following formulation can be use as an acne treatment gel:
______________________________________ %______________________________________BaseSodium chlorite (80% ± 5%) 0.32Tetrasodium EDTA 0.19Poly (sulfonic acid) 45.0(16% solution ± 1%)Sodium hydroxide 1 N 40.0Nacconol 90F 1.8Water q.s.ActivatorSalicylic acid U.S.P. 2.0Isopropyl alcohol U.S.P. 30.0Natrosol 250 MR 2.1Poloxamer 188 0.4Sodium benozate 0.04Water q.s.______________________________________
EXAMPLE 5
The following gel can be used for topical fungal infections, including tinea cruris:
______________________________________ %______________________________________BaseSodium chlorite (80% ± 5%) 0.32Tetrasodium EDTA 0.19Nacconol 90F 1.8Poly (sulfonic acid) 45.0(16% solution ± 1%)Sodium hydroxide 1 N 45.0Water q.s.ActivatorMandelic acid 2.0Poloxamer 188 0.4Sodium benzoate 0.04Natrosol 250 MR 1.75Water q.s.______________________________________
EXAMPLE 6
The following cream cam be used for the topical treatment of leg or decubitus ulcers, topical fungal infections, vaginitis, psoriasis and eczema:
______________________________________ %______________________________________BaseSodium chlorite (80% ± 5%) 0.32Tetrasodium EDTA 0.19Glycerol monostearate 4.0Glucam E-20 distearate 3.0Poly (sulfonic) acid 15.0(16% solution ± 1%)Sodium hydroxide 1 N 15.0Water q.s.ActivatorLactic acid (88% ± 5%) 2.64Natrosol 250 MR 1.25Isopropyl alcohol U.S.P. 5.0Glucam E20 distearate 3.0Glycerol monostearate 4.0Cetyl alcohol 8.0Stearyl alcohol 2.0Sodium benzoate 0.04Water q.s.______________________________________
EXAMPLE 7
This example illustrates that a composition with the active ingredient concentration of Example 1, at concentrations greater than 1:10 dilution with water, inhibits 90% of PMN chemotaxis as shown in FIG. 1. The chemotaxis inhibiting activity decreases with increasing dilution. At the 1:20 dilution with water, a composition with the active ingredient concentration of Example 1 inhibits 60% PMN chemotaxis, whereas after a 1:50 dilution, very little anti-inflammatory activity is noted. Similarly, the known anti-inflammatory agent, ibuprofen, inhibits 50% PMN chemotaxis at a 0.12 mM concentration. When diluted to 0.048 mM or further, ibuprofen shows very little anti-inflammatory activity.
PMNs were obtained from rabbit blood and purified as described in Bandyopadhyay et al., " 111 Indium-Tropolone Labeled Human PMNs: A Rapid Method of Preparation and Evaluation of Labeling Parameters," Inflammation 11:13-22, 1987). Rabbit blood was drawn from the ear vein of four donar rabbits (50 ml each), mixed with acid citrate dextrose (ACD) anticoagulant and 10 ml of Hespan (6% HETASTARCH), and stood at room temperature for 45 minutes to allow spontaneous settling of the Fed blood cells. As rabbit blood appears to be homologous, blood was pooled for purposes of obtaining PMN cells for labeling. The upper layer was collected and centrifuged at 150 g for 8-10 minutes. The upper plasma layer was saved in a different tube and centrifuged at 450 g for 10 minutes to obtain platelet-poor plasma (PPP) and in the labeling of PMNs with 111 Inoxine. The pellet was resuspended in 0.9% saline, and residual red blood cells were lysed by lowering the tonicity with three volumes ice water for 30 seconds. Tonicity was restored by adding one volume Hank's Balanced Salt Solution (HBSS) containing 10 mM buffer, pH 7. The PMNs were then isolated by a single-step density gradient centrifugation method, using Ficoll-Hypaque mixture of density 1.114.
Sixty to eighty microcuries of Indium- 111 -oxine (specific activity greater than 10 mCi/ug) (Mediphysics, Inc., Emeryville, Calif. ) were incubated with PMNs (3×10 6 ) in PPP at 37° C. for 20 minutes. Labeled cells were centrifuged and washed to remove unbound 111 Inoxine prior to injecting the PMNs into the ear veins of the rabbits studied. The viability of the PMSs prior to and following 111 In-labeling was checked in vitro by the conventional trypan blue dye exclusion method in vitro leukocyte chemo taxis was accessed using the modified Boyden Chamber Assay. (Zigmund et al , "Leukocyte Locomotion and Chemotaxis," J. Exp. Med. 137:387-410, 1983.)
EXAMPLE 8
Both ibuprofen and the composition of Example 1 were able to reduce the formation of oxygen-free radicals in vivo as indicated by the concentration of malondialdehyde and conjugated dienes in tissue biopsies from wound regions and from nonwound areas. Very little malondialdehyde and conjugated dienes were noticed in the biopsies from nonwound regions, while appreciable amounts of these two compounds were found in the wound biopsy regions. See FIGS. 2 and 3. FIGS. 2 and 3 indicate the formation of free radicals in the wound area decreases with the duration of the healing process. Maximum concentrations of malondialdehyde in conjugated dienes were noticed in 24-hour wound biopsies, with a progressive decline in later biopsies (days 3 and 6). The activities decreased with time, suggesting the presence of decreased free radicals with the duration of healing time.
In this example malondialdehyde was assayed as described in Das et al., "Affects of Superoxide Anions on The (Na+K)ATPase System in Rat Lung, " Clin. Physiol. Biochem. 2:32-38, 1984. Each tissue sample was weighed and added to 15% trichloroacetic acid (TCA) (30 mg/ml). Tissue was homogenized using a Polytron homogenizer at 0°-5° C. in an ice bath. The contents were transferred to screw cap test tubes. One ml of 0.75% thiobarbituric acid solution in 0.5% sodium acetate was then added to each tube. The tubes were boiled in a water bath for 20 minutes. The samples were centrifuged. Absorbance of supernatants was read at 535 nm. The molar extinction coefficient at 535 nm equaled 156 mM -1 cm -1 . The results are expressed as nmoles of thiobarbituric acid reactive material formed per gram of tissue.
The assay for superoxide generation was done according to the modified method of McCord et al, "The Reduction of Cytochrome C by Milk Xanthine Oxidase," J. Biol Chem. 243:5733-60, 1968. Aliquots of cell suspensions containing 5×10 6 cells/ml (PMNs) were introduced into 12×75 nm polypropylene test tubes. These cells were activated in the presence of 1.0 -7 M FMLP(formyl-methionyl-leucyl-phenylatanine, chemotactic factor). The cells plus the activator were incubated for 20 minutes in the presence of 75 uM horse heart ferricytochrome C (Type III, Sigma). Incubation was terminated by placing the tubes on ice, following which they were centrifuged at 800 g for 10 minutes at 4° C. To determine cytochrome C reduced by the presence of superoxide anion during the incubation, 0.2 ml of cell free of supernatant was mixed with 2.2 ml of buffer (pH 7.9), and the absorbance measured at 550 nm in a Beckman recording spectrophotometer. The amount of cyctochrome C in the reaction mixture was calcuated using an absorbance coefficient of 21.1 mM -1 cm -1 at 550 nm and expressed as nmole of cytochrome C reduced per 10 6 cells. The reagent blank contained the same mixture without the cells, and the absorbance of the nonreduced cytochrome C was subtracted from the total reaction mixture.
The assay for conjugated diene is described by Recknagel et al , "Lipoperoxidation As a Vector in Carbon Tetrachloride Hepatotoxicity," Lab. Invest. 15:132-46, 1966.
EXAMPLE 9
This example illustrates that significant influx of radiolabeled PMNs into the wound region occurred within hours of surgical incision. See FIG. 4. The influx of PMNs decreased with the duration of the healing process, and very little PMN occurred after three days of wound healing. The results by noninvasive, whole-body gamma-scintigraphy was confirmed by counting the radioactivity incorporated in wound and nonwound regions of tissue biopsies. See Table 2 below:
TABLE 2______________________________________Effects of the Composition of Example 1 and Ibuprofenon the In Vivo PMN Influx in the Wound BiopsiesEvaluated by Organ Counting Day 1 Day 3 Day 6______________________________________ (% of injected dose/gram tissue wt)Control 7.165 ± 1.121 0.906 ± 0.003 0.007 ± 0.007Example 1 0.011 + 0.005 0.034 ± 0.022 0.006 ± 0.002Ibuprofen 0.020 ± 0.010 0.007 ± 0.002 0.008 ± 0.009______________________________________
A significantly higher amount of radioactivity was found in the wound biopsies compared to nonwound biopies. A reduced amount of radioactivity was found in the ibuprofen and Example 1 composition treated wounds. The amount of 111 Indium-radioactivity was maximum in the 24-hour wounds, confirming the results of whole-body gamma-scintigraphy.
The principles, preferred embodiments, and modes of operation of the invention have been described in the foregoing specification. However, the invention herein which is intended to be protected is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit and scope of the invention.
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There is disclosed a method for treating dermatologic diseases caused by microbial overgrowth or inflammation, such as psoriasis, fungal infections, eczema, dandruff, acne, genital herpes lesions, and leg ulcers. There is further disclosed an antiviral lubricating composition that is effective in preventing the transmission of the HIV virus and other sexually transmitted diseases. There is also disclosed systemic anti-inflammatory compositions and formulations and a method for reducing tissue inflammation in tissues such as the bowel, muscle, bone, tendon and joints (e.g., arthritis).
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This is a continuation-in-part application of my co-pending application for U.S. Pat. Ser. No. 916,024 filed Oct. 6, 1986 now U.S. Pat. No. 4,767,145.
BACKGROUND
This invention pertains to tools useful in servicing earth wells and particularly running and pulling tools usually used in wireline tool strings to run, operate in and pull tools from a well.
Many forms of running tools, pulling tools, and combination running and pulling tools have been developed to engage external and internal fishing necks on well tools to be run into or pulled from wells on pipe or wireline. Weight or pull is applied to running and pulling tools or they are "jarred", either upwardly or downwardly, to engage tool fishing necks on tools installed in wells, to lock, unlock or operate well tools while engaged and to release from a fishing neck after locking the tool or if the tool cannot be jarred to unlock and be retrieved from the well.
One form of a pulling tool is shown in U.S. Pat. No. 3,051,239 to Dollison. This tool engages an internal fishing neck and can only be released from the fishing neck by jarring downwardly and cannot be released if the tool mandrel or attached prong contacts inside an engaged fishing neck before the outside of the tool contacts the top end of a fishing neck. Also this tool was found to be expensive to manufacture because of close parts tolerances required to strengthen the tool to resist repeated jar impacting and is difficult to release from tool fishing necks manually on the surface.
As well servicing art and tools developed, requirements arose for this type running pulling tool to be jarred upwardly to cause release from a well tool fishing neck. As shown on page 115 of OTIS WIRELINE SUBSURFACE FLOW CONTROLS AND RELATED SERVICE EQUIPMENT, OEC 5121C, a publication of Otis Engineering Corporation, Dallas, Tex., a "GU" shear up adapter was made available to convert the modified "GS" running and pulling tool covered by the Dollison patent into a jar upwardly to release tool. This tool must be assembled with the adapter on the surface as a jar upwardly to release tool or without adapter for a jar downwardly to release tool, before running into the well.
An example of a pulling tool which engages an external fishing neck is covered by U.S. Pat. No. 4,558,895 to Tamplen. This tool must also be assembled on the surface for either upward jar release or downward jar release.
The improved running pulling tool invention provides two embodiments of a tool which may be repeatedly jarred downwardly or upwardly as required after engaging an internal fishing neck and later be released from the fishing neck at any desired time by downward jarring. These tools will release when jarred downwardly on contact of either the lower end of the mandrel with the inside of the engaged fishing neck or by contact of the lower end of the tool outside with the top of the fishing neck. The impact absorbing parts may be positioned to eliminate clearances between assembled parts, which gives the tools extended impact life, permits looser part tolerances and reduces manufacturing costs. After the invention tools have retrieved well tools back to surface, the improved running pulling tools may be easily released from the well tool fishing necks.
Another preferred embodiment of the improved running pulling tool of this invention provides a "user friendly" structure, which may be easily prepared for further use to run or pull well tools. This embodiment includes means for removing all compression from the tool main spring allowing parts of the improved tool to be moved freely by hand to reposition for further use.
One object of this invention is to provide one tool which may be used to run or pull well tools from a well.
Another object of this invention is to provide a running pulling tool which, after engaging a well tool fishing neck, may be either jarred upwardly or jarred downwardly as long as required.
Another object of this invention is to provide a running pulling tool which may be released from a fishing neck at any time after engagement therewith.
Another object of this invention is to provide a running pulling tool which does not have to be retrieved to surface to reverse jarring direction for release.
Another object of this invention is to provide a running pulling tool which, when jarred down, will operate if the tool contacts the well tool fishing neck or if the tool mandrel contacts the well tool.
Also an object of this invention is to provide a less expensive running pulling tool not requiring precisely manufactured parts.
Another object of this invention is to provide a running pulling tool having improved impact resistance when jarred upwardly.
Another object of this invention is to provide an improved running pulling tool which may be easily released from a retrieved well tool.
Also an object of this invention is to provide an improved running and pulling tool which is easy to release from a retrieved tool and prepare for further use.
DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are a sectioned drawing in elevation of the running pulling tool of this invention, shown engaging a fishing neck.
FIG. 2 is the drawing of a cross section along line 2--2 in FIG. 1.
FIG. 3 is the drawing of a cross section along line 3--3 in FIG. 1.
FIGS. 4A and 4B are a sectioned drawing in elevation of the invention tool shown in the first stage of releasing from the fishing neck.
FIGS. 5A and 5B show the invention tool in the second stage of releasing.
FIGS. 6A and 6B show the invention tool released from the fishing neck.
FIG. 7 is an isometric view of latches utilized in the present invention.
FIGS. 8A and 8B are a sectioned drawing in elevation of another embodiment of the running pulling tool of this invention.
FIG. 9 is a drawing of a cross-section of the running pulling tool of this invention along line 9--9 of FIG. 8.
FIGS. 10A and 10B are a sectioned drawing in elevation of the invention tool embodiment of FIGS. 8A and 8B shown in the first stage of releasing from a fishing neck.
FIGS. 11A and 11B show the FIGS. 8A and 8B embodiment released from a fishing neck.
FIG. 12 is an elevational drawing in section of a portion of the running pulling tool of FIGS. 8A and 8B, showing all compression removed from the spring.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B show the running pulling tool 10 of this invention, which has a fishing neck 11 with an external flange 12 and an appropriate thread 13 for connecting the tool to a wireline tool string or pipe. The fishing neck is connected to upper connecting housing 14 with threads 15. The upper housing has bores 14a and 14b, a shoulder 14c, a camming surface 14d, and another bore 14e with openings 14f therein. Slidably mounted in housing bore 14b is a reduced diameter portion 16a of intermediate locking housing 16. This housing has a groove 16b, a bore 16c, an overbore 16d and a camming surface 16e.
Slidably mounted in upper housing bore 14a is a nut 17 connected to tool mandrel 18 by thread 19. A shear pin 20 passes through the upper housing wall, the nut, the mandrel and on through the nut and other housing wall and retains nut 17 on mandrel 18.
Mounted in bore 14e in housing 14 around portion 16a are latches 21, also shown in FIGS. 2 and 7. Each latch has a camming surface 21a engaging surface 14d and end projections 21b and 21c. A compressed spring 22 maintains engagement of surfaces 21a and 14d.
FIG. 1 and FIG. 3 show cammable lugs 23 mounted for lateral movement in openings 24a in lower engaging and releasing housing 24 and held engaged in mandrel recess 18a by bore 16c in the upper housing. Intermediate housing 16 is connected to lower housing 24 by shear pin 25. This shear pin may move longitudinally in lateral opening 18b in mandrel 18. The lower housing is slidably mounted on the mandrel and has an opening 24b, a shoulder 24c, a thread 24d and a bore 24e. Mandrel 18 has a number of grooves 18c adjacent opening 24b. Threadedly connected to the housing by thread 24d is a skirt 26 and a jam ring 27. The skirt has an internal shoulder 26a and openings 26b. A lock screw 28 is threaded through the jam ring into the lower housing to lock the jam ring in position. Disposed in bore 24e and around the mandrel is a compressed spring 29 between shoulder 24c and the top of a spacer ring 30. The spacer has a shoulder 30a and is biased into contact with upper mandrel shoulder 18d by spring 29. Around spacer 30 is a compressed spring 31 between shoulder 30a and retainer ring 32 which biases the retainer and dogs 33 downwardly to engage lower mandrel shoulder 18e. Each dog 33 has a camming surface 33a an external shoulder 33b, an internal shoulder 33c and a lug portion 33d. Shoulders 33c protrude into openings 32a in the retainer. A thread 34 is provided at the lower end of mandrel 18 for attachment of appropriate operating prongs to tool 10. Dogs 33 are shown engaging an internal fishing neck F in FIG. 1B.
After assembly of running pulling tool 10 and before screw 28 is installed, ring 27 is turned to permit skirt 26 to be turned and adjusted so that shoulder 26a contacts dog shoulders 33b. This contact area, in addition to the area of contact between the lower end of dogs 33 and shoulder 18e, is available to share impact force loading on the tool when jarring up. Heretofore the additional area was not available on running pulling tools, even with expensive very close tolerance machining of many tool parts because of cumulative tolerance buildup between a number of parts in an assembly.
After proper adjustment of skirt 26, jam ring 27 should be tightened against the skirt to retain the skirt in proper position, and lock screw 28 should be installed through the ring to lock the ring in skirt jamming position.
The tool 10 of the present invention is used as a running tool by attaching to a tool string and engaging dogs 33 in an internal well tool fishing neck F, as shown in FIG. 1, on the surface. Tool 10 carrying a well tool is then lowered into a well pipe and jarred or weight or pull applied to operate the well tool. The running pulling tool is then jarred downwardly or weight is applied to retract the dogs as shown in FIG. 6 and release it from the well tool fishing neck for retrieval to the surface as described below.
To use the tool 10 of the present invention as a pulling tool, the tool in the form of FIGS. 1A and 1B is connected in a tool string and lowered into well pipe to latch into and engage the internal fishing neck on top of a well tool set in the well pipe. The running pulling tool 10 is then jarred downwardly to release the well tool for pulling from the well. While jarring down, either tool mandrel 18 or the lower end of skirt 26 may impact the well tool or well tool fishing neck. Impact of the invention tool on the well tool is not limited to skirt bottom to fishing neck top only, and the running pulling tool may be operated to release if impact is delivered to the well tool fishing neck through the skirt or mandrel of invention tool 10. If the well tool cannot be released by prolonged jarring downwardly, the tool 10 may be jarred upwardly, which shears pin 20, permitting shoulder 14c in the upper housing to be moved up to contact the lower end of nut 17. As shown in FIG. 4, spring 22 has moved latches 21 upwardly, and camming surfaces 21a moving along camming surface 14d have moved the latch end projections 21b into groove 16b connecting upper housing 14 to intermediate housing 16.
If prolonged upward jarring does not release the well tool, then running pulling tool 10 may again be jarred downwardly to release from the well tool fishing neck.
As the upper and intermediate housings are now connected by latches 21, downward jarring will move fishing neck 11, upper body 14 and intermediate body 16 downwardly, shearing pin 25 and moving bore 16c below lug 23 as shown in FIG. 5. Now, as shown in FIG. 6, compressed spring 29 moves lower housing 24 upward on the mandrel, camming lugs 23 out of mandrel groove 18a and into housing overbore 16d, disconnecting housing 24 from mandrel 18. Spring 29 moves lower housing 24 further upward, lifting skirt 26 and dogs 33 through shoulders 26a and 33b from shoulder 18e. Just before upward travel of the lower housing and dogs is stopped by contact with the lower end of intermediate housing 16, dog camming surface 33a contacts the outside lower end corner of spacer 30, and dogs 33 are cammed inwardly to contact a smaller diameter on mandrel 18, disengaging fishing neck F and releasing tool 10 from the well tool fishing neck for retrieval from the well.
At the surface, retainer 32 may be gripped through skirt openings 26b and moved upwardly on spacer 30, compressing spring 31, lifting dogs 33 from shoulder 18e and camming the dogs to retract inwardly as shown in FIG. 6, releasing tool 10 from the well tool fishing neck.
To prepare running pulling tool 10 for further use, upper housing 14 may be moved upwardly on housing 16 and latch projections 21c pushed in to disconnect the upper housing from the intermediate housing. Housing 14 may now be pushed down on housing 16, returning housing 14 to the position shown in FIG. 1. A screwdriver or other lever, inserted through opening 24b and into a slot 18c, may be used to pry the lower housing and dogs back into fishing neck engaging position as shown in FIG. 1. On replacement of sheared pins 20 and 25, the running pulling tool 10 of this invention will be ready for further use.
FIGS. 8A and 8B show another embodiment 35 of the running pulling tool of this invention, which has a fishing neck 36 with an external flange 36a and an appropriate thread 37 for connecting the tool to a wireline tool string or pipe. The fishing neck has a hole 36b through which a shear pin 38 is passed into a hole in tool mandrel 39 releasably connecting the mandrel and fishing neck. The fishing neck also has a bore 36c and is connected to upper connecting housing 40 with threads 41. The upper housing has a bore 40a, a camming surface 40b, and another bore 40c with openings 40d. Slidably mounted in housing bore 40a is a reduced diameter portion 42a of intermediate locking housing 42. This housing has a groove 42b, a bore 42c, an overbore 42d and a camming surface 42e. Slidably mounted in fish neck bore 36c is a nut 43 which is connected to mandrel 39 by threads 44.
Mounted in bore 40c around lock housing reduced diameter portion 42a are latches 21. Each latch has a camming surface 21a engaging surface 40b and as shown in FIG. 7, end projections 21b and 21c. End projections 21c extend into openings 40d. A compressed spring 22 maintains engagement of surfaces 21a and 40b.
An engaging and releasing housing 45 with openings 45a, is slidably mounted around tool mandrel 39. Cammable lugs 23, releasably connecting housing 45 and mandrel 39, are mounted for lateral movement in openings 45a and are held engaged in mandrel recess 39a by bore 42f in locking housing 42.
Housed in overbore 42g is a C ring 46, shown in FIGS. 8 and 9. This C ring has a camming surface 46a and is contracted into groove 45b on housing 45, positioning housing 42 relative to housing 45.
Housing 45 is slidably mounted around mandrel 39 and has a number of through slots 45c and a thread 45d. Slidably mounted in each slot is a lug 47 having a thread 47a. A release ring 48 having a thread 48a is threadedly connected on each lug. Slidably mounted around mandrel 39 below lugs 47 is a bearing ring 49 and a spring 29. This spring is compressed between ring 49 and a spacer ring 30 which engages an upper shoulder 39b on mandrel 39. Also threaded on housing thread 45d is a skirt 26 and a jam ring 27, which has a lock screw 28.
The skirt has an internal shoulder 26a and openings 26b. Around spacer ring 30 is a spring 31, which is compressed between shoulder 30a and a retainer ring 32, which is slidably mounted around ring 30.
A number of internal fishing neck engaging dogs 33 are positioned in openings 32a in retainer ring 32. Compressed spring 31 biases retainer 32 and dogs 33 downwardly to engage lower shoulder 39c on mandrel 39. Each dog 33 has a camming surface 33a, an external shoulder 33b, an internal shoulder 33c and a lug portion 33d. Shoulders 33c protrude into openings 32a in the retainer. A thread 50 is provided in the lower end of mandrel 39 for attachment of appropriate well tool operating prongs to embodiment 35 of the improved running pulling tool of this invention.
Before using running pulling tool 35, for running or pulling a well tool, the skirt 26 should be properly positioned for contact of dog shoulder 33b with skirt shoulder 26a as previously described for running pulling tool 10. Tool 35 may also be used as a running tool as previously described for tool 10.
Tool 35, when used as a pulling tool is operated the same as and has the improvements of tool 10. To use tool 35 as a pulling tool, this tool in the form shown in FIGS. 8A and 8B, is connected in a tool string and lowered into well pipe to latch into and engage the internal fishing neck on top of a well tool set in the well pipe. Tool 35 is then jarred downwardly to release the well tool for pulling from the well. While jarring down, either tool mandrel 39 or the lower end of skirt 26 may impact the well tool or well tool fishing neck. Impact on the well tool is not limited to skirt bottom to fishing neck top only, and the running pulling tool may be operated to release if impact is delivered to the well tool fishing neck through the skirt or mandrel. If the well tool cannot be released by prolonged jarring downwardly, tool 35 may be jarred upwardly, which shears pin 38 and moves fish neck 36 and housing 40 upwardly around mandrel 39 and housing portion 42a. As shown in FIG. 10, spring 22 has moved latches 21 upwardly, and camming surfaces 21a moving along camming surface 40b have moved the latch end projections 21b into groove 42b, connecting upper housing 40 to intermediate housing 42.
If prolonged upward jarring does not release the well tool, then running pulling tool 35 may again be jarred downwardly to release from the well tool fishing neck.
As the upper and intermediate housings are now connected by latches 21, downward jarring will move fishing neck 36, upper housing 40 and intermediate housing 42 downwardly, camming C ring 46 outwardly by surface 46a to slide down over the upper end of housing 45, moving overbore 42d over lugs 23 as shown in FIG. 11. Now compressed spring 29 moves housing 45 through ring 49, lugs 47 and ring 48 upwardly on the mandrel, camming lugs 23 out of mandrel groove 39a and into housing overbore 42d, disconnecting housing 45 from mandrel 39. Spring 29 moves housing 45 further upward, lifting skirt 26 and dogs 33 through shoulders 26a and 33b from shoulder 39c. Just before upward travel of the lower housing and dogs is stopped by contact with the lower end of intermediate housing 42, dog camming surface 33a contacts the outside lower end corner of spacer 30, and dogs 33 are cammed inwardly to contact a smaller diameter on mandrel 39, disengaging the well tool fishing neck and releasing tool 35 from the fishing neck for retrieval from the well.
To release tool 35 from an internal fishing neck of a retrieved well tool at the surface, retainer 32 may be gripped through skirt openings 26b and moved upwardly on spacer 30, compressing spring 31, lifting dogs 33 from shoulder 39c and camming the dogs to retract inwardly as shown in FIG. 11 releasing tool 35 from the fishing neck and well tool.
If pin 38 was sheared during well tool retrieving operations, upper housing 40 should be moved upwardly on housing 42 and latch projections 21c pushed in to disconnect the upper housing from the intermediate housing. Upper housing 40 may now be moved down around housing 42 to the position shown in FIG. 8, where a new shear pin 38 may be installed.
If the well tool could not be unlocked for retrieval to surface and tool 35 was jarred to release from the well tool, tool 35 will return to surface as shown in FIG. 11.
To return the tool 35 to the form shown by FIG. 8 for further use, ring 48 should be turned moving lugs 47 upwardly, permitting spring 29 and spring 31 to extend and move spacer 30 and ring 49 upwardly on mandrel 39 as shown by FIG. 12. Mandrel 39 is not now held in position by springs and may be moved freely upward by hand, reengaging the lower end of dogs 33 with mandrel shoulder 39c and realigning mandrel recess 39a adjacent lugs 23. Now moving intermediate locking housing 42 upwardly over mandrel 39 and release housing 45 reengages lugs 23 with mandrel recess 39a and ring 46 contracts into groove 45b. Next ring 48 should be turned to recompress springs 29 and 31 as shown in FIG. 8. After replacement of shear pin 38 as previously described, tool 35 is now ready for further use as a running or pulling tool.
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Two embodiments of an improved tool, which may be used as a running tool or a pulling tool for well tools. The improved structures provide running pulling tools which may be jarred upwardly on or jarred downwardly on as long as required after engaging a tool set in well pipe and may be released from the well tool when desired. When the running pulling tools are jarred downwardly, they will operate to release if either the tool mandrels or tool skirts contact with well tool. Each tool skirt is positioned in contact with external dog shoulders, providing increased impact area and eliminating costly precision machining of tool parts. Both improved tools may be manually released from a well tool on surface. One embodiment may be prepared for further use with the aid of hand tools. The other embodiment may be prepared for further use almost by hand.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a medical instrument and to an associated method. More particularly, this invention relates to a medical instrument and method wherein power to an operative tip is automatically controlled.
[0002] Ultrasonic devices have been used to remove soft and hard tissue from mammalian bodies for over three decades, at least. These devices and methods for their use have been well documented in the art, such as U.S. Pat. No. 4,223,676 to Wuchinich, U.S. Pat. No. 4,827,911 to Broadwin and U.S. Pat. No. 5,419,761 to Narayanan et al. Applications include phacoemulsification, ablation of tumors in the liver and spine and subcutaneous removal of adipose tissue, also known as ultrasonic liposuction.
[0003] Most of the instruments used for these applications have several elements in common. These are an electrical generator which transforms line or battery power to relatively high voltage RF frequencies in the 20 kc to 100 kc range, a transducer of either a magnetostrictive or piezoelectric type and a probe or horn which is generally manufactured from titanium and amplifies the motion of the transducer from approximately 20 microns to over 400 microns in some cases. Means have been disclosed which allow the surgeon the ability to switch the output power on or off on demand. These include footswitch controls, finger or thumb switches on the handpiece or even by voice commands if the electronic generator includes the prerequisite software and electronics.
[0004] All of these means require that the surgeon coordinate the application or removal of ultrasonic power to the precise moment at which it is required. In spinal or brain surgery, this is not difficult, since the application of the power is not continuous and he or she has complete view of the operative site. By simply moving his hand, he is able to apply power to the surgical site and remove the tip of the probe even when the power is on, limiting the power input to tissue. In this way, tissue temperature rise is minimized and collateral damage is curtailed.
[0005] However, in applications such as liposuction, the surgeon would have a difficult time in controlling power requirements. In this case, the surgeon moves the handpiece with a piston like action, alternatively advancing and retracting the cannula in a predetermined pattern. See U.S. Pat. No. 5,527,273 for a more complete description of this action. Since the sides of the long cannula are in contact with the tissue at all times, power is being applied to the tissue as long as the probe is activated with ultrasonic energy. In actuality, the power is only required on the pushing stroke, since the ultrasonic power ablates the tissue in direct contact with the distal end of the probe. As the tissue disrupts, it liquefies and the cannula can be advance. In this way, channels or tunnels are created in the adipose tissue.
[0006] When the probe is pulled back to be repositioned and start another tunnel, the tissue contacts the side of the probe. Power is still being applied but tissue liquefaction does not occur, since it is the cavitation and shearing forces created by the probe tip that liquefies and emulsifies the cells. Therefore, this energy can be considered waste and it actually goes into tissue heating. The longer the probe is used, the higher the temperature rise will be. If the temperature rises above the necrosis point, burning, scarring and other deleterious effects will arise.
[0007] It would be difficult and tiring for the surgeon to time the on and off controls with his hand movements, since they are rapid and repetitive. It would be more desirable to have an automatic means to determine the power requirement and have the machine apply energy only when most needed.
[0008] Several embodiments for reducing the amount of ultrasonic power delivered to the tissue or samples have been known to the art for many years. One old technique is pulsing of the output. By automatically turning the output power on and off at specific duty cycles, the power may be reduced in inverse proportion to the output duty cycle. For instance, if the output power was turned on for 2/10 ths of a second and shut off for the remainder of that second, it would be said the output power had a 20% duty cycle. At the beginning of the next second, the power is turned back on for 2/10 ths of a second and so forth. The power input to the tissue or sample would be reduced by 80% over a given period. However, this embodiment does not turn off the power completely when not needed, i.e. on the return stroke, it only lessens it. In fact, the power is even reduced on the push stroke, when it is most needed increasing the effort needed to advance the cannula through the body.
OBJECTS OF THE INVENTION
[0009] An object of the present invention is to provide a medical instrument and/or an associated method wherein the control of power transmission to an operative tip is facilitated.
[0010] Another object of the present invention is to provide such a medical instrument and/or an associated method wherein power transmission to the operative tip is effectuated automatically, without requiring any dedicated separate action on the part of the surgeon.
[0011] A related object of the present invention is to provide a liposuction instrument and/or an associated surgical method for reducing, if not minimizing, trauma to tissues of a patient.
[0012] Yet another object of the present invention is to provide an ultrasonic liposuction instrument that is easier to use than conventional ultrasonic liposuction probes.
[0013] These and other objects of the present invention will be apparent from the drawings and descriptions herein. Although every object of the invention is attained by at least one embodiment of the invention, there is not necessarily any embodiment in which all of the objects are met.
SUMMARY OF THE INVENTION
[0014] The present invention is directed in part to a medical instrument and an associated method wherein power is automatically delivered to an operative tip only when the instrument is being advanced through tissues of a patient. Energy or power is automatically turned off when the instrument and particularly the operative tip is no longer being advanced, for instance, is being retracted.
[0015] A medical instrument in accordance with the present invention comprises a handpiece, an electromechanical transducer disposed in the handpiece, an electrical circuit disposed at least partially in the handpiece for supplying alternating electrical current of a predetermined frequency to the transducer, a probe operatively connected to the transducer for transmitting vibrations generated by the transducer to an operative site in a patient, and a switching device mounted to the handpiece and operatively connected to the circuit and the transducer for enabling the supply of power to the transducer during a motion of the probe in a preselected direction relative to the handpiece and for disabling the supply of power to the transducer upon a termination of motion of the probe in the preselected direction.
[0016] The handpiece may include a main body portion and a grip portion movably coupled to one another. In that case, the switching device including two electrical contacts respectively mounted to the main body portion and the grip portion, the switching device further including a spring carried by the handpiece for biasing the main body portion and the grip portion relative to one another.
[0017] Typically, the spring is a compression spring disposed between the body portion and the grip portion of the handpiece for biasing them away from one another to thereby maintain the electrical contacts spaced from one another. In this embodiment, the handpiece has a distal end and a proximal end, the probe extending from the distal end of the handpiece, while the preselected direction is a distal or forward direction. The grip portion is located proximally of the main body portion. Upon a manual pushing of the handpiece via the grip portion, the frictional contact of the probe with the tissues of the patient reduces the forward motion of the body portion relative to the motion of the grip portion, so that the electrical contacts engage and enable a current flow to the transducer.
[0018] In a particularly useful embodiment of the invention, the probe is elongate, the predetermined frequency is an ultrasonic frequency, and the instrument is an ultrasonic liposuction instrument.
[0019] In accordance with an alternative feature of the invention, the switching device is an inertial mass switch or a load sensor.
[0020] Another embodiment of a medical instrument in accordance with the present invention comprises a handpiece, an operative tip connected to the handpiece, and transmission means mounted at least in part to the handpiece and operatively coupled to the operative tip for supplying power to the operative tip, whereby the operative tip is enabled to effectuate a predetermined kind of surgical operation on a patient. This embodiment additionally comprises a motion sensor mounted to the handpiece and operatively connected to the transmission means for enabling the transmission means to supply power to the operative tip only during motion of the operative tip in a preselected direction defined relative to the handpiece.
[0021] The motion sensor may be a spring-loaded switch. Where the handpiece includes a main body portion and a grip portion movably coupled to one another, the switch includes two electrical contacts respectively mounted to the main body portion and the grip portion and further includes a spring carried by the handpiece for biasing the main body portion and the grip portion relative to one another.
[0022] Alternatively, the motion sensor may be an inertial-mass-type sensor or a load sensor.
[0023] A method for performing a surgical operation utilizes, in accordance with the present invention, a medical instrument having a handgrip at a proximal end and an operative tip at a distal or free end. The method comprises (1) moving the medical instrument in a preselected direction relative to the medical instrument, (2) by virtue of the moving of the medical instrument in the preselected direction, automatically transmitting power to the operative tip during the moving of the medical instrument in the preselected direction, (3) terminating the motion of the medical instrument in the preselected direction, and (4) by virtue of the terminating of the motion of the medical instrument, automatically terminating the transmission of power to the operative tip.
[0024] The medical instrument may be provided with a motion sensor. In that event, the automatic transmitting of power to the operative tip includes operating the sensor to detect motion of the medical instrument in the preselected direction, whereas the automatic terminating of the power transmission to the operative tip includes operating the sensor to detect a cessation of motion in the preselected direction.
[0025] Pursuant to another feature of the present invention, the method further comprises transmitting power to the operative tip only when the medical instrument is being moved in the preselected direction. More specifically, the method comprises transmitting power to the operative tip only when the medical instrument is being moved in the preselected direction through a mass providing frictional resistance to passage of the instrument.
[0026] In a medical instrument in accordance with the present invention, the control of power transmission to an operative tip is facilitated by being made dependent on the motion of the instrument through the organic tissues of the patient. The turning of power alternately on and off is achieved automatically without the surgeon having to operate any control. The surgeon merely moves the instrument in the desired direction and back again.
[0027] A medical instrument in accordance with the present invention reduces trauma to tissues of a patient, for example, in ultrasonically assisted liposuction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a partial longitudinal cross-section view of a handpiece for an ultrasonic liposuction instrument, showing a spring-loaded handgrip containing a motion-actuated power control switch, in accordance with the present invention.
[0029] FIG. 2 is a partial longitudinal cross-section view of another embodiment of a handpiece for an ultrasonic liposuction instrument, showing another spring-loaded handgrip containing a motion-actuated power control switch, in accordance with the present invention.
[0030] FIG. 3 is an end elevational view of the handpiece of FIG. 2 .
[0031] FIG. 4 is a partial longitudinal cross-sectional view of a further embodiment of a handpiece for an ultrasonic liposuction instrument, showing an inertial type motion-responsive power control switch, in accordance with the present invention.
[0032] FIG. 5 is partially a block diagram and partially a schematic partial cross-sectional view of yet another handpiece for an ultrasonic liposuction instrument, showing a load-type motion-sensitive power control switch, in accordance with the present invention.
DEFINITIONS
[0033] The term “medical instrument” is used herein to denote any device that is used in contact with organic tissues of a patient to perform a diagnostic or therapeutic procedure.
[0034] The term “operative tip” as used herein designates a portion of a medical instrument that is placed into contact with organic tissues of a patient during a medical procedure. Typically, the operative tip is functional to effect a surgical operation on organic tissues. For instance, an operative tip may be a free end of an ultrasonically vibrating probe or cannula. Alternatively, an operative tip may be a cauterization element of an electrocautery applicator, a scissors, a vibrating scalpel, a suction port, an irrigation port, etc.
[0035] The word “handpiece” as used herein relates to a casing, frame, holder, or support which can be manually carried and manipulated during a medical operation on a patient.
[0036] A “power-transmission circuit” or “circuit” as that term is used herein means any hardware used to move energy from a source to a load. The power transmitted may be mechanical, electrical, magnetic, hydraulic, or pneumatic. The hardware may include mechanical structural elements, transducers, electrical circuits, electrical leads, magnetic materials, and hydraulic or pneumatic conduits and valves. The hardware may additionally include power sources: voltage or current sources, magnets, pressurized or pressurizable reservoirs of fluid of air.
[0037] The term “switching device” is used herein to generally describe any manually operable control utilizable in conjunction with a power-transmission circuit for alternately enabling and disabling the flow of power through the circuit. A switch may be mechanical, electrical, electromagnetic, magnetic, hydraulic, or pneumatic. Specific examples include spring-loaded electrical contact switches, gravity or inertial switches, and load switches.
[0038] A “motion sensor” as that term is used herein refers to any detector device responsive to a velocity or acceleration. A motion sensor may be mechanical or electromechanical as in the case of a micro-switch functioning in the manner of a hair sensor. A motion sensor may take the form of a gravity switch or an inertial switch or a mercury switch. A motion sensor may be a load sensor such as a stack of piezoelectric crystals sensing compression due to a resistance to motion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Together with improvements disclosed herein, the drawings show sections of a medial instrument handpiece disclosed in U.S. Pat. No. 5,769,211, the disclosure of which is hereby incorporated by reference.
[0040] As illustrated in FIG. 1 , an ultrasonic handpiece comprises a sleeve 12 that surrounds and is movably mounted to a transducer array 14 . Transducer array 14 includes a front driver 16 and a stack of piezoelectric crystals 18 . Front driver 16 is coupled to an ultrasonic horn 20 that amplifies ultrasonic pressure waves produced by the stack of crystals 18 . Front driver 16 is provided at a vibration node with an outwardly extending circumferential flange 22 , while sleeve 12 is provided with an inwardly extending circumferential flange (or a plurality of angularly spaced inwardly extending projections) 24 . A helical compression spring 26 surrounds front driver 16 and is sandwiched between flanges 22 and 24 . Compression spring 26 biases flanges 22 and 24 away from one another.
[0041] Flange 24 carries a switch 28 that is connected to an electrical a-c power supply 30 via a pair of leads 32 . Switch 28 controls the transmission of an ultrasonic-frequency electrical waveform from supply 30 to transducer array 14 . Switch 28 includes a switch body 36 provided with an actuator 38 such as a telescoping plunger element. Switch actuator 38 is attached directly to flange 22 and or indirectly to flange 24 via switch body 36 .
[0042] As disclosed more fully hereinbelow with reference to FIGS. 2 and 3 , sleeve 12 is shiftably mounted to a casing or housing (not shown in FIG. 1 ) and has a length determined from ergonomic studies of the average width of surgeons' hands. The spring 26 provides enough force to maintain actuator 38 extended from switch body 36 so that internal switch contacts (not shown) are separated when the instrument is at rest. A surgeon grasps the handpiece around the sleeve 12 and provides force by pushing the cannula or probe 39 into the target tissues of the patient. Spring 26 is compressed by that force so that the electrical internal contacts of switch 28 close, transmitting electrical power to transducer array 14 as previously disclosed. As long as sufficient resistance exists against the forward movement of the handpiece and cannula 39 , the switch will remain closed and the output energy will be on.
[0043] As the surgeon begins to extract the instrument from the patient, the force on the distal end of the cannula or probe 39 is relieved. Spring 26 pushes the actuator 38 out of switch body 36 thereby separating the internal switch contacts turning the power off. As the surgeon continues to retract the handpiece, the switch 28 remains open, thereby eliminating power input to the site for the entire time the cannula 39 is moving backwards. Tissue temperature cannot rise during the retraction phase and in fact lowers since energy input during ultrasound activation is allowed to conduct away. If the spring 26 has a sufficiently great spring constant, the switch contacts will remain apart even if the handpiece is at rest. Therefore, if the surgeon stops to rest or otherwise pauses the stroking action, the ultrasonic power will remain off until he repositions and advances the cannula 39 again.
[0044] FIGS. 2 and 3 show a handpiece like that of FIGS. 2A and 2B of U.S. Pat. No. 5,769,211 modified to provide an actuator sleeve 40 which surrounds a substantially cylindrical handle or handpiece case 42 . Actuator sleeve 40 has an internal surface provided with a plurality of angularly equispaced grooves 44 which define a plurality of angularly equispaced ribs 46 . Ribs 44 have an internal diameter which is slightly greater than the outside diameter of handpiece case 42 upon which the ribs ride. In this manner, a sliding fit is achieved which allows sleeve 40 to be translated alternately in a distal direction 48 and a proximal direction 50 . A shoulder, ledge or abutment 52 on sleeve 40 is engageable with a shoulder 54 of case 42 to prevent sleeve 40 from being slid off the back of the case. Recesses or grooves 46 on the inner diameter of sleeve 40 reduce the amount of material in contact with handpiece case 42 . This reduced contact decreases friction and prevents debris from collecting between sleeve 40 and handpiece case 42 , which prevents the sleeve from sticking or binding.
[0045] Sleeve 40 has a distally directed surface (not designated) which is faced with an electrically conductive lining 56 which does not corrode in the presence of steam or detergents, such as stainless steel. This lining 56 is either glued or staked to sleeve 40 , using methods known to the art. A mating face 58 is fashioned on handpiece case 42 . This face 58 is manufactured from a material which is generally nonconductive, such as thermoplastics. A switch 60 has parts (see U.S. Pat. No. 5,769,211) provided along lining 56 and face 58 , those parts closing the switch upon an approach of lining 56 and face 58 . The closing of switch 60 conducts current from a power supply 62 to a transducer array or piezoelectric crystal stack 64 .
[0046] Low friction bushings 66 and 68 or other such bearings are located on the handpiece body or case 42 and locate the sleeve so that it is essentially coaxial with the handpiece body itself.
[0047] In order to allow an automatic opening of switch 60 upon an interruption in forward motion of the instrument, owing to the surgeon's reduction in forward force on sleeve 40 , sleeve 40 is spring loaded. As depicted in FIG. 2 , two helical or coil springs 70 and 72 are placed between sleeve 40 and handpiece face 58 . Coil springs 70 and 72 are spaced 90° from each contacts of switch 60 (see U.S. Pat. No. 5,769,211). Two pins 74 and 76 are pressed into handpiece face 58 and are thereby fixed in place. Pins 74 and 76 engage blind holes 78 and 80 drilled into sleeve 40 , whereby the pins perform both a locating or mounting function for coil springs 70 and 72 and a keying junction for sleeve 40 to prevent the sleeve from rotating about a longitudinal axis 82 of handpiece case 42 .
[0048] The coil springs 70 and 72 provide sufficient force to keep the contacts of switch 60 separated during rest. As the surgeon grasps the handpiece around the sleeve 40 , he of she exerts a force in the distal direction, thereby pushing the cannula or probe 83 into the target tissues. Springs 70 and 72 are compressed by the applied force and the contacts of switch 60 close, turning the energy on as previously disclosed. As long as sufficient resistance exists against the forward movement of the handpiece and cannula 83 , the switch 60 will remain closed and the output energy will be on.
[0049] As the surgeon begins to retract the instrument, the force on the distal end of the cannula or probe 83 is relieved. The springs 70 and 72 push the switch contacts apart and the output power is turned off. As the surgeon continues to retract the handpiece, the switch 60 remains open, thereby eliminating power input to the site for the entire time the cannula 83 is moving backwards. Tissue temperature cannot rise during the retraction phase and in fact lowers since energy input during ultrasound activation is allowed to conduct away. If the springs 70 and 72 have sufficient energy, the switch contacts will remain apart even if the handpiece is at rest. Therefore, if the surgeon stops to rest or otherwise pauses the stroking action, the ultrasonic power will remain off until he repositions and advances the cannula 83 again.
[0050] Another embodiment, illustrated in FIG. 4 , incorporates an inertial mass type switch. Here a relatively large mass 84 is suspended by a low friction bearing (not shown) inside a casing or housing 86 so that the mass can move parallel to a long axis 88 of the handpiece. As the handpiece is moved back and forth rapidly, the inertial mass 84 moves in the opposite direction as per Newton's laws of motion. As the mass 84 engages switch contacts 90 and 92 at either end of its travel path, the output of the ultrasound device may be turned on and off simultaneously. Preferably, the switching action occurs upon an initial engagement of the mass 84 with contacts 90 and 92 . Light springs (not shown) can be used to center the mass 84 when at rest. The benefit of this is that the surgeon does not have to overcome force of a heavier spring to activate the output power. It is also useful when the resistance of the tissue or other load is slight.
[0051] In another embodiment, depicted diagrammatically in FIG. 5 , a tubular handpiece casing 94 is connected to or incorporates a load-sensing device 96 . This device could be a piezoelectric sensor, a strain gauge or other force or load-sensing element known to the art. Here, the level of force is measured. An electric switching circuit 98 incorporates logic or sensing circuits 100 that both measure the magnitude this force and provide an analog or digital signal 102 proportional to it. The output amplitude or energy from an ultrasonic transducer array 104 may be modulated by this signal, via a modulator 106 and a modulated power supply 108 , to provide either a stepped on/off output or an output power level that is directly or inversely proportional to the applied force. FIG. 5 shows a simplified or schematic form of this embodiment. The electronic interface circuits required for this type of control are well known to the art.
[0052] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. For example, although the described surgical method describes a liposuction procedure done during plastic surgery, many other surgical procedures may benefit from this invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
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A medical instrument includes a handpiece, an electromechanical transducer disposed in the handpiece, and an electrical circuit disposed at least partially in the handpiece for supplying alternating electrical current of a predetermined frequency to the transducer. A probe is operatively connected to the transducer for transmitting vibrations generated by the transducer to an operative site in a patient. A switching device is mounted to the handpiece and is operatively connected to the circuit and the transducer for enabling the supply of power to the transducer during a motion of the probe in a preselected direction relative to the handpiece and for disabling the supply of power to the transducer upon a termination of motion of the probe in the preselected direction.
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BACKGROUND OF THE INVENTION
The present invention involves a molding machine which utilizes toggle linkage mechanisms to develop the necessary mold lockup forces. More particularly, the present invention involves a molding machine which is improved by virtue of a molding machine which is improved by virtue of a smaller overall size and cost and a high sensitivity for triggering lockup.
Prior art molding machines as shown in U.S. Pat. No. 3,452,399 have used different sets of actuating mechanisms for large scale motions of the mold portions and mold lockup, even though a single actuating means of suitable size could be used for both purposes. The advantages of using separate actuating mechanisms can be attributed to the grossly different requirements for a mold closing system and a mold lockup system. Generally, the mold closing system must produce large scale displacements with relatively small forces while, on the other hand, the lockup system must produce relatively small displacements, but large lockup forces.
In the prior art machines such as shown in U.S. Pat. No. 3,452,399, the actuator for the lockup mechanism is situated along the central axis of the machine and actuates a pair of symmetrically disposed toggle linkages which are brought into operation after traversing actuators have produced the large scale movements that bring the mold portions into engagement. Since the lockup actuator which is a piston and cylinder assembly extends between a stationary platen and the toggle mechanisms, a large displacement of the piston in the assembly is needed to accommodate the movement produced by the mold traversing actuators and the actuator projects a substantial distance rearwardly of the machine. The projecting actuator greatly increases the overall length of the machine. In addition, the fluid capacity of the machine is increased and the various components such as pumps, coolers and filters must be increased to handle the higher capacity. All of the increases in size correspond to increased cost of the machine.
The lockup mechanism for a thermoforming machine illustrated in U.S. Pat. No. 3,632,272 employs two toggle mechanisms which are actuated by a piston and cylinder assembly. Protrusion of the actuating assembly is avoided by connecting the cylinder between a crosshead joined to the toggle mechanisms and the moving platen which is locked by the toggle mechanisms. Additionally, however, the total displacement of the moving platen is relatively limited since the thermoforming process is carried out with sheets and the resulting product does not require large clearances to be removed from the mold.
Accordingly, it is a general object of the present invention to provide a molding machine which has a reduced cost and overall length and which at the same time can be accurately triggered to produce lockup forces at the appropriate time.
SUMMARY OF THE INVENTION
The present invention resides in a molding machine which employs a toggle linkage to develop mold lockup forces when the mold is closed. The molding machine comprises first and second stationary platens and an intermediate third platen which is movable back and forth between the other platens for opening and closing the mold. Separable mold portions are mounted respectively on the first stationary platen and the third movable platen for molding an article while the mold is closed and dispensing the molded article from the machine when the mold is open.
A toggle linkage mechanism is connected between the second stationary platen and the movable third platen for developing lockup forces between the mold portions. The toggle mechanism includes a front linkage connected to the third platen and a rear linkage connected to the second platen pivotally joined to the front linkage. The front and rear linkages move toward a toggle position when the mold portions close and thereby develop the lockup forces.
A movable crosshead positioned between the second and third platens is operatively connected with the front and rear linkages of the toggle mechanism to move the linkages in and out of the toggle position. The crosshead is situated so that it moves away from the third platen and toward the second platen to place the front and rear linkages in the toggle position. Thus, the motion of the crosshead is in a direction opposite to the third platen as lockup forces are developed. Actuating means connected between the moving third platen and the crosshead urge the crosshead away from the third platen when lockup is desired.
Movement of the crosshead away from the third platen during lockup makes the determination of mold closing easier because the distance between the crosshead and third platen increases rapidly as the toggle position is approached. A foreign object between the mold portions can be detected with greater sensitivity at closure because of the rapid change of crosshead position. Furthermore, the lockup actuating means positioned between the crosshead and third platen reduces the overall length of the molding machine.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation view of a molding machine embodying the present invention with the mold closed in the lockup position.
FIG. 2 is a side elevation view of a molding machine in FIG. 1 with the mold in the open position.
FIG. 3 is a top plan view of the molding machine with the mold open.
FIG. 4 is a sectional view of the molding machine as seen along the sectioning line 4--4 in FIG. 1.
FIG. 5 is a sectional view of the molding machine as viewed along the sectioning line 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates generally an injection molding machine incorporating the novel lockup mechanism of the present invention. While an injection molding machine has been selected to illustrate the invention, the injection mechanism forms no part of the invention and any type of mold machine including a thermoforming machine or a die-casting machine may incorporate the invention as well.
The molding machine, generally designated 10, includes a stationary rear platen 12, a stationary front platen 14 and a movable platen 16 which is interposed between the stationary platens 12 and 14. Four equally spaced tie bars 20, 22, 24 and 26 interconnect the two end platens 12 and 14 and hold the end platens in fixed relationship with one another while the movable platen is slidably mounted on the tie bars for reciprocating movement relative to the stationary platens. An article-forming mold 30 is attached to the platens 14 and 16, and in its simplest form the mold is comprised of two mold halves 32 and 34 mounted respectively on the platens 14 and 16. In conventional fashion the mold halves are aligned with one another along a central axis of the machine extending parallel to the tie bars and are moved by the platens 14 and 16 between a closed position illustrated in FIG. 1 and an open position illustrated in FIG. 2. During the period of time in which the molds are closed, a charge of settable material is injected through the platen 14 into the mold cavity which defines the shape of a desired article, and such article is removed from the mold by appropriate knockout equipment (not shown) while the mold halves are open. Since the injection and molding mechanism forms no part of the present invention, further description is not given; however, it is to be understood that in order to properly form an article, it is desirable to have the mold halves 30 and 32 pressed tightly together or locked up during the interval in which the settable material is injected and set. The present invention is accordingly addressed to the lockup mechanism which provides this function.
In order to produce large scale closing and opening movement of the platen 16 relative to the stationary platens 12 and 14, a traversing actuator in the form of an extendible piston and cylinder assembly 38 is connected between the platen 12 and 16. The cylinder 40 is connected at one end to the stationary platen 12 while the piston rod 42 is connected to the moving platen 16. It will be noted that the assembly is mounted in the lower portion of the machine 10 below the central axis as shown in FIG. 1. Such offset mounting develops unbalanced forces on the moving platen as it reciprocates, but two toggle linkage mechanisms 50 and 52 and a crosshead 54 described below act to a large degree to maintain the third platen parallel to the first platen. If such forces were a problem, another piston and cylinder assembly could be readily added at the opposite side of the machine to balance the moments. Extension and retraction of the piston rod by means of an appropriate hydraulic or pneumatic fluid is synchronized with the other operations of the cyclic molding process.
The piston and cylinder assembly 38 is not utilized to develop the lockup forces between the mold halves 32 and 34 and thus the assembly is not a high force output assembly. Instead, the assembly primarily provides displacement. Since the assembly 38 is not needed to develop high lockup forces, its size and, in particular, its piston area may be relatively small. Correspondingly, the overall volume of the fluid actuating system which energizes the various components of the machine need not be sized to handle large volumes of fluid, and the overall cost of the machine is correspondingly reduced.
The lockup mechanism of the present invention employs the two symmetrically disposed toggle linkage mechanisms 50 and 52, the crosshead 54 for operating the toggle mechanisms simultaneously and two parallel fluid actuators comprised of extendible piston and cylinder assemblies 56 and 58 similar to the assembly 38.
The upper toggle mechanism 50 as shown in the top plan view has four front links 60, 62, 64 and 66 pivotally connected at their front ends with the movable platen 16 by means of dual lugs 70 and a connecting pin 72. The mechanism 50 also has two rear links 74, 76 which are pivotally connected to the front links by means of a connecting pin 78 and to the stationary platen 12 at the rear by means of triple lugs 80 and a connecting pin 82. The toggle mechanism is completed by a single, pivotal leaf or crosshead link 84 extending between the crosshead 54 and the connecting pin 78 at the junction of the front and rear links.
The lower toggle linkage mechanism 52 is constructed in the same manner as the mechanism 50 and includes a forward set of links 90, 92, 94 and 96 pivotally connected to the movable platen 16 by means of dual lugs 98 and a pivot pin 100, a rear set of links 102, 104 pivotally connected to the stationary platen 12 by means of triple lugs 106 and a pivot pin 108 and to the forward links by a pivot pin 109, and a leaf link 111 connecting the crosshead 54 with the forward and rear links at the junction established by the pin 109.
It will be observed that all of the pins interconnecting the links of the toggle mechanisms are placed in double shear so that unbalanced movements are not generated when the high lockup forces are developed at the toggle position.
The crosshead 54 is mounted for sliding movement between the stationary platen 12 and the movable platen 16 on two slide rods 110 and 112.
The slide rods are fixedly attached at their forward ends to the movable platen 16 and slide in bushings 114 and 116 respectively attached to the stationary platen 12. Thus, as the platen 16 moves back and forth on the tie bars relative to the stationary platen 14, the slide rods move relative to the bushings 114 and 116. The offset or diagonal positioning of the slide rods in the crosshead is illustrated most clearly in FIG. 4 together with the connecting pins 118 and 120 which join the leaf links 84 and 111 to the center of the crosshead.
The piston and cylinder assemblies 56 and 58 are also diagonally disposed at opposite sides of the crosshead 54 as indicated in FIG. 5 and serve as the actuating means for controlling the position of the crosshead relative to the movable platen 16. Correspondingly, the assemblies control lockup and unlocking of the molding portions 32 and 34 by way of the crosshead and toggle mechanisms 50 and 52. Since the assemblies have the same construction, only assembly 56 is illustrated in section in FIG. 1.
The assembly 56 extends between the crosshead 54 and the movable platen 16 and has a cylinder 130 fixedly attached to the crosshead. An unbalanced piston 132 having the larger effective area facing the stationary platen 12 reciprocates back and forth within the cylinder in response to fluid pressures developed within the cylinder. A piston rod 134 extends from the piston through the crosshead and is fixedly attached to the movable platen 16. In a similar manner, the assembly 58 has a cylinder 140, an unbalanced piston (not visible) within and a piston rod 144 connected between the piston and the movable platen 16.
OPERATION
At the beginning of a molding operation, the platens 14 and 16 are spread as illustrated in FIG. 2 so that the mold portions 30 and 32 are open. The piston and cylinder assembly 38 is then actuated to move the platen 16 toward the stationary platen 14 and place the mold portions 30 and 32 in the moldclosed position shown in FIG. 1. During movement of the platen 16, the control valves regulating the piston and cylinder assemblies 56 and 58 are in a by-pass situation. By maintaining a slightly positive pressure on the fluid system which energizes these assemblies, system fluid merely fills the cylinders without developing significant retarding or output forces until the mold 30 is closed. Due to the geometry of the toggle mechanisms, the crosshead 54 initially moves closer to the platen 16 as both the platen and crosshead advance toward the stationary platen 14 from the position illustrated in FIG. 2. However, when the rear linkages of both mechanisms reach a position perpendicular to the central axis of the machine, the crosshead 54 begins to move slower than the platen 16 and accordingly the distance between the crosshead and platen increases thereafter. As the lockup position of FIG. 1 is approached, the toggle mechanisms 50 and 52 move into the illustrated toggle positions and the relative motion of the crosshead away from the moving platen 16 increases substantially. The rapid increase in such relative motion makes the mold-closed position readily detectable with high sensitivity by means of a position sensing means 150 extending between the crosshead and moving platen 16.
In one form the sensing means may include a limit switch 152 mounted on the crosshead and an operating rod 154 fixedly attached to the moving platen 16. As the platen 16 reaches the mold-closed position, a detent on the rod 154 trips the limit switch 152 and provides a triggering signal for energizing the lockup assemblies 56 and 58. The high velocity movement of the crosshead 54 away from the platen 16 provides a more sensitive parameter for determining when the mold portions are closed than the movement of the platen 16 on the tie bars because of the greater rate of change of the relative movement at the critical position.
The relative movement of the crosshead initially toward the platen 16 reduces the required displacement of the pistons within the assemblies 56 and 58 so that the stroke and corresponding size of the cylinder assemblies 56 and 58 can be less than the total displacement of the moving platen 16. Correspondingly, a further reduction of the fluid system which operates the assemblies 38, 56 and 58 is permitted.
When the mold portions 30 and 32 have made contact or "kissed" and such contact is detected by the sensor 150, the assemblies 56 and 58 are energized simultaneously to push the crosshead 54 farther away from the platen 16 and at the same time positively urge the toggle mechanisms 150 and 152 into the toggle position. As the mechanical advantage of the toggle mechanisms approaches infinity at the toggle position, very high lockup loads are developed through the front and rear linkages and the tie bars connecting the stationary platens 12 and 14 and reacting the lockup loads are stretched in tension. At this point, the molds are locked up and a settable material may be injected into the cavity of the mold 30 through the stationary platen 14.
After the injection step, pressure within the cylinder assemblies 56 and 58 is reversed to insure that the toggle mechanisms are pulled out of the toggle position. Sufficient forces are also developed by the assemblies through the linkages to pull the mold portions 30 and 32 apart with a molded article within and thus break the mold open. Simultaneously or shortly thereafter, the piston and cylinder assembly 38 is actuated to generate the large scale displacement which moves the platen 16 to the mold open position illustrated in FIG. 2. As the assembly 38 begins to translate the platen 16 toward the stationary platen 12, the lockup assemblies 56 and 58 are again placed in by-pass so they do not impede the opening operation.
It will be noted that the unbalanced pistons in the lockup assemblies 56 and 58 develop their greatest output force during lockup of the injection mold 30. Correspondingly, the forces developed by the assemblies when the mold is open are less due to the smaller effective areas of the pistons being utilized. The different magnitudes and relative values of the forces available from the cylinder assemblies are ideally suited to the injection molding machine because the lockup force required is greater than the mold-breaking force. The correspondence of the required force and the available force of the assemblies 56 and 58 enables the assemblies to be scaled to the task which they perform and utilizes their capacities most efficiently in both the lockup and mold-breaking operations. Such scaling eliminates the need for oversize piston and cylinder assemblies and minimizes the capacity of the fluid system that operates the assemblies. The attainment of appropriately scaled assemblies is possible primarily because of the crosshead 54 moves away from the platen 16 during the lockup operation which should be contrasted with the corresponding movement that occurs in the prior art patent 3,632,272 referenced above. Concurrently, a reduction in the overall length of the molding machine is achieved by connecting the lockup cylinder assemblies between the moving platen 16 and the moving crosshead. It will be noted in the illustrated machine that the assemblies even in the open position of the mold in FIG. 2 do not project substantially beyond the stationary platen 12.
Accordingly, an injection molding machine having an improved lockup mechanism has been disclosed. The lockup mechanism does not significantly extend the overall length of the machine beyond the stationary end platens as in many of the prior art structures, and due to the manner in which the locking mechanism functions, actuators of minimize size are used most efficiently to perform the mold lockup and opening functions. An overall cost saving is obtained by corresponding reductions in the size of components and quantity of materials which comprise the machine.
While the present invention has been described in a preferred embodiment, it should be understood that numerous modifications and substitutions can be had. For example, each toggle linkage mechanism illustrated utilizes two sets of front and rear linkages with two front links in each set. It will be readily apparent that forces between the stationary and movable platens can be developed with a lesser number of links. While two different actuating assemblies 56 and 58 have been mounted in diagonally offset relationship on the crosshead 54, a single cylinder centrally mounted in the head might also be employed. Reference to the toggle position in connection with the invention is intended to comprehend not only the condition in which the front and rear linkages are in alignment but also the condition in which the linkages are intentionally restricted within a few degrees of alignment to avoid over-center locking of the linkages. Accordingly, the present invention has been described in a preferred embodiment by way of illustration rather than limitation.
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An injection molding machine has two stationary platens interconnected by tie bars and an immediate third platen which is movable on the tie bars. Separable mold portions are mounted respectively on one of the stationary platens and the third platen so that reciprocating movement of the third platen along the tie bars opens and closes the mold portions. A pair of toggle linkage mechanisms positioned at opposite sides of the machine and connecting with the movable third platen and one of the other platens are used to lockup the mold portions when the linkages assume their toggle positions. To move the toggle mechanisms into the toggle positions, a crosshead on slide rods connects with the mechanisms and is pushed away from the third platen at lockup by two piston and cylinder assemblies extending between the platen and the crosshead. The positioning of the cylinders and crosshead minimizes the overall length of the molding machine and permits mold lockup to be triggered more accurately.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to mechanical drive mechanisms that convert one type of motion to another, and more particularly, to a linear-to-rotary actuator that uses an Archimedean spiral to convert linear motion of a first member into rotary motion of a second member.
2. Description of the Related Art
Actuators used to facilitate the transfer of linear motion to rotary motion and/or rotary to linear motion between engaging members can vary in complexity, as well as the prescribed use. Door hinges, scissor trimming, raising lift linkages, and the steering of a wheel are all examples that illustrate interconversion between linear and rotary motion. While many types of linear-to-rotary actuators exist, very few actuators have a universal application that can convert linear motion of a first member into rotary motion of a second member, or vice-versa, in an easy and efficient manner.
Another basic example of a type of actuator that translates between linear and rotary motion is a screw fastener. Rotation of the screw head translates to linear movement of the screw. While screw fasteners are widely used in many different mechanical applications, they are not very easy to thread or unthread without the use of specialized tools, such as a screwdriver.
Thus, a linear-to-rotary actuator solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The linear-to-rotary actuator includes an elongated drive member constrained to linear movement, and a rotary member constrained to rotary movement. The elongated drive member has a coupling end and an engaging member that projects from the coupling end. The rotary member has a track defining an Archimedean spiral. The track is adapted to receive the engaging member. The engaging member is constrained to slide in the track such that linear movement of the elongated member effects rotation of the rotary member. The track may be a slot, a groove, or other guide. Alternatively, instead of a track defined directly in the rotary member, the actuator may include a linking member (such as a disk or rectangular bracket) attached to the rotary member, the linking member having a track defining an Archimedean spiral defined therein, the engaging member being slidable in the track to convert linear motion into rotary motion.
The elongated drive member may be a linear actuator selected from the group consisting of a hydraulic piston and cylinder assembly, a pneumatic piston and cylinder assembly, and an electric linear actuator. Alternatively, the elongated drive member may be a shaft and a gear assembly for driving the shaft. The gear assembly can be selected from the group consisting of a rack and pinion gear assembly and a worm drive gear assembly. Alternatively, the elongated drive member may be an elongated shaft having a threaded end and a support member having an internally threaded bore. The elongated shaft moves linearly when the threaded end is threaded into and out of the bore in the support member. In another alternative, the linear-to-rotary actuator may have a shaft, an electric motor, and a coupler assembly connecting the motor to the shaft. The coupler assembly selectively reciprocates the shaft. The elongated drive member may comprise a part of any mechanism for imparting linear motion to the elongated drive member.
The rotary member may comprise a door and hinges adapted for connecting the door to a rigid support member. As such, the door is rotatable on the hinges, and linear movement of the elongated member selectively opens and closes the door. Alternatively, the rotary member may be a pivotally mounted arm, post, disk, wheel, shaft, or any other member that can engage in rotary motion.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a chart illustrating an example of an Archimedean spiral.
FIG. 1B is a diagram illustrating construction of a guide curve based upon the principles of an Archimedean spiral.
FIG. 2 is an environmental, perspective view of a crane incorporating a linear-to-rotary actuator according to the present invention.
FIG. 3 is a partial environmental perspective view of door incorporating a linear-to-rotary actuator according to the present invention.
FIG. 4A is a perspective view of a linear-to-rotary actuator according to the present invention having a pair of rotary members on opposite sides of a linearly movable shaft to provide constant torque.
FIG. 4B is a side view of a disk-type rotary member of the linear-to-rotary actuator of FIG. 4A .
FIG. 4C is a side view of the disk-type rotary member of FIG. 4B , shown rotated to the stops of the tracks.
FIG. 5 is an exploded view of an embodiment of a linear-to-rotary actuator according to the present invention having dual rotating members with dual slots defining Archimedean spirals to provide constant torque.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of a linear-to-rotary actuator described herein provide various mechanical devices utilizing an Archimedean spiral configuration provided on the linear-to-rotary actuator to facilitate selective extension, retraction and rotation of connected members with ease of operation.
Referring to the graph shown FIG. 1A , an Archimedean spiral is characterized by the mathematical formula ρ=aθ, where ρ equals the radius or radial vector from the point of origin O, a equals a constant, and θ is the angle expressed in radians, aθ being in polar coordinates. For any given constant a there is a constant proportional relationship between the change in radial length and the change in angle. In other words, any arbitrary point following the above formula will change in radial length at the same proportional constant rate as that of the angular rotation. As used herein, an Archimedean spiral refers to any curve, or portion of a curve, that complies with the formula ρ=aθ, except as specified below.
FIG. 1B shows an example of an Archimedean curve constructed in accordance with the principles of the above formula. The curve 2 defines the linear movement of a member, which will be further described in relation to the various embodiments described herein. In this example, it is desired to move the member a certain linear distance starting from an arbitrary initial point 3 a to an end point 3 e within a desired arc range. The difference between the length of the initial radius ρ 1 and the length of the end radius ρ 5 equals the length of desired linear movement. The intermediate points 3 b , 3 c , 3 d and the intermediate radial lengths ρ 2 , ρ 3 , ρ 4 can be determined by dividing the arc range into equal increments. Joining these points 3 a , 3 b , 3 c , 3 d , 3 e provides a good approximation of the shape of the desired curve 2 . Increasing the increments will result in a more accurate curve 2 .
Further, the curve 2 can also be approximated by a simple circular curve. As shown in FIG. 1B , the curve 2 can have the properties of a simple circular curve where the axis or point of origin O C is offset from the original point of origin O. The radii r 1 , r 2 , r 3 , r 4 , r 5 to each respective point 3 a , 3 b , 3 c , 3 d , 3 e on the curve from the offset point of origin O C are approximately equal to each other. Thus, it can be seen that an Archimedean spiral can also be expressed by a circular curve. The above concepts provide that a relatively smooth and effortless translational curve can be constructed, especially for linear-to-rotary actuators to transfer linear motion to rotary motion for connected mechanical components.
The aforementioned principles of Archimedean spirals, represented by example in the guide curve 2 of FIG. 1B , can be utilized to efficiently and effectively transfer linear motion to rotary motion in several mechanical applications.
Referring to FIG. 2 , there is shown a linear-to-rotary actuator 10 adapted to transfer linear motion into rotary motion in conjunction with a crane. As shown, the actuator 10 includes a first member 12 , or elongated drive member, such as a double-acting hydraulic cylinder and piston assembly 12 , to provide linear motion. The actuator 10 further includes a second member, or arm 16 , adapted for rotary motion, and a linking member or rotary member 14 adapted to transfer linear motion of the first member 12 into rotary motion of the second member 16 .
The elongated drive member assembly 12 includes a piston 18 . The elongated drive member 12 is configured to extend and retract the piston 18 linearly in response to pressure applied by the control lines 22 and 23 . As illustrated, the elongated drive member 12 is constrained in a cylinder 25 , which limits the piston 18 to generally linear movement. The elongated drive member 12 further includes a coupling end 20 , which includes a first engaging member 24 and a second engaging member 26 , projecting from the coupling end 20 and adapted for operative engagement with the rotary member 14 .
The rotary member 14 rotates in response to linear movement of the elongated drive member 12 and piston 18 . The rotary member 14 operatively engages the elongated drive member 12 and the second member 16 , enabling the transfer of linear motion of the elongated drive member 12 into rotary motion of the second member 16 . As shown, the rotary member 14 is connected to the first member 12 at a central axis 30 . As such, the rotary member 14 rotates about the axis 30 , when the elongated drive member 12 and piston 18 move linearly.
As shown, the rotary member 14 has a generally circular configuration conducive for circular rotation about the axis 30 . The rotary member 14 includes a first slot or track 40 defining an Archimedean curve, and adapted to receive the corresponding first engaging member 24 of the elongated drive member 12 . The rotary member 14 further includes a second slot or track 42 , also defining an Archimedean curve, and adapted to receive the corresponding engaging member 26 .
Each respective guide slot 40 and 42 is formed in accordance with, or has the curvature defining, an Archimedean spiral, as previously described in FIG. 1B . Accordingly, upon linear movement of the piston 18 of the elongated drive member 12 , each respective guide 40 and 42 translate linear movement of the respective engaging member 24 , 26 into rotary movement of the rotary member 14 and the connected second member 16 .
In operation, the elongated drive member 12 is activated by the control lines 22 and 23 . As such, hydraulic pressure forces the piston 18 to extend linearly outward from the hydraulic cylinder 12 . As the elongated member 18 moves linearly, the engaging members 24 and 26 , positioned in the corresponding respective guides 40 and 42 , provide a force on the rotary member 14 . As such, the respective engaging members 24 , and 26 slide along the guides 40 and 42 .
As the engaging members 24 and 26 cooperatively travel along the Archimedean shaped guides 40 , 42 , linear forces are applied to the rotary member 14 , thereby rotating the rotary member 14 about the axis 30 , and further cooperatively rotating the connected second member 16 . Linear retraction of the elongated drive member 18 towards the hydraulic cylinder 25 has a reverse effect on the rotary member 14 . As such, linear retraction of the elongated drive member 14 forces the rotary member 14 and connected second member 16 to rotate in an opposite direction.
Referring now to FIG. 3 , there is shown an embodiment of the linear-to-rotary actuator 210 using a slot 240 defining an Archimedean curve to transfer linear motion into rotary motion of a door or window. As shown, the actuator 210 includes a first member 212 or elongated drive member, a linking member 214 having a track or slot 240 formed therein, and a second member 216 , in operative engagement with the joining member 214 and elongated drive member 212 .
The elongated drive member 212 can include a gear assembly or coupler assembly 220 . The assembly 220 provides the actuator with a linear driving force. The gear assembly 220 can be a worm drive gear assembly 220 , including an electric linear actuator, having a motor 222 and a shaft 218 . The assembly 220 connects the motor 222 to the shaft 218 , and selectively reciprocates the shaft 218 linearly.
As shown, the shaft 218 has a threaded end. The assembly 220 or member 220 has an internally threaded bore for receiving the shaft 218 . The shaft 218 is adapted for linear movement into and out of the internally threaded bore formed in the assembly 220 . Linear movement is applied to the shaft 218 , when the threaded end of the shaft 218 is threaded into and out of the bore formed in the support member 220 .
As shown the linking member 214 can be a plate or bracket having a non-circular configuration. The linking member 214 is connected to the second member 216 , which can be a door or window 216 . The linking member 214 further includes a track or slot 240 formed therein defining an Archimedean spiral. As shown the slot 240 is adapted to receive the engaging member 224 of the shaft 218 . As the engaging member 224 is constrained to slide in the slot 240 , linear movement of the shaft 218 can rotate the linking member 214 and connected second member 216 .
As illustrated, the second member 216 , which can be a door or window, is further connected to a hinge 226 and frame 228 , enabling the second member 216 to rotate in response to movement of the joining member 214 .
In operation, a remote control or user interface can activate the electric motor 222 to force the threaded shaft 218 to move in linearly. As the shaft 218 moves linearly, the engaging member 224 slides along the Archimedean slot 240 . Linear movement of the engaging member 224 within the Archimedean slot 240 forces the linking member 214 to rotate. Accordingly, the member 216 , connected to the plate 214 , is forced to also rotate relative to the frame 228 .
With respect to singular rotary members, the driving torque applied on a singular rotary member having an Archimedean spiral varies from the radius change of the rotating angle. The varied torque applied to the member can negatively affect the dynamic application to the linear to actuator. Accordingly it is desirable, when transferring linear motion to rotary motion, that the linear-to-rotary actuator has constant torque.
Referring now to FIGS. 4A-4C , there is shown an embodiment of a linear-to-rotary actuator 310 adapted to provide constant torque during linear-to-rotary motion transfer. The actuator 310 includes a first member 312 , or elongated drive member 312 , a rotary member 314 , 315 , and a rotary member 316 adapted to transfer rotary motion to an associated member.
The elongated drive member 312 can include a cylinder and piston assembly 320 , or pneumatic and piston assembly 320 . As illustrated the piston assembly 320 includes a cylinder and piston 318 . The piston 318 has a coupling end 322 , which includes plural engaging members 324 and 326 configured for operative engagement with the rotary members 314 and 315 . The rotary members 314 and 315 transfer linear motion from the first member 312 into rotary motion of the second member 316 .
FIG. 4A shows the rotary actuator 310 . As shown, the first member 312 can be a cylinder and piston assembly 320 . The piston 318 is adapted for linear reciprocation. The elongated drive member 312 includes plural engaging members 324 , and 326 formed on a coupling end 322 and adapted to cooperatively engage rotary members 314 , 315 to enable the transfer of linear motion of the piston 318 into rotary motion of the rotary members 314 , 315 .
As illustrated, the rotary member 314 includes dual slots, or tracks 340 , 342 and the rotary member 315 includes dual slots or tracks 344 and 346 formed therein. The tracks 340 , 342 , 344 and 346 define an Archimedean curve, similar to the curve illustrated in FIG. 1B . The engaging members 324 and 326 each have two opposing ends that project from the piston 318 . As such, the engaging members 324 and 326 provide four insertable members configured for entry into the corresponding Archimedean slots 340 , 342 , 344 and 346 .
As illustrated in FIGS. 4B and 4C , the respective Archimedean curves 340 and 342 are symmetrically arrayed about the center of the rotary member 314 . The plural grooves 340 , 342 balance the torque change to the constant. As such the driving arm or piston 318 when moving in the constant length of linear motion can drive the symmetric Archimedean grooves 340 , 342 simultaneously and keep the driving torque constant.
As shown in FIG. 4A , the rotary or rotary members 314 , and 315 with an Archimedean groove formed therein can have reverse rotations installed on opposing sides of the engaging members 324 and 326 . It is contemplated that the rotary members 314 and 315 do not be need to be identical. The Archimedean spirals on each side can have different constant in ρ=aθ. They will be matched in motion if and only they follow the same linear motion step with the angular motion different. Notably, it is possible to form the Archimedean slots 340 , 342 on a single disc 180° or less, and by using dual rotary members 314 , 315 , the relative angle of change can be doubled to about 360° or less.
In operation, the elongated drive member 312 selectively receives hydraulic or pneumatic pressure in the cylinder, and pressure is applied to the piston 318 . The piston 318 is constrained to reciprocate linearly. The engaging members 324 and 326 , in response to movement of the connected piston 318 , move linearly. As such, the engaging members 324 and 326 are constrained to slide along the respective Archimedean slots 340 , 342 , 344 , and 346 , so that the rotary members 314 , 315 rotate.
Continuing to FIG. 5 , an embodiment of a fluid-driven linear-to-rotary actuator 410 is shown for transferring linear motion of a first member 412 or elongated drive member 412 into rotary motion of one or more second members, or rotary members 414 , 415 . The linear-to-rotary actuator 410 can use hydraulic pressure or pneumatic pressure to provide a driving forced from the linear-to-rotary actuator 410 . As such, it is contemplated that the elongated drive member 412 , of the linear-to-rotary actuator 410 can be a hydraulic piston and cylinder assembly, or a pneumatic piston and cylinder assembly.
The elongated drive member 412 includes a cylinder 436 , a piston 418 , operatively connected to the cylinder 436 , and a sleeve 434 . The elongated drive member 412 further includes an extension bar 420 defining a coupling end 420 . The extension bar 420 is connected to the piston 418 and configured for reciprocation within the sleeve 434 . The elongated drive member 212 further includes a plurality of cross pins or engaging members 424 and 426 extending generally outward from the extension bar 420 , and adapted to cooperatively engage the rotary members 414 , 415 .
The sleeve 434 includes a plurality of slots or apertures 432 a , 432 b formed therein. The plural slots 432 a , 432 b are adapted to receive corresponding plural engaging members 424 and 426 through the sleeve 434 . The slots 432 a and 432 b enable linear movement of the engaging members 424 and 426 during operation, and also enable the engaging members 424 and 426 to be operatively engaged with the corresponding rotary members 414 and 415 .
The engaging members 424 , 426 include corresponding rollers 448 , adapted for connection to the ends of the respective engaging members 424 , 426 to facilitate sliding movement of the engaging members 424 , 426 during linear engagement with the rotary members 414 , 415 .
As shown, the dual rotary members 415 , 414 pivotally engage the axis 430 on both respective sides of the elongated driving member 412 . The rotary members 414 , 415 have a generally circular configuration, and each includes dual tracks, tracks 440 , 442 for rotary member 414 , and dual tracks 444 , 446 for rotary member 415 to receive respective engaging members 424 and 426 . The tracks 440 , 442 and 444 , 446 each have an Archimedean curve formation to cooperatively provide a balanced and constant driving torque when in rotary motion. As shown, Archimedean tracks 440 , 442 are formed in opposing directions from tracks 444 , 446 such that torque applied by the rotary members 414 and 415 to the connected members is balanced.
In operation, the elongated drive member 412 selectively receives hydraulic or pneumatic pressure in the cylinder 436 . The pressure is applied the piston 418 forcing the piston 418 to reciprocate linearly within the sleeve 434 . The connected extension bar 420 , in response to movement of the piston 418 , moves linearly within sleeve 434 . As such, the engaging member 424 and 426 engage the rotary members 414 and 415 , and are constrained to slide along the respective Archimedean slots 440 , 442 , 444 . Accordingly, the rotary members 414 , and 415 rotate about the axis 430 to transfer linear motion into rotary motion.
Other embodiments are contemplated with respect to using the Archimedean spiral for linear-to-rotary actuators. For example, with respect to safety applications, a linear-to-rotary actuator may have a block including an Archimedean groove. In such application, a sliding bar has an engaging member provided on an end thereof. As force is provided downward, the engaging member provides a force rotating the block in a downward position. As the sliding bar with spring forces extends upward, a linear force rotates the block upward.
In another embodiment, relative rotation angle enlargement for the Archimedean rotator can be used to drive a four-bar linkage system. As such, a pair of identical non-circular shaped rotary members, or Archimedean brackets, are jointly provided on the same sides of the first member or sliding member. As the sliding member with threads are driven by manual crank or motors, the vertical bar with crossed rollers in the identical Archimedean slots will lift up and down the linkages. The relative rotating angles between the upper and lower linkages are doubled as the single Archimedean angle rotated. Moreover, the relative linkage position is automatically self-locked in thread movement.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The linear-to-rotary actuator includes an elongated drive member constrained to linear movement, and a rotary member constrained to rotary movement. The elongated drive member has a coupling end and an engaging member that projects from the coupling end. The rotary member has a track defining an Archimedean spiral. The track is adapted to receive the engaging member. The engaging member is constrained to slide in the track such that linear movement of the elongated member effects rotation of the rotary member. The track may be a slot, a groove, or other guide. Alternatively, instead of a track defined directly in the rotary member, the actuator may include a linking member (such as a disk or rectangular bracket) attached to the rotary member, the linking member having a track defining an Archimedean spiral defined therein, the engaging member being slidable in the track to convert linear motion into rotary motion.
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BACKGROUND
[0001] Steam Assisted Gravity Drainage (SAGD) is a commercial, thermal enhanced oil recovery (“EOR”) process. The SAGD process uses saturated steam injected into a horizontal well, where latent heat is used to heat bitumen in the reservoir. The heating of the bitumen lowers its viscosity, so it drains by gravity to an underlying parallel, twin, horizontal well completed near the reservoir bottom.
[0002] Since the process inception in the early 1980's, SAGD has become the dominant, in situ process to recover bitumen from Alberta's bitumen deposits (Butler, R., “Thermal Recovery of Oil & Bitumen”, Prentice-Hall, 1991). Today's SAGD bitumen production in Alberta is about 300 Kbbl/d with installed capacity at about 475 Kbbl/d (Oilsands Review, 2010). SAGD is now the world's leading thermal EOR process.
[0003] FIG. 1 (PRIOR ART) shows the “traditional” SAGD geometry, using twin, parallel horizontal wells 2 , 4 drilled in the same vertical plane. There is a 5-metre spacing between the horizontal wells 2 , 4 , which are about 800 metres long with the lower well 1 to 2 metres above the (horizontal) reservoir floor. Circulating steam 6 in both wells starts the SAGD process. After communication is established, the upper well 2 is used to inject steam 6 , and the lower well 4 produces hot water and hot bitumen 8 . Fluid production is accomplished by natural lift, gas lift, or submersible pump.
[0004] After conversion to “normal” SAGD operations, a steam chamber 10 forms around the injection 2 and production wells 4 where the void space is occupied by steam 6 . Steam 6 condenses at the boundaries of the chamber 10 , releases latent heat (heat of condensation), and heats bitumen, connate water and the reservoir matrix. Heated bitumen and water 8 drain by gravity to the lower production well 4 . The steam chamber 10 grows upward and outward as bitumen is drained.
[0005] FIGS. 2A-2D (PRIOR ART) show how SAGD matures. A “young” steam chamber 10 has bitumen drainage from steep chamber sides and from the chamber ceiling. When the chamber growth hits the top of the reservoir, ceiling drainage stops, bitumen productivity peaks, and the slope of the side walls decreases as lateral growth continues. Heat loss increases (and steam-to-oil ratio (“SOR”) increases) as ceiling contact and the “surface area” of the steam chamber increases. Drainage rates slow down as the side wall angle decreases. Eventually, the economic limit is reached, and the end-of-life drainage angle is small) (10-20°.
[0006] Produced fluids are near saturated-steam temperature, so it is only the latent heat of steam that contributes to the process in the reservoir. But, some of the sensible heat can be captured from surface heat exchangers (a greater fraction at higher temperatures), so a useful rule-of-thumb for net heat contribution of steam is 1000 BTU/lb. for the P, T range of most SAGD projects ( FIG. 3 PRIOR ART).
[0007] The operational performance of SAGD can be characterized by measurement of the following parameters: 1) saturated steam P, T in the steam chamber ( FIG. 4 PRIOR ART); 2) bitumen productivity; 3) SOR, usually at the well head; 4) sub-cool target, the T difference between saturated steam and produced fluids; and 5) Water Recycle Ratio (“WRR”), the ratio of produced water to steam injected.
[0008] During the SAGD process, the SAGD operator has two choices to make: 1) the sub-cool target T difference and 2) the operating pressure in the reservoir. A typical sub-cool of about 10 to 30° C. is meant to ensure no live steam breaks through to the production well. Process pressure and temperature are linked ( FIG. 4 PRIOR ART) and relate mostly to bitumen productivity and process efficiency.
[0009] Bitumen viscosity is a strong function of temperature ( FIG. 5 ). SAGD productivity is proportional to the square root of the inverse viscosity ( FIG. 6 PRIOR ART) (Butler (1991)). Conversely if pressure (and T) is increased, the latent heat content of steam drops rapidly ( FIG. 3 ). More energy is used to heat the rock matrix and is lost to the overburden or other non-productive areas. So, increased pressure increases bitumen productivity but harms process efficiency (increases SOR). Because economic returns can be dominated by bitumen productivity, the SAGD operator usually opts to target operating pressures higher than native or hydrostatic reservoir pressures.
[0010] Despite becoming the dominant thermal EOR process, SAGD has some limitations and detractions. The requirements for a good SAGD project are:
a horizontal well completed near the bottom of the pay zone to effectively collect and produce hot draining fluids. the injected steam, at the sand face, has a high quality (latent heat drives the process) the process start up is effective and expedient the steam chamber grows smoothly and is contained the reservoir matrix is good quality (porosity (φ)>0.2);
Initial Oil Saturation (S io )>0.6; Vertical permeability (k v )>2D)
net pay is sufficient (>15 metres) proper design and control must achieved to simultaneously; 1) prevent steam breakthrough to the production well and injector flooding; 2) stimulate steam chamber growth to productive zones; and 3) inhibit water inflows to the steam chamber. there must be absence of significant reservoir baffles (e.g. lean zones) or barriers (e.g. shale)
[0020] If these conditions are not attained or other limitations are experienced, SAGD can be impaired, as follows:
[0021] (1) The preferred dominant production mechanism is gravity drainage, and the lower production well is horizontal. If the reservoir is slanted, a horizontal production well will strand significant resources.
[0022] (2) The SAGD steam-swept zone has significant residual bitumen content that is not recovered, particularly for heavier bitumens and low pressure steam ( FIG. 7 ). For example with a 20% residual bitumen (pore saturation) and a 70% initial saturation, the recovery factor is only 71%, not including stranded bitumen below the production well or in the wedge zone between recovery patterns.
[0023] (3) To contain a SAGD steam chamber, the oil in the reservoir must be relatively immobile. SAGD cannot work on heavy (or light) oils with some mobility at reservoir conditions. Bitumen is the preferred target.
[0024] (4) Saturated steam cannot vaporize connate water. By definition, the heat energy in saturated steam is not high enough quality (temperature) to vaporize water. Field experience also shows that heated connate is not usually mobilized sufficiently to be produced in SAGD. Produced Water-to-Oil Ratio (“PWOR”) is similar to SOR. This makes it difficult for SAGD to breach or utilize lean zone resources.
[0025] (5) The existence of an active water zone—either top water, bottom water or an interspersed lean zone within the pay zone—can cause operational difficulties or project failures for SAGD (Nexen Inc., “Second Quarter Results”, Aug. 4, 2011) (Vanderklippe, N., “Long LakeProject Hits Sticky Patch”, CTV News, 2011). Simulation studies concluded that increasing production well stand-off distances can optimize SAGD performance with active bottom waters, including good pressure control to minimize water influx (Akram, F., “Reservoir Simulation Optimizes SAGD, American Oil and Gas Reporter, September 2010).
[0026] (6) Pressure targets cannot (always) be increased to improve SAGD productivity and SAGD economics. If the reservoir is “leaky”, as pressure is increased beyond native or hydrostatic pressures, the SAGD process can lose water or steam to zones outside the SAGD steam chamber. If fluids are lost, the Water Recycle Ratio (WRR) decreases, and the process requires significant water make-up volumes. If steam is also lost, process efficiency drops and SOR increases. Ultimately, if pressures are too high, if the reservoir is shallow, and if the high pressure is retained for too long, a surface breakthrough of steam, sand, and water can occur (Roche, P., “Beyond Steam”, New Tech. Mag., September 2011).
[0027] (7) Steam costs are considerable. If steam “costs” are over-the-fence for a utility including capital charges and some profits, the costs for high-quality steam at the sand face is about $10 to 15/MMBTU. High steam costs can reflect on resource quality limits and on ultimate recovery factors.
[0028] (8) Water use is significant. Assuming SOR=3, WRR=1, and a 90% yield of produced water treatment (i.e. recycle), a typical SAGD water use is 0.3 barrels (bbls) of make-up water per barrel (bbl) of bitumen produced.
[0029] (9) SAGD process efficiency is poor, and CO 2 emissions are significant. If SAGD efficiency is defined as [(bitumen energy)−(surface energy used)]/(bitumen energy), where 1) bitumen energy=6 MMBTU/bbl; 2) energy used at sand face=1MMBTU/bbl bitumen (SOR˜3); 3) steam is produced in a gas-fired boiler at 85% efficiency; 4) there are heat losses of 10% each in distribution to the well head and delivery from the well head to the sand face; 5) usable steam energy is 1000 BTU/lb ( FIG. 3 PRIOR ART); and 6) boiler fuel is methane at 1000 BTU/SCF, then the SAGD process efficiency=75.5% and CO2 emissions=0.077 tonnes/bbl bitumen.
[0030] (10) Practical steam distribution distance is limited to about 10 to 15 km (6 to 9 miles), due to heat losses, pressure losses, and the cost of insulated distribution steam pipes (Finan, A., “Integration of Nuclear Power . . . ”, MIT thesis, June 2007), (Energy Alberta Corp., “Nuclear Energy . . . ”, Canada Heavy Oil Association, pres., Nov. 2, 2006).
[0031] (11) Lastly, there is a natural hydraulic limit that restricts well lengths or well diameters and can override pressure targets for SAGD operations. FIGS. 8A and 8B show what can and has happened. In SAGD, a steam/liquid interface 12 is formed. For a good SAGD operation with sub-cool control, the interface is between the injector 2 and producer wells 4 . The interface is tilted because of the pressure drop in the production well 4 due to fluid flow. There is little/no pressure differential in the steam/gas chamber. If the fluid production rates are too high (or if the production well is too small), the interface can be tilted so that the toe 14 of the steam injector is flooded and/or the heel 16 of the producer is exposed to steam 6 breakthrough ( FIGS. 8A and 8B ). This limitation can occur when the pressure drop in the production well 4 exceeds the hydrostatic head between steam injector 2 and fluid producer 4 (about 8 psi (50 kPa) for a 5 m. spacing).
[0032] As discussed above, SAGD has significant problems, including reduced efficiency (high Steam-to-Oil Ratio), poor productivity, and poor bitumen recovery when dealing with Lean Zones. In particular, SAGD cannot vaporize connate water because it uses saturated steam.
[0033] Lean Zones (LZ) are reservoir zones where hydrocarbon pore saturation is significantly reduced compared to most hydrocarbon reservoirs (<0.6) and where the remaining saturation (>0.4) is mostly water. Lean zones can be interspersed within a reservoir that has higher hydrocarbon saturation. Lean zones can be near the top of a reservoir (transition zone to top water), the bottom of a reservoir (transition zone to bottom water), or the entire pay zone can be classed as a lean zone (<0.6 hydrocarbon saturation). Because of high water saturation, some lean zones can transmit water. The zones can be active (>50 m 3 /d water recharge rate) or limited (<50 m 3 /d recharge rate). Because bitumen density is near water density (API=10) and because bitumen density changed (rapidly) over time by bacterial degradation, bitumen reservoirs can show multiple LZ's—interspersed, top, bottom or whole reservoir.
[0034] A lean-zone reservoir, or part of a reservoir, has a low original oil (bitumen) saturation (S io ) and a corresponding high original water saturation (S iw ). For the purposes of this invention, a lean zone is defined as (S io ≦0.6 (i.e. the original oil/bitumen saturation is less than 60 percent of the pore volume).
[0035] A thief zone is defined as an active zone to which fluids are lost.
[0036] For example, FIGS. 9 , 10 , 11 , and 12 characterize the McMurray formation. FIG. 9 shows the depth of the top of the formation—i.e. the overburden thickness. FIG. 10 shows the thickness of the total deposit—both porous and non-porous zones. FIG. 11 shows the porosity internal—the net thickness of the porous portion of the deposit, with a 10% porosity cut off (this portion contains bitumen, water, and gas occupying the pore volume). FIG. 12 shows the bitumen net pay thickness—a portion of the porosity interval. The difference between the porosity interval and the bitumen pay is an indication of impairment zones for EOR processes—gas, top water, bottom water or lean zones. These zones can be within the bitumen net pay or adjacent (top/bottom)
[0037] Industry reports regarding Lean Zones include the following:
Suncor's Firebag SAGD project and Nexen's Long Lake project each have reported interspersed lean zones that can behave as thief zones when SAGD pressures are too high, forcing the operators to choose SAGD pressures that are lower than desirable (Triangle—“Technical Audit Report, Gas Over Bitumen Technical Solutions”, Triangle Three Engineering, December 2010). Simulation studies of a particular reservoir concluded that a 3 metre standoff (3 metres from the SAGD producer well to the bitumen/water interface) was sufficient to optimize production with bottom water, allowing a 1 metre control for drilling accuracy (Akram (2010)). Allowing for coring/seismic control, the standoff may be higher. Nexen and OPTI have reported that interspersed lean zones seriously impede SAGD bitumen productivity and increase SOR beyond original expectations at Long Lake, Alberta (Vanderklippe (2011), (Bouchard, J. et al, “Scratching Below the Surface Issues at Long Lake—Part 2”, Raymond James, Feb. 11, 2011), Nexen (2011), (Haggett, J. et al, “Update 3—Long Lake Oilsands Output may lag Targets”, Reuters, Feb. 10, 2011). Long Lake lean zones have been reported to make up from less than 3 to 5% (v/v) of the reservoir (Vanderklippe (2011), Nexen (2011)). Oilsands Quest reported a bitumen reservoir with top lean zones that are “thin to moderate”. Some areas had “continuous top thick lean zones” (Oilsands Quest (2011)). Connacher Oil and Gas had an oil sands project with a top lean zone (Johnson (2011). The lean zone was reported to differ from an aquifer in two ways—“the lean zone is not charged and is limited size”. Shell's Peace River Project reportedly had a lean zone, including a “basal lean bitumen zone” (Thimm, H. F. et al, “A Statistical Analysis of the early Peace River Thermal Project Performance,” Journal Canadian Petroleum Technology, January 1993). The statistical analysis of the steam soak process (Cyclic Steam Stimulation (“CSS”)) showed performance correlated with the geology of the lean zone (i.e. the lean zone quality was the important factor). The process chosen took advantage of lean zone properties, particularly the good steam injectivity in lean zones.
[0044] In-Situ Combustion (“ISC”) is the oldest thermal recovery technique. In-situ combustion is basically injection of an oxidizing gas 20 (air or oxygen-enriched air) to generate heat by burning a portion of the residual oil ( FIG. 32 ). Most of the oil is driven toward the producers by a combination of gas drive (from the combustion gases), steam and water drive. This process is also called fire flooding to describe the movement of a burning front inside the reservoir. Based on the respective directions of front propagation and air flow, the process can be forward, when the combustion front advances in the same direction as the air flow, or reverse, when the front moves against the air flow (Brigham, William, et al. “In-situ Combustion” Chapter 16 Reservoir Engineering).
[0045] The peak production period for ISC was in the 1980s, spurred by government incentives. The peak production was 12 Kbbl/d. In the USA, only 23 of the 1980's ISC projects were deemed economic. In Canada, there has been little focus on bitumen ISC (Butler, 1991). However, Petrobank has been pursuing a toe-to-heel version of ISC called the Toe-to-Heel Air Injection (THAI) process. The THAI process uses a horizontal production well and a vertical air injector completed near the toe of the horizontal well. Field testing of the THAI process started in 2006 but results have been disappointing.
[0046] The Combustion Overhead Split Horizontal (COSH)/Combustion Overhead Gravity Drainage (“COGD”) process is another ISC process using a horizontal production well with horizontal vent gas removal wells on the pattern edges, and vertical air injectors are located above the horizontal well. This process was first pursued by Excelsior, but current activity has ceased (New Tech Magazine, “Excelsior Searching . . . COGD Project” Nov. 20, 2009).
[0047] Ramey first suggested the use of oxygen gas, rather than air, for ISC in 1954. Greenwich Oil at Forest Hill, Tex. in 1980 was the first demonstration of successful injection of high concentration oxygen into an oil reservoir; however, other field tests have since been conducted with mixed results (Sarathi, P., “ISC EOR Status”, DOE, 1999).
[0048] It is important to note that there have been no specific targets on lean reservoirs using ISC processes.
[0049] SAGDOX is an improved thermal enhanced oil recovery (EOR) process for bitumen recovery. The process can use geometry similar to SAGD ( FIG. 13 ), but it also has versions with separate vertical wells or segregated sites for oxygen injection and/or non-condensable vent gas removal ( FIGS. 14A , 14 B, 15 A, 15 B, 16 A- 16 C). The process can be considered as a hybrid SAGD+ISC process.
[0050] The objective of SAGDOX is to reduce reservoir energy injection costs, while maintaining good efficiency and productivity. Oxygen combustion produces in situ heat at a rate of about 480 BTU/SCF oxygen, independent of fuel combusted ( FIGS. 17 , 18 Butler (1991)). Combustion temperatures are independent of pressure and they are higher than saturated steam temperatures ( FIGS. 3 , 18 ). The higher temperature from combustion vaporizes connate water and refluxes some steam. Steam delivers EOR energy from latent heat released by condensation with a net value, including surface heat recovery of about 1000 BTU/lb. ( FIG. 3 ).
[0051] Table 1 compares EOR heat injectant properties of steam and oxidant gases. Table 3 presents thermal properties of steam+oxygen mixtures. Per unit heat delivered to the reservoir, oxygen volumes are ten times less than steam, and oxygen costs including capital charges are one half to one third the cost of steam.
[0052] The recovery mechanisms are more complex for SAGDOX than for SAGD. The combustion zone is contained within the steam-swept zone 170 . Residual bitumen, in the steam-swept zone 170 , is heated, fractionated and pyrolyzed by hot combustion gases to produce coke that is the actual fuel for combustion. A gas chamber is formed containing steam combustion gases, vaporized connate water, and other gases ( FIG. 19 ). The large gas chamber can be subdivided into a combustion-swept zone 100 , a combustion-zone, a pyrolysis zone 120 , a hot bitumen bank 130 , a superheated steam zone 140 and a saturated steam zone 50 ( FIG. 19 ). Condensed steam drains from the saturated steam zone 150 and from the ceiling and walls of the gas chamber. Hot bitumen drains from the ceiling and walls of the chamber and from the hot bitumen zone 130 at the edge of the combustion front 110 ( FIG. 19 ). Condensed water and hot bitumen 8 are collected by the lower horizontal well 4 and conveyed (or pumped) to the surface ( FIG. 13 ).
[0053] Combustion non-condensable gases are collected and removed by vent gas 22 wells or at segregated vent gas sites ( FIGS. 13 , 14 A, 14 B, 15 A, 15 B and 16 A- 16 C). Process pressures can be controlled (partially) by vent gas 22 production, independent of fluid production rates. Vent gas 22 production can also be used to influence direction and rate of gas chamber growth.
[0054] In rich reservoirs, SAGDOX cannot vaporize enough connate water to obviate steam 6 injection.
[0055] To summarize, there is no thermal EOR or ISC technology focused on lean zones to recover bitumen.
[0056] However, lean zones can have some redeeming advantages. They are as follows:
Connate water can be significant if it can be mobilized and utilized as steam or produced and recycled as steam Because of high initial water saturations (>0.4), and possible water channels, lean zones can have some fluid injectivity even if the bitumen fraction is immobile. Lean zones with low bitumen saturation (between 0.05-0.20) may provide enough fuel to sustain combustion within the lean zones.
[0060] But for thermal EOR processes using saturated steam, lean zones present the following problems:
(1) In order to mobilize the oil by heating to steam temperatures, the connate water and the rock matrix also have to be heated. The proportion of heat going to the oil/bitumen drops dramatically as the initial oil saturation drops. (2) For a process like SAGD, this is manifested by a rapidly increasing SOR as initial oil saturation drops, as shown in FIG. 20 for a 500 psia saturated steam (242° C.). (3) In any steam EOR process, including SAGD, in the steam-swept zone (GD chamber), a residual oil/bitumen is left behind, unrecovered. For bitumen EOR and for a reasonable range of saturated steam temperatures (180° C. to 260° C.), the residual bitumen saturation is in the range of 0.10 to 0.20 ( FIG. 7 ). This can limit steam EOR recoveries for thermal steam EOR in lean zones, particularly for the lower temperatures and lower initial bitumen saturation levels ( FIG. 21 ). (4) For lean zones with low bitumen (<0.20 initial saturation), there may be zero recovery when steam sweeps the zone. (5) As the initial bitumen saturation drops, most of the (steam) heat goes to heating connate water ( FIG. 22 ). (6) Interspersed lean zones can interrupt SAGD steam chamber growth patterns. Interspersed lean zones have to be heated so that GD steam chambers can envelope the zone and continue growth above and around the lean zone blockage. (7) An interspersed lean zone has higher heat capacity and higher heat conductivity than a zone with higher bitumen content. Even if an aquifer or bottom/top water zone, does not recharge the lean zone for SAGD, the lean zone will create a thermal penalty as the steam chamber moves through and around the lean zone. For SAGD, bitumen productivity will also suffer as the heated zone moves through (and around) the lean zone. (8) If an interspersed lean zone acts as a thief zone, the problems are most severe. The lean zone can channel steam away from the SAGD steam chamber. If the steam condenses prior to removal, the water is lost but some of the heat can be retained. But, if the steam exits the SAGD steam chamber prior to condensing, both the heat and the water are lost to the process. The obvious remedy is to reduce SAGD pressure to minimize the steam/water outflow. But, if this is done, bitumen productivity will be reduced.
[0069] Because of the above problems, lean zones have presented the following disadvantages for thermal EOR:
The EOR goal is to heat bitumen to reduce its viscosity so it can drain to a production well. But as the oil saturation drops, most of the injected heat goes to heating connate water, particularly for the leanest zones ( FIG. 22 ). Saturated steam is not of sufficient quality to vaporize water, only to heat it to near saturated-steam temperature. The residual bitumen in a steam-swept zone can be significant, particularly for heavy bitumens and for cooler thermal EOR processes ( FIG. 9 ). If the initial bitumen saturation in a lean zone is close to (or below) the residual bitumen in a steam-swept zone, steam EOR can recover little or no bitumen from the lean zone. Using a simple model for steam EOR, assuming all bitumen above 0.15 saturation is recovered by heating to 242° C. (500 psia), below an initial bitumen saturation of about 0.4, with modest heat losses, SOR can exceed 5 and steam EOR becomes impractical ( FIG. 21 ).
[0074] Accordingly, there is a need for an EOR applicable to lean reservoirs. Preferably, a SAGDOX process that is applicable to lean reservoirs.
SUMMARY OF THE INVENTION
[0075] LZ-SAGDOX is a process similar to SAGDOX; however, the process is tailored to lean reservoirs and no steam is injected. LZ-SAGDOX creates steam in the reservoir by two ways: 1) vaporizing connate water and 2) as a chemical production of combustion (water of combustion).
[0076] According to one aspect, there is a provided a process to recover oil from a reservoir having at least one lean zone. Preferably, the lean zone has an initial bitumen saturation (S io ) level less than about 0.6. The process comprises an injection of oxygen into the lean zone. The oxygen combustion vaporizes the connate water in the lean zone. The vaporizing of the connate water allows for recovery of oil from the reservoir.
[0077] In one embodiment, the lean zone thickness is less than 25 metres.
[0078] In one embodiment, an initial steam is injected with the oxygen into the reservoir, then the initial steam injection is terminated.
[0079] In one embodiment, combustion occurs at temperatures higher than 400° C.
[0080] In one embodiment, the oxygen has an oxygen content of 95 to 99.9 (v/v) percent.
[0081] In one embodiment, the oxygen is air. In a further embodiment, the air is enriched air with an oxygen containing content of 21 to 95 (v/v) percent.
[0082] In one embodiment, the hydrocarbons are bitumen with an API density less than 10 and in situ viscosity greater than 100,000 cp.
[0083] In one embodiment, the hydrocarbons are heavy oil with an API density greater than 10 but less than 20 and in situ viscosity greater than 1,000 cp.
[0084] According to another aspect of the invention, there is provided a SAGDOX system for recovery of hydrocarbons from a reservoir having at least one lean zone. The lean zone has an initial bitumen saturation level of less than 0.6. The system has a first well, which has a toe and a heel allowing for capture of hydrocarbons from the reservoir. The system has a second well allowing for injection of oxygen into the lean zone containing reservoir. The second well is proximate the toe of the first well. The system further comprises a vent gas means for venting any gas produced in the reservoir.
[0085] In one embodiment, the lean zone thickness is less than 25 metres.
[0086] In one embodiment, the vent gas means is selected from a group consisting of a single substantially vertical well or a plurality of substantially vertical wells.
[0087] In one embodiment, the vent gas means is a segregated annulus section in the heel section of the horizontal well.
[0088] In a further embodiment, the vent gas means is distant said toe of said well.
[0089] In one embodiment, the at least one oxygen injection site is selected from a group consisting of a single substantially vertical well or a plurality of substantially vertical wells.
[0090] According to yet another aspect of the invention, there is provided a SAGDOX system for recovery of hydrocarbons from a reservoir having at least one lean zone. The lean zone has an initial bitumen saturation level of less than 0.6. The system has a well with a toe and a heel, and the well is located within the lean zone containing reservoir. The well further comprises at least one oxygen injection site proximate the toe for injecting oxygen into the reservoir. The well also has a hydrocarbon recovery site for recovery of hydrocarbons from the reservoir. Even further, the well has at least one vent gas site for venting any gas produced in the reservoir.
[0091] In one embodiment, the lean zone thickness is less than 25 metres.
[0092] In one embodiment, the vent gas means is a segregated annulus section in the heel section of the horizontal well.
[0093] In one embodiment, the vent gas means is distant the toe of the well.
[0094] In one embodiment, the oxygen injection site is a segregated toe section of the horizontal well.
[0095] In one embodiment, the toe of the well is at a different level in the reservoir than the heel of the well.
[0096] In one embodiment, the toe of the well is at a higher level in the reservoir than the heel of the well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0097] FIG. 1A is a perspective view of traditional SAGD well geometry;
[0098] FIG. 1B is an end elevational view of FIG. 1A ;
[0099] FIG. 2A is a schematic view of the early stages of the SAGD life cycle;
[0100] FIG. 2B is a schematic view of optimum productivity of an SAGD well;
[0101] FIG. 2C is a schematic view of a maturing/aging SAGD well;
[0102] FIG. 2D is a schematic view of the end of life of an SAGD well;
[0103] FIG. 3 depicts saturated steam properties;
[0104] FIG. 4 depicts the operational performance of an SAGD process;
[0105] FIG. 5 depicts Long Lake bitumen viscosity;
[0106] FIG. 6 depicts the gravdrain equation for SAGD bitumen productivity;
[0107] FIG. 7 depicts residual bitumen in steam-swept zones;
[0108] FIG. 8A depicts SAGD hydraulic limitations and good operation of an SAGD well;
[0109] FIG. 8B depicts SAGD hydraulic limitations and poor operation of an SAGD well;
[0110] FIG. 9 depicts the depth of the top of the McCurray deposit;
[0111] FIG. 10 depicts the thickness of the total McCurray deposit;
[0112] FIG. 11 depicts the net thickness of the porous portion of the deposit of the McMurray deposit;
[0113] FIG. 12 shows the bitumen net pay thickness of the McMurray deposit;
[0114] FIG. 13 depicts SAGDOX well geometry;
[0115] FIG. 14A is a schematic of the preferred embodiment of THSAGDOX;
[0116] FIG. 14B is a piping schematic of THSAGDOX;
[0117] FIG. 15A is a schematic of a Single Well SAGDOX well geometry;
[0118] FIG. 15B is a piping schematic of SWSAGDOX well;
[0119] FIG. 16A is a schematic of a preferred SAGDOX geometry;
[0120] FIG. 16B is a schematic of a preferred THSAGDOX geometry;
[0121] FIG. 16C is a schematic of a preferred SWSAGDOX geometry;
[0122] FIG. 17 depicts combustion heat release;
[0123] FIG. 18 depicts steam and oxygen tube tests 1;
[0124] FIG. 19 depicts SAGDOX mechanisms, including bitumen saturation, water saturation, gas saturation and temperature in relation to distance from an O 2 /steam injector;
[0125] FIG. 20 depicts a steam-to-oil ration for Steam EOR;
[0126] FIG. 21 depicts residual oil/bitumen saturation limits to recovery;
[0127] FIG. 22 depicts Steam EOR Heat Distribution;
[0128] FIG. 23 depicts Produced Water-to-Oil Ratio for LZ-SAGDOX;
[0129] FIG. 24A depicts preferred LZ-SAGDOX geometry;
[0130] FIG. 24B is a well configuration schematic for LZ-SAGDOX;
[0131] FIG. 25 depicts ISC minimum air flux rates;
[0132] FIG. 26 depicts steam and oxygen combustion tube tests II;
[0133] FIG. 27 depicts THAI process well geometry;
[0134] FIG. 28 depicts COGD/COSH process well geometry;
[0135] FIG. 29A is a schematic perspective view of LZ-SAGDOX;
[0136] FIG. 29B is a side schematic of LZ-SAGDOX;
[0137] FIG. 30 is a schematic of LZ-SAGDOX;
[0138] FIG. 31A is a perspective view of SWSAGD SAGDOX (packers);
[0139] FIG. 31B is a side elevational schematic of SWSAGD;
[0140] FIG. 32 is a perspective view of conventional In-Situ Combustion;
[0141] FIG. 33A is a schematic side elevational view of a gas chamber in THSAGDOX in early life;
[0142] FIG. 33B is a schematic side elevational view of the well of FIG. 33A at a mature stage;
[0143] FIG. 33C is a schematic view of the well of FIG. 33A at end of life;
[0144] FIG. 34A is a schematic view of THSAGDOX liquid drawdown heel production;
[0145] FIG. 34B is a schematic view of THSAGDOX liquid drawdown toe production;
[0146] FIG. 35A is a schematic view of SWSAGDOX during mature operations;
[0147] FIG. 35B is a schematic view of SWSAGDOX(U) during mature operations;
[0148] FIG. 36A is a perspective view of LZ-SAGDOX A;
[0149] FIG. 36B is a side schematic view of the well of FIG. 36A ;
[0150] FIG. 37 is a well schematic of LZ-SAGDOX A; and
[0151] FIG. 38 is a table illustrating combustion PWOR.
DETAILED DESCRIPTION OF THE INVENTION
[0152] The SAGDOX process injects some steam (with oxygen) to improve combustion kinetics and to improve heat transfer (particularly lateral heat transfer) in the reservoir. For high bitumen-saturation reservoirs (0.6 to 1.0 saturation), steam addition to oxygen is necessary to attain minimum steam levels in the reservoir. A measure of this minimum has been suggested as Produced Water-to-Oil Ratio (“PWOR”)≧1.0.
[0153] For lean zones, vaporized connate water can capture these benefits without any steam addition from outside the reservoir. For the purpose of this invention, lean zones are porous rocks defined to contain less than or equal to 60 percent of the pore volume, by volume, bitumen and the remainder of the pore volume is mostly water. A lean zone may occupy all or part of the pay zone.
[0154] As far as the reservoir is concerned, LZ-SAGDOX gas mixtures (steam+oxygen) are similar to SAGDOX. The LZ-SAGDOX process simply injects oxygen gas, with no steam (except for start-up) to achieve a SAGDOX EOR process in a lean zone reservoir. Combustion temperatures are in the 500 to 600° C. range ( FIG. 21 ), so combustion heat is of sufficient quality to vaporize lean-zone connate water creating and sustaining a good steam inventory in the reservoir.
[0155] If one assumes the following: 1) the connate water associated with bitumen production and bitumen consumed is all vaporized and recovered as product water (e.g. if the initial bitumen saturation is 0.3, the associated connate water is 2.33 bbl/bitumen); and 2) any water created as a chemical product of combustion is also produced, then Table 4 and FIG. 23 show Produced Water-to-Oil Ratio for LZ-SAGDOX processes. As shown in FIG. 23 , for LZ-SAGDOX, PWOR is not a strong function of the energy-to-oil ratio (“ETOR”), but it is a strong function of initial bitumen saturation. For leaner reservoirs (lower initial bitumen saturation) higher ETOR is expected as most of the heat goes to heat matrix and water zones ( FIG. 20 ).
[0156] An assumption, to attain good water/steam benefits in the reservoir, is that PWOR should equal or exceed 1.0. PWOR is a reflection of steam in the reservoir per bbl of bitumen produced. For LZ-SAGDOX ( FIG. 23 ) this implies a maximum initial bitumen saturation of 0.6. This sets a preferred limit value for the LZ-SAGDOX process.
[0157] Referring to Tables 2 and 5, one can also see the similarity of the processes (SAGDOX vs. LZ-SAGDOX) from the standpoint of the reservoir and predicted PWOR. SAGDOX, using 35% oxygen (v/v) in steam+oxygen injectants in a reservoir with 0.8 initial bitumen saturation and with ETOR=2.0, has a PWOR of 1.3 (Table 2). LZ-SAGDOX, in a reservoir with 0.6 initial bitumen saturation and with ETOR=4.0, has a PWOR=1.2.
[0158] As long as the initial bitumen saturation in the lean zone is above about 0.05, there is enough combustion energy available from this fuel to vaporize all the water in the lean zone pores (95 (v/v) percent). If bitumen saturation is higher than this, some net bitumen can be recovered. A combustion-swept zone has near-zero residual hydrocarbons ( FIG. 19 ), so the bitumen in a lean zone will either be mobilized and produced or consumed as a fuel, as the combustion front sweeps through the lean zone.
[0159] FIGS. 24A , 24 B, 36 A, 36 B and 37 shows the preferred geometry for LZ-SAGDOX, retaining a horizontal production well 4 and vent gas 22 removal using a segregated section (annulus) of the production well 4 . Oxygen 26 is either injected in a separate vertical well or in a segregated, upturned toe section of a single well version of the process. No provision is made for continuous steam 6 injection. Start-up can be accomplished by steam circulation or steam huff-and-puff.
[0160] Preferably, oxygen 26 rather than air is the oxidant injected. If the cost of treating vent gas 22 to remove sulphur components and to recover volatile hydrocarbons is included, even at low pressures the all-in cost of oxygen is less than the cost of compressed air, per unit energy delivered to the reservoir. Further, oxygen occupies about one fifth the volume compared to air for the same energy delivery. Well pipes/tubing are smaller and oxygen can be transported further distances from a central plant site. Another benefit of injecting oxygen is that in-situ combustion using oxygen produces mostly non-condensable CO 2 , undiluted with nitrogen. CO 2 can dissolve in bitumen to improve productivity. Dissolution is maximized using oxygen. Also, vent gas, using oxygen, is mostly CO 2 , and it may be suitable for sequestration Finally, there is a minimum oxygen flux to sustain high temperature oxidation (“HTO”) combustion ( FIG. 25 ). It is easier to attain/sustain this flux using oxygen.
[0161] Preferably, oxygen 26 injection should be kept at a concentrated site. Because of the minimum O 2 flux constraint for in situ combustion ( FIG. 25 ), the oxygen 26 injection well (or a segregated section) should have no more than 50 metres of contact with the reservoir.
[0162] Preferably, oxygen 26 and steam 6 injectants are segregated as much as possible prior to injection. Condensed steam 6 (hot water) and oxygen 26 are very corrosive to carbon steel. To minimize corrosion, there are three options: 1) either oxygen 26 and steam 6 are injected separately ( FIGS. 13 , 14 A and 14 B); 2) comingled steam and oxygen 30 have limited exposure to a section of pipe that can be a corrosion resistant alloy, the section integrity is not critical to the process ( FIGS. 15A and 15B ); or 3) the entire injection string is a corrosion resistant alloy.
[0163] Preferably, the vent gas 22 well or site is near the top of the reservoir, far from the oxygen 26 injection site and laterally offset from the injection 2 /production 4 wells. Because of steam 6 movement and condensation, non-condensable gas concentrates near the top of the gas chamber. The vent gas 22 well should be far from or distant the oxygen injector to allow time/space for combustion.
[0164] Preferably, vent gas 22 should not be produced with significant oxygen content. To mitigate explosions and to foster good oxygen 6 utilization, any vent gas 22 production with oxygen content greater than 5% (v/v) should be shut in.
[0165] Preferably, a minimum amount of steam 6 in the reservoir is attained or retained.
[0166] Steam 6 is added or injected with oxygen 26 in SAGDOX because steam helps combustion. Steam 6 preheats the reservoir so ignition, for HTO, can be spontaneous. Steam 6 adds OH − and H + radicals to the combustion zone to improve and stabilize combustion ( FIGS. 18 and 26 ) (Moore, G. et al, “Parametric Study of Steam Assisted ISC, unpublished, February 1994). This is also confirmed by the operation of smokeless flares, where steam is added to improve combustion and reduce smoke (Stone, D. et al, “Flares,” Chapter 7, gasflare.org, June 2012), (U.S. Environmental Protection Agency “Industrial Flares,” www.EPA.gov, June 2012), (Shore, D. “Making the Flare Safe,” Journal of Loss Prevention in the Process Industries, 9, 363, 1996). The process to gasify fuels also adds steam to the partial combustor to minimize soot production (Berkowitz (1997)). Steam also condenses and produces water that “covers” the horizontal production well and isolates it from gas or steam intrusion. Further, steam condensate adds water to the production well to improve flow performance—water/bitumen emulsions—compared to bitumen alone.
[0167] Steam is also a superior heat transfer agent in the reservoir. If we compare hot combustion gases, mostly CO 2 to steam, the heat transfer advantages of steam are evident. For example, if we have a hot gas chamber at about 200° C. at the edges, the heat available from cooling combustion gases from 500 to 200° C. is about 16 BTU/SCF. The same volume of saturated steam contains 39 BTU/SCF of latent heat—more than twice the energy content of combustion gases. In addition, when hot combustion gases cool they become effective insulators, impeding further heat transfer. When steam condenses to deliver latent heat, it creates a transient low-pressure that draws in more steam-a heat pump, without the plumbing. The kinetics also favour steam/water. The heat conductivity of combustion gas is about 0.31 (mW/cmK) compared to the heat conductivity of water of about 6.8 (mW/cmK)—a factor of 20 higher. As a result of these factors, combustion (without steam) has issues of slow heat transfer and poor lateral growth. These issues can be mitigated by steam injection.
[0168] Finally, since one cannot measure the amount of steam in the reservoir, SAGDOX sets a steam minimum by a maximum oxygen/steam (v/v) ratio of 1.0 or alternately 50% (v/v) oxygen in the steam+oxygen mix.
[0169] Preferably, a minimum oxygen injection is attained or exceeded. Below about 5% (v/v) oxygen in the steam+oxygen mix, the combustion-swept zone is small and the cost advantages of oxygen are minimal. At this level, only about a third of the energy injected is due to combustion.
[0170] Preferably, oxygen injection is maximized. Within the constraints of the above preferred embodiments, because per unit energy oxygen is less costly than steam, the lowest-cost option to produce bitumen is to maximize oxygen/steam ratios.
[0171] Preferred SAGDOX geometries should be used. Depending on the individual application, reservoir matrix properties, reservoir fluid properties, depth, net pay, pressure and location factors, there are three preferred geometries for SAGDOX ( FIGS. 16A-16C ). FIGS. 14A , 14 B, 16 B Toe-to-Heel SAGDOX (“THSAGDOX”) and 16 C (also shown in FIGS. 33A-33C , 34 A and 34 B) Single Well SAGDOX (“SWSAGDOX”) (see FIGS. 35A and 35B ) are best suited to thinner pay resources, with only one horizontal well required. Compared to SAGDOX, THSAGDOX and SWSAGDOX have a reduced well count and lower drilling costs. Also, internal tubulars and packers 18 should be usable for multiple applications.
[0172] Preferably, SAGDOX is controlled or operated by the following:
i) Sub-cool control on fluid production rates where produced fluid temperature is compared to saturated steam temperature at reservoir pressure. This assumes that gases, immediately above the liquid/gas interface, are predominantly steam. ii) Adjust oxygen/steam ratios (v/v) to meet a target ratio, subject to a range limit of 0.05 to 1.00. iii) Adjust vent gas removal rates so that the gases are predominantly non-condensable gases; oxygen content is less than 5.0% (v/v); and to attain/maintain pressure targets. iv) Adjust steam+oxygen injection rates (subject to (ii) above), along with (iii) above, to attain/maintain pressure targets.
[0177] To summarize, LZ-SAGDOX, as shown in FIGS. 29A , 29 B and 30 , is superior to SAGDOX in LZ reservoirs for the following reasons:
LZ-SAGDOX doesn't inject steam (except for start-up). Steam is more costly than oxygen (for combustion), so LZ-SAGDOX operating costs are less than SAGDOX. Because of lower operating costs, LZ-SAGDOX can be applied at lower bitumen saturations. Also, because of lower operating costs, LZ-SAGDOX will increase reserves compared to SAGDOX. LZ-SAGDOX saves one well (or one completion zone) compared to SAGDOX (steam injector). Fresh water or make-up water use for LZ-SAGDOX is zero (except for start-up)
[0183] As discussed above, distinctions between LZ-SAGDOX and SAGDOX include the following:
LZ-SAGDOX has no steam injected; SAGDOX has steam injection; LZ-SAGDOX has one less injectant site (well, port), no steam injector; LZ-SAGDOX has restricted range for bitumen saturation (5 to 60 percent); SAGDOX doesn't; LZ-SAGDOX is a combustion EOR process (based on injectants), SAGDOX is a combined steam and combustion EOR process; SAGDOX uses surface water for steam; LZ-SAGDOX uses no water (except for start-up).
[0189] Distinction between Toe-to-Heel Air Injection (“THAI”) ( FIG. 27 ) and LZ-SAGDOX include the following:
THAI injects air; LZ-SAGDOX prefers oxygen; THAI has no explicit restriction on bitumen saturation; LZ-SAGDOX does; THAI is field tested with poor results. THAI has had problems with lateral growth; no steam added to foster heat transfer; LZ-SAGDOX generates steam from LZ connate water.
[0194] Distinctions between SAGD and LZ-SAGDOX include the following:
SAGD is a pure steam EOR process; LZ-SAGDOX is a pure combustion EOR process (based on injectants); SAGD has no explicit bitumen saturation limits; SAGD doesn't perform well on LZ (poor field history).
[0198] Distinctions between LZ-SAGDOX and Combustion Overhead Split Horizontal (“COSH”) or Combustion Overhead Gravity Drainage (“COGD”) ( FIG. 28 ) include the following:
COSH/COGD prefer air injection; COSH/COGD get lateral growth from position of vent wells; LZ-SAGDOX gets lateral growth from steam produced in situ;
different geometry.
[0202] Distinctions between LZ-SAGDOX and Conventional ISC ( FIG. 32 ) (neither injects water or steam) include the following:
ISC uses vertical wells (HZ for LZ-SAGDOX) ISC prefers air (O 2 for LZ-SAGDOX) no LZ preference for ISC
[0206] Distinctions between LZ-SAGDOX (SW version, FIGS. 29A , 29 B, 30 ) and Single Well SAGD (“SWSAGD”) ( FIGS. 31A and 31B ) include the following:
SWSAGD is a steam process; LZ-SAGDOX is a combustion process no LZ preference for SWSAGD
[0209] Distinctions between LZ-SAGDOX and Combination of Forward Combustion and Water (“COFCAW”) include the following:
COFCAW injects water; LZ-SAGDOX has no water (or steam) injection COFCAW uses vertical wells and conventional ISC geometry ( FIG. 28 )
COFCAW uses air injection; LZ-SAGDOX prefers oxygen;
no LZ preference for COFCAW
[0214] To summarize, the unique Features of LZ-SAGDOX include the following:
Limitation range of bitumen saturation for process applicability ISC process where bitumen saturation is a key factor Focus on lean zones; upper bitumen saturation limit
Consideration of connate water as a steam source and the importance of steam in a ISC process
Upturned toe version for SW LZ-SAGDOX process Focus/preference for oxygen as oxidant source Limitation of oxygen injection contact-zone Focus/preference on bitumen Removal of vent gas in separate well(s) or locations (vent gas not forced to go to fluid production well) No other EOR processes are specifically focused on lean zones Need for a minimum amount of connate water for process to be successful Preferred LZ-SAGDOX geometries ( FIGS. 24A and 24B )
[0000]
TABLE 1
Injectant Heat “Content” for Thermal EOR
Steam
Oxygen
Air
(BTU/lb.)
1000
5700
1318
(BTU/SCF)
47.4
480
100
(MSCF/MMBTU)
21.1
2.08
10.0
[0227] Where—assumes:
steam at 1000 BTU/lb. avg. oxygen at 480 BTU/SCF avg (Butler, (1991)) ideal gas laws air at 20.9% (v/v) oxygen
[0000]
TABLE 2
SAGDOX: PWOR
% O 2 (v/v) in steam and O 2 mixes
0
5
35
50
100
ETOR = 1.0
(1)
3.18
2.07
0.49
0.29
0
(2)
0
0.09
0.21
0.23
0.25
(3)
0
0.01
0.02
0.03
0.03
(4)
0
0.013
.032
.035
.038
PWOR
3.18
2.18
0.75
0.59
0.32
ETOR = 2.0
(1)
6.36
4.14
0.98
0.58
0
(2)
0
0.09
0.21
0.23
0.25
(3)
0
0.02
0.05
0.05
0.05
(4)
0
0.026
0.064
0.07
0.076
PWOR
6.36
4.28
1.30
0.93
0.38
Where
[0000]
(1)=condensed steam
(2)=water (connate) associated with produced bit from comb.
(3) ═water associated with combusted bitumen
(4)=water of combustion
PWOR=(1)+(2)+(3)+(4) (bbls.water/bblB) S io , =0.8; no gas (2), (3), (4) are pro rated by heat from comb (1) is prorated by heat from steam
[0000]
TABLE 3
SAGDOX Injection Gases
% (v/v) O 2 in Steam and O 2 mixes
0
5
9
35
50
75
100
% heat from O 2
0
34.8
50.0
84.5
91.0
96.8
100.0
BTU/SCF mix
47.4
69.0
86.3
198.8
263.7
371.9
480.0
MSCF
21.1
14.5
11.6
5.0
3.8
2.7
2.1
mix/MMBTU
MSCF
0.0
0.7
1.0
1.8
1.9
2.0
2.1
O 2 /MMBTU
MSCF
21.1
13.8
10.6
3.3
1.9
0.7
0
Steam/MMBTU
[0240] Where:
(1) Steam at 1000 BTU/lb. (2) Oxygen at 480 BTU/SCF
[0000]
TABLE 4
LZ-SAGDOX: PWOR
Initial Bitumen Saturation
.2
.4
.6
.8
.10
ETOR = 1.0
(1)
4.00
1.50
0.67
0.25
0.00
(2)
0.67
0.25
0.08
0.04
0.00
(3)
0.06
0.06
0.06
0.06
0.06
PWOR
4.73
1.81
0.81
0.35
0.06
ETOR = 2.0
(1)
4.00
1.50
0.67
0.25
0.00
(2)
1.34
0.50
0.17
0.08
0.00
(3)
0.11
0.11
0.11
0.11
0.11
PWOR
5.45
2.11
0.95
0.44
0.11
ETOR = 4.0
(1)
4.00
1.50
0.67
0.25
0.00
(2)
2.68
1.00
0.33
0.17
0.00
(3)
.22
0.22
0.22
0.22
0.22
PWOR
6.90
2.72
1.22
0.64
0.22
ETOR = 8.0
(1)
4.00
1.50
0.67
0.25
0.00
(2)
5.36
2.00
0.66
0.34
0.00
(3)
0.45
0.45
0.45
0.45
0.45
PWOR
9.81
3.95
1.78
1.04
0.45
Where
[0000]
Entries are bbl water/bbl bitumen
(1)=connate water associated with produced bitumen
(2)=connate water associated with bitumen combustion
(3)=water of combustion
PWOR=(1)+(2)+(3)
Water of combustion=0.056 bbl/MMBTU
Fuel=coke (CH. 5 )
[0000]
TABLE 5
PWOR LZ-SAGDOX
(PWOR bbl water/bblB)
Initial Bitumen Saturation
.2
.4
.6
.8
ETOR = 2: PWOR
5.45
2.11
0.95
0.44
ETOR = 4: PWOR
6.90
2.72
1.22
0.64
ETOR = 8: PWOR
9.81
3.95
1.78
1.04
ETOR = 12: PWOR
12.71
5.17
2.34
1.42
ETOR = 16: PWOR
15.62
6.40
2.90
1.82
Where:
[0000]
PWOR=water associated with bitumen produced+bitumen combusted+water of combustion
fuel ═CH. 5 coke
comb. Water=0.056 bbl/MMBTU
complete HTO combustion
bit. fuel value=6 MMBTU/bbl
O 2 heat at 480 BTU/SCF
[0256] As many changes therefore may be made to the embodiments of the invention without departing from the scope thereof. It is considered that all matter contained herein be considered illustrative of the invention and not in a limiting sense.
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A process to recover hydrocarbons from a reservoir having at least one lean zone, wherein said lean zone has an initial bitumen saturation level less than about 0.6, said process including:
i) Initially injecting of oxygen into said reservoir; ii) Allowing for combustion of said oxygen to vaporize connate water in said at least one lean zone; and iii) Recovering said hydrocarbons from said reservoir.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a linear micrometer designed by the Abbe principle with a measuring spindle sleeve metering into a housing and a scale arranged within the housing in a stationary manner and a readout device correlated with the scale and coupled with the measuring spindle sleeve to indicate measured distances, preferably by digital electrical means.
2. Description of the Prior Art
A linear micrometer is a device for the measurement of small lengths and distances wherein the measuring spindle sleeve is driven by means of crossed helical gears with a slight pitch and the measuring means is a linear scale. Micrometers having an extended measuring range and equipt with rapid setting means which may be released from the helical gears are known (for example, as described in German Offenlegungsschrift No. 16 23 170).
Observation of Abbe's principle requires that the measuring means constitute an extension of gage length, i.e. the axis of the measuring spindle sleeve and the measuring means, are aligned with each other. Concerning the measurement of the displacement of the measuring spindle sleeve, it is known especially in the case of digital electrical distance acquisition to either couple the measuring means with the measuring spindle sleeve and to move it past the stationary readout device, or to couple the readout device with the measuring spindle sleeve and to move it past the stationary scale (as shown in U.S. Pat. No. 2,592,264). The last-mentioned arrangement has the particular advantage of a shorter length of the device, but also poses higher requirements for the accuracy of the guidance of the measuring spindle sleeve (see for example, K. Rantsch "Optics of Fine Measuring Techniques" (1949, page 191.)
A longitudinal distance measuring device is taught in German Auslegeschrift No. 26 05 020 having a scale solidly mounted at its two ends within a housing. The readout device is displaced on a straight line slide bar arranged parallel to the scale by means of a cable line. To maintain a constant reading angle, an additional rotation stop is provided for the readout device. The measuring spindle sleeve is resolved into three rods secured to the readout device and emerging from the housing through three bores. Outside the housing the three rods are maintained together by means of a plate wherein a probe tip is set, the probe being aligned with the axis of the scale. The measuring accuracy in this case depends on the accuracy of the guidance of the readout device relative to the scale. Because the rods forming the measuring spindle are without guidance over their full length, they constitute a relatively long lever around which the probe tip may be rotated out of the axis of the scale, thus violating Abbe's principle.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a linear micrometer of the shortest possible structural length which satisfies Abbe's principle and avoids the effects of guidance errors during the displacement of the measuring spindle relative to the scale over a large measuring range. Further, the rapid setting of the measuring spindle from any of its positions is made possible without affecting the fine adjustment by means of the crossed helical gears.
These and other objects are attained with a linear micrometer of the present invention. Additional advantageous embodiments of the linear micrometer also result from the features set forth hereinafter.
The invention comprises a linear micrometer having a cylindrically shaped housing within which a tube-shaped spindle sleeve is displaceably mounted along the longitudinal axis of the housing and extends outwardly from one end of the housing. A measurement scale is fixedly mounted along the longitudinal axis of the micrometer housing and, at the same time, is slidingly supported inside the spindle sleeve. The micrometer also contains a measurement readout means such as a digital electronic readout coupled to the spindle sleeve for reading and displaying the relative positions of the spindle sleeve with respect to the scale. At one end of the linear micrometer housing, a single point bearing member connects the scale to the end of the housing opposite the ends of the extending spindle sleeve. The single point bearing is preferably in line with the measurement divisions on the scale member. More specifically, the single point bearing comprises a sphere aligned with its center along the longitudinal axis of the scale and contains a means for biasing the scale against the sphere and micrometer housing end. Normally, the biasing means comprises a tension spring which connects to the scale and micrometer housing end and pulls the scale towards the micrometer housing end with the sphere in between.
The spindle sleeve is mounted within the housing on cylindrical slide bearings, at least one of which provides guidance for the spindle sleeve in the housing, and at least one of which provides guidance for the scale within the spindle sleeve.
The linear micrometer also includes a means for the rapid adjustment of the spindle sleeve as well as a means for the fine adjustment of the spindle sleeve in relation to the scale. The rapid setting means or rapid adjustment means comprises at least one locating drive member having a control bolt for adjusting the tension through a means biasing the bolt against the scale. The bolt extends through a longitudinal slit in the housing and the slit defines the area of movement of the adjustment means longitudinally within the housing.
The fine adjustment means on the other hand comprises at least one rod member, and preferably two rod members abutting a fine adjustment knob at one end of the micrometer housing and extending parallel to the spindle sleeve in the housing to a point where it communicates with the rapid adjustment means. Thus, movement of the rapid adjusting means provides gross adjustment of the spindle sleeve to the appropriate length whereas the fine adjustment means provides the exact measurement desired.
The locating drive member comprises in a preferred embodiment a clamping arm member pivotably attached at one end to a mounting member within the housing. The other end of the clamping arm is pivotably attached to a portion of the control bolt that extends within the housing. Movement of the control bolt, therefore, in a direction perpendicular to the spindle sleeve causes corresponding opposite movement at the other end of the clamping arm. Preferably, the clamping arm rests against the rod member extending parallel to the spindle axis. Depending upon the relative tension applied by the control bolt, the clamping arm may either prevent movement of the locating drive member longitudinally within the housing, or permit movement. Of course, the movement is limited by the length of the longitudinal slit.
In a preferred embodiment, the spindle sleeve and the locating drive member are attached to a mounting member displaced within the housing.
The inside surface of the micrometer housing comprises a housing sleeve supported rotatably about the spindle sleeve axis. This sleeve displays a helical groove which intersects with the longitudinal slit in the housing at a point where the locating drive or control bolt portion of the locating drive passes through the longitudinal slit.
At the end of the linear micrometer, that is the end of the spindle sleeve extending from the micrometer, is positioned a probe tip. The probe tip is preferably a replaceable probe tip and may advantageously be secured to a shoe member biased against a measuring object.
The design of the measuring spindle sleeve in the form of a tube provides great rigidity together with low weight. The tube may be guided by means of one or two coaxial slide bearings in a very satisfactory manner. Suitably dimensioned, the tube may be inserted over the scale whereby the desirable short length is attained while ideally observing Abbe's principle. The pressure of the scale in the micrometer housing, which is only unilaterally elastic in combination with the slide bearing support within the spindle sleeve, makes possible a constant relative position between the readout device and the scale. No special alignment of the position of the scale with respect to the guidance of the measuring spindle sleeve is necessary because the sleeve itself guides the scale. The scale is aligned automatically with the axis of the measuring spindle over the entire range of the measurement.
The rapid setting means engages the measuring spindle directly. It is coupled with the fine adjusting means by means of a clamp. The coupling may be released and reinstated in any position. The crossed helical drive of the fine adjustment therefore requires only a slight slope which again favors a short length of the micrometer. The slit provided to guide the control lever of the rapid setting means is automatically covered by a concurrent internal cylinder whereby good protection of the measuring means and the readout device is obtained.
Further advantages of the invention will be found in the description of the preferred embodiments following hereinafter. These embodiments are schematically represented in the drawing attached hereto.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 shows a longitudinal section of the linear micrometer,
FIG. 2 shows another longitudinal section perpendicularly to the first section, and
FIG. 3 shows a cross section of the linear micrometer taken along line 3--3 of FIG. 1 in the area of the rapid adjustment means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the micrometer housing 1 is designed in the form of a cylinder with a circular cross section. It comprises on one of its ends a housing cover 2, wherein the tube shaped measuring spindle sleeve 3 is guided in two slide bearings 5 and 6 arranged coaxially to the longitudinal axis 4 of the micrometer housing 1 and is capable of longitudinal displacement. At its end located in the micrometer housing, the spindle sleeve 3 is screwed into a mounting body 7 to which a locating gear drive for rapid setting (8, 22, 23, 24) and a readout device 9 are also secured.
Two slide bearings 10 are arranged at the end of the spindle sleeve 3 located at the mounting body 7 and within the spindle sleeve concentrically with the housing axis 4. One end of the scale 11 is slidingly supported in the slide bearings. The scale consists of a round rod as the support. The rod is flattened in the longitudinal direction. A reflecting scale for measuring, i.e. with marked divisions 12, is arranged on this flattened part with the direction of the division markings parallel to the housing axis 4. The other end of the scale is connected with a second housing cover 14 by means of a single point bearing formed by a sphere 13, so that the scale may be displaced perpendicularly to the housing axis 4.
The photoelectric scanning of the measuring division is effected by means of a readout device 9, such as is known for example from German Auslegesschrift No. 26 53 545. The readout device consists of an illuminating member 15, a reference grating 16 (see FIG. 2) and a photoelectric receiver system 17. The readout device 9 is rigidly connected with the mounting body 7, while the reference grating is located parallel to the marked scale division 12. To set a certain distance and as security against relative rotation between the reference grating 16 and the marked scale division 12, two plastic knobs 18 are fastened to the readout device 9, which are supported to the right and to the left of the scale by the flat side of the scale support rod 11.
Two control bolts 8 acting perpendicularly to the housing axis 4 are set in opposing bores of the mounting body 7. Outside the micrometer housing 1, pressure plates 19 are placed on said bolts 8 with the pressure plates being supported by means of compression springs 20 on a sleeve 21 which is slidable on the micrometer housing. The ends of each control bolt 8 closest to the housing axis 4 of the micrometer is coupled with a clamping lever 24 by means of a pin/slit connection 22/23. The longitudinal axis of said levers extend in the direction of the housing axis 4. The clamping levers 24 may be rotated at their end facing away from the pin/slit connection, each around an axle 25 is supported in the mounting body 7. Elements 8, 22, 23, 24 constitute the locating drive.
As shown in FIG. 3, the sectional plane containing the control bolts 8 and the clamping levers 24 display two rods 26, 27 arranged parallel and symmetrically to the axis of the housing. In FIG. 1, these rods 26, 27 are shown to extend in the bores 28 through the mounting body 7 and mounted on the one hand in the housing cover 2 with an axial clearance and displaceable in the longitudinal direction and, on the other hand, passed through the housing cover 14 without play. Adjacent housing cover 14, the two rods 26, 27 are connected with each other by means of a plate 29.
The position of the rods 26, 27 is chosen so that they may be secured by clamping by means of the clamping levers 24 in their bores 28. The clamping levers are secured under the pressure of the springs 20. In order to improve the clamping action, the rods 26, 27 are advantageously flattened at their sides facing the clamping levers, and the clamping levers are rounded in the pressure area, whereby the center of curvature of the rounding is located in front of the rotational axis 25. This provides a favorable force translation ratio to the lever arm provided by the distance between the rotational axes 25 and 22.
The compression of the pressure plates 19 releases the arrest of the rods 26, 27 so that the spindle sleeve 3, together with the readout device 9 which is rigidly coupled with the spindle sleeve, may be displaced along the housing axis 4. The control bolts 8 are guided in the process in the slit 31 of the housing wall which is parallel to the housing axis 4. This design simultaneously represents a rotation stop for the spindle sleeve 3. In order to protect the inside of the micrometer housing 1 against dirt, a thin walled cylinder 32 is arranged underneath the groove 31 inside the housing 1. The cylinder is supported rotatingly by the two covers 2 and 14. Two helical grooves are machined into the cylinder 32 which crossingly intersect with groove 31. The control bolts 8 are passed through the intersection. Upon the actuation of the rapid setting means or device, this intersection slides along groove 31 due to the ability of the cylinder 32 to be rotated. The openings remaining because of the slope of the helices in the groove 31 adjacent to the above-mentioned intersection are covered by the sleeve 21.
As soon as the rods 26, 27 are clamped securily in the mounting body 7, the fine setting of the measuring spindle sleeve 3 may be effected by means of pressure or tension on the rods 26, 27. For this purpose, a fine threading 33 is provided on the housing cover 14, upon which a nut 35 equipped with a knurled head 34 may be adjusted in the direction of the housing axis 4. In the area of the knurled head 34, the opening of the nut 35 is covered with a plate 36. The plate 29 connecting the rods 26, 27 lies against the plate 36 under the pressure of two springs 37, which are supported by the cover 14. The plate 29 is supported by means of a sphere as a single point bearing 38.
For the purpose of scanning the workpiece, a spherical probe tip 40 is set in the spindle sleeve 3. In a special application, even an object table 41 may be displaced measuringly with the aid of a stationary linear micrometer. In this case, it is convenient to couple the spindle sleeve 3 by way of the probe tip 40 with the object table 41. This coupling may be effected, for example, by means of a shoe 42 set on the probe tip 40, said shoe being rigidly connected with the object table. Within the shoe 42, the probe tip 40 is pressured by springs 43 against the sole 44.
The sectional view of FIG. 2 displays the flattening of the scale 11 and the position of the readout device 9 relative to the scale. The view particularly shows the safety against rotation of the scale provided by the plastic knobs 18 and the aerial distance between the reference grating 16 and the scale 11. Because the scale division 12 is located on the flattened part of the scale 11 and because according to Abbe's principle, the gage length should be a straight line extension of the embodiment of the measure, the apex of the spherical surface of the probe tip 40 is placed out of the axis 4 of the housing into the plane of the scale division 12. The support surface 45 on the object table 41 is also located in this plane.
As another detail of the view in FIG. 2, the pressure bearing support of the scale 11 on the housing cover 14 may also be seen. The sphere 13 is supported, for example, in a conical bore 46 in the scale division axis on the cover 14. The end of the scale 11 is clamped in a clamp 47 by means of a screw 48. The terminal surface 49 of the clamp 47 is pulled against the sphere 13 by springs 50 hooked into the cover 14 and the clamp 47. This support maintains the terminal surface of the scale 11 without redundancy in determination with respect to the scale guidance in the spindle sleeve.
The sectional view in FIG. 3 demonstrates the clamping between the rods 26, 27 and the mounting body 7. The design of the photoelectric scale reading 11, 15, 16, 17, is also shown schematically.
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Disclosed is a linear micrometer which comprises a cylindrically shaped housing, a tube-shaped sleeve displaceably mounted along the longitudinal axis of the housing and extending from one end of the housing, a measurement scale fixedly mounted along the longitudinal axis of the housing and slidingly supported inside the spindle sleeve, and a measurement readout means couple to the spindle sleeve for reading and displaying the relative position of the spindle sleeve to the scale. A rapid adjusting means and fine adjusting means are also provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation Application (Division) of U.S. patent application Ser. No. 10/766,632, filed Jan. 28, 2004, which claims priority of Provisional Patent Application No. 60/442,989, filed Jan. 28, 2003, the contents of all of which are fully incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A “MICROFICHE APPENDIX”
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and system for the placement and installation of a synthetic resin composite as an aesthetic restoration of the surface on a tooth, which is otherwise discolored or disfigured.
2. General Background of the Invention
The placement of composites or plastic surfacing or fillings, are widely used as aesthetic restorations. The restorations mimic the natural tooth color and shape to present a “filling” which replaces or resurfaces the defective area of a tooth and thus creates a more pleasing appearance for the wearer. In the application of aesthetic fillings or restorations, it is usual that as soon as the composite material used placed and shaped, it is cured, or polymerized, customarily by light activation, using a special lamp and light guide to direct the high intensity light to the desired locations on the tooth. In the alternative, the composite may be cured by the inclusion of an added agent to promote polymerization, with the set-up of the material occurring without any additional assist. Those skilled in the art recognize that the application of composite and curing process is one which requires particular skill and technique to produce a composite on the tooth which has the requisite strength for long term use.
Common materials utilized in these composites are an acrylic resin which functions as a matrix for other contained materials. The composite may contain filler particles for strength, and color particles for color matching, or opaquers for concealing tooth discoloration. These filler particles are frequently accompanied by a coupling phase which facilitates the bonding of the various components. The resin most commonly used in aesthetic restorations is a bis-GMA, which is the reaction product of bisphenol A and a glycidal methacrylate. The resin is a dimethacrylate monomer which is induced to polymerize by the presence of free radicals (introduced by chemical reaction or by external energy such as heat or light). The chemically activated resins come usually as a two component system—a first paste containing a benzol peroxide initiator and the second containing a tertiary amine activator Immediately prior to application, the two pastes are mixed, i.e., spatulated by hand with such as a spatula or blended by a mixing syringe, such that the amine reacts with the benzoyl peroxide to from free radicals that initiate the polymerization. This spatulated or blended mixture must be promptly applied to the tooth as the polymerization begins immediately, thereby leaving limited time for the dentist to form the restoration.
The light activated resin comes as a single paste, either in a syringe or a compule. The paste contains the photoinitiator module (usually camphroquinone) and an amine activator. When the resin is exposed to a special light, the photoinitiator becomes excited and reacts with the amine to produce the free radicals, which initiate the polymerization process. It should be appreciated that the composite begins to polymerize upon exposure even to normal room light and that the special light the process is accelerated and carried out to a greater depth in the composite.
Whether the resin is applied to the tooth by spatula, syringe or compule, the placement is critical, as is the application of a properly limited amount, neither too much nor too little, so that the formation of the restoration may be affected quickly. The present invention, as will become evident, greatly facilitates the placement of the proper amount of resin for an effective, expedient restoration.
The present invention is directed to a novel packaging of the compule of restorative resin for the expedient aesthetic restoration. Preferably, the resin is the light activated variety which cures primarily when exposed to a curing light. Use of this particular resin provides a much longer (comparatively) “working” time, in that it sets up principally under the curing light, and when exposed, it does so more rapidly than the chemically activated resins. It must be appreciated however, that the light activated resins only cure to the depth of the light penetration, so deep restorations may require the application of multiple layers of resin.
While the choice and application of the particular resin in the aesthetic restoration is of paramount importance, these factors are only part of those considered in the process. Integral steps of the restoration include the draping or damming of the site of the procedure. It is customary in the preparation of a tooth for an amalgam or aesthetic restoration that the tooth be isolated from those around it throughout the procedure. In the instance of application of an aesthetic restoration, care is taken to ensure that the added resin is precluded from contacting adjacent teeth, and keeping the interstices open between teeth. Accordingly, the present invention provides for the packaging and management of a single dose of light activated resin composite, enabling the convenient and efficacious placement of the resin on the selected tooth for working into an aesthetic restoration.
Patents have issued on different dosage and packaging features, from general purpose to special purpose for dental products. By way of example, a patent to Volker Marckardt (U.S. Pat. No. 3,756,386) discloses a multi-chamber container for separately carrying reacting materials which, when mixed, are ready for use as dental composites.
U.S. Pat. No. 4,921,137 to Heijenga discloses a dispensing container for liquid or paste type materials. U.S. Pat. No. 5,947,278 to Sawhney discloses a single-dose, double cup package for dental materials.
U.S. Pat. No. 4,125,190 to Davie, et al. discloses blister packaging which is child resistant.
A patent to Werner Schmidt, et al (U.S. Pat. No. 5,472,991) is directed to a photopolymerizable dental compound for curing in two curing steps.
U.S. Pat. No. 5,636,736 to Jacobs et al. discloses packaging for curable materials, namely orthodontic brackets which are attached to teeth and subsequently connected to retainers and the like for straightening or repositioning teeth. U.S. Pat. Nos. 4,978,007 to Jacobs et al. and 5,762,192 to Jacobs et al. also disclose additional packaging for curable materials.
U.S. Pat. No. 6,159,009 to Berk et al. is discloses an amalgam carrier or syringe for a packaged composite resin for dental restorations. The carrier and replacement sleeves are specifically for carrying light activated resins.
U.S. Pat. No. 6,261,094 to Dragan discloses a syringe for a unit dose of composite materials to a tooth, specifically overcoming stated prior art problems of spatula, palate or like tool. The patent contains a recitation of several patents to capsule syringe dispensers for placement of composite materials.
SUMMARY OF THE INVENTION
The principal objective of the present invention is to provide a packaged unit of composite for performing an aesthetic restoration and a method of applying a restorative with a pre-packaged composite. In the present invention, the unit is mounted on a film carrier material and is covered and sealed with the same or otherwise suitable covering film. The film may be an elongated strip containing serially placed units of composite, each readily separable from the strip for individual usage. This packaging may be enclosed in light restrictive outer packaging since the preferred unit of composite is of a light-cured material such as bis-GMA.
In preferred packaging, the unit dose is singular and the film carrier is adapted with tabs to facilitate the draping or damming of the subject tooth from adjacent teeth to facilitate application of the composite. In preferred embodiments, the single unit packaging of composite carrier film includes embrasure tabs for selective insertion in the embrasure between the teeth, and in a further preferred embodiment, the carrier film includes an incisal tab to cover the incisal edge of the tooth and may also include a gum tab on the side opposite the incisal tab.
In use, the protective cover film is removed from the unit of composite and the single unit is carefully placed over the region of the tooth to be resurfaced, and then the composite is contoured, preferably while the carrier film is still in place by spatuling over the film rather than directly on the composite. In so doing, the surface of the unit composite being worked is not exposed to the air such that an oxygen inhibited layer builds up on the composite which otherwise interferes with the complete curing of the composite applied. Additionally, as those familiar with the procedure, the composite material readily sticks to anything that touches it, including dentists tools such as the spatula. By the inclusion of the film, spatuling may be smoothly accomplished by working the composite under the film without direct contact of the spatula, allowing a much more expedient application with less accumulation of composite on the spatula.
These and other objects and advantages of the invention will become readily apparent to those skilled in the art from the following description of several preferred embodiments taken in conjunction with the included drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of one embodiment of the invention
FIG. 2 is a side elevation of the invention shown in FIG. 1 .
FIG. 3 is a plan view of an alternative embodiment of the invention.
FIG. 4 is a side elevation of the invention shown in FIG. 3 .
FIG. 5 is an exploded pictorial view of an embodiment in a strip form.
FIG. 6 is a pictorial view of one embodiment of the invention in a singly packaged form.
FIG. 7 is a pictorial view of an alternative embodiment of the invention in a singly packaged form.
FIG. 8 is a plan view of another alternative embodiment of the present invention.
FIG. 9 is a side elevation of the alternative embodiment of FIG. 8 .
FIG. 10 is a pictorial view of the alternative embodiment of FIGS. 8 and 9 in relation to a tooth.
FIG. 11 is a pictorial view of the embodiment of FIG. 10 of the present invention partially mounted on a tooth
FIG. 12 is side pictorial of a single tooth upon which an alternative embodiment of the present invention shown in FIG. 8 , mounted on a tooth.
FIG. 13 is a pictorial view of a single tooth and the alternative embodiment of FIG. 11 partially applied thereto.
FIG. 14 is a pictorial view of an alternative embodiment of the present invention illustrated in FIG. 10 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention relates to the field of cosmetic dentistry wherein the visible teeth, such as the incisors and cuspids, if they become diseased, disfigured or discolored, are treated with an aesthetic restoration to improve, if not duplicate the original appearance. This invention is best understood by comparison with the current methods for applying these aesthetic composite restorations.
As related in the Background of the Invention, currently used composites are either mixed immediately prior to application to the tooth followed by being troweled or spatulated on the tooth, to as closely to the final profile as is possible. In working with the mixed composite, working time is limited since the polymerization of the resin begins with the mixing of the two components of the composite. In the instance of the use of a light cured resin, the composite is usually delivered to a tooth from a syringe, and is then spatulated to the final profile. While the polymerization does not begin until the application of a special light source, however the light curable resin attracts oxygen and the exposed surface of the resin becomes somewhat compromised in that it will not cure to the degree as the unexposed material—meaning that working time with the light cured resin is also limited. In both applications, the tooth is cleaned and prepared for the application of the composite. The tooth is dammed, or draped such that it is isolated from the surrounding teeth. The surface of the tooth is etched and then the bonding adhesive is applied, following which the composite is applied as described above. In both applications, the adhesive nature of the composite causes it to stick to the spatula or other working instrument during forming, rendering the application very technique sensitive.
Following the working of the composite to as final a profile as possible, the composite is then further shaped and polished as necessary with the customary rotary tools, including fine diamonds, stones or burrs. The polishing of the surface of the composite to a high gloss is done with discs or rubber tips. It may be necessary to adjust and polish the interproximal surfaces with fine grit finishing strips.
In order that the present invention might be better appreciated, reference is made to FIGS. 1 and 2 which illustrate one embodiment of the present inventive packaging for a composite to be used in aesthetic restoration. Upon an underlying strip of a carrier 10 , a quantity of composite 12 , such as a light-activated bis-GMA or other similar material of the type utilized for restorations, is placed. The amount of composite material may vary according to the need anticipated by the dentist. The amount of light-cured composite now available in “single dose” and multiple dose injection ampules varies from about 0.25 to about 0.5 grams in a tip to about 5 to 15 grams per syringe for the syringe applicators. The composite 12 is then covered by a protective layer as cover 14 which is sealed against the carrier around the periphery of the composite 12 . The cover 14 may be formed of a variety of materials such as including one of the non-adhesive materials such as silicone, polyethylene or fluoropolymer such as Teflon from E. I. du Pont de Nemours or Silicone Premium from General Electric Company if the cover contacts composite 12 . In the alternative, if the cover does not contact the composite, as being a dome-like shape as illustrated in FIGS. 5 , 6 and 7 , it may be of a formed polystyrene or equivalent material which will withstand deformation in normal handling. The carrier 10 and protective layer 14 may, in turn, also be contained in additional packaging ( FIGS. 5 , 6 and 7 ) which restrict light from the composite as well as providing a sterile environment for the packaged composite 12 . Preferably, the composite 12 is in a preform (resembling a droplet), somewhat approximating the shape of the tooth upon which to be placed, thereby minimizing the amount of reworking, as by spatula, required by the dentist to get the composite to a final acceptable form on a tooth. In the instances of aesthetic restorations, the applied layer of light-cured composite may be up to about 2 mm in thickness, that thickness approaching the practical limit of curing by light. The composite may include opaquers or colorants to cover stains or cause the color of the restoration to match the adjacent teeth. In the preferred embodiments, the individually packaged composite 12 will be also available in a variety of colors (as now available in the tip or syringe delivery form) in order that the adjacent tooth color may be matched. The subject tooth is prepared in the usual way by cleaning the surface of the tooth and followed by the application of an adhesive to cause the composite to securely adhere to the underlying tooth.
In the illustrated and described embodiments, the underlying carrier 10 is formed of a strong, pliable clear film such as one of the polyester films such as those sold under the trademark MYLAR and by E. I. du Pont de Nemours. “Clear” in this context means translucent to the actinic radiation applied to the composite to cure it. The film carrier 10 should be of a thickness to withstand the spatuling required of the dentist to shape the composite 12 to its final form such that the carrier 10 preferably not be removed until the composite has been worked to substantially its final form on the tooth and cured in place, for reasons later explained. In the preferred embodiments illustrated, the thickness of the carrier 10 is from about 0.025 mm to about 0.25 mm, depending upon the particular film material selected, as in order to provide a sufficient tensile strength and resilience to enable the efficient working of the composite under the film. By not removing the carrier 10 until after curing, the composite is not exposed to the air during spatuling such that any oxygen contamination of the surface of the composite 12 is minimized thereby enabling the curing of the entire exposed surface of the formed composite.
As related above in the Background of the Invention, one of the drawbacks of the light-cured composite material is that on exposure to oxygen, the exposed layer absorbs oxygen from the air, which oxygenated surface resists curing by the light activator through the polymerization of the composite material. Also, by spatuling over the carrier 10 , the spatula does not directly contact the composite 12 and accordingly, forming and smoothing the composite to the final shape is facilitated since the composite is not dragged or rolled because of its tendency to stick to the spatula if directly contacted.
As illustrated in FIGS. 1 , 2 and 5 , the composite 12 may be disposed in sequence on the carrier 10 , forming a row of formed ampule-like containers 16 of composite 12 (hereinafter called “compules”). In the illustration, carrier 10 (and the rest of the packaging) is perforated, scored or otherwise weakened at regular intervals intermediate the compules 16 . In use of the packaging illustrated in FIGS. 1 , 2 and 5 , the dentist will break or otherwise tear off a single compule 16 from the carrier 10 /strip 19 , and once the tooth is prepared to receive the composite, the dentist will remove the cover 14 , lift the quantity of composite 12 by removing the carrier from the strip 19 and apply the exposed surface of the composite 12 to the prepared surface of the subject tooth using the carrier 10 to avoid contact between the dentist or adjacent teeth and the composite 12 . The dentist will then work or shape the composite with the carrier 10 still in place over the composite, working the composite through the carrier as though it was not there. Once the preferred shape and configuration of composite 12 is achieved, the dentist focuses a curing light, such as an XL 3000 curing light available from 3M of St. Paul, Minn. on the composite 12 through the film. Following the required curing, the dentist then removes the film of carrier 10 and further smoothes and/or polishes the installed composite as needed, by powered polishing wheels or abraders, or by hand tools as is known in the art. As seen in FIGS. 6 and 7 , the carrier may be mounted in single packaging strip 19 to which cover 14 is sealed, having therebetween the composite 12 mounted on a carrier 10 . If cover 14 and strip 19 constitute the outer packaging of compule 16 , both are colored or otherwise made masked to impede any light getting to the composite 12 . As previously mentioned, since the composite is oxygen sensitive, it is preferable the compule 16 be sealed against moisture and air, and may be filled with an inert gas to exclude any oxygen absorption. Though not illustrated, compules 16 may be packaged in parallel rows on a strip 19 , if preferable.
Referring now to FIGS. 3 and 4 , alternative styles of individually packaged compules 16 are illustrated. Figures In FIGS. 3 and 4 , compules 16 are individually mounted on a single strip of film carrier 10 . The film is of a similar material as in the multiple compule strip illustrated in FIGS. 1 and 2 , namely about 0.025 mm in thickness to about 0.25 mm in thickness, and about 1 cm to about 3 cm long and about 0.5 cm to about 1 cm wide. In the single strip embodiment of FIGS. 3 and 4 , after the cover 14 has been removed and the composite 12 is to be applied, the tails 18 of the strip may be used for handling the composite to position it on the tooth and as an embrasure tab 20 , being placed in the space between the teeth adjacent the subject tooth upon which the restoration is being done. Tabs 20 thus function as handles and also to isolate the composite material 12 from the adjacent teeth during the application of the composite and avoid the necessity to otherwise dam or drape the adjacent teeth with traditional equipment. With this embodiment of the present invention, once the tabs 20 are inserted in the embrasures, the dentist may grasp them with a forceps on the posterior side of the tooth and pull them taught, prior to or as the surface of the compule 16 /composite 12 is being smoothed with the spatula. With this dual approach for finishing the restoration, the amount of later contouring or polishing is minimized, and as in the previous embodiment, the composite may be fully cured without concerns over oxygen inhibition.
FIGS. 8 and 9 illustrate a further preferred embodiment for a compule 16 , wherein in addition to the embrasure tabs 20 , a third tab being an incisal tab 22 is included. FIGS. 10 , 11 and 13 illustrate the application of the composite 12 wherein embrasure tabs 20 are interposed between adjacent teeth ( FIG. 11 ) and the incisal tab 22 is folded rearwardly to behind the tooth to position 22 ′ ( FIG. 13 ). After the embrasure tabs 20 are inserted in the embrasure openings, tab 22 is folded tightly over the incisal edge of the tooth, and pulled rearwardly, to further assist in the profiling of the composite 12 to the tooth shape adjacent the incisal edge. The combined pulling of the tabs 20 , 22 rearwardly cause composite 12 to be flattened against the tooth, with the edges being flared around the periphery of the tooth T, thereby eliminating much of the forming otherwise required to be done with a spatula. As with the embodiment of FIGS. 3 and 4 , any necessary remaining contouring may be done with the spatula, after which the composite is cured with the preferred light source, providing a well cured aesthetic restoration wherein the common problem of an oxygen inhibited composite surface may be minimized, if not totally avoided. Additionally, the features of the tabs for the embrasures and the incisal edges of the teeth facilitate the draping of the tooth as well as the contouring of the composite, thereby reducing the overall time of the procedure as well as greatly facilitating the contouring of the composite which will improve on the aesthetic appearance of the restoration. The embodiments of FIGS. 3 and 4 and 8 and 9 may be packaged individually on an outer strip 19 as illustrated in FIG. 6 , however cut to a size commensurate with mounting a single carrier 10 of FIGS. 3 , 4 and 7 , 9 . A single cover 14 may be mounted and sealed over strip 19 thereby creating a single compule 16 incorporating a single carrier 10 and composite 12 .
FIG. 14 illustrates a further embodiment of the carrier 10 , having extended embrasure tabs 21 , enabling a further reach behind the tooth for pulling and forming. Likewise, in addition to the incisal tab 22 , a gum tab 23 is provided to facilitate working of the composite under the carrier 10 in the region of the gum G. Those skilled in the art that a variety of special forms of tabbed carriers may be provided, each adapted for particular types of restoration.
In the embodiment illustrated in FIG. 5 , it is preferred that the strip of compules 16 have an outer package 17 , comprised of a sequence of covers 14 which may be similar to the cover illustrated in the embodiments of FIGS. 1 and 2 or supplemental thereto and a continuous strip 19 which may be a film or other moisture and air tight material, such as polyester or ptfe, or another similar material. The outer covers 14 and strip 19 preferably are colored or shaded so as to not be transparent or translucent, at least to the wavelengths of light which are capable of curing composite 12 . Additionally, by using such an outer package 17 , it is also feasible to provide a plurality of packaged compules 16 wherein the carrier includes tabs such as the embrasure tabs 20 and the incisal tab 22 (as illustrated in FIG. 10 ) to better enable the handling of the composite 12 and isolation of the adjacent teeth. As illustrated in the individually packaged embodiment illustrated in FIGS. 6 and 7 , individual outer packaging of the composite 12 may include a single cover 14 ′ disposed over the composite 12 and singular mounting carrier 10 ′, which are mounted on singular strip 19 ′, wherein differing shapes, colors and dosages of composite 12 may be packaged. By including the outer package 17 , whether the compules 16 are in singular or strip form, they may be freely handled in the dentist's office and not be compromised by being exposed to light. It is envisioned that the compules 16 , whether in single or strip form will be additionally packaged for transit, as for being placed in inventory and shipped to customers.
The packaging and application of an aesthetic restoration according to the present invention provides significant advantage over those in the present art. Though the use of light curable composites avoid the difficulties of mixing the polymers, there is also significant improvement over current application techniques of light curable polymers. Since the composite is initially laid on the affected tooth, and is manipulated or formed through the carrier film, the spatula or trowel never come directly into contact with the composite. The composite is characteristically very sticky, and even with experienced use of the trowel or spatula, the material sticks to the instrument during forming of the composite which invariably induces bubbles and voids into the composite which must be worked out, if at all possible. By working the composite through the film, the working time is shortened, is much less sensitive as to technique and provides a more durable and better cure (by the avoidance of bubbles, voids and oxygen absorption and the unhindered smoothing of the composite). The problem of the composite sticking to any of the normally utilized tools is eliminated since it is smoothed to shape under the carrier 10 , and cured while still under the carrier, such that when the carrier is finally removed, the composite is cured and there is no longer sticky on its surface. The ability to now package single dose compules enables the providing of a wider variety of colors of composite, and sized dosages to better match the amount required for a single restoration, or multiple restorations, if necessary. Since the aesthetic restoration is commonly done on the central incisor, the lateral incisor or cuspid and the size of these teeth vary from one another, as well as from human to human, the dentist may be assured of a pre-sized, premixed compule which will better match both dosage and color requirement.
With the convenience provided by the inventive packaging and application, the prepackaged/light-cured composite becomes a superior alternative to other mechanisms for the aesthetic restoration. As detailed above, the prepackaged/light-cured composite is clearly easier to use and provides a much more consistently cured end result that either of the mixed polymers for polymerization in place, or the injector applied light-cured composite. The other alternative to these materials is the use of a porcelain veneer, which requires the removal of tooth structure first, to provide a proper base upon which the veneer is fixed with an adhesive, and then shaped, as necessary. The application of a porcelain veneer is quite technique sensitive and not all dentists attempt the technique, which may make it somewhat difficult to find one when the procedure is needed. Secondly, the material and procedure are very expensive, when contrasted to the polymerized composite, whether mixed or light-cured.
PARTS LIST
The following is a list of parts and materials described and illustrated for use in the present invention:
10
carrier
10′
single carrier
12
composite
14
cover
14′
single cover
16
compule
17
outer packaging
17′
single outer package
18
carrier tabs
19
packaging strip
19′
single package strip
20
embrasure tab
21
extended embrasure tab
22
incisal tab
23
gum tab
G
gum
T
tooth
As will be apparent to persons skilled in the art, various additional modifications, adaptations and variations of the foregoing specifically disclosed embodiments and methods of coating removal may be made without departing form the objectives and scope of the present invention. Various modifications and changes may be made to the embodiments disclosed herein by those skilled in the art and such are contemplated by the present invention and are to be understood as included within the spirit and scope of the appended claims.
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A packaged unit of composite for performing an aesthetic restoration. The unit is mounted on a polymeric film carrier material and is covered and sealed with the same or otherwise suitable covering film. The carrier film may be an elongated strip containing serially placed units of composite, each readily separable from the strip for individual usage. This packaging is in light restrictive outer packaging since the preferred unit of composite is of a light-cured material such as bis-GMA. In preferred packaging, the unit dose is singular and applicable to the tooth surface with the film carrier which is adapted with tabs to facilitate handling and the draping or damming of the subject tooth from adjacent teeth to facilitate application of the composite. The composite is then worked, i.e., formed on the tooth with the film intermediate the composite and the customary forming tools. In preferred embodiments, the single unit packaging of composite is mounted on a clear carrier film which includes embrasure tabs for selective insertion in the embrasure between the teeth, and in a further preferred embodiment, the carrier film includes an incisal tab to cover the incisal edge of the tooth. The clear carrier is contained in further outer packaging which limits actinic radiation from reaching the composite.
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FIELD OF THE INVENTION
The present invention relates to a mirror drive for use in an automotive remote-controlled rear-view mirror, and more particularly to an electrical connection structure enclosed in a power unit casing and which supplies power to two motors which drive the horizontal and vertical turns of the mirror.
DESCRIPTION OF THE PRIOR ART
In the automotive remote-controlled rear-view mirror assembly, a mirror is disposed changeably in direction in an opening in a mirror housing, and a mirror drive to drive the mirror is designed in the form of a power unit casing fixed inside the mirror housing. The power unit casing consists of two insulative parts, upper and lower, and has two motors disposed therein. Generally, the power unit casing is made waterproof by interposing an O-ring, or applying a sealant, between the junction surfaces of the upper and lower subcasings. The motors are so electrically connected at the terminals thereof to the battery and control switch that the mirror is turned horizontally and vertically by running the two motors in the casing forwardly or reversely as desired. Normally, the terminals of these motors have connected thereto sheathed wires which are led out of the mirror assembly through lead-out ports formed in the casing. In such conventional electrical connection structure, there is between each sheathed wires and wire lead-out ports gaps through which rain or the like possibly enters into the casing. To prevent such rain or the like from entering into the casing, a remote-controlled rear-view mirror assembly has been proposed which has a casing molded integrally with plural electrically conductive plates of which ends are so placed inside the casing as to be connected to the terminals of each motor while the other ends are so exposed outside the casing as to electrically be connected to the battery and control switch. A remote-controlled rear-view mirror assembly is disclosed in, for example, in the Japanese Unexamined Utility Model Publication No. 61-204845 (laid open on Dec. 12, 1986). For integral molding of the casing and plural conductive plates, the latter are inserted at one end thereof in vertical recess formed in the movable mold and the other end of the conductive plate is moved toward the vertical recess formed in the stationary mold opposite to the movable mold and thus the other end of each conductive plate is inserted into the vertical recess in the stationary mold, whereby the plural conductive plates are positioned. In such condition, a resin is injected into the clearance between the movable and stationary molds, whereby each conductive plate is molded integrally with the casing. For molding such conventional improved electrical connection structure, one end of each conductive plate is inserted in the vertical recess formed in the movable mold and the other end is moved toward the vertical recess formed in the stationary mold. So much care must be taken for controlling the positioning of the conductive plates, and the controlling is very difficult. Namely, if the other ends of the conductive plates are not inserted together into the vertical recess formed in the stationary mold, some of the conductive plates will be so bent that the other ends of the conductive plates which are to be exposed out of the casing to a predetermined length will not be correctly exposed so, with the result that the molding yield of the power unit casing will be low. In other such electrical connection structure, the edge of the vertical recesses in the movable and stationary molds are tapered for easy insertion of the ends of the conductive plates. When molding the power unit casing, a synthetic resin flows to the edges of the vertical recesses in the movable and stationary molds. As a result, a set synthetic resin will reside at the portions exposed out of the casing of the conductive plates molded integrally with the casing, and particularly the exposed portions of the conductive plates outside the casing provide for connections with an external connector and so the synthetic resin residing on the connections will block the insertion of such external connector. The aforementioned electrical connection structure is such that the ends of the conductive plates are exposed out of the casing bottom. Therefore, the direction of the conductive plates must be the same as the moving direction of the movable mold, that is, the ejecting direction of the mold. This electrical connection structure having the conductive plate ends exposed out of the casing bottom is advantageous when it is adopted in a power unit casing which is to be fixed inside a shell-type mirror housing having a sufficient depth such as the fender mirror assembly. However, for use in a so-called door mirror assembly employing a thin mirror housing, the power unit casing is also to be thin, and in such door mirror assembly, the power unit casing is usually fixed with the rear side of the casing secured to a bracket disposed on the mirror housing. Therefore, the sheathed wires connected to the terminals of the two motors are usually led out from the insertion hole formed in the lateral side of the casing; so it is difficult from the viewpoint of the ejecting direction of the mold to apply the aforementioned well-known electrical connection structure to the power unit of the door mirror assembly.
The present invention has a primary object to overcome the above-mentioned drawbacks of the conventional techniques by providing a mirror drive for use in a remote-controlled rear-view mirror assembly, having an electrical connection structure for connection to two motors inside a power unit casing and which is highly waterproof and easy to assemble.
The present invention has another object to provide a mirror drive for use in a remote-controlled rear-view mirror assembly, having an electrical connection structure preferably usable in a door mirror assembly including a thin power unit casing corresponding to a thin mirror housing.
The present invention has a yet another object to prove a mirror drive for use in a remote-controlled rear-view mirror assembly having an electrical connection structure for connection to two motors inside a power unit casing, which can be integrally molded with an improved yield and without any residual synthetic resin on the exposed portions of conductive plates used therein.
SUMMARY OF THE INVENTION
The above objects are attained by providing a mirror drive for use in a remote-controlled rear-view mirror assembly, comprising, according to the present invention, two motors to drive the horizontal and vertical turns of a mirror pivotably supported in a mirror housing, an airtight container housing the two motors and consisting of two synthetic resin-made casings which are closely attached to each other, gear means disposed in the airtight container and which decelerate the rotation of the output shafts of the two motors, means engaged with the gear means to convert the rotary motion of the gear means into a substantial linear motion and also projected out of the airtight container to transmit the linear motion to the mirror, and means for electrically connecting terminals of the two motors to external connectors outside the airtight container, the electrical connecting means being composed of an insulative block secured to the lateral wall of either of the casings of the airtight container and which covers an opening formed in the lateral wall, and a plurality of electrically conductive plates previously buried in the insulative block, each being at one end thereof electrically connected to a corresponding terminal of the two motors while the other end is led out through the opening formed in the casing. Since the plurality of conductive plates electrically connected to the respective terminals of the two motors are previously buried in the insulative block and this insulative block is secured covering the operation in such a manner that the other ends of the plural conductive plates are led out through the opening in the casing, the waterproofness of the airtight container is improved and the power-supply wiring of the two motors to the terminals is unnecessitated so that the mirror drive can be easily mounted into the rear-view mirror assembly. Also since the plural conductive plates are so configured as to be led out of the lateral wall of the casing, a mirror drive can be provided which is suitably usable in a remote-controlled door mirror assembly having a mirror housing which is of small depth, namely, thin.
Furthermore, in the molding process of either of the casings of the airtight container, the insulative block in which the plural conductive plates are previously buried with both ends thereof being exposed outside can be integrally molded in such a manner that the lateral side of the insulative block at which the other ends of the insulative plates are exposed forms the lateral side of the casing. The advantages of the integral molding, in the molding process of the casings, of the insulative block in which the plural conductive plates are previously buried are the improved yield of the molding, no residual synthetic resin on the exposed portions of the conductive plates and thus no adverse affect to the connection with external connectors since the insulative block can be securely immobilized between a stationary and movable molds so that the conventional positioning by inserting the ends of thin conductive plates into the recesses in the stationary and movable molds is unnecessitated.
These and other objects and advantages of the present invention will be better understood from the ensuing description made, by way of example, of the embodiments of the mirror drive for remote-controlled rear-view mirror assembly according to the present invention with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing one embodiment of the mirror drive for remote-controlled rear-view mirror assembly according to the present invention, which is applied to a door mirror, with a portion omitted;
FIG. 2 is a perspective view showing the entire power unit composing the mirror drive;
FIG. 3 is a perspective view showing the inside of the power unit with one of the two casings forming the power unit removed;
FIG. 4 is a perspective view, enlarged in scale, of the essential portion of the power unit in FIG. 3;
FIG. 5 is an explanatory drawing showing the installation to the casings of the insulative block in which the plural conductive plates are previously buried;
FIG. 6 is a schematic view showing the state of the insulative block installed to the casings;
FIG. 7 is a plan view showing another embodiment of the mirror drive for remote-controlled rear-view mirror according to the present invention, showing one of the casings as partially fragmented; and
FIGS. 8 (a) to (c) are explanatory drawings showing the processes, respectively, of integrally burying, in the molding process of the casings, the plural conductive plates into the insulative block.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, the internal structure of the remote-controlled rear-view mirror is illustrated which has a mirror housing 10 mounted to a mirror base (not shown) which is to be fixed on the door of a car. A mirror 12 is disposed as fixed to a mirror body 14, covering the opening of the mirror housing 10. The reference numeral 16 indicates a mirror drive unit, namely, a power unit, disposed as fixed by means of a bracket 18 inside the mirror housing. This power unit 16 is so constructed as to be capable of turning the mirror body 16 horizontally or vertically under the remote-control by the control switch located around the driver's seat.
The mirror body 14 is pivotably supported with respect to the power unit 16. The power unit 16 comprises two synthetic resin-made casings 16a and 16b which house two motors 100 and 200 and are so shaped as to be closely attached to each other. The mirror body 14 is supported by a means including a pivot junction consisting of a hollow, semispheric member 20 formed near the center of the rear side of the mirror body 14 and a semispheric seat member 22 formed on the surface of the casing 16a opposite to the semispheric member 20. The seat member 22 has disposed integrally therewith at the center thereof a conical protrusion 24 having a through-hole formed coaxially with the pivot of the pivot junction On the other hand, the semispheric member 20 has disposed in the bore therein a pressing member 26 formed so as to fit the inner wall of the bore. The pressing member 26 has formed at the center thereof a through-hole coaxial with, and also of a nearly same diameter as, the one formed in the protrusion 24. These through-holes have introduced therein bolts 28 of which the heads are in contact with the flat portion of the pressing member 26 while the external thread portion of the bolts 28 are screwed in the square nuts 30 located inside the casing 16a. The nut 30 is disposed as checked against any rotation within a cylindrical portion 32 having a square section and which is integrally molded inside the casing 16a, and there is fitted in the cylindrical portion 32 a coil spring 34 which presses the nut 30 toward the casing 16b. Therefore, the semispheric member 20 of the mirror body 14 can be appropriately forced to the seat member 22 by means of the pressing member 26, and supported pivotably with respect to the power unit 16. The structure per se of such pivot junction is well known, and so it will not be described in further detail.
As will be seen in FIG. 3, there is formed at the joining boundary between the casings 16a and 16b a recess 40 in which an O-ring (not shown) is disposed. These two casings 16a and 16b are coupled to each other by means of screwing members 42. The rotation of the two motors 100 and 200 housed in such casings is transmitted to drive gear mechanisms 58 and 60, respectively, through reduction gears 54 and 56 including worms 50 and 52, respectively, fixed to the output shafts of the motors 100 and 200, respectively. The drive gear mechanisms 58 and 60 have formed on the outer circumferences of cylindrical members thereof gears 62 and 64, respectively, which are in mesh with the reduction gears 54 and 56, respectively, and pawl-shaped elastic pieces (not shown) at the ends of the cylindrical members. Rotary members 66 and 68 each having a pair of elastic arm members (not shown) extending inwardly of the cylindrical members are fixed to the cylindrical members rotatably therewith. The reference numerals 70 and 72 indicate actuating members, respectively, which turn the mirror body 14 horizontally and vertically, respectively. The actuating members 70 and 72 have balls 74 and 76, respectively, formed at the ends thereof, and also small cylindrical portions (not shown) which can be inserted into the cylindrical members, respectively, composing the drive gear mechanisms 58 and 60. The cylindrical portion has formed on the inner circumference thereof an internal thread portion (not shown) into which the aforementioned pawl-shaped elastic piece. The balls 74 and 76 are fitted in spherical seats 78 and 80 formed on the rear side of the mirror body 14 as checked against any rotation. Therefore, as the gear 62 or 64 is rotated, the rotary member 66 or 68 rotates along with the pair of elastic arm members and the pawl-shaped elastic piece on each elastic arm member rotates as engaged in the internal thread portion formed on the inner circumference of the actuating member 70 or 72, so that the actuating member 70 or 72 checked against any rotation will move forward or backward according to the running direction of the motor 100 or 200, whereby the mirror body 14 will be turned horizontally or vertically.
In this embodiment in which the mirror drive according to the present invention is applied to a door mirror, terminals 102 and 104, and 204 and 204 of the motors 100 and 200, respectively, are electrically connected to a connector 300 electrically connected to a remote-control switch located around the driver's seat and the battery by means of three electrically conductive plates 401, 402 and 403 buried in a synthetic resin-made insulative block 400. The terminal 102 is connected to the conductive plate 401, the terminals 104 and 202 are connected to the conductive plate 402, and the terminal 204 is connected to the conductive plate 403. These conductive plates 401, 402 and 403 are integrally formed in the molding process of the insulative block 400, and the one exposed end of each conductive plate is so shaped to have a shape edge as to be engageable into the small hole formed in each terminal of the motors 100 and 200 while the other end is so shaped as to be engaged with a corresponding terminal of the connector 300. The other end of each conductive plate which is to be connected to the connector 300 is exposed out of an end face 410 of the insulative block 400, and the end face 410 is closely secured to the inner circumferential edge of the opening formed in the lateral wall 17 of the casing 16a and thus covers the opening. The exposed end of each conductive plate is exposed out of the casing from the opening and connected to the connector 300. The reference numeral 500 indicates a socket formed as protruded outwardly of the outer circumferential edge of the opening formed in the lateral wall 17 of the casing 16a, and it is so constructed that when the connector 300 is fully inserted the exposed ends of the conductive plates are electrically connected to the corresponding terminals of the connector 300.
When assembling the aforementioned insulative block 400 into the casing 16a, the insulative block 400 lowers down to the bottom of the casing 16a owing to its own weight as guided by the pin 21 by lowering the insulative block 400 as somehow slanted until the exposed end of each conductive plate is exposed outside the casing through the opening formed in the lateral side 17 of the casing 16a and fitting thereafter the pin 21 formed on and integrally with the casing 16a into the small hole 412 formed in the insulative block 400. Then, the insulative block 400 is positioned as slightly rotated around the pin 21 until the end face 410 of the insulative block 400 touches the lateral wall 17 of the casing 16a. Thereafter, the insulative block 400 is fixed to the casing 16a by thermally calking the apex of the pin 21. Further, when a sealant which also serves as adhesive, applied to the junction between the end face 410 of the insulative block 400 and the lateral wall 17 of the casing 16a from the side of the socket 500 is hardened, the assembling of the insulative block 400 into the casing 16a is complete.
When the assembling of the insulative block 400 into the casing 16a is over, the motors 100 and 200 can easily be connected electrically to the external connector 300 by fitting the sharp ends of the conductive plates 401, 402 and 403 into the small holes in the ends of the terminals 102 and 104 and 202 and 204. Thus, the electrical connection between the two motors 100 and 200 disposed inside the sealed container formed by the casings 16a and 16b and the connector 300 outside the container needs no manual disposition and connection of plural wires which would be required in the conventional mirror assembly. The intended purpose can easily be attained owing to the disposition of the insulative block 400 having buried therein the conductive plates 401, 402 and 403 molded integrally therewith and the disposition at predetermined positions of the two motors 100 and 200.
FIGS. 7 and 8 (a) to (c) show another embodiment of the present invention. In these Figures, the same or similar elements as in the first embodiment are indicated with the same or similar reference numerals. In this second embodiment, the insulative block 400 is molded integrally with the casing 16a in the molding process of the casing 16a. FIG. 7 is a partially fragmental rear view of the drive unit, and FIGS. 8 (a) to (c) are explanatory drawings generally showing the molding processes of the casing 16a.
Referring now to FIGS. 8 (a) to (c), a further explanation will be made below. In Figures, one of the three conductive plates 401, 402 and 403, namely, only the conductive plate 401 is shown and the remainder is omitted because they are identical. Each conductive plate is buried in the insulative block 400, having disposed as projected vertically from the top of the insulative block 400 the end thereof connected to the terminal of each motor and also having disposed as projected horizontally from the end face 410 of the insulative block the other end connected to the external connector. The insulative block 400 has formed on the bottom thereof a small cylindrical foot 413 projecting vertically downward and also it has formed therein a through-hole 412 open at the top and bottom thereof. Further, the insulative block 400 has a plurality of small holes formed in the top thereof. The insulative block 400 is disposed with the foot 413 thereof being in contact with the stationary mold 600. As shown in FIG. 8 (a), the insulative block 400 holds itself in place by moving the movable molds 602 and 604 over a predetermined distance in the directions of arrows X and Y. More particularly, the movable mold 602 has a vertical face 610 which is in contact with the end face 411 of the insulative block 400 and a horizontal face 613 which is in contact with the top of the insulative block 400. Furthermore, there is formed in the horizontal face 613 a recess 614 in which inserted is the end of each conductive plate which is to be connected to the terminal of each motor. Also there is formed in a position corresponding to the through-hole 412 a concavity 616 having a somewhat larger area than the opening area of the through-hole 412, and in the positions corresponding to the plural small holes 618 protrusions 618 which are to be fitted into the small holes 414. The movable mold 604 has a vertical face 620 which is in contact with the end face 410 of the insulative block 400 and horizontal faces 622 and 623 which are in contact with the surface of the stationary mold 602 and the horizontal face 612 of the movable mold 602, respectively. The vertical face 620 has formed therein a horizontal recess 624 in which the end of each conductive plate which is to be connected to the external connector 300, and a recess 626 which forms a socket 500. The recesses 614 and 620 formed in the movable molds 602 and 604, respectively, are provided primarily for housing the end of each conductive plate, and their openings are tapered for easiness of inserting the end of each conductive plate. For retention of the insulative block 400 in place, the vertical position of the insulative block 400 is determined as the horizontal face 613 of the movable mold 602 appropriately presses the top of the insulative block 500 on the stationary mold 600, while the horizontal position of the insulative block 400 is determined as the vertical face 620 of the movable mold 604 appropriately presses the end face 410 of the insulative block 400 with the end face 411 of the insulative block 400 being in contact with the vertical face 610 of the movable mold 602 and with the plural protrusions 618 formed on the movable mold 602 being fitted in the plural small holes 414 formed in the insulative block 400. This condition is shown in FIG. 8 (b). In this condition, a synthetic resin is injected into a space defined by the molds and insulative block 400 and thereafter it is hardened. It is obvious to those skilled in the art that after the synthetic resin is hardened, the movable molds 602 and 604 are removed as moved in the directions of arrows X' and Y' and thus the insulative block 400 is formed integrally with the casing 16a as schematically shown in FIG. 8 (c). The reference numeral 415 indicates a protrusion formed on the top of the insulative block 400 as the result of the injection and hardening of the synthetic resin in a space defined by the through-hole 412 in the insulative block 400 and the concavity 616 in the movable mold 602. This protrusion 415 ensures the integrity of the insulative block 400 with the casing 16a.
In the embodiment having been described just in the foregoing, the conventional positioning of the insulative block 400 by inserting the ends of each conductive plate into the recesses provided in the stationary and movable molds is not required, but the molding yield of the casing 16a is improved since the insulative block 400 itself is positioned as pressed by the molds. The recesses 624 and 614 formed in the movable molds 602 and 604, respectively, are provided primarily for housing the ends of the insulative plates. As the exposed ends of the conductive plates are so arranged against any direct contact with the injected synthetic resin, the synthetic resin does not reside on the exposed ends of the conductive plates, thus the connection with the external connector will not adversely be affected.
In the aforementioned two embodiments, the terminals of the motors are connected with the ends of the conductive plates which are exposed from the end of the insulative block, by a simple mechanical contact. By soldering these contact portions, a more secure connection can be attained. Also it will be evident to those skilled in the art that for forward run of the motor 100, the conductive plate 401 is connected to the positive pole of the battery and the conductive plates 402 and 403 are connected to the negative pole, while for reverse run of the motor 100, the conductive plate 401 is connected to the negative pole of the battery and the conductive plates 402 and 403 are connected to the positive pole, and that for forward run of the motor 200, the conductive plate 403 is connected to the positive pole of the battery and the conductive plates 401 and 402 are connected to the negative pole, while for reverse run of the motor 200, the conductive plate 403 is connected to the negative pole of the battery and the conductive plates 401 and 402 are connected to the positive pole.
|
The mirror drive for remote-controlled rear-view mirror assembly includes an air-tight container housing two motors to drive the horizontal and vertical turns of the mirror and which is composed of two synthetic resin-made casings which are closely attached to each other. Plural conductive plates which electrically connect terminals of the two motors to external terminals outside the airtight containers are previously buried in an insulative block with both ends there being exposed outside of the block. The insulative block covers the opening formed in the lateral wall of either of the casings and is secured to the lateral wall of the casing. Of the exposed ends of the plural conductive plates, those ones which are connected to the terminals of the motor are located inside the casings, while the other ends which are connected to the external connectors are led out through the opening in the casing.
| 8
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TECHNICAL FIELD
[0001] Embodiments are generally related to sensor methods and systems. Embodiments are also related to diesel exhaust after-treatment devices. Embodiments are additionally related to techniques and devices for simultaneously measuring one or more properties associated with diesel exhaust.
BACKGROUND OF THE INVENTION
[0002] Environmental pollution, such as air pollution, is a serious problem that is particularly acute in urban areas. Much of this pollution is produced by exhaust emissions from motor vehicles. NO x gases, which are present in automotive exhaust pollution, are known to cause various environmental problems such as smog and acid rain. The term NO x actually refers to several forms of nitrogen oxides such as NO (nitric oxide) and NO 2 (nitrogen dioxide). Nitrogen oxide (NO x ) contained in exhaust gas can directly effect the human body. NO x and its emission concentrations in various exhaust gases also contribute to the formation of “acid rain” and photochemical smog. Hence, it is necessary to remove NO x from exhaust gas.
[0003] Selective Catalytic Reduction (SCR) is a technique that is used to inject urea—often a liquid-reductant agent—into an exhaust stream of a diesel engine, which is then adsorbed onto the surface of a catalytic converter. In an SCR system, urea is used as a reductant that is converted to ammonia which reacts in the presence of a catalyst to convert NO x to nitrogen and water which is then expelled through a vehicle tailpipe. Precise ammonia and NOx measurements are required to develop and characterize optimal catalyst strategies in order to prevent excess ammonia emissions or un-reacted NO x emissions. Note that the term “ammonia slip” refers to excessive ammonia emission which in practice may be caused by exhaust gas temperatures that are too cold for the SCR reaction to occur (such as during a cold start), or if the urea injection device feeds too much reductant into the exhaust gas stream for the amount of NO x produced by the engine combustion.
[0004] A technology that can immediately control the NH 3 feed rate according to the load change, fluctuation in NO x concentration, and so forth, is therefore needed in order to realize high-efficiency NO x removal without leaving un-reacted NH 3 . A measuring technology with a high-speed response capable of simultaneous and continuous measurement of NO x and NH 3 would be indispensable. Sensors designed for NO x or NH 3 , however, are often significantly cross-sensitive to each other. Distinguishing these components is therefore critical to successfully controlling an SCR device. It is believed that the control of SCR devices would benefit from the simultaneous measurements of NO x and NH 3 .
[0005] One approach for the development of simultaneous NO x /NH 3 sensor in exhaust gas involves the use of two identical sensors for measuring NO x and NH 3 by splitting the exhaust path in two and running each path through a different catalyst prior to entry into the respective sensor. This technique is suitable for stationary power plant application but is very expensive to implement and takes up a great deal of space and is thus not suitable for automotive applications.
[0006] In an effort to address the foregoing difficulties, it is believed that two sensors with dissimilar sensitivities and cross sensitivities to NO x and NH 3 can be combined and a decoupling observer algorithm applied for simultaneously measuring NO x and NH 3 in diesel exhaust as described in greater detail herein.
BRIEF SUMMARY
[0007] The following summary is provided to facilitate an understanding of some of the innovative features unique to the embodiments disclosed and is not intended to be a full description. A full appreciation of the various aspects of the embodiments can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
[0008] It is, therefore, one aspect of the present invention to provide for an improved sensor method and system.
[0009] It is another aspect of the present invention to provide for improved diesel exhaust after treatment devices.
[0010] It is a further aspect of the present invention to provide for a method and system for simultaneously measure one or more properties (e.g., concentrations NO x and ammonia, temperature, etc) associated with an exhaust gas mixture.
[0011] The aforementioned aspects and other objectives and advantages can now be achieved as described herein. A method and system for simultaneously measuring a plurality of properties (e.g., gas, temperatures, etc.) of an exhaust gas mixture (e.g., diesel exhaust) is disclosed. Signals from a plurality of sensors that are cross-sensitive to a first property (e.g., NO x ) and a second property (e.g., NH 3 ) can be combined. A decoupling observer algorithm can be applied, such that these cross-sensitivities are decoupled and the sensors simultaneously obtain an estimate of one or more such properties. Such a method and system can enable the use of inexpensive sensor technologies that have been previously ruled out due to their cross-sensitivities. Possible configurations utilizing such sensors and a decoupling observer algorithm can include, for example, control module (ECM) based configurations, intelligent sensor configurations, and/or intelligent sensor configuration for on board diagnostics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the embodiments and, together with the detailed description, serve to explain the embodiments disclosed herein.
[0013] FIG. 1 illustrates a block diagram of an example data-processing apparatus, which can be adapted for use in implementing a preferred embodiment;
[0014] FIG. 2 illustrates a schematic diagram of a closed-loop SCR control system 200 based on ECM configuration for simultaneously measuring NO x and NH 3 , in accordance with a preferred embodiment;
[0015] FIG. 3 illustrates a schematic diagram of a closed-loop SCR control system based on intelligent sensor configuration for simultaneously measuring NO x and NH 3 , which can be implemented in accordance with an alternative embodiment;
[0016] FIG. 4 illustrates a schematic diagram of a closed-loop SCR control system based on intelligent sensor configuration for on-board diagnostics (OBD) for simultaneously measuring NO x and NH 3 , which can be implemented in accordance with an alternative embodiment; and
[0017] FIG. 5 illustrates a high level flow chart of operations illustrating logical operational steps of a method for simultaneous measurement of NO x and ammonia in diesel exhaust, in accordance with an alternative embodiment.
DETAILED DESCRIPTION
[0018] The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
[0019] FIG. 1 illustrates a block diagram of a data-processing apparatus 100 , which can be adapted for use in implementing a preferred embodiment. It can be appreciated that data-processing apparatus 100 represents merely one example of a device or system that can be utilized to implement the methods and systems described herein. Other types of data-processing systems can also be utilized to implement the present invention. Data-processing apparatus 100 can be configured to include a general purpose computing device 102 . The computing device 102 generally includes a processing unit 104 , a memory 106 , and a system bus 108 that operatively couples the various system components to the processing unit 104 . One or more processing units 104 operate as either a single central processing unit (CPU) or a parallel processing environment. A user input device 129 such as a mouse and/or keyboard can also be connected to system bus 108 .
[0020] The data-processing apparatus 100 further includes one or more data storage devices for storing and reading program and other data. Examples of such data storage devices include a hard disk drive 110 for reading from and writing to a hard disk (not shown), a magnetic disk drive 112 for reading from or writing to a removable magnetic disk (not shown), and an optical disc drive 114 for reading from or writing to a removable optical disc (not shown), such as a CD-ROM or other optical medium. A monitor 122 is connected to the system bus 108 through an adapter 124 or other interface. Additionally, the data-processing apparatus 100 can include other peripheral output devices (not shown), such as speakers and printers.
[0021] The hard disk drive 110 , magnetic disk drive 112 , and optical disc drive 114 are connected to the system bus 108 by a hard disk drive interface 116 , a magnetic disk drive interface 118 , and an optical disc drive interface 120 , respectively. These drives and their associated computer-readable media provide nonvolatile storage of computer-readable instructions, data structures, program modules, and other data for use by the data-processing apparatus 100 . Note that such computer-readable instructions, data structures, program modules, and other data can be implemented as a module 107 . Module 107 can be utilized to implement the methods 300 , 400 and 500 depicted and described herein with respect to FIGS. 3 , 4 and 5 . Module 107 and data-processing apparatus 100 can therefore be utilized in combination with one another to perform a variety of instructional steps, operations and methods, such as the methods described in greater detail herein.
[0022] Note that the embodiments disclosed herein can be implemented in the context of a host operating system and one or more module(s) 107 . In the computer programming arts, a software module can be typically implemented as a collection of routines and/or data structures that perform particular tasks or implement a particular abstract data type.
[0023] Software modules generally comprise instruction media storable within a memory location of a data-processing apparatus and are typically composed of two parts. First, a software module may list the constants, data types, variable, routines and the like that can be accessed by other modules or routines. Second, a software module can be configured as an implementation, which can be private (i.e., accessible perhaps only to the module), and that contains the source code that actually implements the routines or subroutines upon which the module is based. The term module, as utilized herein can therefore refer to software modules or implementations thereof. Such modules can be utilized separately or together to form a program product that can be implemented through signal-bearing media, including transmission media and recordable media.
[0024] It is important to note that, although the embodiments are described in the context of a fully functional data-processing apparatus such as data-processing apparatus 100 , those skilled in the art will appreciate that the mechanisms of the present invention are capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal-bearing media utilized to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, recordable-type media such as floppy disks or CD ROMs and transmission-type media such as analogue or digital communications links.
[0025] Any type of computer-readable media that can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital versatile discs (DVDs), Bernoulli cartridges, random access memories (RAMs), and read only memories (ROMs) can be used in connection with the embodiments.
[0026] A number of program modules, such as, for example, module 107 , can be stored or encoded in a machine readable medium such as the hard disk drive 110 , the magnetic disk drive 112 , the optical disc drive 114 , ROM, RAM, etc or an electrical signal such as an electronic data stream received through a communications channel. These program modules can include an operating system, one or more application programs, other program modules, and program data.
[0027] The data-processing apparatus 100 can operate in a networked environment using logical connections to one or more remote computers (not shown). These logical connections can be implemented using a communication device coupled to or integral with the data-processing apparatus 100 . The data sequence to be analyzed can reside on a remote computer in the networked environment. The remote computer can be another computer, a server, a router, a network PC, a client, or a peer device or other common network node. FIG. 1 depicts the logical connection as a network connection 126 interfacing with the data-processing apparatus 100 through a network interface 128 . Such networking environments are commonplace in office networks, enterprise-wide computer networks, intranets, and the Internet, which are all types of networks. It will be appreciated by those skilled in the art that the network connections shown are provided by way of example and that other means and communications devices for establishing a communications link between the computers can be used.
[0028] FIG. 2 illustrates a schematic diagram of a closed-loop SCR control system 200 based on ECM configuration for simultaneously measuring NO x and NH 3 , in accordance with a preferred embodiment. An SCR control algorithm may require simultaneous estimates of both NOx and NH 3 emissions levels in order to determine the level of urea dosing that is appropriate for the urea dosing unit. Such an algorithm can be provided in a software module, such as, for example, module 107 depicted in FIG. 1 , and processed via a processing device or microprocessor, such as the processor 104 also depicted in FIG. 1 .
[0029] The SCR control algorithm 210 as shown in FIG. 2 can be configured to collect information from various sensors operating within system 100 and the host system and to provide control signals that affect the operations of system 100 and/or the host system. SCR control algorithm 210 can be a module 107 programmed or hardwired within an ECM (Electronic control module) 215 as shown in FIG. 2 in order to perform operations dedicated to certain functions. The SCR control algorithm 210 can thus be provided as software that is stored as instructions and/or data within a memory device 106 of an ECM 215 for execution by a processor 104 operating within the ECM 215 . Alternatively, SCR control algorithm 210 can be a module 107 that is separate from other components of a host system.
[0030] As illustrated in FIG. 2 , the system 200 can include a urea dosing unit 225 , a urea injector 235 , the SCR control algorithm 210 , an exhaust system 240 , and an SCR catalyst component 230 . Arrow 241 indicates the flow of exhaust and/or other gases from the exhaust system 240 to the urea injector 235 , which is connected to and forms a part of the SCR catalyst component 230 . Urea injector 235 can be provided as a device that is hardware and/or software controlled and which extracts the urea solution from the urea dosing unit 225 . The SCR catalyst component 230 can allow the NO x molecules within the exhaust gas engine 240 out to react with ammonia molecules to produce molecular nitrogen (N 2 ) and water (H 2 O). Further, system 200 can include physical sensors 245 and 250 that can be configured to measure and/or analyze NO x emissions exhausted from the exhaust system 240 after the use of the SCR catalyst component 230 .
[0031] The sensors 245 and 250 can also provide actual NO x emission values to SCR control algorithm 210 based on the use of decoupling observer algorithm 220 associated with system 200 . Note that algorithm 220 can also be provided as a software module, such as, for example, module 107 of FIG. 1 . The data-processing apparatus 100 together with the SCR control algorithm 210 can therefore be utilized to monitor and control the operations associated with SCR system 200 . According to one embodiment of the present invention, SCR control algorithm 210 can be implemented as a part of an Engine Control Module (ECM) 215 that monitors and controls the operation of an engine associated with system 200 .
[0032] The SCR control system 200 can inject a source of NH 3 usually urea 235 from a urea dosing unit 225 into the exhaust gas engine output path 240 . The dosing of urea solution into the urea injector 235 can be precisely controlled by the urea dosing unit 225 . The NH 3 is then adsorbed on to the surface of the SCR catalyst 230 and reacts with the exhaust NO x from the exhaust gas engine output path 240 to form harmless N 2 and H 2 O emissions, which pass through and out the exhaust gas tailpipe 254 as indicated by arrow 255 . The true concentration of NO x and NH 3 from the exhaust gas is shown as w 1 and w 2 in FIG. 2 . Poor NH 3 mixing, temperature-dependant catalyst efficiencies, catalyst aging, rapidly changing engine-out exhaust gas 240 properties and so forth are factors that can contribute to non-ideal chemical reactions and thus elevated NO x or NH 3 tailpipe emissions as indicated by arrow 255 . It can be appreciated that although the embodiments discussed herein relate to the simultaneous measurement of NO x and NH 3 in diesel exhaust, the embodiments can apply to measuring other types of gases. NO x and NH 3 are therefore presented herein for general illustrative purposes. Other types of gases can also be measured according to the general methodology and configuration discussed herein.
[0033] In the ECM configuration of system 200 , the decoupling observer algorithm 220 can be located onboard the ECM 215 . The DOA 220 receives signals y 1 and y 2 as illustrated in FIG. 2 from the sensors 245 and 250 and converts such signals into estimates of NO x and NH 3 as respectively shown as z 1 and z 2 in FIG. 2 . The SCR controller algorithm 210 then uses the estimated NO x and NH 3 values z 1 and z 2 to command an appropriate amount of urea u as shown through urea dosing unit 225 into urea injector 235 such that tailpipe-out emissions as indicated by arrow 255 satisfy NO x and NH 3 emissions targets.
[0034] The signal processing design for NO x can be represented as follows. The response of the first sensor 245 can be modeled by the dynamical relationship as indicated by equation (1) below:
[0000] y 1 ( t )= g 11 ( s ) w 1 ( t )+ g 12 ( s ) w 2 ( t ) (1)
[0035] where g 11 represents the response of sensor 245 to NO x and g 12 represents the response of sensor 245 to NH 3 . Where the notation x(t) represents a signal as a function of time t. In this context, the notation g(s) refers to a transfer function defined as follows
Let the signal x(t) be the input to a general linear time-invariant system, and let the signal y(t) be the output, and the Laplace transform of x(t) and y(t) be respectively
[0000]
X
(
s
)
=
L
{
x
(
t
)
}
:
=
∫
-
∞
∞
x
(
t
)
-
st
t
and
Y
(
s
)
=
L
{
y
(
t
)
}
:
=
∫
-
∞
∞
y
(
t
)
-
st
t
Then the output “y” is related to the input signal “x” by the transfer function g(s) as
[0000] Y ( s )= g ( s ) X ( s ) And the transfer function itself is therefore
[0000]
g
(
s
)
=
Y
(
s
)
X
(
s
)
[0039] First to highlight the benefits of the inventive two-sensor and signal processing technique, we present a brief overview of the issues involved in attempting to measure NOx using only a single sensor with a typical response as shown in equation (1). Since only a single sensor is available, then we can write the signal processing logic as the scalar function as indicated by equation (2) below:
[0000] z 1 ( t )= h 11 ( s ) y 1 ( t ) (2)
[0040] where h 11 (s) represents a signal processing filter. Then assuming that we want to obtain an estimate of the NO x in the tailpipe, we will require that z 1 ≈w 1 over the frequency range of interest. Then combining the signal processing algorithm in equation (2) with the sensor response equation (1), we find that satisfying z 1 =w 1 requires h 11 (jω)=g 11 (jω) −1 and g 12 (jω)=0. The requirement of h 11 (jω)=g 11 (jω) −1 is a straightforward signal processing design requirement. But on the other hand, the requirement that g 12 (jω)=0 means that one must impose the very demanding requirement of zero-cross-sensitivity on the sensor hardware itself. Constructing a sensor with negligible cross-sensitivities is well-known to be more challenging and expensive than permitting some cross-sensitivities.
[0041] With this in mind, now consider the inventive technique of adding a second sensor of dissimilar sensitivities to NO x and NH 3 . Analogous to the discussion on NO x sensing, the second sensor 250 response can be provided as given by a similar linear dynamical relationship as indicated by equation (3) below:
[0000] y 2 ( t )= g 21 ( s ) w 1 ( t )+ g 22 ( s ) w 2 ( t ) (3)
[0042] where g 21 represents the frequency response of sensors 245 and 250 to NO x and g 22 represents the response of sensors 245 and 250 to NH 3 .
[0043] The two sensor responses as shown in equation (1) and (3) can be combined into a single equation as follows:
[0000]
[
y
1
(
t
)
y
2
(
t
)
]
=
[
g
11
(
s
)
g
12
(
s
)
g
21
(
s
)
g
22
(
s
)
]
[
w
1
(
t
)
w
2
(
t
)
]
(
5
)
[0044] Next, consider designing a multivariable signal processing algorithm from the raw sensor signals measured as shown in equation (2) and (4):
[0000]
[
z
1
(
t
)
z
2
(
t
)
]
=
[
h
11
(
s
)
h
12
(
s
)
h
21
(
s
)
h
22
(
s
)
]
[
y
1
(
t
)
y
2
(
t
)
]
(
6
)
[0045] Then in order to design the 2-by-2 transfer matrix for a signal processing filter H(s) such that z 1 =w 1 and z 2 =w 2 , the sensors 245 and 250 response G(s) to NO x and NH 3 need to be invertible in the frequency range of interest. (The frequency response of a stable transfer function such as (6) may be obtained by substituting s=jω where ω represents the frequency and j=√{square root over (−1)}.) This leads to a much milder requirement on the sensors 245 and 250 cross-sensitivities than for a single sensor. Using two sensors leads to the much easier condition can be applied as shown in equation (7) over the frequency range of interest.
[0000] g 11 ( s ) g 22 ( s )≠ g 21 ( s ) g 12 ( s ) (7)
[0000] which represents a strict mathematical condition for the invertibility of the transfer matrix in G(s) in (5). A practical extension of the condition would necessarily require that the matrix be well-conditioned in addition to invertible. In other words, that the condition number of the interaction matrix G(s) in (5) (defined as the ratio between the maximum and minimum singular values) satisfies,
[0000]
cond
(
G
(
j
ω
)
)
≡
σ
_
(
G
(
jω
)
)
σ
_
(
G
(
jω
)
)
∞
(
8
)
[0000] for all frequencies |ω|<ω c . Where ω c represents the highest frequency of interest.
[0046] Which does not require zero cross-sensitivities in either of the two sensors, and can still produce estimates of both NO x and NH 3 . Thus combining the information provided by two sensors of dissimilar sensitivities allows obtains more information than could have been obtained by separate analysis of both sensors in isolation.
[0047] From equation (7) it becomes mathematically possible to design H(s) as a decoupling observer algorithm by designing H(jω)≈G(jω) −1 in equation (6). For linear systems, there are many fairly standard techniques for design of decoupling observer algorithm H(s) with respect to the sensor characteristics G(s). The transfer matrix norm-based techniques for design of decoupling observer algorithm denoted by transfer matrix H(s) with respect to the sensor characteristics modeled by transfer matrix G(s) are depicted in equation (9) and (10).
[0000]
H
∞
norm
min
I
-
H
(
s
)
stable
H
(
s
)
G
(
s
)
∞
(
9
)
H
2
norm
min
I
-
H
(
s
)
stable
H
(
s
)
G
(
s
)
2
(
10
)
[0048] More complex techniques also exist for nonlinear systems.
[0049] FIG. 3 illustrates a schematic diagram of a closed-loop SCR control system 300 based on an intelligent sensor configuration for simultaneously measuring NO x and NH 3 in accordance with an alternative embodiment. Note that in FIGS. 1-4 , identical or similar parts or elements are generally indicated by identical reference numerals. Additionally, it can be appreciated that although properties such as NO x and NH 3 can be measured according to the method and system disclosed herein, other properties such as the temperature of an exhaust gas mixture can also be measured, in addition concentrations of various gases associated with the exhaust gas mixture. The feature applies equally to all embodiments disclosed herein.
[0050] The intelligent sensor configuration of system 300 contains the same functional blocks as in the ECM configuration 200 as shown in FIG. 2 . The difference between the configurations of FIGS. 2 and 3 lies in the packaging arrangement. The intelligent sensor or system 300 produces NO x and NH 3 estimates, which can potentially be used in the context of the third party SCR control algorithm 210 described above
[0051] Referring to FIG. 4 , a schematic diagram of a closed-loop SCR control system 400 based on an intelligent sensor configuration for on board diagnostics (OBD) 410 for simultaneously measuring NO x and NH 3 , is illustrated, in accordance with an alternative embodiment. Note that in FIGS. 1-4 , identical or similar parts or elements are generally indicated by identical reference numerals. Tailpipe emissions indicated by arrow 255 can be monitored by the OBD unit 410 on a continual basis. NO x level monitoring can also accomplish monitoring of the presence of urea in the system.
[0052] The OBD 410 can support actions such as warning the operator when urea tank (not shown) levels are low, which will trigger an enforcement action if the urea tank is empty or near empty. Additionally, a triggering warning and enforcement action may occur if fluid other than urea is filled into the urea tank and detected by a urea concentration or ammonia sensor. In such a situation, an alert can be provided warning the operator and/or triggering enforcement action if the NO x levels exceed a particular threshold or limits. Enforcement actions of increasing severity can be triggered depending upon the duration of high NO x levels.
[0000] It will be obvious to those skilled in the art that the method disclosed herein can be extended for use by combining N sensors, each with different sensitivities, to separately estimate the levels of N different chemical species. For example, consider N=3 in diesel exhaust, wherein three sensors of dissimilar sensitivities to NO, NO 2 and NH 3 are combined. In such a case, signal processing logic could be designed by the method described above to provide estimates of the amounts NO, NO 2 , and NH 3 species in the exhaust. There are many applications (including the operation of SCR aftertreatment devices) in which understanding NOx in terms of its constituent NO and NO 2 components would be valuable.
[0053] Referring to FIG. 5 , a high-level flow chart of operations illustrating logical operational steps of a method 500 for the simultaneous measurement of NO x and ammonia in diesel exhaust is illustrated, in accordance with a preferred embodiment. The sources of ammonia (e.g., usually urea) can be injected into an exhaust gas path 240 , as depicted at block 510 . Thereafter, as indicated at block 520 , ammonia can be adsorbed onto the catalytic surface 230 , which reacts with NO x in order to form harmless N 2 and H 2 O. Two sensors 245 and 250 having dissimilar sensitivities and cross-sensitivities to NO x and NH 3 can be combined, as shown at block 530 . Next, as described at block 540 , the cross-sensitivities of NO x and NH 3 can be decoupled and measured using the previously described decoupling observer algorithm 220 . An appropriate amount of urea can be commanded using an SCR control algorithm 210 , as depicted at block 550 , which is then used to inject a source of ammonia into the exhaust gas path.
[0054] It can be appreciated that a variety of alternative embodiments can be implemented in accordance with the methods and systems described herein. For example, one alternative embodiment can utilize simultaneous NO x and NH 3 measurements in the feedback control of an aftertreatment device with active ammonia dosing. SCR is the most common example of such aftertreatment devices. Such configurations and related methods thereof are preferably independent of the cross-sensitivities and decoupling algorithms discussed previously. Such a situation addresses the problem where for example, an NO x sensor and an NH 3 sensor do not possess significant cross-sensitivities.
[0055] The overall concept disclosed herein is actually general in nature. The embodiments discussed herein have been described in the context of the two properties NO x and NH 3 , but the disclosed invention can be extended to consider N sensors of dissimilar cross-sensitivities to N different physical properties in diesel exhaust. A few specific examples include:
[0056] With N=3 one can measure NO, NO 2 and NH 3 . An aftertreatment device can benefit from additional implementations regarding the partitioning of NO x into its constituent NO and NO 2 . For example, the response and effectiveness of an SCR aftertreatment device is strongly dependant on the ratio of NO to NO 2 in the exhaust NO x .
[0057] With N=3 again, consider measuring NO x and NH 3 and decoupling cross-sensitivity to Temperature. The decoupling of temperature sensitivity is a crucial issue in practically all sensor design problems.
[0058] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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A method for simultaneously measuring one or more properties (e.g. temperature, concentration of NO x and ammonia, etc) in an exhaust gas mixture. Signals from one or more sensors that are cross-sensitive to one or more gases can be combined. A decoupling observer algorithm can be applied, such that these cross-sensitivities are decoupled. The sensors simultaneously obtain an estimate of one or more gases in the diesel exhaust. A decoupling observer algorithm can be structured and arranged to be operable among a plurality of positions corresponding to several internal configurations.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the fields of biology and chemistry where a number of sample containers need to be kept on ice in an organized fashion.
[0003] 2. Description of the Prior Art
[0004] In the field of biological or chemical sciences there is often a need to maintain the temperature of a sample close to 0° C. To accomplish this, containers of various shapes and sizes (e.g. test tubes, beakers, etc.) which contain the samples are manually forced into crushed or chipped ice. The chipped or crushed ice stably keeps the temperature of a sample just above freezing for long periods of time. However, in the process of forcing a container into crushed ice, several undesired things can happen. First, loose pieces of ice can be dislodged and fall into open containers. Second, containers tend to enter the ice on an axis which is not perfectly vertical, potentially causing spillage and taking up more space than necessary. Third, large numbers of samples are difficult to organize, which can cause confusion about sample identity and mistakes. Fourth, very small containers, which can be as small as a single piece of crushed ice, are easily buried.
[0005] Alternative methods for keeping samples close to the freezing point have been developed. These include frozen, fluid filled or solid blocks, fashioned with slots or holes that accept containers of specific sizes. This method has several drawbacks. First, the total number of samples held is pre-determined by the number of available positions (i.e. it is possible to run out of space). Second, once the block has warmed it must be cooled in a freezer, which may take several hours. Third, the frozen block needs to be of significant size in order not to warm too rapidly. This uses up valuable space in a freezer.
[0006] Another alternative method for keeping samples organized and cold involves a thin flat piece of foamed plastic which contains holes and is laid on top of a bed of crushed ice. Containers are pushed through the holes into the crushed ice on the other side. This method has one of the previous drawbacks: it predetermines the number of samples which can be held at one time. Another drawback is that the container is held by the foam, so the container could be held above the ice, rather than in it, causing inadequate cooling. Finally, removing a tube from the foam sheet requires the use of two hands. One hand is used to pull out the tube and the other to hold the foam sheet down so as not to dislodge all remaining tubes from the ice.
BRIEF SUMMARY OF THE INVENTION
[0007] It is the object of this invention to keep biological or chemical samples cooled in crushed or chipped ice while at the same time minimizing effort and maintaining sample organization.
[0008] The structure of this invention is a mold with a hard flat surface, to which are attached multiple vertical spikes arranged in a grid pattern. Each spike has the approximate shape and size of the containers which will hold samples (for example, with the shape of a 1.5 mL Eppendorf tube). The spiked side of the mold is then driven down into a container of crushed or chipped ice, forcing the ice to take the shape of the mold. At the same time, the hard flat surface to which the spikes are attached forces loose pieces of ice to form a flat uniform surface. A handle on the top of mold can then be used to remove it from the ice. The result is that the surface of the crushed ice is molded into a flat surface containing pits, into which sample containers fit perfectly.
[0009] This overcomes the problems of using crushed ice alone as described earlier. First, after being molded, the crushed ice does not have any loose pieces which can fall into open containers. Second, the invention optimizes space by making a uniform pattern of pits for sample containers to sit in. Third, the uniform pattern of pits facilitates organization of sample containers. And lastly, with a uniform flat surface between the pits, small containers are not easily buried.
[0010] This invention also overcomes the disadvantages of using frozen blocks and foam covers. First, there is no limit to the number of samples held. The invention can be used in multiple places in a single container of crushed ice, creating multiple zones of organized pits for samples. Second, the invention does not ever have to be frozen. This saves freezer space by eliminating the need for frozen blocks. Third, crushed ice is normally always available, and there is no need to wait for a sample block to refreeze after thawing. Fourth, a container sitting in a molded pit is completely in contact with ice, ensuring even cooling. And finally, the containers sitting in the molded ice pits can be easily placed and removed with one hand.
[0011] The preferred embodiment of this invention utilizes spikes of the shape and size of a standard 1.5 mL Eppendorf tube, however, the invention is not limited by any particular shape or size. Any shaped or sized spikes can be obviously substituted, as well as any shaped or sized flat surface. The number of spikes contained on the flat surface can be obviously changed to accommodate the need for a greater or lesser number of pits. The grid pattern created in the ice by the mold can obviously be modified to any kind of pattern. The design of the invention is so simple that it can be made from a wide range of material (e.g. plastic or metal).
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a side view of the invention.
[0013] FIG. 2 illustrates a view of the invention from the side and slightly above.
[0014] FIG. 3 illustrates a view of the invention from below and on an angle.
[0015] FIG. 4 illustrates a view of the invention from above and on an angle.
[0016] FIG. 5 illustrates a view of the invention from directly below.
[0017] FIG. 6 illustrates a view of the invention from directly above.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 illustrates a side view of the preferred embodiment of this invention showing the handle 10 , the flat surface 12 , and the spikes 14 . The invention would be used by firmly pressing the spikes 14 into crushed or chipped ice until the ice reaches the flat surface 12 . The invention would then be removed by grasping the handle 10 and pulling the invention out of the ice. The pits made in the ice by the spikes 14 will be the approximate the size of the spikes 14 . In this embodiment the spikes 14 would make a pit approximately the size of a 1.5 mL Eppendorf tube. The grid pattern of the spikes 14 would form a grid of pits in the crushed ice. In this embodiment spikes 14 are lined in a four by four grid pattern, totaling sixteen spikes 14 . When the flat surface 12 reaches the crushed ice it will force the surface of the ice to flatten. Upon removal of the invention from the ice, the ice surface would be flat.
[0019] FIG. 2 illustrates the same preferred embodiment as in FIG. 1 , however, the view is from the side and above. The handle 10 , the flat surface 12 , and spikes 14 can be seen.
[0020] FIG. 3 illustrates the same preferred embodiment as in FIG. 1 , however, this view is seen from below and slightly rotated. The flat surface 12 and spikes 14 can be seen with this view.
[0021] FIG. 4 illustrates the same preferred embodiment as seen in FIG. 1 , however, this view is from above and slightly rotated. The handle 10 , the flat surface 12 , and spikes 14 can be seen.
[0022] FIG. 5 illustrates the same preferred embodiment as seen in FIG. 1 , however, this view is from directly beneath the invention. The flat surface 12 and the spikes 14 can be seen.
[0023] FIG. 6 illustrates the same preferred embodiment as seen in FIG. 1 , however, the view is from directly above the invention. The handle 10 and flat surface 12 can be seen.
BACKGROUND OF THE INVENTION
[0024] 1. Field of the Invention
[0025] This invention relates to the fields of biology and chemistry where a number of sample containers need to be kept on ice in an organized fashion.
[0026] 2. Description of the Prior Art
[0027] In the field of biological or chemical sciences there is often a need to maintain the temperature of a sample close to 0° C. To accomplish this, containers of various shapes and sizes (e.g. test tubes, beakers, etc.) which contain the samples are manually forced into crushed or chipped ice. The chipped or crushed ice stably keeps the temperature of a sample just above freezing for long periods of time. However, in the process of forcing a container into crushed ice, several undesired things can happen. First, loose pieces of ice can be dislodged and fall into open containers. Second, containers tend to enter the ice on an axis which is not perfectly vertical, potentially causing spillage and taking up more space than necessary. Third, large numbers of samples are difficult to organize, which can cause confusion about sample identity and mistakes. Fourth, very small containers, which can be as small as a single piece of crushed ice, are easily buried.
[0028] Alternative methods for keeping samples close to the freezing point have been developed. These include frozen, fluid filled or solid blocks, fashioned with slots or holes that accept containers of specific sizes. This method has several drawbacks. First, the total number of samples held is pre-determined by the number of available positions (i.e. it is possible to run out of space). Second, once the block has warmed it must be cooled in a freezer, which may take several hours. Third, the frozen block needs to be of significant size in order not to warm too rapidly. This uses up valuable space in a freezer.
[0029] Another alternative method for keeping samples organized and cold involves a thin flat piece of foamed plastic which contains holes and is laid on top of a bed of crushed ice. Containers are pushed through the holes into the crushed ice on the other side. This method has one of the previous drawbacks: it predetermines the number of samples which can be held at one time. Another drawback is that the container is held by the foam, so the container could be held above the ice, rather than in it, causing inadequate cooling. Finally, removing a tube from the foam sheet requires the use of two hands. One hand is used to pull out the tube and the other to hold the foam sheet down so as not to dislodge all remaining tubes from the ice.
BRIEF SUMMARY OF THE INVENTION
[0030] It is the object of this invention to keep biological or chemical samples cooled in crushed or chipped ice while at the same time minimizing effort and maintaining sample organization.
[0031] The structure of this invention is a mold with a hard flat surface, to which are attached multiple vertical spikes arranged in a grid pattern. Each spike has the approximate shape and size of the containers which will hold samples (for example, with the shape of a 1.5 mL Eppendorf tube). The spiked side of the mold is then driven down into a container of crushed or chipped ice, forcing the ice to take the shape of the mold. At the same time, the hard flat surface to which the spikes are attached forces loose pieces of ice to form a flat uniform surface.
[0032] A handle on the top of mold can then be used to remove it from the ice. The result is that the surface of the crushed ice is molded into a flat surface containing pits, into which sample containers fit perfectly.
[0033] This overcomes the problems of using crushed ice alone as described earlier. First, after being molded, the crushed ice does not have any loose pieces which can fall into open containers. Second, the invention optimizes space by making a uniform pattern of pits for sample containers to sit in. Third, the uniform pattern of pits facilitates organization of sample containers. And lastly, with a uniform flat surface between the pits, small containers are not easily buried.
[0034] This invention also overcomes the disadvantages of using frozen blocks and foam covers. First, there is no limit to the number of samples held. The invention can be used in multiple places in a single container of crushed ice, creating multiple zones of organized pits for samples. Second, the invention does not ever have to be frozen. This saves freezer space by eliminating the need for frozen blocks. Third, crushed ice is normally always available, and there is no need to wait for a sample block to refreeze after thawing. Fourth, a container sitting in a molded pit is completely in contact with ice, ensuring even cooling. And finally, the containers sitting in the molded ice pits can be easily placed and removed with one hand.
[0035] The preferred embodiment of this invention utilizes spikes of the shape and size of a standard 1.5 mL Eppendorf tube, however, the invention is not limited by any particular shape or size. Any shaped or sized spikes can be obviously substituted, as well as any shaped or sized flat surface. The number of spikes contained on the flat surface can be obviously changed to accommodate the need for a greater or lesser number of pits. The grid pattern created in the ice by the mold can obviously be modified to any kind of pattern. The design of the invention is so simple that it can be made from a wide range of material (e.g. plastic or metal).
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 illustrates a side view of the invention.
[0037] FIG. 2 illustrates a view of the invention from the side and slightly above.
[0038] FIG. 3 illustrates a view of the invention from below and on an angle.
[0039] FIG. 4 illustrates a view of the invention from above and on an angle.
[0040] FIG. 5 illustrates a view of the invention from directly below.
[0041] FIG. 6 illustrates a view of the invention from directly above.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 1 illustrates a side view of the preferred embodiment of this invention showing the handle 10 , the flat surface 12 , and the spikes 14 . The invention would be used by firmly pressing the spikes 14 into crushed or chipped ice until the ice reaches the flat surface 12 . The invention would then be removed by grasping the handle 10 and pulling the invention out of the ice. The pits made in the ice by the spikes 14 will be the approximate the size of the spikes 14 . In this embodiment the spikes 14 would make a pit approximately the size of a 1.5 mL Eppendorf tube. The grid pattern of the spikes 14 would form a grid of pits in the crushed ice. In this embodiment spikes 14 are lined in a four by four grid pattern, totaling sixteen spikes 14 . When the flat surface 12 reaches the crushed ice it will force the surface of the ice to flatten. Upon removal of the invention from the ice, the ice surface would be flat.
[0043] FIG. 2 illustrates the same preferred embodiment as in FIG. 1 , however, the view is from the side and above. The handle 10 , the flat surface 12 , and spikes 14 can be seen.
[0044] FIG. 3 illustrates the same preferred embodiment as in FIG. 1 , however, this view is seen from below and slightly rotated. The flat surface 12 and spikes 14 can be seen with this view.
[0045] FIG. 4 illustrates the same preferred embodiment as seen in FIG. 1 , however, this view is from above and slightly rotated. The handle 10 , the flat surface 12 , and spikes 14 can be seen.
[0046] FIG. 5 illustrates the same preferred embodiment as seen in FIG. 1 , however, this view is from directly beneath the invention. The flat surface 12 and the spikes 14 can be seen.
[0047] FIG. 6 illustrates the same preferred embodiment as seen in FIG. 1 , however, the view is from directly above the invention. The handle 10 and flat surface 12 can be seen.
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A structure and method for molding crushed or chipped ice to hold a number of sample containers comprised of spikes in the shape of a desired container, a flat surface to level the crushed or chipped ice, and a handle for easy removal from ice. Pressing into and then removing the invention from crushed or chipped ice results in an imprint of the spikes and flat surface. The pits formed in the ice by the spikes can be used to hold sample containers.
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[0001] The instant invention relates to liquid compositions comprising derivatives of diaminostilbene, binders and divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing.
BACKGROUND OF THE INVENTION
[0002] Ink jet printing has in recent years become a very important means for recording data and images onto a paper sheet. Low costs, easy production of multicolour images and relatively high speed are some of the advantages of this technology. Ink jet printing does however place great demands on the substrate in order to meet the requirements of short drying time, high print density and sharpness, and reduced colour-to-colour bleed. Furthermore, the substrate should have a high brightness. Plain papers for example are poor at absorbing the water-based anionic dyes or pigments used in ink jet printing; the ink remains for a considerable time on the surface of the paper which allows diffusion of the ink to take place and leads to low print sharpness. One method of achieving a short drying time while providing high print density and sharpness is to use special silica-coated papers. Such papers however are expensive to produce.
[0003] U.S. Pat. No. 6,207,258 provides a partial solution to this problem by disclosing that pigmented ink jet print quality can be improved by treating the substrate surface with an aqueous sizing medium containing a divalent metal salt. Calcium chloride and magnesium chloride are preferred divalent metal salts. The sizing medium may also contain other conventional paper additives used in treating uncoated paper. Included in conventional paper additives are optical brightening agents (OBAs) which are well known to improve considerably the whiteness of paper and thereby the contrast between the ink jet print and the background. U.S. Pat. No. 6,207,258 offers no examples of the use of optical brightening agents with the invention.
[0004] WO 2007/044228 claims compositions including an alkenyl succinic anhydride sizing agent and/or an alkyl ketene dimmer sizing agent, and incorporating a metallic salt. No reference is made to the use of optical brightening agents with the invention.
[0005] WO 2008/048265 claims a recording sheet for printing comprising a substrate formed from ligno cellulosic fibres of which at least one surface is treated with a water soluble divalent metal salt. The recording sheet exhibits an enhanced image drying time. Optical brighteners are included in a list of optional components of a preferred surface treatment comprising calcium chloride and one or more starches. No examples are provided of the use of optical brighteners with the invention.
[0006] WO 2007/053681 describes a sizing composition that, when applied to an ink jet substrate, improves print density, colour-to-colour bleed, print sharpness and/or image dry time. The sizing composition comprises at least one pigment, preferably either precipitated or ground calcium carbonate, at least one binder, one example of which is a multicomponent system including starch and polyvinyl alcohol, at least one nitrogen containing organic species, preferably a polymer or copolymer of diallyldimethyl ammonium chloride (DADMAC), and at least one inorganic salt. The sizing composition may also contain at least one optical brightening agent, examples of which are Leucophor BCW and Leucophor FTS from Clariant.
[0007] The advantages of using a divalent metal salt, such as calcium chloride, in substrates intended for pigmented ink jet printing can only be fully realized when a compatible water-soluble optical brightener becomes available. It is well-known however that water-soluble optical brighteners are prone to precipitation in high calcium concentrations. (See, for example, page 50 in Tracing Technique in Geohydrology by Werner Käss and Horst Behrens, published by Taylor & Francis, 1998.)
[0008] Accordingly, there is a need for a water-soluble optical brightener which has good compatibility with sizing compositions containing a divalent metal salt.
DESCRIPTION OF THE INVENTION
[0009] It has now been found that optical brighteners of formula (1) have surprisingly good compatibility with sizing compositions containing a divalent metal salt.
[0010] The present invention therefore provides a sizing composition for optical brightening of substrates, preferably paper, which is especially suitable for pigmented ink jet printing, comprising
(a) at least one binder; (b) at least one divalent metal salt, the at least one divalent metal salt being selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium iodide, magnesium iodide, calcium nitrate, magnesium nitrate, calcium formate, magnesium formate, calcium acetate, magnesium acetate, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds; (c) water, and (d) at least one optical brightener of formula (1)
[0000] [M + ] n [X + ] 6-n
[0000] in which
M and X are identical or different and independently from each other selected from the group consisting of hydrogen, an alkali metal cation, ammonium, ammonium which is mono-, di- or trisubstituted by a C1-C4 linear or branched alkyl radical, ammonium which is mono-, di- or trisubstituted by a C1-C4 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0017] Preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of an alkali metal cation and trisubstituted C1-C4 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0020] More preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of Li, Na, K and trisubstituted C1-C3 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0023] Especially preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of Na, K and triethanolamine, or mixtures of said compounds and n is in the range from 0 to 6.
[0026] The concentration of optical brightener in the sizing composition may be between 0.2 and 30 g/l, preferably between 1 and 15 g/l, most preferably between 2 and 12 g/l.
[0027] The binder is typically an enzymatically or chemically modified starch, e.g. oxidized starch, hydroxyethylated starch or acetylated starch. The starch may also be native starch, anionic starch, a cationic starch, or an amphipathic depending on the particular embodiment being practiced. While the starch source may be any, examples of starch sources include corn, wheat, potato, rice, tapioca, and sago. One or more secondary binders e.g. polyvinyl alcohol may also be used.
[0028] The concentration of binder in the sizing composition may be between 1 and 30% by weight, preferably between 2 and 20% by weight, most preferably between 5 and 15% by weight.
[0029] Preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds.
[0030] Even more preferred divalent metal salts are selected from the group consisting of calcium chloride or magnesium chloride or mixtures of said compounds.
[0031] The concentration of divalent metal salt in the sizing composition may be between 1 and 100 g/l, preferably between 2 and 75 g/l, most preferably between 5 and 50 g/l.
[0032] When the divalent metal salt is a mixture of a calcium salt and a magnesium salt, the amount of calcium salt may be in the range of 0.1 to 99.9%.
[0033] The pH value of the sizing composition is typically in the range of 5-13, preferably 6-11.
[0034] In addition to one or more binders, one or more divalent metal salts, one or more optical brighteners and water, the sizing composition may contain by-products formed during the preparation of the optical brightener as well as other conventional paper additives. Examples of such additives are carriers, defoamers, wax emulsions, dyes, inorganic salts, solubilizing aids, preservatives, complexing agents, surface sizing agents, cross-linkers, pigments, special resins etc.
[0035] In an additional aspect of the invention, the optical brightener may be pre-mixed with polyvinyl alcohol in order to boost the performance of the optical brightener in sizing compositions. The polyvinyl alcohol may have any hydrolysis level including from 60 to 99%. The optical brightener/polyvinyl alcohol mixture may contain any amount of optical brightener and polyvinyl alcohol. Examples of making optical brightener/polyvinyl alcohol mixtures can be found in WO 2008/017623.
[0036] The optical brightener/polyvinyl alcohol mixture may be an aqueous mixture.
[0037] The optical brightener/polyvinyl alcohol mixture may contain any amount of optical brightener including from 10 to 50% by weight of at least one optical brightener. Further, the optical brightener/polyvinyl alcohol mixture may contain any amount of polyvinyl alcohol including from 0.1 to 10% by weight of polyvinyl alcohol.
[0038] The sizing composition may be applied to the surface of a paper substrate by any surface treatment method known in the art. Examples of application methods include size-press applications, calendar size application, tub sizing, coating applications and spraying applications. (See, for example, pages 283-286 in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992 and US 2007/0277950.) The preferred method of application is at the size-press such as puddle size press or rod-metered size press. A preformed sheet of paper is passed through a two-roll nip which is flooded with the sizing composition. The paper absorbs some of the composition, the remainder being removed in the nip.
[0039] The paper substrate contains a web of cellulose fibres which may be synthetic or sourced from any fibrous plant including woody and nonwoody sources. Preferably the cellulose fibres are sourced from hardwood and/or softwood. The fibres may be either virgin fibres or recycled fibres, or any combination of virgin and recycled fibres.
[0040] The cellulose fibres contained in the paper substrate may be modified by physical and/or chemical methods as described, for example, in Chapters 13 and 15 respectively in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992. One example of a chemical modification of the cellulose fibre is the addition of an optical brightener as described, for example, in EP 884,312, EP 899,373, WO 02/055646, WO 2006/061399, WO 2007/017336, WO 2007/143182, US 2006-0185808, and US 2007-0193707.
[0041] The sizing composition is prepared by adding the optical brightener (or optical brightener/polyvinyl alcohol mixture) and the divalent metal salt to a preformed aqueous solution of the binder at a temperature of between 20° C. and 90° C. Preferably the divalent metal salt is added before the optical brightener (or optical brightener/polyvinyl alcohol mixture), and at a temperature of between 50° C. and 70° C.
[0042] The paper substrate containing the sizing composition and of the present invention may have any ISO brightness, including ISO brightness that is at least 80, at least 90 and at least 95.
[0043] The paper substrate of the present invention may have any CIE Whiteness, including at least 130, at least 146, at least 150, and at least 156. The sizing composition has a tendency to enhance the CIE Whiteness of a sheet as compared to conventional sizing compositions containing similar levels of optical brighteners.
[0044] The sizing composition of the present invention has a decreased tendency to green a sheet to which it has been applied as compared to that of conventional sizing compositions containing comparable amounts of optical brighteners. Greening is a phenomenon related to saturation of the sheet such that a sheet does not increase in whiteness even as the amount of optical brightener is increased. The tendency to green is measured is indicated by from the a*-b* diagram, a* and b* being the colour coordinates in the CIE Lab system. Accordingly, the sizing composition of the present invention affords the user the ability to efficiently increase optical brightener concentrations on the paper in the presence of a divalent metal ion without reaching saturation, while at the same time maintaining or enhancing the CIE Whiteness and ISO Brightness of the paper.
[0045] While the paper substrates of the present invention show enhanced properties suitable for inkjet printing, the substrates may also be used for multi-purpose and laserjet printing as well. These applications may include those requiring cut-size paper substrates, as well as paper roll substrates.
[0046] The paper substrate of the present invention may contain an image. The image may be formed on the substrate with any substance including dye, pigment and toner.
[0047] Once the image is formed on the substrate, the print density may be any optical print density including an optical print density that is at least 1.0, at least 1.2, at least 1.4, at least 1.6. Methods of measuring optical print density can be found in EP 1775141.
[0048] The preparation of a compound of formula (1) in which M=Na and n=6 has been described previously in WO 02/060883 and WO 02/077106. No examples have been provided of the preparation of a compound of formula (1) in which M≠X and n<6.
[0049] The compounds of formula (1) are prepared by stepwise reaction of a cyanuric halide with
[0000] a) an amine of formula
[0000]
[0000] in the free acid, partial- or full salt form,
(b) a diamine of formula
[0000]
in the free acid, partial- or full salt form,
and
c) diisopropanolamine of formula
[0000]
[0051] As a cyanuric halide there may be employed the fluoride, chloride or bromide. Cyanuric chloride is preferred.
[0052] Each reaction may be carried out in an aqueous medium, the cyanuric halide being suspended in water, or in an aqueous/organic medium, the cyanuric halide being dissolved in a solvent such as acetone. Each amine may be introduced without dilution, or in the form of an aqueous solution or suspension. The amines can be reacted in any order, although it is preferred to react the aromatic amines first. Each amine may be reacted stoichiometrically, or in excess. Typically, the aromatic amines are reacted stoichimetrically, or in slight excess; diisopropanolamine is generally employed in an excess of 5-30% over stoichiometry.
[0053] For substitution of the first halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 0 to 20° C., and under acidic to neutral pH conditions, preferably in the pH range of 2 to 7. For substitution of the second halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 20 to 60° C., and under weakly acidic to weakly alkaline conditions, preferably at a pH in the range of 4 to 8. For substitution of the third halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 60 to 102° C., and under weakly acidic to alkaline conditions, preferably at a pH in the range of 7 to 10.
[0054] The pH of each reaction is generally controlled by addition of a suitable base, the choice of base being dictated by the desired product composition. Preferred bases are, for example, alkali metal (e.g., lithium, sodium or potassium) hydroxides, carbonates or bicarbonates, or aliphatic tertiary amines e.g. triethanolamine or triisopropanolamine. Where a combination of two or more different bases is used, the bases may be added in any order, or at the same time.
[0055] Where it is necessary to adjust the reaction pH using acid, examples of acids that may be used include hydrochloric acid, sulphuric acid, formic acid and acetic acid.
[0056] Aqueous solutions containing one or more compounds of general formula (1) may optionally be desalinated either by membrane filtration or by a sequence of precipitation followed by solution using an appropriate base.
[0057] The preferred membrane filtration process is that of ultrafiltration using, e.g., polysulphone, polyvinylidenefluoride, cellulose acetate or thin-film membranes.
EXAMPLES
[0058] The following examples shall demonstrate the instant invention in more details. If not indicated otherwise, “parts” means “parts by weight” and “%” means “% by weight”.
Example 1
[0059] Stage 1:
[0060] 31.4 parts of aniline-2,5-disulphonic acid monosodium salt are added to 150 parts of water and dissolved with the aid of an approx. 30% sodium hydroxide solution at approx. 25° C. and a pH value of approx. 8-9. The obtained solution is added over a period of approx. 30 minutes to 18.8 parts of cyanuric chloride dispersed in 30 parts of water, 70 parts of ice and 0.1 part of an antifoaming agent. The temperature is kept below 5° C. using an ice/water bath and if necessary by adding ice into the reaction mixture. The pH is maintained at approx. 4-5 using an approx. 20% sodium carbonate solution. At the end of the addition, the pH is increased to approx. 6 using an approx. 20% sodium carbonate solution and stirring is continued at approx. 0-5° C. until completion of the reaction (3-4 hours).
[0061] Stage 2:
[0062] 8.8 parts of sodium bicarbonate are added to the reaction mixture. An aqueous solution, obtained by dissolving under nitrogen 18.5 parts of 4,4′-diaminostilbene-2,2′-disulphonic acid in 80 parts of water with the aid of an approx. 30% sodium hydroxide solution at approx. 45-50° C. and a pH value of approx. 8-9, is dropped into the reaction mixture. The resulting mixture is heated at approx. 45-50° C. until completion of the reaction (3-4 hours).
[0063] Stage 3:
[0064] 17.7 parts of Diisopropanolamine are then added and the temperature is gradually raised to approx. 85-90° C. and maintained at this temperature until completion of the reaction (2-3 hours) while keeping the pH at approx. 8-9 using an approx. 30% sodium hydroxide solution. The temperature is then decreased to 50° C. and the reaction mixture is filtered and cooled down to room temperature. The solution is adjusted to strength to give an aqueous solution of a compound of formula (1) in which M=X=Na and n=6 (0.125 mol/kg, 17.8%).
Example 2
[0065] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 4.5≦n≦5.5 (0.125 mol/kg, approx. 18.0%) is obtained following the same procedure as in Example 1 with the sole difference that an approx. 30% potassium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stage 3.
Example 3
[0066] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 2.5≦n≦4.5 (0.125 mol/kg, approx. 18.3%) is obtained following the same procedure as in Example 1 with the sole differences that 10 parts of potassium bicarbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2 and an approx. 30% potassium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stages 2 and 3.
Example 4
[0067] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 (0.125 mol/kg, approx. 18.8%) is obtained following the same procedure as in Example 1 with the sole differences that an approx. 30% potassium hydroxide solution is used in place of an approx. 30% sodium hydroxide solution in Stages 1, 2 and 3, an approx. 20% potassium carbonate solution is used instead of an approx. 20% sodium carbonate solution in Stage 1, and 10 parts of potassium bicarbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2.
Example 5
[0068] An aqueous solution of a compound of formula (1) in which M=Na, X=Li and 4.5≦n≦5.9 (0.125 mol/kg, approx. 17.7%) is obtained following the same procedure as in Example 1 with the sole difference that an approx. 10% lithium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stage 3.
Example 6
[0069] An aqueous solution of a compound of formula (1) in which M=Na, X=Li and 2.5≦n≦4.5 (0.125 mol/kg, approx. 17.3%) is obtained following the same procedure as in Example 1 with the sole differences that 3.7 parts of lithium carbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2 and an approx. 10% lithium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stages 2 and 3.
Example 7
[0070] A compound of formula (1) in which M=H is isolated by precipitation with concentrated hydrochloric acid of the concentrated solution of the compound of formula (1) obtained in Example 1, followed by filtration. The presscake is then dissolved in an aqueous solution of 7 equivalents of triethanolamine to give an aqueous solution of a compound of formula (1) in which M=Na, X=triethanolammonium and 1≦n≦3 (0.125 mol/kg, approx. 24.2%).
Example 8
[0071] Optical brightening solution 8 is produced by stirring together
an aqueous solution containing compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 prepared according to example 4, a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s and water
while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0075] The parts of each component are selected in order to get a final aqueous solution 8 comprising a compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 prepared according to example 4 at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution 8 is in the range 8-9.
Application Examples 1 to 8
[0076] Sizing compositions are prepared by adding an aqueous solution of a compound of formula (1) prepared according to Examples 1 to 8 at a range of concentrations from 0 to 50 g/l (from 0 to approx. 12.5 g/l of optical brightener) to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
[0077] The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
Comparative Example 1
[0078] Sizing compositions are prepared by adding an aqueous solution of the Hexasulfo-compound disclosed in the table on page 8 of the US 2005/0124755 A1 at a range of concentrations from 0 to 50 g/l (from 0 to approx. 12.5 g/l of optical brightener) to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
[0079] The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
[0000]
TABLE 1
CIE Whiteness
Com-
parative
Conc.
Application example
exam-
g/l
1
2
3
4
5
6
7
8
ple 1
0
103.7
103.7
103.7
103.7
103.7
103.7
103.7
103.7
103.7
20
130.3
131.4
131.7
131.9
131.4
131.7
132.0
132.2
129.0
30
134.7
135.0
135.4
135.8
134.7
135.1
135.9
136.5
132.5
40
137.3
137.8
138.0
138.3
137.1
137.2
138.5
139.8
134.6
50
140.3
140.7
141.2
141.7
139.8
140.4
142.0
143.0
138.0
[0080] The results in Table 1 clearly demonstrate the excellent whitening effect afforded by the compositions of the invention.
[0081] Printability evaluation was done with a black pigment ink applied to the paper using a draw down rod and allowed to dry.
[0082] Optical density was measured using an Ihara Optical Densitometer R710. The results are shown in Table 2.
[0000]
TABLE 2
Optical Density
Paper sheet treated
2
1.02
according to application
4
1.12
example
7
1.06
Paper sheet treated
1
1.02
according to comparative
example
Optical Density = log 10 1/R
Where R = Reflectance
[0083] The results in Table 2 show that the composition of the invention has no adverse effect on ink print density.
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The instant invention relates to liquid compositions comprising derivatives of diaminostilbene, binders and ink fixing agents such as divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing.
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This invention is the result of a contract with the Department of Energy (Contract No. W-7405-ENG-36).
BACKGROUND OF THE INVENTION
The invention described herein is generally related to acoustic and thermal transducers.
Analyses directed to the measurement of acoustic characteristics in various environments have previously relied primarily on the use of conventional acoustic transducers to measure the power density level and directional characteristics of sound. Such analyses typically involve the measurement of such acoustic characteristics as dynamic pressure and dynamic pressure gradient at different points in space, to determine the optimum design for a given structure for purposes of noise suppression, sound transmission, or for other purposes.
The outputs of conventional acoustic transducers can be combined and processed to determine what is known as the real acoustic power density level, or the acoustic intensity, in a gas or other fluid. There is however another variable, known as the reactive acoustic power density, which is different from real acoustic power density and which may provide additional useful information relating to the acoustic characteristics of various environments. The difference between real and reactive acoustic power density is discussed below. It is sufficient to note here that there has not been previously available any single sensor or transducer for directly measuring either the real or the reactive acoustic power density in a fluid.
The present invention is based on a phenomenon which has been studied by the applicants and which underlies the operation of a class of devices previously disclosed by the applicants in their U.S. Pat. Nos. 4,398,398 and 4,489,553 which are hereby incorporated by reference in the papers "Experiments With an Intrinsically Irreversible Acoustic Heat Engine," J. Wheatley et al., Phys, Rev. Lett. 50, 499 (1983) and "An Intrinsically Irreversible Thermoacoustic Heat Engine," J. Wheatley et al., J. Acoustical Soc. Am. 74, 153 (1983). The phenomenon is a heat transfer process which is intrinsically irreversible in the thermodynamic sense. In practical application, the phenomenon is a heat transfer process by which acoustic energy in a fluid medium produces a temperature gradient and a resultant heat flow in a second medium which is in imperfect thermal contact with the fluid medium. As disclosed and claimed in the above-referenced patent applications, the phenomenon can be utilized, for example, to produce an acoustically driven heat pump which has no moving mechanical parts.
Although the phenomenon is based on a heat transfer process which is intrinsically irreversible in the thermodynamic sense, the process is functionally reversible in practical application, thus also realizing the production of a heat engine that operates at acoustic frequencies and which also has no moving mechanical parts. The present invention represents yet another practical application of the intrinsically irreversible heat transfer phenomenon, which application is generally related to and yet altogether distinct from the above-mentioned applications.
SUMMARY OF THE INVENTION
It is the object and purpose of the present invention to provide a method and apparatus for measuring both the intensity and the directionality of reactive acoustic power density in a gas or other fluid.
It is another object of the invention to provide a device with which can be measured the directionality as well as both the real and the reactive acoustic power density levels in a fluid.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which 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 objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention provides a method and an associated apparatus for measuring reactive acoustic power density in a fluid. The apparatus of the invention is referred to herein as a thermoacoustic couple. The thermoacoustic couple comprises temperature sensing means disposed adjacent substantially parallel opposite edges of at least one thermally conductive plate. In a preferred embodiment the temperature sensing means comprises a plurality of thermocouple elements. The thermocouple elements are electrically connected in series so as to form a thermopile which is of enhanced sensitivity to small temperature differences between the opposite edges of the conductive plate. Additionally, in the preferred embodiment there are a plurality of such plates stacked in parallel and spaced from one another, with the thermopiles of the stacked plates also connected in series to form a single thermopile. The voltage produced by the thermopile is representative of the temperature difference between the opposite edges of the plates, which is in turn representative of the reactive acoustic power density in a fluid in which the couple is situated.
The method of the invention comprises the positioning of at least one thermally conductive plate in a fluid medium, and measuring the difference in temperature between opposite parallel edges of the plate. The temperature difference is representative of, and can be directly correlated with, the reactive acoustic power density level in the fluid. The reactive power density level which is measured is the quantity of acoustic energy moving back and forth in reciprocating manner in the fluid medium along the direction parallel to the plane of the plate and transverse to the edges of the plate at which the temperature difference is measured. The measured temperature difference is approximately proportional to the cosine of the angle between this direction and the direction of reciprocal motion of the acoustic energy, thus enabling directionality of the acoustic energy in the fluid to be determined.
The apparatus and method are sensitive to both reactive and real acoustic power density, although the sensitivity to reactive power density is approximately an order of magnitude greater than the sensitivity to real power density. Also, the polarity of the signal generated by the apparatus is reversed in the case of real power density, all other parameters held constant.
The thermoacoustic couple measures a quantity which is proportional to the product of acoustic pressure and acoustic velocity. It is most sensitive to this product when the two are 90 degrees out of time phase with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate certain embodiments of the present invention and, together with the following description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is an isometric view of one embodiment of the thermoacoustic couple of the present invention, with a portion of the couple removed for purposes of illustration;
FIG. 2 is an end view of the embodiment shown in FIG. 1;
FIG. 3 is a top view of one plate element 10a of the embodiment shown in FIG. 1;
FIG. 4 is a top view of an alternative plate element 10a that may be used in a couple such as that shown in FIG. 1; and
FIG. 5 is a graphical representation of experimental results obtained with a prototype thermoacoustic couple constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates one preferred embodiment of a thermoacoustic couple constructed in accordance with the present invention. The couple consists of a set of nine polymerized epoxy resin (fiberglass) plates 10 which are parallel to one another and which are spaced apart by small fiberglass spacers 12. Each plate is approximately 1.0 inch long, 0.5 inch wide and 0.003 inch thick. The spacing between the plates is approximately 0.040 inch.
There are three plates in the middle of the stack, which are designated 10a in FIGS. 1 and 2. Each of the plates 10a includes a set of thermocouples which are formed of vapor-deposited strips 14 of chromel (a nickel-chromium alloy) and strips 16 of constantan (a copper-nickel alloy). The chromel strips 14 are deposited on the upper sides of the plates 10a and the constantan strips 16 are deposited on the lower sides. The strips 14 and 16 are arranged so as to meet at the opposite longitudinal edges of the plates, where they form a set of bimetallic junctions along the opposite edges. Each connected pair of bimetallic junctions forms a thermocouple which produces an electrical signal having a voltage that is proportional to the difference in temperature between the opposite edges of the plate. In the illustrated embodiment, there are eight pairs of bimetallic junctions on each plate, which together form a thermopile consisting of eight thermocouples. The thermopiles of the three plates 10a are also connected in series, thus forming a thermopile arrangement consisting of a total of 24 thermocouples.
The couple has a longitudinal axis 18 which is defined as being perpendicular to the longitudinal edges of the plates and also parallel to the planes of the plates. In practice, the thermoacoustic couple is most responsive to acoustic energy having a directionality parallel to the axis 18, as further discussed below.
In the embodiment of FIGS. 1-3, the bimetallic thermocouple junctions are located along the edges of the plates 10a. However, it is not strictly necessary that the junctions be located in this manner; it is sufficient for the junctions to be located at spaced apart locations along the plates, preferably as near to the longitudinal edges as possible. Accordingly, an alternative embodiment is shown in FIG. 4, in which the metallic strips 14 and 16 and the associated bimetallic junctions are all located on one side of the plate, with the junctions being located near the opposite edges of the plate. The assembly of FIG. 4 is easier to construct because all of the metallic strips can be deposited on only one side of the plate, and without the necessity of forming the junctions along the edges of the plates. The embodiment of FIG. 4 is presented because it represents a substantially simpler and more economical construction with little sacrifice in efficiency.
The temperature difference ΔT across the thermoacoustic couple is given by the equation: ##EQU1## where R eff is the effective thermal resistance between the ends of the couple, P a is the acoustic pressure amlitude, V a is the component of the acoustic velocity amplitude parallel to the plate axis, π is the length of the perimeter of a section through the plates of the couple normal to its axis, δ.sub.κ is the thermal penetration depth (δ.sub.κ =(2κ/ω) 1/2 , where κ is thermal diffusivity of the gas and ω the radian frequency of the acoustic wave), σ is the Prandtl number of the gas (σ=ν/κ, where ν is kinematic viscosity), and φ is the phase angle by which the velocity leads the pressure at the couple. Those skilled in the art will understand that the term reactive acoustic power generally refers to power such as that which exists in a pure standing acoustic wave, for which φ=π/2, whereas the term real acoustic power refers to the power in a travelling wave, for which φ=0. In either case, the power density is equal to the product P A V a . For ordinary gases, σ≲1, so that the coefficient of sin φ in Eq. (1) is much larger than that of cos φ and hence the couple is most sensitive to reactive power.
The thermoacoustic couple of the illustrated test device has sufficient sensitivity to generate an easily measurable temperature difference so long as the dynamic pressure of the sound is on the order of a tenth of a percent of the static pressure. However, it is to be noted that even a single plate having thermocouple junctions along its opposing edges would produce the effect on which the invention is based. Multiple-plate devices are preferred however because they are considerably more efficient. The lesser efficiency of a single-plate device is due not only to the fewer number of thermocouple junctions, but also due to the fact that the thermal conductivity of the surrounding gas is sufficiently high to effectively prevent the development of as large a temperature difference between the opposing edges of the plate as can be obtained in a multiple-plate device. In the multiple-plate device the multiple plates effectively suppress the thermal conductance of the gas by increasing the relative amount of heat conducted by the solid plates. It is for this reason that the illustrated preferred embodiment has plates which are non-functional in the sense that they do not include thermocouple arrays.
Any suitable low-noise amplifier may be used to detect and amplify the signal produced by the thermoacoustic couple in response to a sound level. A typical sensitivity of a single chromel-constantan electrical thermocouple is on the order of 60 microvolts per degree Celsius.
The acoustic couple has directional as well as amplitude sensitivity. Specifically, the sensitivity of the couple varies as a function of the cosine of the angle between the longitudinal axis 18 of the couple and the direction of dynamic reciprocal gas flow. This result holds true both in the case of a standing wave and in the case of a traveling wave.
The thermoacoustic couple is also sensitive to real acoustic power density, particularly in the majority of common gases which have a Prandtl number on the order 2/3, although such sensitivity is approximately an order of magnitude less than the sensitivity with respect to reactive power density of the same level. However, it will be recognized that real acoustic power density can be readily converted to reactive power density, and thus measured with greater sensitivity, by placing an acoustic reflector behind the acoustic couple. Such a reflector converts traveling acoustic waves passing through the couple to standing waves, the reactive power density of which can be measured with relatively greater sensitivity.
The actual operation of the embodiment shown in FIGS. 1 through 3 is illustrated in FIG. 5. FIG. 5 presents the results of an experiment in which sound was generated in a one inch diameter metal tube by means of an acoustical driver a (loudspeaker) positioned at one end of the tube. The opposite end of the tube was sealed. The thermoacoustic couple was positioned at various points within the tube to obtain the measurements presented in FIG. 5, wherein the position of the thermocouple along an arbitrary section of the tube is designated in millimeters (x). The tube was filled with 4 He at a pressure of 2.55 bars. The frequency of the acoustical driver was adjusted to a resonant frequency of approximately 1 kHz to produce a standing wave in the tube. Under these conditions, the phase angle φ in Equation 1 is usually approximately plus or minus π/2 as the couple is moved along the tube. In a standing wave, the quantity P a V a is a sinusoidal function of position, giving rise to the sinusoidal variation in the observed temperature difference Δ T.
It is contemplated that the acoustic couple will find practical application in the art of acoustic analysis and engineering. Specifically, it is contemplated that the ability to measure the directionality, as well as both real and reactive acoustic power density levels in a fluid, all with a single, simple device, will augment and enhance conventional acoustic analyses, which until now have relied entirely on the measurement of acoustic power density levels using combinations of conventional acoustic transducers.
It is also contemplated that the present invention will be most efficiently manufactured through the use of photolithographic techniques such as are used to manufacture integrated microelectronic circuits. With such techniques it is considered feasible to construct a multi-plate thermoacoustic couple having on the order of ten thousand thermocouple junctions, thereby greatly increasing the sensitivity of the device over the prototype devices described above.
The foregoing description of certain preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The illustrated embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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A method for determining reactive acoustic power density level and its direction in a fluid using a single sensor is disclosed. In the preferred embodiment, an apparatus for conducting the method, which is termed a thermoacoustic couple, consists of a stack of thin, spaced apart polymeric plates, selected ones of which include multiple bimetallic thermocouple junctions positioned along opposite end edges thereof. The thermocouple junctions are connected in series in the nature of a thermopile, and are arranged so as to be responsive to small temperature differences between the opposite edges of the plates. The magnitude of the temperature difference, as represented by the magnitude of the electrical potential difference generated by the thermopile, is found to be directly related to the level of acoustic power density in the gas.
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This application is a division of application Ser. No. 954 506, filed Oct. 25, 1978, now U.S. Pat. No. 4,318,262.
FIELD OF THE INVENTION
This invention relates to a bar-positioning member which quickly permits the forming of frames or gratelike members from bars, and its forming apparatus. More particularly, it relates to a reinforcing steel bar-positioning member, useful for quickly assembling steel bars into gratelike reinforcements prior to placing concrete in constructing the floor and wall of a reinforced concrete structure, and its forming apparatus.
BACKGROUND OF THE INVENTION
When conventionally constructing a reinforced concrete floor and wall, concrete placement is normally preceded by first putting marks at suitable intervals around the area where reinforcing bars are to be disposed. Then a gratelike reinforcing bar frame is formed by placing reinforcing bars at the marked intervals, and binding together the intersecting bars at their intersecting points with steel wire and so on.
This conventional method requires considerable skill in arranging the reinforcing bars at regular intervals or exactly parallel to each other. In addition, binding them together with wire requires much time. These shortcomings prevent saving the construction cost of using reinforced concrete structures.
Accordingly, an object of this invention is to provide a reinforcing bar-positioning member that eliminates the aforesaid shortcomings by permitting assembling reinforcing bars into a grate or frame quickly and without requiring skill. Another object of this invention is to provide a forming apparatus that can continuously and automatically make said reinforcing bar-positioning member.
SUMMARY OF THE INVENTION
The bar-positioning member according to this invention comprises a steel wire or wire rod. Usually it is used with a reinforcing steel bar, spot-welded on and parallel to the latter. The wire rod has a plurality of bends formed by bending part thereof at given intervals. Each bend constitutes an indentation or a bar-inserting recess to receive a second reinforcing steel bar that is placed intersectingly with respect to said first reinforcing bar. This indentation has only one opening that opens in the direction of the longitudinal axis of the wire rod and a bottom whose shape conforms to the circumference of the second reinforcing bar to be inserted therein. To firmly keep the second reinforcing bar in position, the indentation opening is designed to be smaller than the maximum diameter of the second reinforcing bar, and the bottom shaped to fit close to the circumference thereof. To prevent slipping of the second reinforcing bar out of the indentation, a holding projection is formed opposite to the bottom, which prevents the inserted second reinforcing bar from moving toward the opening, engaging with the circumference thereof. The indentation may also be so designed as to contain a plurality of reinforcing bars, and with a plurality of said projections.
The forming apparatus according to this invention is used for manufacturing the above-described bar-positioning member. It forms said indentations on a long wire or wire rod at desired intervals. This apparatus comprises a main shaft that is intermittently rotated from one side to the other and axially moved back and forth, and an armlike mold member whose base end is fixed to said main shaft. The mold member functions as a mold to form the indentation of said bar-positioning member. The base end shape of the mold member is designed to conform to the cross section of the reinforcing bar to be used. When round steel bars are used, for example, the base end is designed to have a semi-circular contour that is coaxial with the main shaft. When deformed steel bars are used, the base end contour agrees with part of the cross section of the deformed bar.
A groove extending aslant to the longitudinal axis of said mold member opens in the free-end surface of the mold member, the other end of the groove opening on one side of the mold member. This groove receives a long wire or wire rod that is formed into the bar-positioning member, is totally exposed on one side of the mold member, and has a width and a depth that are larger than the diameter of the wire or wire rod. There is a notch on the other side of the mold member, which forms the projection in the indentation of the bar-positioning member. A punch to push part of the wire or wire rod into this notch is provided in the vicinity of the main shaft, interlockingly therewith. When the mold member has completed its rotation, the punch pushes part of the wire into the notch to form the projection in the indentation of the bar-positioning member.
A transfer device to intermittently move the formed wire longitudinally, and a grip device to hold the formed wire, are also provided. These devices are also interlocked with the main shaft.
In the beginning, the main shaft and mold member, not rotating, move axially to receive part of a wire in the groove of the mold member. When the main shaft is turned through a given angle, the wire is longitudinally bent about the axis of the main shaft. At this time, part of the wire is wound around the base end of the mold member to form a bend or an indentation conforming to the contour of the base end. When the rotating main shaft stops, the punch moves ahead toward the notch on one side of the mold member and pushes part of the wire therein to form the holding projection. As the punch withdraws from the notch, the main shaft moves axially again, but in the opposite direction, and the mold member moves toward the wire, whereupon the wire in the groove of the mold member becomes automatically released. Then, the transfer device longitudinally moves the wire through a given length, and the main shaft rotates back through the given angle to return the mold member to the original position.
This apparatus is capable of continuously forming the bar-positioning member having an indentation or eyelike portion, bending part of the wire while moving it longitudinally.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view illustrating the conventional reinforcing steel bar assembling method.
FIG. 2 is a side elevation of a bar-positioning member according to this invention.
FIGS. 3 through 7 are perspective views showing the bar-positioning member of this invention in use.
FIG. 8 is a plan view of a forming apparatus of this invention that forms the bar-positioning member in FIG. 2 from a long, straight wire or wire rod.
FIG. 9 is a partial enlarged perspective view of the apparatus shown in FIG. 8.
FIG. 10 is a cross-sectional view looking in the direction of the arrow X--X in FIG. 9.
FIG. 11 is a longitudinal cross section of the apparatus in FIG. 8 in the non-operating condition.
FIG. 12 is a longitudinal cross section of the same apparatus in the operating condition.
FIG. 13 is a plan view similar to FIG. 8, but showing the apparatus in the operating condition.
FIG. 14 is a cross-sectional view looking in the direction of the arrow XIV--XIV of FIG. 12.
FIG. 15 is a cross-sectional view looking in the direction of the arrow XV--XV of FIG. 12.
FIG. 16 is a correlation diagram showing the operating cycle of the apparatus of this invention, with the operating conditions of its individual parts.
DETAILED DESCRIPTION
Embodiments of the invention will be described by reference to the accompanying drawings. First, however, the conventional reinforcing bar assembling method and its defects will be explained by reference to FIG. 1.
As shown in FIG. 1, the conventional reinforcing bar assembling method comprises the steps of providing point marks c at given intervals where longitudinal reinforcing bars a and transverse reinforcing bars b are to be placed, placing the longitudinal and transverse reinforcing bars a and b to match the point marks c, and binding together the longitudinal and transverse reinforcing bars a and b at their intersecting points P with steel wire etc. to make up a reinforcing bar assembly U.
But this conventional method requires considerable skill in placing the longitudinal and transverse reinforcing bars with exact intervals and parallelism. In addition, it involves inefficient wire binding of the longitudinal and transverse reinforcing bars at their intersecting points P, which increases the construction cost of reinforced concrete structures.
To eliminate such shortcomings with the conventional method, the inventor invented a bar-positioning member that eliminates the binding and pre-arranging steps, together with an apparatus that can continuously manufacture such bar-positioning members.
FIGS. 2 and 3 show an embodiment of the bar-positioning member according to this invention.
As illustrated in FIGS. 2 and 3, a bar-positioning member 1 is made by bending part of a long wire or wire rod 5 of suitable diameter into a bar-accommodating indentation 3 with an approximately U-shaped bend 2, at suitable even intervals L, and bending another part of the wire 5 toward the inside of said indentation 3 to form a holding projection 4 to prevent an inserted bar from slipping out.
The bar-accommodating indentation 3 of the wire 1 is formed by bending the long wire 5 back to a suitable length T, as indicated by reference numeral 6. The width S of the opening 3b of the indentation 3 is somewhat smaller than the diameter d of a reinforcing bar 11 to be inserted therein. The indentation 3 gradually expands from its opening 3b toward its bottom 3a. The bottom 3a has a circular shape that conforms to the circumference of the reinforcing bar 11 to be inserted in the indentation 3. Although the width S of the opening 3b is smaller than the diameter d of the reinforcing bar 11, the opening 3b can be readily opened by pressing the bar 11 into the bottom 3a, the bend 6 over the indentation 3 having adequate elasticity.
The U-shaped bend 2 constituting the reinforcing bar receiving indentation 3 comprises a rising portion 8, the overlapped bend 6, the circular bottom 3a and a base portion 9. In the illustrated embodiment, a small projection 4 to prevent the reinforcing bar from slipping out is formed at a suitable position of the base portion 9, preferably in the vicinity of a virtual circle E (having the same diameter as the reinforcing bar 11) contacting the bottom 3a.
This projection 4 forms a slope 4b on the side of the opening 3b and a vertical plane 4a on the side of the bottom 3a.
Referring now to FIGS. 3 through 6, the method of using the above-described bar-positioning member 1 will be described. As shown in FIG. 3, this member 3 is preliminarily fixed on and throughout the entire length of a reinforcing steel bar 10, disposed parallel to other similar bars, by spot welding 7.
FIGS. 4 through 6 illustrate how to make a reinforced concrete surface (for example, of a base or slab) using the reinforcing bars 10 with said bar-positioning members fixed thereon.
According to this method, a suitable number of reinforcing bars 10 (for instance, this embodiment has two such bars, one on each side), with bar-positioning members thereon, are placed in given positions at given intervals, in the direction of M-N. The bars are placed on blocks BB so that the indentations 3 of the parallel reinforcing bars 10 are aligned in the direction Q-R. Then another set of reinforcing bars 10' with bar-positioning members thereon, which bars 10' extend in the Q-R direction, are pressed into the indentations 3 on the first set of reinforcing bars 10, so that the bar-accommodating indentations 3 on the second set of reinforcing bars 10' are aligned in a straight line in the M-N direction. In this embodiment, the adjacent reinforcing bars 10' with the bar-positioning members thereon are disposed with two ordinary reinforcing bars 11 therebetween, which bars 11 are devoid of bar-positioning members 1. Then, additional reinforcing bars 11 extending in the M-N direction are press-fitted into the bar-accommodating indentations 3 on the reinforcing bars 10', thus making up a gratelike reinforcing bar assembly 20.
In press-fitting the second reinforcing bar 10' (or the ordinary reinforcing bar 11) into the indentations 3 on the first reinforcing bar 10, the second reinforcing bar 10' (or 11) is pushed along the slope 4b, over the projection 4 in the bar accommodating indentation 3 and into the bottom 3a. The holding projection 4 thus prevents the reinforcing bar 10' (or 11) from slipping out of the indentation or recess.
FIG. 7 shows how reinforcing bars are fixed where they are joined together. As seen, two reinforcing bars 11 are inserted in one accommodating indentation 3.
The bar positioning member 1 of this invention is applicable not only to horizontal planes as described above, but also to vertical surfaces of reinforced concrete structures and such structures as bridges and tunnels.
The favorable results achieved by the bar positioning member 1 of this invention are as follows:
1. The bar-positioning member 1 fixed to the reinforcing bar 10 (or 10') has the bar-accommodating indentations 3 at suitable even intervals. Accordingly, longitudinal and transverse reinforcing bars can be positioned and assembled accurately and quickly by simply press-fitting the intersecting reinforcing bars 11 in the bar-accommodating indentations 3 on the reinforcing bars 10. This simple operation increases working efficiency and enables accurate bar assembling without requiring skill.
2. The holding projection 4 formed inside the bar-accommodating indentation 3 firmly grasps the inserted reinforcing bar 11, which eliminates the need of readjusting the assembled reinforcing bars.
FIGS. 8 through 14 show an apparatus for forming the bar-positioning member 1 shown in FIG. 2. This forming apparatus comprises a pendulumlike mold member swinging intermittently, a main shaft engaging the base end of said mold member and undergoing reciprocating axial and rotating motions, a transfer device to move the formed wire in its longitudinal direction, and a grip device to hold part of the wire being formed.
FIG. 8 is a plan view of the forming apparatus looking down from above. Reference numeral 21 designates a cranklike mold member whose base end is fixed to a main shaft 51. The main shaft 51 moves axially at right angles to the drawing and rotates reciprocatingly. As shown in FIG. 9, the mold member 21 is a pendulumlike body 30 extending sideward from the main shaft 51. In the top surface of the body 30 there is cut a groove 33 extending from the free end to one side thereof. As shown in FIG. 10, the width and depth of this groove 33 are considerably larger than the diameter of the wire 5 to be formed. The groove 33 opens outwardly through the top surface of the body 30 of the mold member 21. Therefore, as the mold member 21 moves axially following the axial motion of the main shaft 51, the wire 5 moves in and out of the groove 33, as will be described later. This groove 33 divides the body 30 of the mold member 21 into two sections 31 and 32 (see FIG. 9).
The configuration of the section 31 is defined by a flat side 31a, a base end 31b consisting of an arc that is coaxial with and slightly larger than the main shaft 51, an inside surface 31c sloping from the base end 31b to a free end 31d so as to intersect with the side 31a, and said free end 31d consisting of a small-diameter arc. This section 31 has a long ovoid shape.
In this embodiment, the side 31a and the inside surface 31c (i.e., the wall of the wire holding groove 33) form an angle of approximately 30 degrees.
The configuration of the section 32 is defined by a slightly bent exterior side 32a, a sharp-angled rear end 32b, an inside surface 32c extending parallel to the inside surface 31c of the section 31, and a front end 32d consisting of a small-diameter arc. Section 32 has a winglike shape, and a smaller area than the section 31.
A trapezoid notch 31e is cut in the side 31a of the section 31, in the vicinity of a virtual circle E. The arched base end 31b forms part of the circumference of the virtual circle E. Also, a groove 32e having a semi-circular cross section is formed in the inside surface 32c of the section 32 to prevent the wire 5 from slipping out (see FIG. 10).
In FIG. 8, reference numeral 22 denotes a punch to press-fit part of the wire 5 into the notch 31e of the mold member 21 to form the small projection 4 (see FIG. 2) in the indentation 3. Reference numeral 23 designates a holding member to push the U-shaped bend 2 against the rising portion 8, as will be described later. Item 24 is a wire feed claw to advance the formed wire F, as described hereinafter. The mold member 21, punch 22, holding member 23 and feed claw 24 operate in a given cycle to form the U-shaped bend 2 in the wire 5 and to continuously forwardly advance the formed wire F with the bends 2 therein.
Referring now to FIG. 11, a mechanism to drive the mold member 21, punch 22, holding member 23 and feed claw 24 in a given cycle is illustrated.
FIG. 11 shows the positional relationship between the individual components, with the mold member 21 at a standstill. FIG. 12 shows a similar relationship with the mold member 21 in motion.
The mold member 21 is fixed to the upper end of the main shaft 51 which is rotated by a motor 41 through a clutch mechanism 50 and a pair of gears 42 and 43. Paired upper driving teeth 45 and lower driving teeth 46 are provided inside a cylindrical clutch box 44 that constitutes the driving member of the clutch mechanism 50. The clutch box 44 is welded to gear 43 and rotates continuously and integrally therewith.
The main shaft 51 carries a driven disc 54 that is contained in the clutch box 44 and constitutes the driven member of the clutch mechanism 50. Paired upper driven teeth 55 and lower driven teeth 56 are integrally formed above and below the driven disc 54, disposed at right angles with each other as shown in FIG. 14. This driven disc 54 moves up and down with the main shaft 51, as will be described later. It is so designed that not both but either of the upper driven teeth 55 and lower driven teeth 56 of the driven disc 54 alternately engage with the upper driving teeth 45 or lower driving teeth 46, respectively, inside the clutch box 44.
Referring to FIGS. 11 and 12, members carried by the main shaft 51 will be described in descending order. An auxiliary cam device 57 having a camming rod 58 to actuate the punch 22 and a camming rod 59 to actuate the holding member 23 is provided below the mold member 21. A cam follower 53, which moves up and down in contact with a stationary cam 87 (shown in FIG. 15 and described later) and thereby imparts the vertical motion to the main shaft 51, is disposed below the clutch mechanism 50. A crank disc 81 spline-connected with the lower end 52 of the main shaft 51 is provided therebelow.
In FIGS. 8 through 13, reference character C denotes a driving mechanism for the punch 22, D a driving mechanism for the holding member 23, and E a driving mechanism for the feed claw 24.
The punch driving mechanism C comprises said camming rod 58, a driven rod 64 rotated through a given angle by the camming rod 58 when the main shaft 51 rises, a rotatable shaft 63, having rod 64 fixed thereto, a push arm 65 rotating with said shaft 63 to push the punch 22 into the notch 31e in the mold member 21, and a spring 66 to return the punch 22 to its original position. Reference numeral 67 designates a stop for the push arm 65.
The holding member driving mechanism D comprises said camming rod 59, a driven rod 72 rotated through a given angle by the camming rod 59 when the main shaft 51 rises, a rotatable shaft 71 fixed to rod 72 and also having said holding member 23 fixed thereto, and a spring 73 to return the holding member 23 to its original position. Reference numeral 74 denotes a stop for the holding member 23.
The feed claw driving mechanism E comprises said rotatable crank disc 81, a reciprocating connecting rod 83 connected thereto, and a linearly reciprocal base unit 84 connected to rod 83 for reciprocating the feed claw 24. The inside of the shaft of the crank disc 81 forms a spline shaft hole 82 (see FIG. 12) to engage with the spline shaft end 52 of the main shaft 51. The reciprocating stroke S (equal to the pitch between adjacent U-shaped bends 2) of the moving base unit 84 or the feed claw 24 may be changed to S 1 , S 2 and S 3 according to the positions P 1 , P 2 , and P 3 where the end 83a of the connecting rod 83 is fitted to the crank disc 82.
As shown in FIG. 15, the stationary cam 87 comprises a small semi-circular inner cam 88 and a large semi-circular outer cam 89 (opposite to the inner cam 88) disposed coaxially about the main shaft 51 on a lowermost support or camming surface 86.
The cam follower 53 comprises an inner follower 61 engageable with the inner cam 88 and an outer follower 62 engageable with the outer cam 89.
The inner cam 88 and the outer cam 89 have inclined camming surfaces 88a and 89a, flat camming surfaces 88b and 89b, and vertical camming surfaces 88c and 89c, respectively. In this embodiment, the flat camming surfaces 88b and 89b extend through an angle of approximately 200 degrees with respect to the axis of the main shaft 51.
When the inner follower 61 and outer follower 62 ascend along the inclined camming surfaces 88a and 89a, the main shaft 51 and other items carried thereby (i.e., the mold member 21, auxiliary cam device 57, driven disc 54 and cam follower 53; hereinafter the main shaft 51 and these items are collectively called the driven unit B) also start to rise. When they rest on the flat camming surfaces 88b and 89b, the driven unit B is in the highest position. When they fall across the vertical camming surfaces 88c and 89c onto the lowermost camming surface 86, the driven unit B is in the lowest position.
This upward and downward motion of the driven unit B is due to the rotation of the cam follower 53, or that of the driven unit B itself. In other words, it is due to the rotation of the driven disc 54. When moving upward or downward, this driven disc 54 receives rotating force not through both but through either of the upper driving teeth 45 or the lower driving teeth 46 of the clutch box 44.
When the driven disc 54 rises from below (where the lower driving teeth 46 engage with the lower driven teeth 56), the clutch box 44 rotates idle through an angle of approximately 90 degrees until the upper driving teeth 45 engage with the upper driven teeth 55. The same thing occurs when the driven disc 54 descends from above. This is because the upper teeth 55 and lower teeth 56 of the driven disc 54 intersect perpendicularly, while the upper teeth 45 and lower teeth 46 of the clutch box 44 are disposed in the same direction with respect to the common vertical plane.
The object of this design in this embodiment is to insure smooth operation of the entire apparatus by temporarily stopping the driven unit B when it moves up or down.
In the figures, reference character A designates a driving unit including the clutch box 44 and gear 43.
In FIGS. 8, 11 and 13, reference numerals 77 designates a guide roller having a groove 77a to guide the wire 5, 90 designates a casing to cover the entire apparatus, 91 designates a cover plate for the casing 90, 92 designates guide plates to guide the formed wire F, 93 designates an opening in the cover plate 91 through which the mold member 21 moves in and out, 94 designates a groove through which the feed claw 24 runs, 95 designates a cam chamber cover, 96 designates an intermediate plate, 97 designates a long groove in plate 96, and 98 designates a guide plate for the moving base unit 84.
Now the operation of the forming apparatus of this invention will be described by reference to FIG. 16 which shows the relationship among the above-described driving unit A, driven unit B, holding member 23, feed claw 24, cam follower 53, punch push rod 65 and formed wire F.
It is apparent from FIG. 16 that one operating cycle of this apparatus ranges from phase I to phase VI. During this period, the driving unit A rotates 540 degrees (1.5 revolutions), the driven unit B rotates 360 degrees (1 revolution) and makes one up-down reciprocation, the holding member 23 swings back-and-forth once, the feed claw 24 makes one reciprocation, the cam follower 53 rotates one revolution, the punch push rod 65 swings back-and-forth once, and the formed wire F moves longitudinally through a one-pitch distance.
In detail, phase I shows the initiation of a forming cycle. Initially the driven unit B is in its raised position and the follower 60 of cam follower 53 is engaged with flat camming surface 88b directly adjacent the upper end of the inclined camming surface 88a. In this initial position, the mold member 21 is positioned as shown in FIGS. 8 and 12 so that the wire 5 passes through the grip groove 33. The cam follower 53 then rotates through an angle of 90 degrees along the flat camming surface 88b. At this time, the driven unit B is rotated since the upper driven teeth 55 are engaged with the upper driving teeth 45 of the driving unit A. This causes the mold member 21 to be rotated in the direction of arrow R in FIG. 8.
In phase II, the mold member 21 is rotated from the 90-degree position to the 210-degree position. When the mold member 21 has thus rotated 210 degrees, the flat side 31a of the section 31 thereof extends in the direction in which the wire 5 is withdrawn. During phases I and II, the wire 5 is wound around the mold member 21 to form the U-shaped bend 2, as shown in FIGS. 2 and 3.
In the later period of phase II, the holding member 23 and the punch push rod 65 are swung into the FIG. 13 positions to straighten the rising portion 8 of the U-shaped bend 2 and to form the projection 4, respectively.
While the mold member 21 rotates from the 0-degree position to the 210-degree position during phases I and II, the feed claw 24 returns from the advanced position (FIGS. 8 and 11) to the retracted or original position (FIGS. 12 and 13).
At the end of phase II, that is when the driving unit A has rotated through an angle of 210 degrees, the cam follower 53 disengages from the cams 88 and 89 and the driven unit B descends, thus disengaging the mold member 21 from the wire 5. At the same time, the upper driving teeth 45 of driving unit A are disengaged from the upper driven teeth 55 of driven unit B, and the driven unit B stands still.
In phase III, the driving unit A rotates from the 210-degree position to the 300-degree position, but the driven unit B and other members remain stationary. At the end of phase III, the lower driving teeth 46 of driving unit A are positioned in engagement with the lower driven teeth 56 of the driven unit B.
The driving unit A then rotates 60 degrees during phase IV and an additional 90 degrees during phase V (i.e., from the 300-degree position to the 450-degree position), and the driven unit B also rotates through the same angle, or 150 degrees. During this period, the mold member 21 rotates, in its lowered position, returning from the condition of FIG. 13 to the initial condition of FIG. 8. The feed claw 24 also advances from the position of FIG. 13 to that of FIG. 8, pushing the bottom 3a of the U-shaped bend 2 and moving forward the formed wire F by one pitch.
At the end of phase V, the cam follower 60 re-engages the inclined cam surface 88a to raise the driven unit B so that mold member 21 is lifted to re-engage wire 5 within groove 33. Also, the lower driving teeth 46 of the driving unit A are disengaged from the lower driven teeth 56 of the driven unit B. The driving unit A then rotates idle through an angle of 90 degrees, from the 450-degree position to the 540-degree position, during phase VI.
Between phases I and VI, the driving unit A rotates through a total angle of 540 degrees (1.5 revolutions), while the driven unit B rotates 360 degrees (1 revolution) and makes one up-down reciprocation. During the same period, the mold member 21 turns, gripping the wire 5 in the groove 33, to form the U-shaped bend 2. The feed claw reciprocates once to advance the formed wire F by one pitch.
The foregoing embodiments describe the use of the bar-positioning member with round reinforcing steel bars mainly for building use. This invention is also applicable for deforming reinforcing bars whose cross sections are not exactly circular. In such applications, the bottom 3a of the member 1 is shaped in conformity with the cross section of the bar to be deformed. Likewise, the configuration of the base end of the mold member 21 is shaped similar to the cross section of the deformed bar.
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.
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An apparatus for making a bar positioning member of a single wire which has a plurality of S-shape doubled-back portions spaced along the length thereof to form indentations for receiving metal bars transverse to the wire. The apparatus comprises guide means for intermittently moving a wire along a fixed path and a pendulumlike mold member swingable about the base end thereof. The mold member has a grip to hold an intermediate portion of the wire, and the contour of the base end is shaped in conformity with the shape of the identation. After forming a S-shaped indentation in the wire by rotation of the mold member through about 180° the mold member is retracted to allow the wire to be advanced for formation of the next indentation. Also, notch means on the mold member and corresponding punch means provide an inwardly directed projection for retaining a bar in the indentations.
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FIELD OF THE INVENTION
[0001] The present invention is directed towards a method for applying an odor control agent to carpet or other floor coverings made from fibrous material at various manufacturing stages. The odor control agent controls odor associated with deposits, particularly spills of organic material, on carpet fibers or other fibrous materials.
BACKGROUND OF THE INVENTION
[0002] Carpet is widely used as a floor covering in both residential and commercial application. Carpet is very versatile, offering numerous qualities including durability, aesthetics, comfort, safety, warmth and quietness. With modem manufacturing and dyeing techniques, carpeting may also be provided in almost any color, texture and pattern. Carpet may be manufactured from diverse types of materials including natural materials such as wool or cotton, or synthetic materials from various polymers such as polypropylene, polyamide, etc. Each of these materials will be referenced herein as carpet fibers and includes these fibers utilized in other fiber floor coverings. The majority of carpet, particularly for residential and commercial use, is manufactured from synthetic polymer material such as polypropylene, polyester, and polyamide. Among the polyamides, T-6 and T-6,6 are common. Regardless of the material used in the manufacture, a typical synthetic yarn manufacturing process involves first extruding the carpet fiber and converting to continuous filament or staple yarns through a series of air entangling, drafting, carding, mechanical twisting, or other means to create a single threadline made up of numerous individual fibers made up of various natural and synthetic materials.
[0003] Various finishes and lubricants are applied at each of these stages to either enable further processing, provide identifications, enhance performance properties, or help enhance final carpet appearance. Threadlines, in various combinations, are wound and rewound on bobbins at various stages in the manufacturing process before being ready to be dyed prior to tufting into carpet, or, in the case of solution-dyed yams in which the fibers are intrinsically dyed in the extrusion process, to be tufted. Methods to pre-dye yam, in addition to that mentioned for solution-dyed extruded yams, include the skein dye method in which spun or filament yams are dyed in vats or tanks with or without pressure, and a stock dyed method in which spun fibers are vat dyed before making them into yam. In both cases, further mechanical twisting and heat setting processes occur before the yam is ready to be tufted. Finishes and lubricants are also applied to the yam after these stages in the manufacturing process.
[0004] Carpet floor coverings made from polypropylene, polyester, wool and nylon may be susceptible to odors and staining from organic sources. In order to prevent staining, it is known in the industry to use stain blockers. The stain blockers act to prevent or reduce the ability of organic dyes, particularly acid dye colorants from chemically reacting with and bonding to the nylon. The carpets are also commonly coated with a fluorochemical or hydrocarbron anti-soiling agent. These agents reduce the tendency of soil to adhere to the fiber. Examples of such stain blockers are illustrated in U.S. Pat. Nos. 4,680,212 and 4,925,707.
[0005] Generally, fluorochemicals are topically applied to carpet. One method is to form an aqueous dispersion of the fluorochemical and then spray that dispersion on the top face of the carpet. Another method is to make an aqueous based foam containing the fluorochemical and then apply the foam to the top face of the carpet. Heat is usually applied to drive off excess water and to fix the fluorochemical to the carpet fibers.
[0006] In addition to staining, especially in residential locations, the possibility of deposits of organic matter such as feces or urine from babies and pets can result in not only soiling of the carpet but also a lingering odor and may, in extreme cases, require the replacement of the carpet. Furthermore, bacteria may grow from the soil organic matter. These bacteria may have the potential of causing mold and mildew. Some of these bacteria may themselves give rise to odor due to incomplete digestion of organic material. There have been attempts to reduce the presence and number of bacteria present in carpet by utilizing various anti-microbial agents such as described in U.S. Pat. Nos. 4,110,504 and 5,024,840. The use of anti-microbials, while reducing the number of bacteria associated with carpet, may raise other concerns such as the potential that some of the bacteria may become resistant to effects of the anti-microbials.
[0007] Many bacterial and fungal genera are known for use in odor control due to their capability for producing enzymes that are capable of breaking down organic material. Such bacteria are particularly useful where the organic material, if allowed to remain, will give rise to malodors. Several such bacterial and fungal genera such as Bacillus, Lactobacillus, Enterobacter, Streptococcus, Rhizopus, Nitrosomonas, Nitrobacter, Pseudomonas, Alcaligens and Klebsiella, among others, are known for use in such applications with Bacillus being the most prevalent in use in various applications.
[0008] For example, preparations of active Bacillus in a vegetative form suitable for spraying or otherwise distributing on a deposit, especially of pet urine and feces, on a carpet for controlling odor are presently marketed by The Bramton Company of Dallas, Tex. under the trademark OUTRIGHT. The bacterial preparations are used to deodorize a deposit by application directly on the deposit.
[0009] However, application of an odor treatment after installation of the carpet is only available if an individual notices the organic deposit. This may be difficult for commercial carpet installations and in some residences due to the size of the carpet or location of the organic deposit.
[0010] Accordingly, there is a need in the art for an effective odor treating agent that can be manufactured into carpet fibers and other similar floor coverings so that it does not have to be applied by the carpet owner.
[0011] There is also a need in the art for an odor treating agent that does not have to be reapplied in the event of a new deposit, such as a dormant or sporulated bacterial form, that would become active only when needed.
[0012] There is a further need in the art for a manufacturing technique that would bind such an odor treating agent into carpet fibers in a manner which is cost effective.
[0013] Furthermore, there is a need in the art for a manufacturing technique that provides a carpet with an anti-soiling property and odor treating property that is easy and economical to conduct.
SUMMARY OF THE INVENTION
[0014] The present invention is a method for manufacturing a floor covering comprising of fibers. The method includes providing a carpet fiber and applying an odor control solution to the fiber carpet. The odor control solution includes a bacteria spore blend and a bacteria spore blend binder wherein the solution has a pH within the range of 1 to 12.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be more readily understood from a reading of the following specifications and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
[0016] [0016]FIG. 1 is illustrates the application of an odor treatment solution to a pre-dyed carpet fiber;
[0017] [0017]FIG. 2 is a block diagram illustrating an exemplary method of performing the present invention wherein the odor control agent and the odor control agent binder are topically applied to the tufted carpet yarn simultaneously with the application of an anti-soiling treatment before the carpet yarn is dried during the continuous dyeing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention is directed towards a method for applying an odor control agent to carpet fibers or other floor coverings made of fibrous materials during the carpet manufacturing process or to the fibers themselves prior to the carpet manufacturing process for controlling odor associated with deposits of organic material. For the purposes of this disclosure, the odor control agent is a bacterial form or forms referenced herein as the “bacteria spore blend”.
[0019] Many bacterial genera are known to produce enzymes capable of breaking down organic material. Such bacteria are particularly useful where the organic material, if allowed to remain, will give rise to malodors. Several such bacterial genera such as Bacillus, LactoBacillus, Enterobacter, Streptococcus, Nitrosomonas, Nitrobacter, Pseudomonas, Alcaliaens and Klebsiella amongst others are known for use in such applications, with Bacillus and Lactobacillus being the most prevalent in use in various applications. Strains of bacteria from any of the above noted genera are useful in practicing the present invention. Preferably, the bacterial preparation for use in the present invention is one or more strains of Bacillus or LactoBacillus. More preferably, the strains of bacteria for use in the present invention are selected from Bacillus lichenifonnis, Bacillus pasteurii, Bacillus laevolacticus and Bacillus amyloliquefaciens. Each of these species have characteristics which make them most effective against particular types of organic materials.
[0020] All of these species are capable of enhanced anaerobic and aerobic growth. Bacillus pasteurii is known for superior lipase production, while Bacillus laevolacticus has a very fast germination cycle. Bacillus amyloliquefaciens is high in production of protease enzymes.
[0021] The selection of the strains of bacteria for use in the present invention may depend upon many factors. One such factor is the nature of the organic material most commonly expected for the particular application. For example, in a commercial application, the most commonly expected deposits would be soil tracked in from out-of-doors, beverages such as coffee, tea, other food and the like, especially in a restaurant environment, and possibly, inks or toners for printers and other office equipment. Many of these materials are high in fatty components so the bacterial preparation may be enhanced for strains having high activity against such materials. One example of such a bacteria is Bacillus pasteurii described above.
[0022] In a residential environment, the nature of the deposits may differ with out-of-doors soils. For example, beverages, food and urine and feces from pets and children being the most commonly encountered. Depending upon the nature of the deposited material, the bacteria spore blend may be selected to contain strains having enhanced activity against such materials. Another factor which may affect the nature of the deposit is the geographical location of the installed carpet. This factor would especially relate to the nature of deposits of out-of-doors soil and to the nature of food deposits. Different regions are known to have different soil types and different regions may also have differences in the foods commonly consumed due to cultural and environmental factors. In addition, the temperature of the carpet to be treated will influence the activity of the bacteria. Depending on the strain selected, the bacteria will tend to exhibit enhanced activity at higher temperatures. At lower ambient temperatures, more active strains may be desired.
[0023] The bacteria spore blend will typically comprise one or more strains selected from the genera and species described above. When utilizing a mixture of more than one strain, each of the individual strains may comprise between 3% and 97% of the total of the bacteria present in the bacteria spore blend. Depending upon the bacteria, these percentages are based on the total cell number or colony forming units or the total mass of the bacterial preparation. For the Bacillus, the percentages are based on total cell number. Preferably, each of the strains is present in sufficient numbers to make up 10% to 70% of the total bacteria in the bacteria spore blend. When mixtures of more than two strains are employed, each of the strains is preferably present in an amount of from 20% to 40% of the total bacteria in the bacteria spore blend. Particularly preferred bacteria spore blends for general use in almost all applications are as follows:
% of total bacteria Species Range Preferred Bacillus licheniformis 20-60 40 Bacillus pasteurii 10-30 20 Bacillus laevolacticus 10-30 20 Bacillus amylolicruefaciens 10-30 20
[0024] In a preferred embodiment of the present invention, an effective amount of bacteria spore blend comprising one or more strains selected from the group consisting of Bacillus licheniformis, Bacillus pasteurii, Bacillus laevolacticus and Bacillus amyloliquefaciens, and combinations thereof, is provided in a state in which the bacteria spore blend may be applied to a carpet fiber or other fibrous material. The effective amount of bacteria spore blend is a sufficient amount of bacteria to provide a relatively uniform coverage of the fiber such that when any portion of the carpet is exposed to a deposit of an odor causing organic material, the bacteria will undergo rapid growth and consume the odor causing material. The factors which can affect the number of bacteria to be used relate in most part to the nature of the carpet material. Such factors include the nature of the fiber in terms of the material, e.g. nylon or polypropylene and the like, the characteristics of the yam in the terms of the denier and number of filaments and the characteristics of the fiber in terms of the number of yams and the twist. These factors relate to the nature of the carpet in terms of the weight (oz) and height of the yams. All of these factors will affect the amount of exposed surface of the fibers which might be covered by the bacteria spore blend. For most applications on carpet, between about 10 6 and 10 8 cells per gram of carpet fiber having a weight between about 20 oz and 40 oz is most effective with 10 7 cells per gram of carpet fiber being most preferred.
[0025] The bacteria spore blend may be provided as a simple aqueous preparation of a suspension of the Bacillus species in a suitable aqueous carrier, such as in distilled water, tap water, a saline solution, foam, spray or other such aqueous solutions. Preferably, the aqueous composition comprises the odor controlling dormant bacterial strain or strains and an effective amount of bacteria spore blend binder. The binder may be a fluorochemical, hydrocarbon, or any other topically applied treatments such as anti-stats, yam spin finishes, lubricant, etc.
[0026] When utilized with the bacteria spore blend binder the Bacillus species may be provided as active cells. The term “active cells” encompass cells in a vegetative form capable of immediate growth when exposed to food sources usually utilized by the bacteria. The term “dormant cells” is intended to encompass cells which are in a state which are required to be activated before they can undergo growth. One example of a dormant cell is a sporulated form of the bacteria where the spores must undergo activation and germination before growth of the bacteria can occur.
[0027] As noted above, due to the protective effects of the bacteria spore blend binder, the active bacteria would be protected from the possible effects of environmental factors. If the bacteria are provided in an active form, it is thought that they may become dormant after the application by undergoing sporulation until a deposit of organic material is encountered. In a preferred embodiment, the bacteria are provided in an already dormant or sporulated form. By providing the bacteria in a dormant or sporulated form, the bacteria are further protected from environmental factors which may prove detrimental to active bacterial cells. These environmental factors may include low moisture or humidity, as the carpet or other fibrous material would generally be kept in a dry state. Other factors may include exposure to heat, chemical agents, radiation from sunlight as well as the exposure to air for those strains which may be predominantly anaerobic.
[0028] The sporulated or dormant strains of bacteria become activated and undergo germination in response to being exposed to organic material including organic material which can cause odors. The factors which promote the activation of the dormant or sporulated bacteria include the moisture and various organic compounds present in the deposit of organic material. Once activated, the bacteria undergo growth and replication, consuming the organic material in the deposit until the material is consumed. After the material is consumed, the bacteria will then become dormant by undergoing sporulation to await exposure to another deposit of organic material. It is thought that the bacteria will also be somewhat cannibalistic, in that as the bacteria break down after the depletion of the organic material, the degradation products of the break down would be utilized as a food source by other of the bacteria. Once the potential energy source is reduced and the number of bacteria is also reduced, it is thought that the remaining bacteria undergo sporulation to return to a dormant state.
[0029] The bacteria spore blend odor control treatment can be applied to the carpet fibers at various stages of the manufacturing process. Additionally, the bacteria spore blend odor control treatment may be applied directly to the fibers prior to manufacturing. The following examples illustrate exemplary techniques for practicing the present invention.
[0030] [0030]FIGS. 1 and 2 illustrate an exemplary method of performing the present invention wherein the bacteria spore blend is topically applied to carpet utilizing a bacteria spore blend binder. Various carpet fiber compositions are suitable for bacteria spore blend application. For the purposes of this disclosure, the carpet fiber may consist of nylon 6, nylon 6,6, olefin, olefin nylon blends, extruded solution dyed nylon, extruded solution dyed polyester, polypropylene, wool, cotton or acrylic or polyester fibers or combination thereof. Each of these carpet fiber compositions are equally suitable for practicing the present invention and may be utilized in other fibrous floor coverings.
[0031] For this embodiment, the bacteria spore blend is applied to the carpet fibers to provide the carpet fibers with effective resistance to organic odors. Preferably, the bacteria spore blend binder is provided in solution with the bacteria spore blend. Preferably, the bacteria spore blend binder may be a fluorochemical, a hydrocarbon, or other topically applied treatment. The advantage of using a specific bacteria spore blend binder is that additional characteristics may be incorporated into the carpet fibers. For example, if a fluorochemical binder is utilized, anti-soiling properties may be incorporated into the carpet as well as acting as a binding agent for the bacteria spore blend. Hereinafter, the bacteria spore blend and bacteria spore blend binder are referred to as an odor treatment agent.
[0032] In the preferred embodiment, prior to application to the carpet, the odor treatment agent is diluted with a diluting agent which is preferably water to provide an odor treatment solution. Preferably, the odor treatment agent is intermixed with the water such that the odor treatment agent is 7.5% to 10.8% of the odor treatment solution wherein the bacteria spore blend component is of an amount resulting in a product on carpet as a percentage of face yam weight of 0.9% to 1.29%. Additionally, the odor treatment solution has a pH range between 1.0 to 12.0 with the preferable pH range being from 5.0 to 8.0. The odor treatment solution may be applied to the carpet fibers prior to manufacturing of the carpet or onto the carpet directly. If the odor treatment solution is applied to the carpet fibers prior to manufacturing, the carpet fibers must be pre-dyed.
[0033] When the odor treatment solution is applied to the carpet during manufacturing, it is important that the odor treatment solution be applied after all dying processes are complete. In the preferred embodiment, the odor treatment solution is applied at 15% wet add on, however wet add ons of between 5% to 25% are acceptable. Once applied, the odor treatment solution is cured. While the odor treatment solution may cure at ambient temperature, it is preferred that the carpet with the odor treatment solution is cured in a dry heat zone wherein the face temperature of the fibers are exposed to normal drying temperatures.
[0034] It has been found by the inventors, that two different properties may be applied to the carpet simultaneously saving product costs and manufacturing time. For instance, when utilizing an anti-staining agent such as a fluorochemical or a hydrocarbon as the bacteria spore blend binder during the odor treatment process, if a sufficient amount of fluorochemical or hydrocarbon is utilized in the odor treatment solution, the carpet will also be able to incur an anti-staining property. This requires that an additional amount of fluorochemical or hydrocarbon be present in the odor treatment solution other than an amount which would function solely as a binder for the bacteria spore blend.
[0035] If a fluorochemical is utilized as a bacteria spore blend binding agent, the fluorochemical component of the odor treatment solution is preferably 1.25% to 4.0% fluorine with a product on carpet of 150 ppm fluorine to 600 ppm fluorine. Accordingly, with this preferred embodiment, the carpet incorporates an odor control agent resulting from the incorporation of the bacteria spore blend bound to the carpet fibers via utilization of the fluorochemical in addition to incorporating an anti-soiling agent via the presence of the additional fluorochemical. This is the preferred embodiment as the carpet is treated with two separate desired treatments simultaneously resulting in cost savings.
[0036] In addition to spraying the odor treatment solution onto the carpet, the odor treatment solution may be applied via foam. When applied as a foam, the odor treatment solution has the same characteristics as previously described. When applied as foam the odor treatment solution may be required to be associated with a foam stabilizer and is preferably applied at a blow ratio of between 4:1 to 10:1.
[0037] Alternatively, a hydrocarbon may be utilized as the bacteria spore blend binder. When a hydrocarbon known as PM3180, provided by 3M Corporation of St. Paul Minn., was utilized, the odor treatment agent consisted of between 2 to 4% of the odor treatment solution with the product on yield percentage of face fiber of between 0.3% and 0.6% and applied at pH of between 1.0-12.0 with the preferable range being between 5.0 to 8.0 to achieve the desired anti-soiling properties.
[0038] In yet another alternative embodiment, the bacteria spore blend can be topically applied to carpet yarns using a yarn spin finish binder. Effective resistance to organic odors can be achieved by applying effective amounts of bacteria spore blend during the extrusion process. At this stage in the manufacturing process, the carpet yarn consists of extruded solution dyed nylon, extruded solution dyed polyester and polypropylene. The details of the extrusion process are known to those skilled in the art and thus it is beyond the scope of this disclosure to examine it in detail here. For the purposes of this embodiment, the extruded carpet yarn is treated with bacteria spore blend, either in liquid form or by utilizing an aqueous medium as described in detail in the embodiment previously described, at levels of product on carpet of 0.9% to 1.29%.
[0039] In yet another alternative embodiment of the present invention, bacteria spore blend may be applied to pre-dyed carpet fibers in liquid form, along with fluorochemical compounds, at a stage upstream from the final winding process that turns the carpet fibers into yarn.
[0040] Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
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The present invention is a method for treating a fibrous material to control odor associated with deposits of organic matter. The present invention involves the steps of providing a fibrous material; applying an effective amount of an odor treatment solution which includes a bacteria splore blend wherein the solution has a pH within the range of 1 to 12. The invention also contemplates simultaneously applying an odor control agent and an anti-soil treatment to carpet fibers.
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This is a continuation of application Ser. No. 08/779,952 filed Dec. 23, 1996, now U.S. Pat. No. 5,727,502.
BACKGROUND OF THE INVENTION
This invention relates to a convertible structure which can be assembled for use either as a pet home or as an exercise pen for the pet and which can be readily converted between the two uses. The invention is intended primarily for use as a dog home and exercise pen but can also be used for other animals such as rabbits.
Separate dog homes and exercise pens are currently available and if pet owners desire each item, they must make two separate purchases. This is a large outlay, since each item can be somewhat expensive. The current practice is also inconvenient in its use of storage space, since typically only one item is in use at any time, and is wasteful of materials in that similar wall panels may be used in each product, but are not utilized together.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a combination structure which can be assembled either as a pet home or as an exercise pen, which can be readily converted between the two uses and which can be knocked down, when not in use to form a compact readily transportable and storable package.
It is another object of the invention to provide a combination structure as above which is converted from a home to an exercise pen by the addition of a wall module assembly. A further object of the invention is to provide the combination with the facility for adding further wall module assemblies, as required, to increase the size of the exercise pen.
Another object of the invention is to provide a combination structure, as above, which is more economical to manufacture and purchase than a separate pet home and exercise pen of comparable scale.
Still another object of the invention is to provide a combination pet home and exercise pen in which maximum use is made of the wall panels of the pet home when converting the structure into an exercise pen.
Yet another object of the invention is to provide a combination pet home and exercise pen which is simple to set up, take down and convert from one use to the other.
Generally stated, the invention provides a combination pet home/exercise pen structure comprising a plurality of interconnected hinged panels, preferably wire mesh panels, which fold into a compact package with the panels overlaid one on another, which can be erected into a pet home having a base, side walls, end walls and a flat roof, by unfolding the panels and clipping adjacent panel edges together, and which can be converted from a pet home to an exercise pen by unclipping the panels, setting the pet home on one end, folding the end walls in against the base, opening out the side walls and roof and clipping one or more additional wall module assemblies (each comprising two or more hinged wall panels of similar configuration to the side wall panels) to free outer edges of the one side wall and the roof respectively to form a pen enclosure.
In a preferred form of the invention, the base of the structure may comprise upper and lower walls defining a compartment therebetween forming a storage receptacle for the additional pen-forming wall module assembly with its respective panels folded together one against another. The base may also include a second compartment for a slide-out tray for pet droppings, etc.
Conveniently, hooks may be provided at the edges of selected walls of the structure for hooking onto end rods of adjacent walls to clip the walls together when the structure is erected and which can readily be unhooked when the structure is to be folded. The configuration of the clips, the side walls, the end walls and the roof, may be such that in the erected position of the pet home, the roof can be unhooked from the side walls and end walls and hinged open, like the lid of a box, without affecting the integrity of the side walls and end walls. Other forms of clipping means can also be used however.
A first pet access door may be provided in one of the end walls and a second pet access door may be provided in one of the panels of the additional wall module assembly. The pet home portion of the structure can be sold separately (without the additional wall module assembly) for users who do not require the exercise pen facility and likewise, additional wall module assemblies can also be sold separately as add-ons. The size of the exercise pen can be increased by further add-on assemblies, as required.
Additional features and advantages of the invention will become apparent from the ensuing description and claims read in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic end view of a convertible structure according to the invention, in a folded configuration for storage and transport;
FIG. 2 is a diagrammatic perspective view of the structure showing a first stage of unfolding same to erect a dog home;
FIG. 2A is a diagrammatic perspective view of the structure showing a second stage of unfolding same to erect a dog home;
FIG. 3 is a diagrammatic perspective view of the structure when erected as a dog home;
FIG. 3A is a rear end view of the erected dog home;
FIG. 3B is a plan view of the dog home;
FIG. 3C is a side view of the dog home;
FIG. 3D is a front end view of the dog home;
FIG. 3E is an enlarged perspective view of one top corner of the dog home;
FIG. 4 is a diagrammatic perspective view of the structure showing a first stage in converting the dog home into an exercise pen;
FIG. 5 is a diagrammatic perspective view of the structure showing a second stage in converting the dog home into an exercise pen by adding on an additional wall module assembly;
FIG. 6 is a plan view of the completed exercise pen;
FIG. 7 is a plan view of an enlarged exercise pen made by adding on a further additional wall panel assembly;
FIG. 7A is a side view of the additional wall module assembly;
FIG. 7B is an enlarged part-sectional plan view of a part of FIG. 7A;
FIG. 7C is an enlarged plan view of another part of FIG. 7A; and
FIGS. 8 and 9 are enlarged plan and side views respectively of hooks which are provided on selected walls of the structure for clipping adjacent walls together when erecting the structure.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings show a collapsible structure 10 (FIG. 1) which can be erected to form a dog home as illustrated in FIGS. 3-3E, which can be converted from the dog home into an exercise pen for the dog as shown in FIGS. 6-7, and which can be folded and collapsed into a flat compact package as shown in FIG. 1. The collapsible structure comprises two basic modules, namely a dog home forming module 12 and an additional pen-forming wall module 14, both of which modules are made up of wire mesh panels or grids.
The home forming module 12, (See particularly FIGS. 1-3) comprises a rectangular base 15 with a top wall 16, end walls 18, 20 hinged to opposite ends of the base, side walls 22, 24 hinged to opposite sides of the base and a roof 26 hinged at one side to the top edge of side wall 24. The end walls 18, 20 can fold down onto the top wall 16 of the base one over another, followed by side walls 22 and 24 and roof 26, which can fold down onto side wall 24. Thus module 12 can be collapsed into the compact substantially flat package shown in FIG. 1.
The base 15 is formed by upper and lower shallow rectangular trays 28, 30 both made of wire mesh and which may be secured together by crimped cylinders 31 (see FIGS. 3A and 3D) engaged around adjacent rods of the respective trays, or by other suitable attachment means. Top wall 16 is similarly attached to tray 28. Tray 28 forms a receptacle for a slide-in animal droppings pan 32 and tray 30 forms a receptacle for folded wall forming module 14. A bar 36 at one end of tray 30 (see FIG. 3A) forms a stop for module 14 and bars 38 at the opposite end of tray 28 form a stop for pan 32. A pivotal wire rod clip 40 may be provided at the other end of tray 28 to form a releasable catch holding pan 32 in place. Clip 40 is similar to clip 26 which is disclosed in copending application Ser. No. 08/459,497 field Jun. 2, 1995 and commonly assigned herewith, the contents of which are expressly incorporated herein by reference.
End walls 18 and 20 are pivotally connected to opposite ends of top wall 16 by further crimped cylinders 31. At its sides, tray 28 extends somewhat above wall 16, and wall 24 is pivotally attached at one side of tray 28 by additional crimped cylinders 31 while wall 22 is similarly attached to the other side of tray 28 at a slightly higher level so that the side walls, end walls and roof can be folded down onto the base in a stacked arrangement as shown in FIG. 1. Roof 26 is pivotally connected to side wall 24 by further crimped cylinders 31. (In the pivotal connections between the respective walls, it is understood that in each case, the cylinders 31 are crimped around adjacent end rods of the grids forming the respective walls as, for example, the end rods 24a, 26a shown in FIG. 3E by way of example.)
The roof 26 is provided along its free edges with hooks 42 for releasably clipping the roof to side wall 22 and to end walls 18, 20. The side walls 22 and 24 have like hooks 42 at their opposite ends for releasably clipping to the end walls 18, 20. As shown in FIGS. 8 and 9, each hook 42 is formed from a wire rod bent in a yoke-like shape with elongated legs 42a welded to a respective one of the walls 18-24 or roof 26, and a resilient saddle-shaped top hook portion 42b which is depressed at 42c to provide a resilient obstruction for an end rod of one of the walls of the structure when it is fitted into the hook. In each case, the hooks are welded in place so that the closed end of the hooks project slightly from the end of the respective wall on which they are attached. The arrangement is such, in each case, that as the structure is unfolded and opened out, the end rods of the respective walls can be push fitted into the hook of an adjacent wall to connect the walls together into a rigid elevated structure. FIG. 3E shows, for example, how end rod 18a of wall 18 fits into hook 42 on the roof 26 and how end rod 18b fits into hook 42 on the side wall 24. As seen in FIG. 3, the roof 26 has three hooks 42 along one side to connect with side wall 16 and two hooks 42 at each end to connect with end walls 18 and 20. The side walls 18 and 20 have two hooks 42 at each end to connect with the end walls 18 and 20. The remaining figures show a smaller model in which the number of roof hooks is reduced by one along each side of the structure.
End wall 18 has a pivotal lift-up animal access door and latch structure 44 for the dog home of like form to the door structure 28 described in the above-noted copending patent application and the details of which will not therefore be described herein. Reference is made to the copending application for such detail. When erected, the dog home is used in known manner and it will be understood that it can again be collapsed and folded, when required, by reversing the steps described above.
When the structure is collapsed into the package shown in FIG. 1, end walls 18, 20 are folded down onto base wall 16 with wall 18 lying over wall 20. Side wall 22 at its upper end is hooked to roof 26 by the hooks 42 along the side edge of the roof but all of the other hooks 42 are disconnected. This allows the side walls and roof to be folded down as a hinged unit onto base wall 16 over the end walls 18, 20 with side wall 24 lying over end wall 18, roof 26 lying over side wall 24 and side wall 22 at the top.
To elevate and erect the structure into a dog home, wall 22 and roof 26 are lifted by their hooked-together edges, see FIG. 2 and the side walls and roof are unfolded, opened out and elevated into an open-ended box as seen in FIG. 2A. Then, the end walls 18, 20 are raised from the base and their edges are engaged in the hooks 42 provided at the ends of the side walls and roof. This forms the structure into a rigid dog home as shown in FIG. 3. To collapse the dog home, the procedure is reversed, the end walls first being unhooked and folded down onto the base and the hooked-together side walls and roof being mutually folded and collapsed back through the FIG. 2 configuration down onto the base over the end walls. In these operations, the roof remains hooked to side wall 22 and the hooks 42 act as hinges during the unfolding and folding operations.
According to another feature of the invention, when the dog home is erected as shown in FIG. 3, there is sufficient flexibility in the structure to allow all of the roof hooks 42 to be released, by pressing in the top edges of the side walls and end walls while the wall hooks 42 remain engaged, so that the roof 26 can be hinged open in the manner of a box lid as shown in the dotted line position. The roof can be hooked again to the side walls and end walls in similar manner.
The dog home shown in FIG. 3 can be formed into an exercise pen in the manner illustrated in FIGS. 4 to 6 by using the additional wall-forming module 14. As shown in FIG. 4, the home-forming module 12 is set on one end, and the end walls 18 and 20 are folded in against the base 15 (or are kept folded against the base if starting from FIG. 1). A pivotal S-type hook 46 (FIGS. 3A, 3B) may be provided on a rod of one end wall to clip an adjacent rod of the other end wall to retain the end walls in place against the base. For this operation, the roof 26 is unhooked from side wall 22, side wall 22 is folded out to the position shown in FIG. 4, as are the side wall 24 and roof 26.
The additional wall-forming module 14, in the illustrated embodiment, is formed by four pivotally interconnected walls 48, 50, 52, 54 each formed by a metal grid of the same dimensions as the side walls 22, 24 and being pivotally interconnected along their longer edges by additional crimped cylinders 31. Walls 48-54 can fold against one another as shown in FIG. 1 to fit into tray 30 and can be removed and opened out to the position shown in FIGS. 5 and 6 to be attached to the home-forming module.
Wall 54 has hooks 42 along one edge to fit with end rod 22a of wall 22 (FIG. 7c) and the end rod of wall 48 fits into the hooks 42 on the adjacent edge of wall 26 to form the structure into an enclosed exercise pen as shown in FIG. 6. Wall 52 has a cut-out 52a (See FIG. 5) for a pivotal access door 52b secured by crimped cylinders 31 and provided with releasable S-type clips 46 for opening and closing the door. It is evident that the exercise pen can be readily dismantled and folded away into the package shown in FIG. 1. Additional S-type hooks may be provided on the roof 26 or wall 24 to clip onto wall 22 in the folded condition of the structure to retain the walls in place.
It is evident that the exercise pen can be readily reconverted into the dog home, or knocked down and refolded into the package shown in FIG. 1.
If a larger exercise pen is required a second wall module like wall module 14 and comprising walls 48', 50', 52', and 54' can be connected between wall 54 and wall 22 as shown in FIG. 7.
While only preferred embodiments of the invention have been described herein in detail, the invention is not limited thereby and modifications can be made within the scope of the attached claims.
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A collapsible pet home having a base, side walls, end walls and a roof can be converted into an exercise pen for the pet by folding the end walls down onto the base, setting the base on end and using the base, side walls and roof to form peripheral walls of the exercise pen. An additional pen-forming module is provided to connect with the roof one side and one of the side walls on the other side to complete the peripheral wall of the exercise pen. The base may have a compartment for storing the additional module when it is not in use. The entire structure folds down into a compact package.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for driving tools and in particular relates to pneumatically driven tools for use in combination with other machine tools.
2. Description of the Prior Art
Many machine tool applications, particularly production applications, require a variety of special tooling packages specifically designed for one type of application. Often this requires production of custom tooling to suit a specific customer's needs. For example, pneumatic valve grinders such as shown by Kelly, "Valve Grinder", U.S. Pat. No. 2,614,372, or pneumatic crank pin grinders such as shown by Prill, "Crank Pin Grinder", U.S. Pat. No. 2,257,619, typify apparatus which are not only specifically designed for a particular type of grinding or tooling application, but are also customized to a specific model valve seat or crank pin.
Other pneumatic grinders are also well known in the art where the grinder serves as a fixed machine head or as a general-purpose hand-held tool, such as used for polishing as shown by Birkenstock, "Pneumatic Polishing Tool", U.S. Pat. No. 691,740, Kakimoto, "Pneumatically Driven Grinder", U.S. Pat. No. 3,885,335, or Kakimoto, "Small Diameter Cylindrical Air Motor for Driving Grinders and the Like", U.S. Pat. No. 3,827,834. However, when applied in combination with standard lathes or milling machines, such independently driven grinding apparatus have typically been mechanically powered by gear trains or belts and pulleys by the same machinery used to power the lathe. An example of this prior art practice is shown by Blood, "Grinding Machine", U.S. Pat. No. 1,970,645, and by Fletcher, "Pneumatic Tool", U.S. Pat. No. 833,710.
Even in those cases where a pneumatically driven tool is combined with a standard engine lathe its use has been limited and restricted by the limitations imposed upon the tooling by the fixed mechanical coupling, usually through a drive shaft, between the pneumatic motor and the grinding wheel, see, for example, Rhinevault, "Grinding Machine", U.S. Pat. No. 1,236,604.
What is needed is some means of configuring a pneumatically driven tool so that it can be treated as a universal tool used in combination with standardized, quick-change tool holders in conventional milling machines or lathes. In addition, some means is needed to conveniently select both the position and the orientation of the pneumatically driven tool with respect to the workpiece without having a customized tool for each position or oeientation. In addition, a means is needed whereby the operating speed of the grinding wheel coupled to the pneumatically driven motor wheel can be varied or changed, again without having a completely separate tool for each application.
These and other objects of the present invention can be best understood by considering the following brief summary of the invention.
BRIEF SUMMARY OF THE INVENTION
The present invention is an improvment in a pneumatic drive for a tool such as a grinder used in combination with conventional engine lathes, milling machines and the like, and is particularly adapted for coupling to a conventional quick-change tool holder. The improvement comprises a pneumatic motor included within a modular turbine housing including a drive shaft extending from the pneumatic motor for engagement with the tool or grinding wheel. A modular delivery tube is connected to the turbine housing and supports the turbine housing in the predetermined orientation and position. The delivery tube also includes an internal tube for delivering pressurized air to the pneumatic motor. By reason of this combination of elements, the tool may be pneumatically driven in an arbitrary position and orientation by appropriate selection of the shape and length of the modular delivery tube connected to the turbine housing, thereby allowing the pneumatically driven tool or grinder to be easily adapted for use with standardized production machinery. The delivery tube is arranged and configured at its end, distal from the turbine housing, for connection with the quick-change tool holder so that the pneumatic drive of the present invention is as quickly interchangeable with the quick-change tool holder as a standardized tool. In addition, the delivery tube is interchangeable with a plurality of pneumatic motors which are included within a corresponding turbine housing connected to the delivery tube so that pneumatic motors characterized by different operating speeds can be selectively coupled to the delivery tube for each application.
These and other embodiments of the present invention can best be understood by viewing the following Figures in light of the Detailed Description of the Preferred Embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view showing the principal operable portion of a standard engine lathe having a quick-change tool holder coupled to a grinding bar devised according to the present invention.
FIG. 2 is a perspective view in enlarged scale of the grinding bar shown in FIG. 1.
FIG. 3 is a sectional view in enlarged scale taken through lines 3--3 of FIG. 2.
FIG. 4 is a sectional view taken through lines 4--4 of FIG. 3.
FIG. 5 is a sectional view taken through lines 5--5 of FIG. 3.
FIG. 6 is a perspective view of a second embodiment of the present invention wherein the turbine housing and delivery tube are oriented at right angles with respect to each other.
FIG. 7 is a perspective view of a third embodiment of the present invention wherein the delivery tube is combined with an inlet collar allowing the delivery tube to be rotated.
FIG. 8 is a sectional view in enlarged scale taken through lines 8--8 of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is an improved universal pneumatic grinding bar which can be coupled to standardized quick-change, tool holders and used in combination with conventional lathe and milling machines. The length of the grinding bar, as well as the shape, may be changed by combining interchangeable parts which constitute the grinding bar, as described in greater detail below. The pneumatic motor used in combination with the grinding bar may also be easily changed to effect various operating speeds.
Referring now to FIG. 1, a standard lathe 10 is generally denoted by a reference character 10 and includes a spindle housing 12 coupled to a conventional three jaw chuck 14. Bed 16 of lathe 10 provides the support base for a conventional tail stock 18 and carriage 20. In the application illustrated in FIG. 1 carriage 20 provides a means for mounting a standardized, quick-change tool holder 22 generally used as a universal tool post. The grinding bar of the present invention, generally denoted by reference number 24, is clamped into tool holder 22 in a conventional manner and centered with respect to workpiece 26. In the illustrated embodiment, workpiece 26 is a boiler tube in which hard sediments 28 have accumulated. Tube 26 has been removed from the boiler and placed within engine lathe 10 for internal grinding by grinding bar 24.
Grinding bar 24 includes a grinding wheel or tool 32, turbine housing 34 and delivery tube 36. Drive shaft 30, a segment of which is shown in FIG. 1, is coupled to conventional grinding wheel 32 which is used to ream sediment 28 from pipe 26. Grinding wheel 32 is driven by shaft 30 by a pneumatic motor shown and described in greater detail in connection with FIGS. 3 and 4 which motor is included within turbine housing 34. Turbine housing 34 in turn is connected to delivery tube 36 which is directly mounted in quick-change tool holder 22. The end of delivery tube 36 is provided with an end cap 38 which includes a fitting for high pressure air hose 40. Air pressure is delivered from a conventional air source (not shown) through house 40 via delivery tube 36 to the pneumatic motor contained within turbine housing 34 to drive grinding wheel 32.
As will be discussed below, various types of pneumatic motors included with turbine housing 34 may be combined with any given delivery tube 36, and similarly a plurality of different shapes and lengths of delivery tubes 36 may be combined with any given turbine housing 34 to arbitrarily orient and position grinding wheel 32 with respect to workpiece 26.
Referring now to FIG. 2, a perspective view of grinding bar 24 is shown in enlarged scale which more clearly illustrates the basic components of grinding bar 24. Grinding bar 24 is modular in construction, as described above. A plurality of pneumatic motors insertable in turbine housing 34 can be combined with differently shaped delivery tubes 36 of different lengths to obtain a grinding bar having the operating speed and configuration desired for any given application.
In the illustration of FIG. 2, drive shaft 30 is clearly shown wth grinding wheel 32 removed. In the preferred embodiment, turbine housing 34 and delivery tube 36 each have a generally cylindrical, elongated outer configuration of substantially equal diameter. Delivery tube 36 can be conveniently clamped within a corresponding cylindrical bore (not shown) within standardized quick-change tool holder 22 shown in FIG. 1.
FIG. 2 also illustrates in greater detail the configuration of stationary end cap 38 when cap 38 is disconnected from house 40. End cap 38 is connected to that end of delivery tube 36 distal from turbine housing 34 and includes a plurality of exhaust ports 42 circumferentially defined about an axial inlet port 44. Hose 40 couples to inlet port 44 through a threaded nipple and provides high pressure air through inlet port 44 to the pneumatic motor described in greater detail in FIG. 3. The exhaust air, once having expended its energy in the pneumatic motor, is then returned through a bore defined in delivery tube 36, again better described in connection with FIG. 3, to exhaust ports 42 in end cap 38. Thus, large volumes of expended air are released from grinding bar 24 at a position well separated from maching site so that debris and cutting oil are not disturbed or blown about by the spent exhaust air of the pneumatic motor.
The internal details of operation of grinding bar 24 can now be described and understood in connection with FIG. 3. FIG. 3 is a sectional view in enlarged scale taken through lines 3--3 of FIG. 2 along the longitudinal axis of grinding bar 24. Beginning with the righthand end of grinding bar 24 in FIG. 3, end cap 38 is shown as connected to delivery tube 36 by means of conventional threading 46. Exhaust ports 42 are extended to form axial passages 48 through end cap 38, each axial passage 38 lying in a direction parallel to the longitudinal axis of grinding bar 24 and uniformly offset therefrom. Axial inlet port 44 is also shown as including conventional threading 50 into which is standardized fitting 52 has been threaded as illustrated in FIG. 3. Inlet port 44 extends into end cap 38 to form an axial passage 54 therethrough for communication and coupling to a pressure tube 56. Pressure tube 56, included as part delivery tube 36, slip fits into passage 54 and provides an axial tube through an internal bore 58 defined in a support housing 60 which forms the outside casing of delivery tube 36. Pressurized air from an external source is delivered through fitting 52, passage 54 and into pressure tube 56 in bore 58 to the opposing end of delivery tube 36.
Delivery tube 36 is best coupled to turbine housing 34 by means of conventional threading 62. Turbine housing 34 and support housing 60 are separated by a space 64 between end 66 of support housing 60 and a shoulder 68 of turbine housing 34. Space 64 is best shown in plan view in FIG. 5 which shows a sectional view through lines 5--5 of FIG. 3.
Referring now to FIG. 5, space 64 is shown as including a plurality of metering ports 70 which are defined in turbine housing 34 and circumferentially disposed about the longitudinal axis of support housing 60. Thus, as will be described in greater detail below, ports 70 provide a means by which spent air from the pneumatic motor moves from turbine housing 34 into bore 58 of delivery tube 36 for eventual exhaust into the ambient environment through exhaust ports 42.
Referring now, again, to FIG. 3, the operation of the pneumatic motor, generally denoted by reference numeral 72, can better be described. As shown by the arrows, air enters motor 72 through an "L-shaped" inlet port 74 in a channel bushing 102 into which port 74 pressure tube 56 slip fits. Inlet port 74 directs the pressurized air upward, as shown in FIG. 3, into a inlet passage 76 in a rear bearing holder which then distributes the pressurized air across three motor inlet ports 78.
As better seen in sectional view in FIG. 4, taken through the lines 4--4 of FIG. 3, turbine housing 34 includes an axial cylindrical bore 80 into which pneumatic motor, generally denoted by reference character 72, is inserted. Pneumatic motor 72 is comprised of a motor housing in the form of a ovulate cylindrical casing 82 with flattened surface 86 through which motor outlet ports 88 are defined. Pressurized air from inlet passage 76 enters delivery slot 84 defined in the ovulate portion of casing 82 and is distributed into an internal turbine bore 90 of motor 72. A rotary turbine 92 is axially disposed within turbine bore 90 and includes three radial vanes 94 providing a sliding seal with bore 90. Vanes 94 divide turbine bore 90 into three chambers. As shown in FIG. 4, as one chamber fills with pressurized air it is driven in a counterclockwise sense, rotating until the leading vane 94 uncovers motor outlet ports 88 allowing a sudden decrease of pressure. Pressurized air exhausted through outlet port 88 is communicated through an exhaust passage 96, a portion of which is shown in FIG. 3, which passage 96 ultimately communicates with each of metering ports 70 communicating with space 64 as described above in connection with FIG. 5. Ports 70 are defined by a plurality of cylindrical exhaust bores 71 defined in turbine housing 34, each bare 71 having a longitudinal axis parallel to the longitudinal axis of turbine housing 34. Bores 71 extend far enough into turbine housing 34 to communicate with space 96 defined between bore 80 of turbine housing 34 and flat surface 86 of motor casing 82, as shown in FIG. 4, into which space 96 the exhaust air from motor 22 is delivered. The surface of bore 80 intersects the surface of bores 71 so that bores 71 are half-opened cylindrical passages everywhere except in the right hand portion of turbine housing 34 as shown in FIG. 3 where the bores 71 form circular ports 70 shown in FIG. 5. Each of the plurality of exhaust bores 71 are communicated by an annular ring-shaped passage 73 defined in bore 80 of turbine housing 34. As shown in FIG. 5, no exhaust bore 71 is formed in turbine housing 34 where delivery slots 84 in casing 82 are disposed. Passage 73 communicates with bores 71 at a point to the left of slots 84 as depicted in FIG. 3.
Returning again to FIG. 3, drive shaft 30, from which vanes 94 radially extend, is shown as journaled at each end within motor casing 82 by conventional ball bearings 98. The ends of motor casing 82 are pneumatically sealed by means of end plate 100 on the left end and by means of a rear bearing holder 101 which includes inlet passage 76 at the right end of motor casing 82 as shown in FIG. 3. Bearing holder 101 is forced against channel bushing 102, which in turn bears against the bottom portion of turbine housing 34.
Turbine housing 34 includes an end cap 106 screwed to the end of turbine housing 34 to securely retain bearings 98 and motor 72 within turbine housing 34. Bushing and rear bearing holder 101 on the right hand side of FIG. 3 must be aligned with delivery slots 84 formed in casing 82 in addition to having motor casing 82 fixed or stabilized within turbine housing 34. As shown in FIG. 5, an alignment pin 104 is provided which extends from motor casing 82 at one end through channel bushing 102 and into turbine housing 34 at its other end. Although shown in the lower portion of motor casin 82 for clarity in FIGS. 3 and 5, alignment pin 104 may be placed near and offset from inlet passage 76 in the ovulate portion of casing 82, thereby insuring the stability and alignment of motor 72 within turbine housing 34.
Therefore, different operating speeds can be obtained by inserting differently designed pneumatic motors 72 in turbine housing 34. Turbine housing 34 and motor 72 together with end cap 106 may alternatively form a unit which can then be coupled or uncoupled to delivery tube 36 as desired. Different motors can thus be inserted or coupled to delivery tube 36 as desired for each application at hand by a quick connect screw type fitting.
As described above, delivery tube 36 and turbine casing 34, together with motor 72, may assume a variety of angular orientations with respect to each other to enhance the adaptability of grinding bar 24. For example, referring to FIG. 6, a second embodiment is shown wherein the grinding bar, generally denoted by reference character 108, is shown as including a delivery tube, generally by reference character 36, which tube is coupled at right angles to a turbine housing, generally denoted by reference character 110. Instead of coupling through the end of turbine housing 110 as is the case of turbine housing 34 in the embodiment of FIG. 3, delivery tube 36 is coupled through the side of turbine housing 110 by means of a screw fitting 112 provided for that purpose. The details of fitting 112 are not shown, but can be deduced using design principles well known in the art. For example, the inlet passage coupled to the pneumatic motor included within turbine housing 110 of FIG. 6 could be extended through the side wall of turbine housing 110 at its mid-axial length as shown in FIG. 6 and then extended at right angles therefrom to screw type fitting 112. Fitting 112 would then include a metering plate similar to plate 64 of the embodiment of FIGS. 3-5.
A third embodiment of the present invention is illustrated in FIG. 7 wherein delivery tube 36 and turbine housing 34 of the embodiment of FIGS. 2-5 are modified so as to be coupled to a rotating end cap 114 held within an inlet collar 116. The details of rotating end cap 114 and inlet collar 116 are better understood in connection with FIG. 8 which is a sectional view in enlarged scale taken through lines 8--8 of FIG. 7.
Rotating end cap 114 includes a solid stem 118 integrally formed with body 120. Body 120 has defined therein a diametric, transverse passage 122 communicating with an axial passage 124 also defined in body 120. As before, pressure tube 56 of delivery tube 36 slip fits into axial passage 124 of body 120 but loosely enough to allow body 120 to rotate with respect to pressure tube 56. Body 120 also has defined therein a plurality of circumferential exhaust passages 126 which communicate with internal bore 58 of delivery tube 36, and which communicate with corresponding exhaust ports 128. Exhaust passages 126 are axially defined passages offset from the longitudinal axis of rotating end cap 114, which passages communicate with corresponding transverse passages 130, which in turn terminate in exhaust ports 128. Spent air from pneumatic motor 72 communicates through internal bore 58 of delivery tube 36 to exhaust passages 126 and thence ultimately to the ambient environment through exhaust ports 128.
Rotating end cap 114 is disposed through a corresponding axial bore 132 defined in inlet collar 116. End cap 114 rotates with respect to inlet collar 116 and is pneumatically sealed by means of a pair of O-rings 134 laid in annular O-ring grooves 136 defined in inlet collar 116. Rotating cap 114 is longitudinally retained to inlet collar 116 by means of a pair of snap rings 38 disposed in annular snap ring grooves 140. Snap rings 38 extend from snap ring grooves 140 to engage the side of inlet collar 116.
Inlet collar 116 has an inlet passage 142 defined in a stem portion which passage 142 terminates in an outlet port 144 into which a standard nipple fitting 146 is shown disposed. At its opposing end inlet passage 142 terminates in a ring-shaped passage 148 which communicates with the openings of transverse passage 122 defined in body 120. Thus, as end cap 114 rotates, the two end openings of transverse passage 122 are always in free communication with the angular ring-shaped passage 148 of inlet collar 116. Ring-shaped passage 148 forms an open, collar-shaped passage around end cap 114 so that pressurized air is supplied through inlet collar 116 into rotating end cap 114 without any impediment to the free flow of air into end cap 114 dependant on their relative angular orientation.
Although the present invention has been described in context of a particularly illustrated embodiment, it must be understood that many modifications and alterations may be made by those having ordinary skill in the art without departing from the spirit and scope of the present invention. For example, although delivery tube 36 has been shown either in a straight configuration as shown in FIG. 2, or in a right angle configuration as shown in FIG. 6, it is clearly contemplated within the present invention that delivery tube 36 may be angled along its length or curved to an arbitrary degree to provide any orientation of drive shaft 30 with respect to workpiece 26 as desired. For example, it is entirely within the scope of the present invention that an adjustable joint could be included as part of delivery tube 36 whereby an arbitrary bend in delivery tube 36 could be effected and fixed. Similarly, although turbine casing 34 of the embodiment of FIG. 2 has been shown as being coupled to delivery tube 36 in the embodiment of FIG. 7, it is expressly contemplated that turbine casing 110 with end fitting 112 could also be fitted to delivery tube 36 of the embodiment of FIG. 7 with equal ease and operability. Thus, the right angled bend of the embodiment of FIG. 6 could be used in combination with the rotating end cap 114 of the embodiment of FIG. 7.
Therefore, what has been described is a universal, pneumatically driven machine tool which can be easily adapted and used in combination with a conventional, quick-change tool holder in standard lathes and milling machines without the limitations and restrictions of custom designed, pneumatic grinding machinery typified by the prior art. By virtue of the interchangeability of the various components of the present invention, differing speed and power rated pneumatic motors can be combined with various types of delivery tubes to provide a large combinational variety of grinding bars for virtually any application.
Therefore, the above embodiments have been described only for the purposes of clarification and example and should not be taken as limiting the scope of the invention as set forth in the following claims.
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A universal grinding bar adapted to be connected to a standardized, quick-change tool holder can be devised for use with conventional engine lathes, milling machines and the like and used as a standardized tool without the limitations of direct coupling to the drive of the engine lathe or milling machine. The universal grinding bar includes a modular delivery tube of selected shape and length and a modular turbine housing connected to the delivery tube and including a selected one of a plurality of pneumatic motors characterized by different operating speeds. Pressurized air is coupled through the end of the delivery tube distal from the turbine housing and is delivered to the pneumatic motor through a pressure tube. The spent air is then returned through a metering plate between the turbine housing delivery tube through an internal bore within the delivery tube to exhaust ports at the distal end. The delivery tube is of such diameter to allow connection to a conventional quick-change tool holder. By appropriate selection of the pneumatic motor and length and shape of the delivery tube, a grinding tool driven by the pneumatic motor can be arbitrarily positioned and oriented with respect to a workpiece without the need for special drives or attachments.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to water-soluble organotin catalysts.
2. Description of the Prior Art
The use of organotin compounds as catalysts for esterification and transesterification reactions and for preparing or curing polymers, especially polyurethanes, polysiloxanes and polyesters, is known.
Examples of organotin catalysts common on the market are mono- and dialkyltin compounds of tetravalent tin, of the formulae:
R a SnX a 3 , R a 2 SnX a 2 , [R a 2 SnO] x , R a SNOOH
or
where
R a =alkyl group of 1 to 8 carbon atoms,
R b =R a or X a ,
X a =—O—, —OH, —O—, halide, —OR d , OOCR d , —SR d , where R d is a linear or branched, saturated or unsaturated, unsubstituted or substituted alkyl group,
x is ≧2, and y is ≧1.
The precise structure of the organotin oxides is unknown, it being assumed, however, that they are present at least as dimers.
Their use for conducting addition polymerization, polyaddition, polycondensation or curing frequently takes place in aqueous or water containing systems, in connection, for example, with the production of coatings, water-blown polymer foams, etc.
When used in aqueous or water-containing systems, organotin catalysts according to the prior art have the disadvantages of lack of solubility in water and/or lack of stability to hydrolysis and/or lack of catalytic activity.
The great majority of the known organotin compounds are insoluble or only sparingly soluble in water. If used as catalysts in aqueous systems, therefore, they cannot be used as homogeneous solutions in water but must be incorporated heterogeneously as mixtures, emulsions or suspensions, in some cases with the assistance of solvents, detergents or other auxiliaries.
Only a few organotin compounds of good solubility in water are known. Primarily these comprise highly acidic monoalkyltin and dialkyltin compounds having short-chain alkyl groups, examples being (C 4 H 9 )SnCl 3 , (CH 3 ) 2 SnCl 2 , (CH 3 ) 2 Sn(O 3 SCH 3 ) 2 , and (C 4 H 9 ) 2 Sn(O 3 SCH 3 ) 2 .
When such organotin compounds are dissolved in water, an at least partial hydrolysis takes place immediately; stannoxanes—which are initially soluble in the acidic system—and the corresponding acids (e.g., HCl, HO 3 SCH 3 ) are formed. The acidic solutions which form are highly corrosive, which is disadvantageous for the majority of applications. Furthermore, the acids which are released reduce the catalytic activity of the organotin compounds, rendering such solutions unsuited to many catalytic applications (the condensation of silicones, for example).
If it is attempted to neutralize such acidic solutions, the organotin compounds are precipitated as stannoxanes, polystannoxanes or organotin oxides.
Organotin carboxylates and organotin alkoxides are generally neither soluble in water nor stable to hydrolysis. On contact with water, they decompose with the formation and precipitation of stannoxanes, polystannoxanes or organotin oxides.
Organotin mercaptides are generally likewise insoluble in water. Compared with other organotin compounds, however, they are notable for their greater stability to hydrolysis. However, the stability goes hand in hand with a markedly reduced catalytic reactivity.
While in certain systems (in a mixture with isocyanates, for example) a subsequent chemical or thermal activation of organotin mercaptides can take place, with the formation of more active catalysts, the catalytic activity of these mercaptides in less reactive systems, such as silicones, is inadequate, if indeed it is present at all.
There is thus a need to find organotin catalysts which are intended for use in aqueous or water-containing systems and which are storage-stable and soluble in water, contain no free strong acids, possess catalytic activity, and do not lose this activity even on prolonged storage in or contact with water.
SUMMARY OF THE INVENTION
The invention is directed to a process for preparing water-soluble organotin catalysts by contacting organotin compounds of a select formula with polyelectrolytes and, if appropriate, subsequent removal of water.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention is achieved by contacting organotin compounds having the general formula I
R n SnX 4−n (I)
in which
R=C 1 -C 4 alkyl, preferably CH 3 or C 4 H 9
n=1 or 2,
X=anionic radical —O—, —OH, F, Br, I, Cl preferred, —OR 1 , —SR 1 , —OOCR 1 , —SO 3 R 1 , preferably an anion of a strong acid, with particular preference for Cl or SO 3 R 1 , where
R 1 =unsubstituted or substituted alkyl, aryl or aralkyl and R, X and R 1 can each be identical or different, with polyelectrolytes, especially polymers or copolymers of the general formula(e) II and/or III
in which
Y=H or CH 3
A=—COOZ, —SO 3 Z, —OSO 3 Z or —PO 3 Z 2
Bio=the radical of a biopolymer,
Z=H, an unsubstituted or substituted alkyl group or a cationic radical selected from the group consisting of alkali metal salts, alkaline earth metal salts or ammonium salts, preferably Z is H, CH 3 , Na, K, Ca or NR 2 R 3 R 4 R 5 where R 2 to R 5 =H or a substituted or unsubstituted alkyl group of 1-10 carbon atoms, preferably CH 3 , hydroxyethyl or hydroxyisopropyl, B=the radical of an ethylenically unsaturated monomer such as, for example, ethylene, propylene, butadiene, isoprene, vinyl chloride, vinylidene chloride or vinylidene fluoride, styrene, indene, vinyl acetate, vinyl alcohol, vinylformal, acrolein, methyl vinyl ketone, vinylpyrrolidone, maleic anhydride, acrylonitrile, vinyl ethers, (meth)acrylic acid, (meth)acrylamide, (meth)acrylic esters, cyanoacrylic esters, and the like; and Y, A, Z and B within k, 1 and m can each be identical or different, m being ≧0, 1 and k=0-200, especially 50-150, preferably 60-100, where 1+K≧20, the ratio of (1+K)/m being chosen such that the polymers in the dissociated form are soluble in water.
The polyelectrolytes which are used in accordance with the invention can comprise both biopolymers such as algic acid, gum-arabic, nucleic acids, pectins, proteins and the like, and chemically modified biopolymers such as carboxylmethylcellulose, ligninsulfonates and, in particular, synthetic polymers such as, for example, poly(meth)acrylic acid, polyvinylsulfonic acid, polyvinylphosphoric acid (vinylphosphonic acid polymers), polymaleic acid and copolymers thereof with one another and with unsaturated olefins such as, for example, ethylene, propylene, butadiene, isoprene, vinyl chloride, vinylidene chloride or vinylidene fluoride, styrene, indene, vinyl acetate, vinyl alcohol, vinylformal, acrolein, methyl vinyl ketone, vinylpyrrolidone, maleic anhydride, acrylonitrile, vinyl ethers, (meth)acrylamide, and cyanoacrylic esters.
In accordance with the invention it is possible to use all polyelectrolytes whose proportion of dissociable groups—which can be a constituent or substituent of the polymer chain—is sufficiently great that the polymers in the dissocited form are soluble in water.
In accordance with the invention, the polyelectrolytes used are preferably the so-called polyacids. On dissociation, these give off protons to form polyanions, which can be both inorganic and organic polymers. Examples of polyacids, whose salts are referred to as polysalts, having the groups I-V as characteristic base units are: poly(meth)acrylic acid (I), polyvinylsulfuric acid (II), polyvinylsulfonic acid (III), polyvinylphosphonic acid (IV), and polymaleic acid (V):
In addition to the base units having dissociable groups, it is also possible to use ethylenically unsaturated monomers such as, for example, ethylene, propylene, butadiene, isoprene, vinyl chloride, vinylidene chloride or vinylidene fluoride, styrene, indene, vinyl acetate, vinyl alcohol, vinylformal, acrolein, methyl vinyl ketone, vinylpyrrolidone, maleic anhydride, acrylonitrile, vinyl ethers, (meth)acrylic acid, (meth)acrylamide, (meth)acrylic esters, cyanoacrylic esters, and the like.
The proportion of these monomers, also ethylenically unsaturated, in the polymer can be adjusted according to the particular desired end properties of the catalyst, in respect, inter alia, of the fields of use. The distribution of the individual monomers in the polymer molecule can be random, or it is possible to polymerize blocks of individual monomers, with one another or among one another.
The sole condition is that the proportion of dissociable groups in the polymer is sufficiently great to keep both the polymer itself and the mixture, or the reaction product of compounds of the general formula (I) with the polyelectrolytes of the general formula (II), soluble in water.
Both the basic units and the processes for preparing the corresponding homopolymers and copolymers are part of the known prior art (compare CD Römpp, Chemie Lexikon-Version 1.0, Stuttgart/New York). Organotin compounds of the general formula (I) which can be used in accordance with the invention are monomethyltin, monobutyltin, dimethyltin and dibutyltin oxides, hydroxides, alkoxides, halides, mercaptides, carboxylates and sulfonates, preferably MeSnCl3, Me 2 SnCl 2 , BuSnCl 3 , MeSn(O 3 SCH 3 ) 3 , Me 2 Sn(O 3 SCH 3 ) 2 , BuSn(O 3 SCH 3 ) 3 or Bu 2 Sn(O 3 SCH 3 ) 2 .
The contacting or reaction can be performed, if appropriate, advantageously in aqueous solution. A preferred procedure in accordance with the invention is to carry out dropwise addition, at room temperature and with intimate mixing, of an aqueous solution of the tin compound of the general formula (I) to an aqueous solution of the polyelectrolyte, this solution being introduced into a vessel as initial charge. The rate of addition is such that the solution in said vessel remains continuously clear. At an increased rate of addition, however, it is possible to carry out subsequent stirring until the solution in said vessel becomes clear. The amount of compounds of the general formula I is chosen such that, on the one hand, the amount of Sn present is sufficient for the intended purpose and such that, on the other hand, the catalyst still remains soluble in water. Optimization can also be undertaken by means of simple preliminary tests.
Results which are positive in accordance with the invention are generally obtained if organotin compounds of the general formula I are used in a molar ratio of 0.01-0.8, in particular 0.1-0.5, based on the groups Z of the polyelecrolytes of the general formula (e) II and/or II.
The catalyst solution prepared in this way can be used directly without further treatment stages, or stored. Alternatively, it can also be dewatered and dried by means of the known techniques and stored and used in water-free form.
EXAMPLES
Parts and percentages are by weight unless stated otherwise.
Example 1
72.0 g (0.2 mol) of a 30% strength aqueous solution of poly (sodium methacrylate) (from Aldrich, M w : about 6500 by GPC, M n : about 4000, pH=about 9) were stirred together with 72.0 g of water. 11.0 g (0.05 mol) of dimethyltin dichloride were dissolved in 100 g of water at room temperature (pH of this solution=1). The poly (sodium methacrylate) solution was introduced into a vessel and the dimethyltin dichloride solution was added dropwise at room temperature with stirring. Stirring was continued at room temperature for 2 h to give a clear solution.
The product contained 2.3% Sn and 88% water. It had a pH of 7 and was still stable after 21 weeks of storage.
Example 2
72.0 g (0.2 mol) of a 30% strength aqueous solution of poly (sodium methacrylate) were stirred together with 72.0 g of water. 8.8 g (0.04 mol) of dimethyltin dichloride were dissolved in 49.6 g of water at room temperature (pH of this solution=1). The poly (sodium methacrylate) solution was introduced into a vessel and the dimethyltin dichloride solution was added dropwise at room temperature with stirring. Stirring was continued at room temperature for 2 h to give a clear solution.
The product contained 2.4% Sn and 85% water. It had a pH of 7 and was still stable after 17 weeks of storage.
Example 3
To prepare a 50% strength aqueous dimethyltin methylsulfonate chloride solution, 6.78 g (0.02 mol) of dimethyltin bis (methylsulfonate) and 4.40 g (0.02 mol) of dimethyltin dichloride were dissolved in 11.18 g of water and stirred at 70° C. for 4 h.
72.0 g (0.2 mol) of a 30% strength aqueous poly (sodium methacrylate) solution were stirred together with 72.0 g of water. 11.2 g (0.02 mol) of the 50% strength aqueous dimethyltin dimethylsulfonate chloride solution were added dropwise at room temperature. Stirring was conducted at room temperature for 30 minutes in order to dissolve solid constituents. Then a further 11.2 g (0.02 mol) of the 50% strength aqueous dimethyltin methylsulfonate chloride solution were added dropwise at room temperature and the mixture was stirred at 60° C. for 2 h until a clear solution was obtained.
The product contained 2.9% Sn and 80% water. It had a pH of 7 and was still stable after 15 weeks of storage.
2 g of this water-containing product were dried at 105° C. for 2 hours, giving 0.3 g of a solid having a tin content of 16%. This dry product was redissoluble at 20° C. in water; its aqueous solution showed the same properties as the water-containing product prior to drying.
Example 4
72.0 g (0.2 mol) of a 30% strength aqueous solution of poly(sodium methacrylate) were stirred together with 72.0 g of water. 13.6 g (0.04 mol) of dimethyltin bis(methylsulfonate) were dissolved in 60.0 g of water at room temperature (pH of this solution=1). The poly(sodium methacrylate) solution was introduced into a vessel and the dimethyltin bis (methylsulfonate) solution was added dropwise at room temperature with stirring. Stirring was continued at room temperature for 2 h to give a clear solution.
The product contained 2.2% Sn and 84% water. It had a pH of 7 and was still stable after 12 weeks of storage.
Example 5
Description of Experiment 5A (Comparative Example)
In a paper cup (capacity about 600 ml), 20 g of Lupranol 2022 (polyether polyol, MW about 3500, supplier: BASF) were mixed thoroughly with 0.74 g of water, 0.24 g of Silicon SC 162 [silicone] (supplier: Union Carbide) and 0.056 g of Dabco 33 LV (cocatalyst, diazabicyclooctane, 33%, supplier: Air Products Chemicals), with stirring. In order to simplify handling, a master blend of water, the silicone and Dabco was prepared beforehand and metered into the polyether polyol.
0.0133 g of dibutyltin dilaurate is added to the mixture and completely incorporated by stirring within 45 s. In order to simplify handling, the dibutyltin dilaurate was dissolved beforehand in a portion of the polyether polyol and then metered into the mixture.
To this mixture there was added 9 g of tolylene 2,4-diisocyanate (supplier: Aldrich) and the reaction mixture was stirred vigorously for 10 seconds.
A polyurethane foam was developed which expanded and, in doing so, hardened. The rise time (time to maximum expansion of the foam), height of rise (height reached on maximum expansion of the foam) and duration of hardening (time until the foam present is dried to touch) were observed.
The comparative examples 5B-5E and also the experiments 5F-5G (in accordance with the invention) were carried out analogously using the ratios of amounts given in Table 1. In all experiments in which tin catalysts were used the concentrations of tin were equal.
TABLE 1
Tolyene
Luprano
2,4-
DABCO
Silicon
Example
1 2022
diisocyanate
33/0
SC162
Water
Catalyst
5A
100
45 parts
0.28
1.2
3.7
0.066 parts of
(Comparative)
parts
parts
parts
parts
dibutyltin dilaurate
5B
100
45 parts
0.28
1.2
3.7
0.023 parts of
(Comparative)
parts
parts
parts
parts
dimethyltin dichloride
5C
100
45 parts
0.28
1.2
3.7
0.031 parts of
(Comparative)
parts
parts
parts
parts
dimethyltin bis
(methylsulfonate)
5D
100
45 parts
0.28
1.2
3.7
0.25 parts of
(Comparative)
parts
parts
parts
parts
poly(sodium
methacrylate)
solution, 30% in water
5E
100
45 parts
0.28
1.2
3.7
—
(Comparative)
parts
parts
parts
parts
5F
100
45 parts
0.28
1.2
3.7
0.53 parts of catalyst
parts
parts
parts
parts
from Example 1
5G
100
45 parts
0.28
1.2
3.7
0.57 parts of catalyst
parts
parts
parts
parts
from Example 4
TABLE 2
Results
Duration of
hardening until
Rise time
Height of rise
dry to touch
Example
(min)
(cm)
(min)
5A
195
10.5
180
(Comparative)
5B
240
9.5
420
(Comparative)
5C
240
9.5
300
(Comparative)
5D
300
9
240
(Comparative)
5E
240
8
480
(Comparative)
5F
210
10
180
5G
210
10
180
Example 6
Description of Experiment 6A (Comparative Example)
100 parts of trimethoxymethylsilane, 100 parts of water and 10.6 parts of dibutyltin dilaurate were introduced into a glass vessel and mixed together and the vessel was sealed and stored at room temperature. The condition of the mixture was assessed after 1 day.
The comparative examples 6B-6C and also the experiments 6D-6E (in accordance with the invention) were carried out analogously using the ratios of amounts given in Table 2. In all experiments in which tin catalysts were used the concentrations of tin were equal.
TABLE 3
Trimethoxy-
Example
methylsilane
Water
Catalyst
6A
100 Parts
100 Parts
10.6 parts
(Comparative)
dibutyltin-
dilaurate
6B
100 Parts
65 Parts
50 parts of
(Comparative)
poly (sodium
methacrylate)
solution, 30%
in water
6C
100 parts
100 parts
—
(Comparative)
6D
100 parts
24.3 parts
85.8 parts of
catalyst from
Ex. 1
6E
100 parts
22.8 parts
90.1 parts of
catalyst from
Ex. 4
TABLE 4
Results:
Example
Condition after 1 day
6A
½ solid
semi-hard
glassy-
pH of aq.
(Comparative)
white
phase 5
6B
⅓
gelatinous
glassy
pH of aq.
(Comparative)
solid
phase 10
6C
no solid
water-clear liquid
pH of aq.
(Comparative)
phase 5
6D
½ solid
soft
white
pH of aq.
phase 7
6E
½ solid
soft
white
pH of aq.
phase 7
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The invention relates to a process for preparing water-soluble organotin catalysts by contacting organotin compounds with polyelectrolytes and, optionally, subsequently removing the water.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to light guide plates, and particularly to a light guide plate used for a liquid crystal display.
[0003] 2. The Prior Art
[0004] In a typical liquid crystal display, a backlight module provides a surface light source for illuminating the liquid crystal display. Generally, the backlight module includes a light guide plate and a light source arranged adjacent to one side of the light guide plate. The light guide plate changes light beams received from the light source into surface light beams, and directs the surface light beams to a liquid crystal panel of the liquid crystal display.
[0005] FIG. 8 shows a conventional backlight module 100 . The backlight module 100 comprises a light source 110 , a light guide plate 120 , a diffuser 130 , and a prism sheet module 140 . The light guide plate 120 includes a light incidence surface 121 , a light-emitting surface 122 , and a bottom surface 123 .
[0006] Referring to FIG. 9 , a distribution of scattering-dots 124 on the bottom surface 123 of the light guide plate 120 is shown. To improve the uniformity of the surface light beams of the backlight module 100 , the scattering-dots 124 are evenly arranged on the bottom surface 123 of the light guide plate 120 .
[0007] With this configuration, when light beams from the light source 110 enter the light guide plate 120 from the light incidence surface 121 , the scattering-dots 124 reflect and diffract the light beams. The light beams are thus changed into uniform surface light beams, which are output from the light-emitting surface 122 of the light guide plate 120 . However, in one or more predetermined regions of the light guide plate 120 , especially one or more small regions, it is difficult to control and micro-adjust the configuration of the scattering-dots 124 to ensure uniformity and brightness of the output light beams.
[0008] FIG. 10 is a simplified view of a plurality of scattering-dots 230 on a bottom surface 210 of another conventional light guide plate 200 . Sizes of the scattering-dots 230 progressively increase with increasing distance away from a light incidence surface 220 . With this configuration, the uniformity and brightness of light beams output from a light-emitting surface (not shown) can be improved overall. However, in one or more predetermined regions of the light guide plate 200 , especially one or more small regions, it is difficult to control and micro-adjust the configuration of the scattering-dots 230 to ensure uniformity and brightness of the output light beams.
[0009] A new light guide plate with a new distribution of scattering-dots on a bottom surface thereof is desired in order to overcome the above-described problems.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a light guide plate which is micro-configured in one or more predetermined regions thereof to ensure that intensities of light beams output from the light guide plate are uniform and bright.
[0011] In order to achieve the object set out above, a light guide plate according to the present invention comprises a light incidence surface for receiving light beams, a light-emitting surface for guiding light beams out of the light guide plate, and a bottom surface reflecting and scattering light beams in directions toward the light-emitting surface. The bottom surface comprises a plurality of scattering-dots thereon, and a predetermined region of the bottom surface also comprises a plurality of sub-scattering-dots thereon. At least one sub-scattering-dot is disposed around each scattering-dot, and the at least one sub-scattering-dot is smaller than the scattering-dot.
[0012] The light guide plate has the following advantages. In one aspect according to the invention, by the utilization of the sub-scattering-dots with a smaller size cooperating with the scattering-dots in the predetermined region, it is easier to provide a configuration that yields high uniformity and brightness of light beams exiting the light-emitting surface. This is especially the case where appropriate micro-configuration is needed in small parts of the predetermined region. In another aspect according to the invention, the utilization of the sub-scattering-dots can compensate for micro differences in the light manipulation effects of the scattering-dots affecting the whole light-emitting surface, thereby providing improved uniformity and luminance of light beams exiting the whole light-emitting surface.
[0013] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a simplified, side view of a light guide plate according to a first embodiment of the present invention;
[0015] FIG. 2 is a simplified, plan view of a bottom of the light guide plate of FIG. 1 , showing a distribution of scattering-dots on a bottom surface of the light guide plate;
[0016] FIG. 3 is an enlarged view of a circled portion III of FIG. 2 ;
[0017] FIG. 4 is a simplified, plan view of a bottom of a light guide plate according to a second embodiment of the present invention, showing a distribution of scattering-dots on a bottom surface of the light guide plate;
[0018] FIG. 5 is an enlarged view of a circled portion V of FIG. 4 ;
[0019] FIG. 6 is a simplified, plan view of a bottom of a light guide plate according to a third embodiment of the present invention, showing a distribution of scattering-dots on a bottom surface of the light guide plate;
[0020] FIG. 7 is a simplified, plan view of a bottom of a light guide plate according to a fourth embodiment of the present invention, showing a distribution of scattering-dots on a bottom surface of the light guide plate;
[0021] FIG. 8 is an exploded, isometric view of a conventional backlight module;
[0022] FIG. 9 is a simplified, plan view of a bottom of a light guide plate of the module of FIG. 8 , showing a distribution of scattering-dots on a bottom surface of the light guide plate; and
[0023] FIG. 10 is a simplified, plan view of a bottom of another conventional light guide plate, showing a distribution of scattering-dots on a bottom surface of the light guide plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] As shown in FIGS. 1 to 3 , a plate-like light guide member 300 of the first embodiment of the present invention includes a light incidence surface 310 , a light-emitting surface 320 connecting with the light incidence surface 310 , and a bottom surface 330 opposite to the light-emitting surface 320 .
[0025] The bottom surface 330 has a plurality of scattering-dots 341 distributed thereon as a first scattering element, for eliminating total internal reflection of light beams in the light guide plate 300 . That is, light beams incident on the bottom surface 330 are reflected and scattered at the scattering-dots 341 in directions toward the light-emitting surface 320 . The scattering-dots 341 have a same size and are uniformly arranged as an array on the bottom surface 330 . Furthermore, in a predetermined region of the bottom surface 330 , a plurality of sub-scattering-dots 342 as a second scattering element are disposed at peripheries of the scattering-dots 341 . The sub-scattering-dots 342 have the same function as the scattering-dots 341 . At least one sub-scattering-dot 342 is located at the periphery of each scattering-dot 341 in the predetermined region. The sub-scattering-dots 342 are smaller than the scattering-dots 341 . Preferably, a diameter of each sub-scattering-dot 342 is less than 10 μm, or is equal to a tenth of the size of each scattering-dot 341 .
[0026] In operation, when light beams from a light source (not shown) enter the light guide plate 300 via the light incidence surface 310 , the light beams are reflected and diffused by the scattering-dots 341 of the bottom surface 330 in directions toward the light-emitting surface 320 . Further, in the predetermined region, certain of the light beams are reflected and diffused by the scattering-dots 341 and the sub-scattering-dots 342 of the bottom surface 330 in directions toward the light-emitting surface 320 . The number and sizes of the sub-scattering-dots 342 within different parts of the predetermined region can vary, to account for differences in uniformity and intensity of the light beams reaching the different parts of the predetermined region. Thus, the light beams are uniformly transmitted out from the light-emitting surface 320 in a direction roughly perpendicular to the light-emitting surface 320 .
[0027] The dots 341 , 342 are formed by using the so-called LIGA process (in German: Lithographie, Galvanoformung, Abformung). LIGA includes three basic steps: lithography, electroforming, and micro molding. Firstly, a light guide plate body is formed by injection molding, the body including the light incidence surface 310 , the bottom surface 330 and the light-emitting surface 320 opposite to the bottom surface 330 . Secondly, a mold with a plurality of printing-dots is formed by LIGA. Finally, the light guide plate 300 with the plurality of scattering-dots 341 and sub-scattering-dots 342 is formed by hot pressing the bottom surface 330 with the mold.
[0028] A light guide plate 400 according to the second embodiment of the present invention is shown in FIGS. 4 and 5 . The light guide plate 400 has a structure similar to the light guide plate 300 . A plurality of scattering-dots 431 and sub-scattering-dots 432 are distributed on a bottom surface 420 of the light guide plate 400 . The sub-scattering-dots 432 are located at peripheries of scattering-dots 431 that are in a predetermined region of the bottom surface 420 . At least one sub-scattering-dot 432 is located at the periphery of each scattering-dot 431 in the predetermined region. The scattering-dots 431 have a same size. A distribution density of the scattering-dots 431 progressively increases with increasing distance away from a light incidence surface 410 of the light guide plate 400 . The number and sizes of the sub-scattering-dots 432 within different parts of the predetermined region can vary, to account for differences in uniformity and intensity of the light beams reaching the different parts of the predetermined region, and/or to account for differences in the light manipulation effects of the scattering-dots 431 in the different parts of the predetermined region.
[0029] FIG. 6 shows a light guide plate 500 according to the third embodiment of the present invention. The light guide plate 500 has a structure similar to the light guide plate 300 . A plurality of scattering-dots 531 and sub-scattering-dots (not shown) are disposed on a bottom surface 520 of the light guide plate 500 . The. sub-scattering-dots are located at peripheries of scattering-dots 531 that are in a predetermined region of the bottom surface 520 . At least one sub-scattering-dot is located at the periphery of each scattering-dot 531 in the predetermined region. The scattering-dots 531 are uniformly arranged on the bottom surface 520 . Sizes of the scattering-dots 531 progressively increase with increasing distance away from a light incidence surface 510 of the light guide plate 500 . The number and sizes of the sub-scattering-dots within different parts of the predetermined region can vary, to account for differences in uniformity and intensity of the light beams reaching the different parts of the predetermined region, and/or to account for differences in the light manipulation effects of the scattering-dots 531 in the different parts of the predetermined region.
[0030] FIG. 7 shows a light guide plate 600 according to the fourth embodiment of the present invention. In the light guide plate 600 , a plurality of scattering-dots 631 and sub-scattering-dots (not shown) are distributed on a bottom surface 620 of the light guide plate 600 . The sub-scattering-dots are located at peripheries of scattering-dots 631 that are in a predetermined region of the bottom surface 620 . At least one sub-scattering-dot is located at the periphery of each scattering-dot 631 in the predetermined region. A distribution density and sizes of the scattering-dots 631 both progressively increase with increasing distance away from a light incident surface 610 of the light guide plate 600 . The number and sizes of the sub-scattering-dots within different parts of the predetermined region can vary, to account for differences in uniformity and intensity of the light beams reaching the different parts of the predetermined region, and/or to account for differences in the light manipulation effects of the scattering-dots 631 in the different parts of the predetermined region.
[0031] In summary, the light guide plate 300 has the following advantages. In one aspect according to the present invention, by the utilization of the sub-scattering-dots 342 with a smaller size cooperating with the scattering-dots 341 in the predetermined region, it is easier to provide a configuration that yields high uniformity and brightness of light beams exiting the light-emitting surface 320 . This is especially the case where appropriate micro-configuration is needed in small parts of the predetermined region. In another aspect according to the invention, the utilization of the sub-scattering-dots 342 can compensate for micro differences in the light manipulation effects of the scattering-dots 341 affecting the whole light-emitting surface 320 , thereby providing improved uniformity and luminance of light beams exiting the whole light-emitting surface 320 .
[0032] Furthermore, a plurality of scattering-dots and sub-scattering-dots can be arranged selectively on the light-emitting surface 310 of the light guide plate 300 . In any of the above-described embodiments, the scattering-dots and the sub-scattering-dots can be hemispherical, sub-hemispherical, pyramidal, or any suitable combination of these shapes.
[0033] Further, it is to be understood that even though numerous characteristics and advantages of the present invention have been set out in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A light guide plate ( 300 ) includes a light incidence surface ( 310 ) for receiving light beams, a light-emitting surface ( 320 ) for guiding light beams out of the light guide plate, and a bottom surface ( 330 ) reflecting and scattering light beams in directions toward the light-emitting surface. The bottom surface includes scattering-dots ( 341 ), and a predetermined region of the bottom surface also includes sub-scattering-dots ( 342 ). At least one sub-scattering-dot is disposed around each scattering-dot. The sub-scattering-dots are smaller than the scattering-dots. With this micro-configuration, intensities of light beams output from the light guide plate are uniform and bright.
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FIELD OF THE INVENTION
[0001] The present invention relates to containers for use in shipping, storing, and/or displaying product, and more particularly, to containers or trays that can be nestably stacked together.
BACKGROUND OF THE INVENTION
[0002] A large number of different container structures are utilized by manufacturers to ship a variety of different products to end users, which may be wholesale or retail customers. These containers may also be used to store and/or display products. Many of these boxes, trays, or like container carriers have perpendicular side walls in order to efficiently and effectively utilize the internal volume of the container for storing or displaying a product while at the same time minimizing the space needed to store or transport the containers. Additionally, many of these containers are made out of a rigid or semi-rigid material such as plastic to further the transport, support, or display of a product. However, these containers, even those with an open top, e.g., tray-like containers, have the disadvantage of not being able to be compactly stored when not in use. Empty containers that cannot be compactly stored for reuse take up valuable warehouse or storage space and also increase shipping costs as they require more space in a vehicle while being returned for reuse.
[0003] One style of container that does allow for compact storage when not in use is one that has its side walls obtusely angled out from its bottom or base wall. This style of a container allows empty containers to be nested or stacked together in a relatively compact fashion. However, for some products, these style of containers have the disadvantage of wasting internal space within the container and not allowing for the effective display or storage of products. For example, for some products, space within the container, particularly near the top of the container, is wasted due to the angling out of the side walls. Additionally, when these style containers are placed next to one another for shipping or storage, space between the containers, particularly at the bottom of the container is wasted due again to the angling out of the side walls. Hence, shipping and storage costs are increased.
[0004] Another style of containers have employed a collapsible method for achieving compact storage when not in use, but these types of boxes have the disadvantage of being required to be assembled or de-assembled before or after use, and may also lack other advantageous properties such as the rigidity of a plastic-like material which may be lacking in a cardboard-style container.
[0005] Accordingly, there is a need for a container with generally perpendicular side walls for shipping, storing, and/or displaying a product that also allows for the compact storing or nesting of the containers or trays when not in use. There is further a need for a method to produce such a stackable container.
SUMMARY OF THE INVENTION
[0006] The present invention provides a container or tray for holding product therein during shipment, storage, and/or display and being returned for reuse. Specifically, the container has a generally rectangular base and side walls which are normally perpendicular to the base. The side walls are not attached to each other so that the corners formed between the side walls are cutaway or open. A portion of the base is adapted to flex or pivot so that a second container can be stackably nested within a first container, thereby saving space for shipping or storage purposes. When the second container is placed within the first container, a central portion of the base and the side walls of the first container form an obtuse angle which allows the second container to be nested within the first. Moreover, the base and the side walls are biased, independently or in combination, to form a right angle between the base and the side walls both before the second container is nested within the first and after the second container is unstacked from the first container. In a preferred embodiment, the container is made out of a thermoplastic material which may be a polypropylene foam or any other suitable material. However, the material from which the container is made may vary. It is the inherent properties of the material from which the container is made which enable the side walls to spring back or return to their original positions after one or more inner trays or containers is/are removed from the interior of the outside container.
[0007] In one embodiment, the base of the container or tray has a plurality of aligned openings therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These openings, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container side walls to allow multiple containers to be nested and stacked together.
[0008] In another embodiment, the base of the container or tray has a plurality of aligned tabs formed by C-shaped cuts therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These tabs, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container sidewalls relative to a central portion of the base to allow multiple containers to be nested and stacked together.
[0009] The present invention also provides for a stack of containers nestably stacked inside each other, each having a base and a plurality of side walls, which are not attached to each other, but which are integral with the base. The base and the side walls of at least one outer container form an obtuse angle allowing additional containers to be nested inside the outer container or containers. The base and the side walls, individually or in combination, are biased so that the container side walls form right angles with a central portion of the base before another container is nested inside the container and also after the containers are separated.
[0010] The nestably stackable containers of the present invention can be formed by providing a blank and a heat source, heating the blank with the heat source along fold lines, bending the blank along the fold lines whereby side walls are formed perpendicular to the base and extending upwardly from the base. The base and side walls are then allowed to cool in their preferred orientation or position. In a preferred embodiment, a thermoplastic material is used to form the container which enables the container to return to its original position after being emptied of other containers. Additionally, a plurality of openings may be created in the base by removing material from select locations of the blank. Alternatively, a plurality of tabs may be created in the base by cutting the blank at select locations in predetermined shapes or configurations. The openings or tabs create hinges or pivot points about which the side walls hinge or pivot when another like container is nestably stacked therein.
[0011] The present invention provides a box, container or tray which has side walls which are sturdy or strong enough to keep objects therein and which is also nestably stackable. The above and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
[0013] FIG. 1 is a perspective view of a preferred embodiment of the container of the present invention;
[0014] FIG. 1A is a cross-sectional view taken of line 1 A- 1 A of FIG. 1 ;
[0015] FIG. 1B is a cross-sectional view of a portion of a stack of containers shown in FIGS. 1 and 1 A;
[0016] FIG. 2 is a perspective view of another embodiment of container in accordance with the present invention;
[0017] FIG. 2A is a cross-sectional view taken of line 2 A- 2 A of FIG. 2 .;
[0018] FIG. 2B is a cross-sectional view of a portion of the container shown in FIGS. 2 and 2 A being flexed when additional like containers are nested within it;
[0019] FIG. 3 is a perspective view of another embodiment of container in accordance with the present invention;
[0020] FIG. 3A is a cross-sectional view taken of line 3 A- 3 A of FIG. 3 ;
[0021] FIG. 3B is a cross-sectional view of a portion of the container shown in FIGS. 3 and 3 A being flexed when additional like containers are nested within it;
[0022] FIG. 4 is a perspective view of a flat blank used to form the container shown in FIGS. 2 and 2 A before the side walls are bent into position;
[0023] FIG. 4A is a perspective view of another blank used to form the container shown in FIGS. 2 and 2 A before its side walls are bent into position;
[0024] FIG. 4B is a perspective view of another blank used to form the container shown in FIGS. 3 and 3 A before its side walls are bent into position;
[0025] FIG. 5 is a perspective view showing the blank shown in FIG. 4 positioned over a heat source; and
[0026] FIG. 6 is a perspective view of the tray shown in FIGS. 1 and 1 A, showing a first side wall being bent into position.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to FIG. 1 , there is illustrated a container or tray 10 according to one embodiment of the present invention. The container 10 comprises a base 12 and a plurality of side walls 14 , 16 , 18 and 20 , all extending upwardly from the perimeter of the base 12 and being perpendicular to the base 12 . The base 12 and side walls 14 , 16 , 18 and 20 define an interior 21 of the container 10 for storing or displaying products or items (not shown). The side walls 14 , 16 , 18 , 20 each are illustrated with at least one aperture or hole 22 which may be used as handles for transporting the container 10 . If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container 10 .
[0028] As shown in FIG. 1A , the side walls, 14 , 16 , 18 and 20 are not attached to each other. Hence, the container 10 has open or cutaway corners 24 . Although one configuration or shape of openings at the corners 24 is illustrated, the open corners 24 may be other sizes or shapes. The side walls 14 , 16 , 18 and 20 are connected to the base 12 at a fold line 27 and form a right angle 28 with the base member 12 . See FIGS. 1 and 1 A. The side walls 14 , 16 , 18 and 20 have upper edges 30 , 32 , 34 and 36 , respectively. Although the upper edges of the side walls are illustrated as being co-planar due to the side walls being the same height, the side walls may be different heights if desired, in which case the upper edges of the side walls would not be co-planar. This may be the case in any of the embodiments described herein.
[0029] As shown in FIG. 1B , when a second container 11 like the container 10 , having a base 13 and sidewalls 15 is nested inside the interior 21 of the outer container 10 , the side walls 14 , 16 , 18 and 20 of the outer container 10 flex outward about a flex or pivot point 26 located along base 12 . See FIG. 1B . FIG. 1B also shows a third tray or container 17 having a base 19 and sidewalls 23 nested or nestably stacked within the second container 11 . The second and third containers 11 and 17 are shown in FIG. 1B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 is made, the side walls 14 , 16 , 18 , 20 of the container 10 return to their position shown in FIG. 1A after the containers 11 and 17 are taken out or removed from the interior 21 of the container 10 . Although two containers 11 and 17 are shown nestably stacked inside container 10 , any number of containers may be nestably stacked together to save space during shipping and/or storage.
[0030] FIG. 2 shows an alternative embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “a” designation after the number. In this embodiment, container 10 a comprises a base 12 a and a plurality of side walls 14 a , 16 a , 18 a and 20 a , all extending upwardly from the perimeter of the base 12 a and being perpendicular to the base 12 a . The base 12 a and side walls 14 a , 16 a , 18 a and 20 a define an interior 21 a of the container 10 a for storing or displaying products or items (not shown). The side walls 14 a , 16 a , 18 a , 20 a each are illustrated with at least one aperture or hole 22 a used as handles for transporting the container 10 a . If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container 10 a.
[0031] As shown in FIG. 2 , the side walls 14 a , 16 a , 18 a and 20 a are not attached to each other. Hence, the container 10 a has open or cutaway corners 24 a . Although one configuration or shape of openings at the corners 24 a is illustrated, the open corners 24 a may be other sizes or shapes. The side walls 14 a , 16 a , 18 a , and 20 a are connected to the base 12 a along a fold line 27 a and each side wall forms a right angle 28 a with the base 12 a . See FIGS. 2 and 2 A. The side walls 14 a , 16 a , 18 a and 20 a have upper edges 30 a , 32 a , 34 a and 36 a , respectively.
[0032] The base 12 a of the container 10 a shown in FIGS. 2, 2A and 2 B has a plurality of aligned tabs 40 formed by C-shaped cuts 42 through the base 12 a . The tabs 40 are located generally near the intersection between the base 12 a and the side walls 14 a , 16 a , 18 a and 20 a . Although the tabs 40 are illustrated as being in a generally C-shape and a particular size, the shape and size of the tabs 40 may be different than as is shown. These tabs 40 , as shown in FIG. 2B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together.
[0033] As shown in FIG. 2B , when a second container 11 a like the container 10 a , having a base 13 a and sidewalls 15 a is nested inside the interior 21 a of the outer container 10 a , the side walls 14 a , 16 a , 18 a and 20 a of the outer container 10 a flex outward about a flex or pivot point 26 a along the base 12 a . See FIG. 2B . Due, at least in part due to the position of the tabs 40 , an outer portion 44 of the base 12 a , along with the side walls flexes or pivots about a pivot point 19 a . FIG. 2B also shows a third tray or container 17 a having a base 19 a and sidewalls 23 a nested or nestably stacked within the second container 11 a . The second and third containers 11 a and 17 a are shown in FIG. 2B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 is made, the side walls 14 a , 16 a , 18 a and 20 a of the container 10 a return to their position shown in FIG. 2A after the containers 11 a and 17 a are taken out or removed from the interior 21 a of the container 10 a . Although two containers 11 a and 17 a are shown nestably stacked inside container 10 a , any number of containers may be nestably stacked together to save space during shipping and/or storage.
[0034] FIG. 3 shows yet another embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “b” designation after the number. In this embodiment, container 10 b comprises a base 12 b and a plurality of side walls 14 b , 16 b , 18 b and 20 b , all extending upwardly from the perimeter of the base 12 b and being perpendicular to the base 12 b . The base 12 b and side walls 14 b , 16 b , 18 b and 20 b define an interior 21 b of the container 10 b for storing or displaying products or items (not shown). The side walls 14 b , 16 b , 18 b , 20 b each are illustrated with at least one aperture or hole 22 b used as handles for transporting the container 10 b . Of course, the handles may be omitted on any side wall, if desired. Alternatively, any number of handles of any shape or configuration may be incorporated into the container 10 b.
[0035] As shown in FIG. 3 , the side walls 14 b , 16 b , 18 b and 20 b are not attached to each other. Hence, the container 10 b has open or cutaway corners 24 b . Although one configuration or shape of openings at the corners 24 b is illustrated, the open corners 24 b may be other sizes or shapes. The side walls 14 b , 16 b , 18 b , and 20 b are connected to the base 12 b along a fold line 27 b and each side wall forms a right angle 28 b with the base 12 b . See FIGS. 3 and 3 A. The side walls 14 b , 16 b , 18 b and 20 b have upper edges 30 b , 32 b , 34 b and 36 b , respectively.
[0036] The base 12 b of the container 10 b shown in FIGS. 3, 3A and 3 B has a plurality of aligned generally rectangular openings 46 created by removing material from the base 12 b . The openings 46 are located generally near the intersection between the base 12 a and the side walls 14 a , 16 a , 18 a and 20 a . Although the openings 46 are illustrated as being a particular shape and a particular size, the shape and size of the openings 46 may be different than as is shown. These openings 46 , as shown in FIG. 3B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together.
[0037] As shown in FIG. 3B , when a second container 11 b like the container 10 b , having a base 13 b and sidewalls 15 b is nested inside the interior 21 b of the outer container 10 b , the side walls 14 b , 16 b , 18 b and 20 b of the outer container 10 b flex outward about a flex or pivot point 19 b along the base 12 b . See FIG. 3B . Due, at least in part due to the position of the openings 46 , an outer portion 48 of the base 12 b , along with the side walls flexes or pivots about a pivot point 26 b . FIG. 3B also shows a third tray or container 17 b having a base 19 b and sidewalls 23 b nested or nestably stacked within the second container 11 b . The second and third containers 11 b and 17 b are shown in FIG. 3B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 b is made, the side walls 14 b , 16 b , 18 b and 20 b of the container 10 b return to their position shown in FIG. 3A after the containers 11 b and 17 b are taken out or removed from the interior 21 b of the container 10 b . Although two containers 11 b and 17 b are shown nestably stacked inside container 10 b , any number of containers may be nestably stacked together to save space during shipping and/or storage.
[0038] FIGS. 4-6 illustrate the method of making container 10 . The first step in the method is providing a blank 50 die cut or otherwise formed from a flat piece of stock. Handles 22 may be cut from the blank 50 , if desired. In a preferred embodiment, the blank 50 is made of polypropylene foam. However, any like thermoplastic material could be used with the claimed process. Polyethylene is advantageous because it is a thermoplastic material which allows it to be heated, bent, and then retains its new shape when cooled. Polyethylene is a non-brittle thermoplastic which allows the container to have greater flexibility when multiple containers are nested together and it also has a surface temperature which is appropriate for many container applications.
[0039] As shown in FIG. 5 , the blank 50 is positioned over a heat source 52 which may be a wire, light source, or other like heating mechanism. FIG. 5 illustrates a pair of heated wires 54 as the heat source 52 . The blank 50 and the heat source 52 are positioned so that the heat source 52 will heat the blank 50 along desired fold lines. Once the blank 50 is sufficiently heated, as shown in FIG. 5 , the side wall 14 is bent upward along the fold line 27 thereby creating a side wall 14 perpendicular to the base 12 . After the blank 50 is bent into shape, it is allowed to cool. Once it cools, it will retain its new shape. The process can then be repeated for each of the other side walls 16 , 18 and 20 until a container or tray is completely formed.
[0040] As shown in FIG. 4A , the method may include a step of creating a plurality of tabs 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when the container 10 a is formed. As shown in FIG. 4A , a cutting tool 56 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to a stationary cutting tool 54 to cut the blank 50 at the desired locations to form the tabs 40 .
[0041] As shown in FIG. 4B , the method may include a step of creating a plurality of openings 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when the container 10 b is formed. As shown in FIG. 4B , a cutting tool 58 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to a stationary cutting tool 58 to cut the blank 50 at the desired locations to form the openings 46 .
[0042] While various embodiments of the present invention have been illustrated and described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspect is, therefore, not limited to the specific details, representative system, apparatus, and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
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The present invention provides a container for holding product therein during shipment, storage, or display and being returned for reuse. The container has a base and perpendicular side walls. The side walls are not attached to each other. The base and side walls are adapted, individually or in combination, to flex so that a second container can be nested within a first container. When the second container is placed within the first container, a portion of the base and the side walls of the first container form an obtuse angle. The base and the side walls are biased to form a right angle before the second container is nested within the first and after the second container is unstacked from the first container.
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FIELD OF THE INVENTION
The present invention relates generally to switching power supplies, and, more particularly, to a control circuit for synchronous rectifiers.
BACKGROUND OF THE INVENTION
Manufacturers of electronic components increasingly demand switching power converters that have a very low voltage loss and a high output current. One type of a switching power converter uses a synchronous rectification technique. Synchronous rectifiers typically are implemented as metal-oxide semiconductor field-effect transistors (MOSFETs), although other switches such as bipolar junction transistors (BJTs), insulated-gate field-effect transistors (IGBTs), or other switches may be used. Synchronous rectification improves the efficiency of a power converter by substituting a transistor for a rectifier diode. This type of switching power converter is generally formed by a switching circuit, a transformer, a rectifying circuit, and at least one control circuit.
The switching circuit typically includes a bridge circuit arranged in a push-pull configuration with a transformer. For example, four switching devices (switches) may define the bridge circuit. The first and second switches are connected in series. The third and a fourth switches are also connected in series, and the series pairs are connected in parallel across a direct current (DC) voltage source. The transformer, which has a primary winding and a secondary winding, connects to the first and the second switches at one end of the primary winding. The other end of the primary winding connects to the third and the fourth switches. A rectifying circuit including two synchronous rectifiers connects to the secondary side of the transformer. A primary control circuit connects to the switching circuit. The primary control circuit generates a drive signal for each of the switches.
A secondary control circuit drives the synchronous rectifiers in accordance with drive signals output by the primary control circuit. In one configuration, the secondary control circuit includes two logical OR gates. The drive signals used to control the first and fourth switches define inputs to the first logical OR gate. The first logical OR gate outputs a drive signal to one of the two synchronous rectifiers. The drive signals used to control the second and third switches define inputs to the second logical OR gate. The second logical OR gate outputs a drive signal to the other of the two synchronous rectifiers. An example of such a configuration may be seen with respect to U.S. Pat. No. 6,504,739 issued Jan. 7, 2003, and assigned to the assignee of the present invention, the disclosure of which is incorporated by reference in its entirety herein.
While the switching power converter described above has a low voltage loss and a high current output, it may not address all of the parasitic components that potentially exist in a synchronous rectifier circuit. For example, a zero phase shifted full bridge, zero voltage switching (ZVS) converter includes transformer leakage inductance. Transformer leakage inductance causes a delay in the actual voltage of the secondary winding relative to the voltage across the primary winding. It may also increase the time necessary for the drain current passing through the synchronous rectifier to deplete to zero with respect to the primary winding voltage. This voltage and current delay increases as the load current increases. When the synchronous rectifiers turn off, the drain current through the MOSFET transfers to the body diode of the MOSFET, thereby increasing the voltage drop across the MOSFET. These conduction losses are higher than if the drain current was able to pass through a drain-to-source on-resistance.
SUMMARY OF THE INVENTION
The present invention is directed to circuit including a secondary controller and a delay circuit coupled to the secondary controller. The delay circuit receives a first synchronous rectifier control signal from the secondary controller and a load current signal. The delay circuit applies a predetermined delay to the first synchronous rectifier control signal. A synchronous rectifier control circuit is coupled to the secondary controller and to the delay circuit. The synchronous rectifier control circuit receives the delayed first synchronous rectifier control signal and controls a synchronous rectifier in accordance with the first synchronous rectifier control signal. The delay applied to the first synchronous rectifier control signal varies in accordance with the load current signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a synchronous rectifier control circuit for synchronous rectification in accordance with the present invention;
FIG. 2 is a schematic diagram of a switching power converter in accordance with one embodiment of the present invention;
FIGS. 3A-3D are schematic diagrams of a secondary control circuit for the power converter of FIG. 2 ;
FIG. 4 depicts waveforms describing operation of a portion of a circuit of FIG. 2 for a light load region of load current;
FIG. 5 depicts waveforms describing operation of a portion of a circuit of FIG. 2 for a mid-load region of load current;
FIG. 6 depicts waveforms describing operation of a portion of a circuit of FIG. 2 for a heavy load region of load current;
FIG. 7 is a graph illustrating an exemplary turn-off delay for a synchronous rectifier versus load current;
FIG. 8 is a graph illustrating power efficiency versus load for a power converter arranged in accordance with the principles of the present invention;
FIG. 9 is a graph illustrating power loss versus load on a power converter;
FIG. 10 is a graph illustrating an exemplary turn-off delay for a synchronous rectifier versus load current;
FIG. 11 is a schematic diagram of a delay circuit for synchronous rectification; and
FIG. 12 is a block diagram of a current sensing circuit for providing the current sense signal of FIGS. 3A-3D .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, similar reference numbers are used in the drawings to identify similar elements.
The present invention increases the efficiency of power converters by reducing the body diode conduction due to transformer leakage inductance. This is accomplished by optimizing control of the synchronous rectifier relative to the output load current. For example, turning a synchronous rectifier to an off state is delayed until the drain current is nearly zero in the synchronous rectifier. This reduces body diode conduction through the synchronous rectifier. Moreover, the cost to manufacture a switching power converter is reduced since lower performing components may replace more expensive components while still attaining power efficiency requirements.
Although the following description generally relates to a full bridge converter, it is readily understood that the broader aspects of the present invention are applicable to other types of converter topologies (e.g. push-pull topologies, half bridge topologies, etc.) that use synchronous rectification. In particular, the present invention may be applied to soft switched full bridge, full bridge, forward half bridge, and flyback converters that use synchronous rectification.
FIG. 1 depicts a block diagram of a synchronous rectifier control circuit 10 for delaying a signal to turn off a synchronous rectifier. Synchronous rectifier control circuit 10 includes synchronous rectifier controller 12 , delay selector circuit 16 , and synchronous rectifier delay control circuit 18 .
Primary side drive signals enter synchronous rectifier controller 12 from a primary control circuit (not shown). Synchronous rectifier controller 12 controls the application of the primary side drive signals to synchronous rectifier delay control circuit 18 and to delay selector circuit 16 . A load current signal (I SEN ), which depends upon the magnitude of a load current I LOAD , is input to delay selector circuit 16 . Based upon I LOAD , delay selector circuit 16 determines the desired delay. A delay signal is then output from delay selector circuit 16 to synchronous rectifier delay control circuit 18 . Synchronous rectifier delay control circuit 18 then generates a control signal to turn off a selected synchronous rectifier.
FIG. 2 is a detailed embodiment of a zero phase shifted full bridge, zero voltage switching (ZVS) power converter 100 . Power converter 100 comprises input voltage source 132 (V IN ), switching circuit 134 , transformer 136 , rectifying circuit 138 , primary control circuit 140 , secondary control circuit 142 .
Switching circuit 134 includes a first switching device (switch) Q A connected in series to a second switch Q B to form a first switching leg. Switching circuit 134 also includes a third switch Q C connected in series to a fourth switch Q D to form a second switching leg. The switching legs are connected in parallel across input voltage source 132 . In one embodiment, one or more of the primary switches are metal-oxide semiconductor field-effect transistors (MOSFETs) switches, although one skilled in the art will recognize that bipolar junction transistor (BJTs), insulated-gate field-effect transistors (IGBTs) or other suitable switches may also be used. Switching circuit 134 connects to transformer 136 , which includes a primary side having primary winding 112 and a secondary side including secondary winding 114 . One end of primary winding 112 connects to first node 116 , and the other end of the primary winding 112 connects to second node 118 .
Primary control circuit 140 generates drive signals for each of the switches Q A , Q B , Q C , and Q D of switching circuit 134 . In one configuration, primary control circuit 140 generates drive signals of various phases to the Q A /Q D pair of switches and drive signals of various phases to the Q C /Q B pair of switches. The control signals to switch pair Q A /Q D are generally complementary to control signals to switch pair Q C /Q B . This allows diagonal switches (i.e., Q A /Q D and Q C /Q B ) to conduct alternately to effect a push-pull configuration across primary winding 112 . Thus, primary control circuit 140 provides ZVS, phase shifted control over switching circuit 134 .
Rectifying circuit 138 includes two synchronous rectifiers connected to a center-tapped secondary winding 114 of transformer 136 . A first rectifying switch FETQ 1 (also referred to as first synchronous rectifier) connects to a first end of secondary winding 114 , and a second rectifying switch FETQ 2 (also referred to as second synchronous rectifier) connects to the other end of secondary winding 114 . An inductor L connects between a center tap of secondary winding 114 and an output terminal providing an output voltage V 0 to a load 126 in parallel with capacitor 156 .
Secondary control circuit 142 connects to switches FETQ 1 and FETQ 2 of the rectifying circuit 138 . Control signals Q A , Q B , Q C , Q D from primary control circuit 140 provide input signals to secondary control circuit 142 to activate and to deactivate synchronous rectifiers FETQ 1 , FETQ 2 . In a conventional drive configuration, when a first pair of diagonal switches on the primary side of transformer 136 are both conducting, one of the two synchronous rectifiers FETQ 1 , FETQ 2 is typically in an on state. After both of the first pair of diagonal switches is driven to an off state by primary control circuit 140 , secondary control circuit 142 drives the one of the two synchronous rectifiers FETQ 1 , FETQ 2 to an off state. In an embodiment of the present invention, secondary control circuit 142 delays turn off of the control signal for the second switch of a diagonal pair to correspondingly delay turn off of the associated synchronous rectifier. More specifically, the synchronous rectifier control signal that controls the later switch to be turned off of the switch pairs Q A /Q D and Q C /Q B is delayed by secondary control circuit 142 . As described herein, active refers to active high.
FIGS. 3A-3D depict secondary control circuit 142 of FIG. 2 which includes a delay selection section 162 and delay element section 164 . Except where noted, delay element section 164 includes substantially identical halves a and b, and like elements are referred to using like reference numerals having suffixes a and b. Generally, the amount of delay to turn off a synchronous rectifier depends on the delay elements operating in delay element section 164 . Delay selection section 162 determines the delay elements operating in the delay element section 164 .
Delay selection section 162 selects the delay element to operate in the delay element section 164 based on the magnitude of the load current flowing through the load 126 of FIG. 2 . Referring to FIG. 3A , I SEN is determined based upon I LOAD using a conventional current sensing circuit 200 as shown in FIG. 12 , as will be described in greater detail herein. I SEN passes through resistor R 101 , and a capacitor C 101 provides low pass filtering. The voltage at the anode of capacitor C 101 is referred to as V ISEN .
The V ISEN voltage is applied to comparators U 2 and U 1 via respective resistors R 103 and R 107 . Resistors R 104 and R 105 form a voltage divider for a reference voltage V REF to provide a reference voltage applied to the inverting input of comparator U 2 . The output signal CON 2 is determined by comparing the voltage at the inverting input to the voltage at the non-inverting input of comparator U 2 . When the voltage at the non-inverting input exceeds the voltage at the inverting input, CON 2 is high. If the voltage at the non-inverting input is less than the voltage at the inverting input, CON 2 is low. A feedback resistor R 102 provides hysteresis at the non-inverting input.
The output signal CON 1 from comparator U 1 is similarly determined. Resistors R 108 and R 109 form a voltage divider for a reference voltage V REF to provide a reference voltage applied to the inverting input of comparator U 1 . The output signal CON 1 is determined by comparing the voltage at the inverting input to the voltage at the non-inverting input of comparator U 2 . If the voltage at the non-inverting input is less than the voltage at the inverting input, CON 1 is low. If the voltage at the non-inverting input exceeds the voltage at the inverting input, CON 1 is high. A feedback resistor R 106 provides hysteresis at the non-inverting input of comparator U 1 . CON 1 and CON 2 are applied to the delay element section 164 .
Delay element section 164 includes first and second delay circuits 170 a , 170 b . First delay circuit 170 a will be described herein. One skilled in the art will recognize that second delay circuit 170 b operates similarly. First delay circuit 170 a connects to an input of a first OR gate 160 a . Drive signal Q A connects to the input of first OR gate 160 a through a parallel connection of resistor R 1 a and D 1 a of first delay circuit 170 a . Drive signal Q D connects to the other input of the first OR gate 160 a . First OR gate 160 a outputs a drive signal to the synchronous rectifier FETQ 1 . As will be described in greater detail herein, activating CON 1 and/or CON 2 correspondingly activates respective switches S 1 a and S 2 a to selectively introduce varying capacitances between the Q A input of OR gate 160 a and ground.
The CON 1 output of comparator U 1 connects to a voltage divider that includes resistors R 4 a , R 3 a , and R 2 a . One terminal of resistor R 4 a connects to an 8 volt source and the other terminal of resistor R 4 a connects to resistor R 3 a . One node of the voltage divider connects to the gate of switch S 1 a . Switch S 1 a includes a capacitance Coss across its drain and source, which connects to ground. The capacitance Coss may be the small output capacitance of switch S 1 a , or it may be an external capacitance.
Similarly, CON 2 connects to a voltage divider that includes resistors R 7 a , R 6 a , and R 5 a . One terminal of resistor R 7 a connects to an 8 volt source, and the other terminal of resistor R 7 a connects to resistor R 6 a . The drain of switch S 2 a connects to a node interconnecting capacitors C 2 a and C 3 a to provide a path from the interconnecting terminal of C 3 a , through switch S 2 a , to ground.
Delay element section 164 generates a delay that depends upon which, if any, of switches S 1 a , S 2 a are activated by respective signals CON 1 and CON 2 . FIGS. 3B-3D depict circuits describing the operation of secondary control circuit 142 based upon the load current signal I SEN , which varies in accordance with the load current I LOAD . By way of example, I LOAD may fall into one of three regions, a low load region, a mid-load region, or a high load region. The low load region ( FIG. 3B ) is generally between 0 ampere (A) and 30 A. The mid-load region ( FIG. 3C ) is generally between 30 A and 65 A. The high load region ( FIG. 3D ) is generally greater than 65 A. These regions of the load current I LOAD determine the amount of delay introduced prior to switching the synchronous rectifiers FETQ 1 , FETQ 2 to an off state. One skilled in the art will recognize that load currents defining these regions and the number of regions may vary.
The arrow in FIG. 3B illustrates the circuit path through selected capacitive elements of the delay element circuit 164 when the I LOAD is in the low load region. V ISEN is below the threshold voltage level to turn on comparators U 2 and U 1 . Specifically, the inverting input voltages exceed the non-inverting input voltages, thereby causing the CON 1 and CON 2 outputs of comparators U 1 and U 2 to be low. With the output signal CON 1 and CON 2 low, switches S 1 a and S 2 a are off. With switches S 1 a and S 2 a off, capacitors C 1 a , C 2 a , and C 3 a form a series connection between the input of first OR gate 160 a and ground. This configuration minimizes equivalent capacitance between the input to OR gate 160 a and ground, and the corresponding delay. For the circuit of FIG. 3B , the signal to turn FETQ 1 to an off state has a delay of about 20 ns when I LOAD is in the low level region. FIG. 4 depicts exemplary waveforms representing such a delay. As stated above, skilled artisans will understand that the capacitance between the drain and source off switch S 1 a may be implemented using the Coss of FET S 1 a if the timing requirements meet the design criteria.
FIG. 3C illustrates the circuit path through selected capacitive elements of delay element circuit 164 when I LOAD is in the mid-load region. When I LOAD is in the mid-load region, V ISEN is above the threshold level for comparator U 1 to turn on, driving CON 1 high. CON 1 then turns on the switch S 1 a , effectively, shorting capacitor C 1 a and placing capacitors C 2 a and C 3 a in series between the input to OR gate 160 a and ground. The equivalent series capacitance of C 2 a and C 3 a exceeds the equivalent series capacitance of capacitors C 1 a , C 2 a and C 3 a . For the circuit of FIG. 3C , the signal to turn FETQ 1 off has a delay of about 100 ns. FIG. 5 depicts exemplary waveforms representing such a delay.
FIG. 3D illustrates the circuit path through selected capacitive elements of delay element circuit 164 when I LOAD is in the heavy load region. In this scenario, V ISEN is above the threshold level for comparators U 1 and U 2 to turn on, thereby driving CON 1 and CON 2 is high. This activates switches S 1 a and S 2 a . Activating switch S 1 a causes the circuit to operate similarly as described above. Activating switch S 2 a provides a current path from capacitor C 3 a , through switch S 2 a , to ground. This leaves only capacitor C 3 a between the input to OR gate 160 a and ground. The equivalent capacitance of capacitor C 3 a exceeds the equivalent capacitance of the series connection of capacitors C 2 a and/or C 3 a , thereby increasing the delay. For the circuit of FIG. 3D , the signal to turn FETQ 1 has a delay of approximately 150 ns. FIG. 6 depicts exemplary waveforms representing such a delay.
From the description of FIGS. 3A-3D , skilled artisans will appreciate that various components of the circuits described herein may have various values. Exemplary values for selected components are provided in the attached figures. One skilled in the art will further appreciate that the values shown in the figures may vary in accordance with various design criteria for implementing the present invention.
From the embodiments described herein, it will be apparent that the turn-off delay of the synchronous rectifier control increases as the I LOAD increases. Similarly, the turn-off delay of the synchronous rectifier decreases when I LOAD decreases. FIG. 7 shows a graphical example of the linear relationship between the turn-off delay and the I LOAD .
This process of delaying the signal to turn-off a synchronous rectifier reduces or eliminates the body diode conduction through the synchronous rectifier FETQ 1 , FETQ 2 , thereby increasing the efficiency of power converter 100 . Referring to FIGS. 8 and 9 , the power converter 100 of the present invention increases the efficiency and reduces power loss. The power converter used to generate FIGS. 8 and 9 used a 12V/110 A phase shifted ZVS full bridge power supply operating at 300 kHz. FIGS. 8 and 9 depict curves corresponding to a power converter operating without and with the delay circuit of the present invention.
One skilled in the art will recognize that numerous relationships between the load current and turn-off delay exist. FIG. 10 shows a stepped relationship between the turn-off delay and the load current. For example, one skilled in the art will recognize that N discrete steps relating load current regions and turn-off delay may be utilized. In the embodiment of FIGS. 3A-3D , three discrete steps were utilized. One skilled in the art will also recognize that both linear and non-linear relationships between turn-off delay and load current may be implemented.
FIG. 11 shows an alternate embodiment for generating a delay to turn off a synchronous rectifier. FIG. 11 is a schematic diagram of a control circuit 400 which may be substituted for delay circuits 170 a , 170 b of delay element section 164 of FIGS. 3A-3D . FIG. 11 utilizes BJTs in place of FETs for switches S 1 a and S 2 a . BJTs provide a relatively low output capacitance compared to the FETs. BJTs thus provide a delay that more closely attains zero current in the body diode of the synchronous rectifiers FETQ 1 and FETQ 2 . In the configuration of FIG. 11 , freewheeling diodes DS 1 a and DS 2 a provide a discharge path for the capacitors C 2 a and C 3 a.
FIG. 12 depicts a diagram of a current sensing circuit 200 used to sense I LOAD and generate I SEN . Current sensing circuit 200 is implemented as a half-wave capacitive-filter rectifier having an output connected to a buffer amplifier. A current transformer 190 is arranged to sense the load current I PRI at the primary side. The secondary winding of transformer 190 connects to a diode 194 and load resistor 196 . A filter capacitor 198 in parallel with resistor 196 provides filtering of the rectified signal. Buffer amplifier 192 outputs the sense signal I SEN to the input of delay selection section 162 of FIGS. 3A-3D . Resistor R 101 and capacitor C 101 cooperate to provide a low pass filter function for I SEN .
While the invention has been described in its presently preferred form, it will be understood that the invention is capable of modification without departing from the spirit of the invention as set forth in the appended claims.
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A circuit for controlling the operation of synchronous rectifiers. The circuit delays the turn-off of the synchronous rectifiers in accordance with the load current. The magnitude of the load current is examined to determine which of a plurality of delay elements is selected to delay turn-off of the synchronous rectifiers. Delay is accomplished by holding up for a predetermined time period one of a plurality of control signals utilized to determine when the synchronous rectifier should be turned-off.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon PCT Application No. PCT/CN2010/077410, filed Sep. 28, 2010, now pending, the contents of which are wholly incorporated herein.
FIELD OF THE INVENTION
The present invention relates to the field of wireless communication technique, and more specifically, to a base station based on an Orthogonal Frequency Division Multiplexing (OFDM) scheme and a method of communication resource allocation therein the base station, a user equipment based on an OFDM scheme and a method of communication control therein.
BACKGROUND OF THE INVENTION
With rapid popularization of a user equipment such as a mobile phone, the user equipment is playing a more and more important role in people's life. Other functions besides communication in the user equipment are being more and more widely used, for example, accessing to Wireless Local Area Network (WLAN) with the user equipment. Moreover, interfaces such as infrared, BLUETOOTH, and Universal Serial Bus (USB) gradually become a standard configuration of the user equipment, in order to facilitate the communication link, data exchange and the like between the user equipment and other equipment. Particularly, the BLUETOOTH headset is becoming more and more widely used. Both the WLAN system and the BLUETOOTH system work at the Industry, Science and Medical (ISM) frequency band. For example, the frequency band 2400 MHz-2483.5 MHz is one of the international ISM frequency bands, and is also one of the ISM frequency bands used most frequently.
In a case in which the frequency band on which the communication between the user equipment and a base station is based is close to or a multiple of the frequency band on which the communication between the user equipment and other equipment is based, those two types of communications may interfere with each other. For example, the advanced Long Term Evolution (LTE) system in the wireless communication system is one of the system beyond 3G (beyond IMT-2000). According to the LTE standard series [36.101], the LTE system may work at several frequency bands. Among these LTE working frequency bands, some frequency bands are adjacent to the ISM frequency band, such as the frequency band 40 for deploying a LTE Time Division Duplexing (TDD) system, 2300 MHz-2400 MHz, and the frequency band 7 for deploying a LTE Frequency Division Duplexing (FDD) system, uplink 2500 MHz-2570 MHz, downlink 2620 MHz-2670 MHz. If a certain LTE user equipment works at the above frequency band while the WLAN system or the Bluetooth system in this user equipment is in an activated state, then due to adjacent frequency band leakage, the LTE system and the ISM system (WLAN system, the Bluetooth system and the like) which work in the adjacent frequency bands in this user equipment may interfere with each other, and may even fail to communicate because of too high a bit error rate.
A conventional approach to resolve this problem is to provide a transmission filter with higher performance both in the transmission side (such as the LTE system) for communication with the base station on the user equipment and in the transmission side (such as the ISM system) for communication with other equipment on the user equipment, so as to decrease the adjacent frequency band leakage as much as possible. The disadvantage of this approach is that the cost of the user equipment will be significantly increased.
SUMMARY OF THE INVENTION
One embodiment of the present invention is a base station for communicating with a user equipment in a time division duplexing manner based on an orthogonal frequency division multiplexing scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. The base station may include a cycle determination device, a judgment device, and a communication control device. The cycle determination device may determine a cycle which a present frame belongs to, wherein the cycle consists of a predetermined number of frames of the plurality of frames. The judgment device may determine whether each of subframes of the present frame is marked as a first state or a second state different from the first state according to an allocation pattern, wherein the allocation pattern marks each subframe of each frame of the cycle as the first state or the second state. The communication control device may, in case of determining that the subframe is marked as the first state, enable the base station to communicate with the user equipment over the subframe, and in case of determining that the subframe is marked as the second state, disable the base station from performing the communication only relating to the user equipment over the subframe.
One embodiment of the present invention is a user equipment for communicating with a base station in a time division duplexing manner based on an orthogonal frequency division multiplexing scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. The user equipment may include a first transceiver, a second transceiver, and a control device. The first transceiver may perform the communication with the base station. The second transceiver may perform another communication with at least one peripheral device based on another wireless communication scheme. The control device may control the first transceiver and the second transceiver according to an allocation pattern, wherein the plurality of frames are divided into cycles including a predetermined number of frames, and the allocation pattern marks each subframe of each frame of the cycles as a first state or a second state different from the first state. The control device may control the first transceiver to communicate with the base station over each subframe in case of determining that the subframe is marked as the first state, and control the second transceiver to perform the other communication with the at least one peripheral device in a time period corresponding to each subframe in case of determining that the subframe is marked as the second state and is not used by the user equipment for receiving system information.
One embodiment of the present invention is a method of communication resource allocation in a base station. The base station is adapted for communicating with a user equipment in a time division duplexing manner based on an orthogonal frequency division multiplexing scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. According to this method, a cycle which a present frame belongs to may be determined, wherein the cycle consists of a predetermined number of frames of the plurality of frames. It may be determined whether each of subframes of the present frame is marked as a first state or a second state different from the first state according to an allocation pattern, wherein the allocation pattern marks each subframe of each frame of the cycle as the first state or the second state. In case of determining that the subframe is marked as the first state, the base station may be enabled to communicate with the user equipment over the subframe, and in case of determining that the subframe is marked as the second state, the base station may be disabled from performing the communication only relating to the user equipment over the subframe.
One embodiment of the present invention is a method of communication control in a user equipment. The user equipment communicates with a base station in a time division duplexing manner based on an orthogonal frequency division multiplexing scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. According to this method, a first transceiver for the communication with the base station and a second transceiver for another communication with at least one peripheral device based on another wireless communication scheme may be controlled according to an allocation pattern. The plurality of frames are divided into cycles including a predetermined number of frames. The allocation pattern marks each subframe of each frame of the cycles as a first state or a second state different from the first state. The controlling may comprise controlling the first transceiver to communicate with the base station over each subframe in case of determining that the subframe is marked as the first state, and controlling the second transceiver to perform the other communication with the at least one peripheral device in a time period corresponding to each subframe in case of determining that the subframe is marked as the second state and is not used by the user equipment for receiving system information.
BRIEF DESCRIPTION OF THE DRAWINGS
Above and other objects, features and advantages will be more easily to be understood referring to the following descriptions made to the embodiments of the present invention in conjunction with the accompanying drawings. In the accompanying drawings, the same or corresponding reference numeral is adopted to denote the same or corresponding technical feature or component.
FIG. 1 is a schematic diagram showing the performing of a first communication between a user equipment and a base station and a second communication between a user equipment and other equipment in a time division multiplexing manner;
FIG. 2 is a block diagram showing an exemplary structure of a base station according to one embodiment of the present invention;
FIG. 3 is a flow chart showing an exemplary procedure of a method of communication resource allocation in a base station according to one embodiment of the present invention;
FIG. 4 shows uplink\downlink frame configurations 0 to 6 of a LTE TDD scheme;
FIG. 5 shows a location of a subframe in a frame structure, individually defined by respective sets in a first example;
FIG. 6 shows a location of a subframe in a frame structure, individually defined by respective sets in a second example;
FIG. 7 shows a location of a subframe in a frame structure, individually defined by respective sets in a third example;
FIG. 8 shows a location of a subframe in a frame structure, defined by respective sets in a fourth example;
FIG. 9 shows a location of a subframe in a frame structure, individually defined by respective sets in a fifth example;
FIG. 10 shows a location of a subframe in a frame structure, individually defined by respective sets in a sixth example;
FIG. 11 shows a location of a subframe in a frame structure, individually defined by respective sets in a seventh example;
FIG. 12 is a block diagram showing an exemplary structure of a base station according to one embodiment of the present invention;
FIG. 13 is a flow chart showing an exemplary procedure of a method of communication resource allocation in a base station according to one embodiment of the present invention;
FIG. 14 is a block diagram showing an exemplary structure of a user equipment according to one embodiment of the present invention;
FIG. 15 is a flow chart showing an exemplary procedure of a method of communication control in a user equipment according to one embodiment of the present invention;
FIG. 16 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 0 of a LTE TDD scheme;
FIG. 17 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 1 of a LTE TDD scheme;
FIG. 18 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 2 of a LTE TDD scheme;
FIG. 19 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 3 of a LTE TDD scheme;
FIG. 20 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 4 of a LTE TDD scheme;
FIG. 21 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 5 of a LTE TDD scheme; and
FIG. 22 is a block diagram of an exemplary structure of a computer in which an apparatus and a method of the present invention are implemented.
DETAILED DESCRIPTION OF THE INVENTION
In the following, embodiments of the present will be described referring to the accompanying drawings. It should be noted that, for the sake of clarity, denotations and descriptions of components and processes that are irrelevant to the present invention and known to those skilled in the art will be omitted in the accompanying drawings and the description.
In the user equipment, two types of communications may be performed simultaneously, one is the communication between the user equipment and the base station (hereinafter, referred to as a first communication for convenience of the description), and the other is the communication between the user equipment and other equipment (such as BLUETOOTH headset) (hereinafter, referred to as a second communication for convenience of the description), and the frequency bands on which the first communication and the second communication are based are adjacent to each other. In such a case, due to adjacent frequency band leakage, there is a possibility that one of the first communication and the second communication interferes with the other, or the first communication and the second communication interfere with each other. The inventor recognizes that this interference may be avoided by performing the first communication and the second communication in a time division multiplexing manner. FIG. 1 is a schematic diagram showing the performing of a first communication and a second communication in a time division multiplexing manner. As shown in FIG. 1 , in each of the cycles in time domain, the first communication and the second communication are performed alternately. Although each cycle includes two time periods for respectively performing the first communication and the second communication in FIG. 1 , more than one time period for performing the first communication and\or the second communication may be included. The base station may allocate the subframe resource used by the first communication, wherein the first communication is enabled over the subframe corresponding to the time period for performing the first communication, and the first communication is disabled over the subframe corresponding to the time period for performing the second communication. In the user equipment, the communication control may be performed, wherein according to the channel resource allocation performed by the base station, the first communication is enabled over the subframe corresponding to the time period for performing the first communication, and the second communication is enabled over the subframe corresponding to the time period for performing the second communication.
FIG. 2 is a block diagram showing an exemplary structure of a base station 200 according to one embodiment of the present invention. The base station 200 may communicate with the user equipment in a time division duplexing manner based on an OFDM scheme. The physical transmission resources for the communication between the base station and the user equipment may be divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes.
As shown in FIG. 2 , the base station 200 includes a cycle determination device 201 , a judgment device 202 and a communication control device 203 .
The cycle determination device 201 may determine a cycle which a present frame belongs to, wherein the cycle consists of a predetermined number of frames of the plurality of frames. The predetermined number may be the number of one or more than one as required in practical implement. In a case in which the predetermined number is more than one, the determining a cycle which a present frame belongs to also involves determining the location of the present frame in the cycle.
The judgment device 202 may determine whether each of subframes of the present frame is marked as a first state or a second state different from the first state according to an allocation pattern, wherein the allocation pattern marks each subframe of each frame of the cycle as the first state or the second state.
The communication control device 203 may, in case of determining that the subframe is marked as the first state, enable the base station to communicate with the user equipment over the subframe. The communication control device 203 may also, in case of determining that the subframe is marked as the second state, disable the base station from performing the communication only relating to the user equipment over the subframe. The communication only relating to the user equipment dose not include the broadcasting of the system information (such as the system information in the LTE TDD system) by the base station to all the user equipments. The communication control device 203 may implement this enabling and disabling by resource allocation.
FIG. 3 is a flow chart showing an exemplary procedure of a method of communication resource allocation in a base station according to one embodiment of the present invention. The base station may communicate with the user equipment in a time division duplexing manner based on an OFDM scheme. The physical transmission resources for the communication between the base station and the user equipment may be divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes.
As shown in FIG. 3 , the method begins at step 300 . At step 302 , a cycle which a present frame belongs to is determined, wherein the cycle consists of a predetermined number of frames of the plurality of frames. The predetermined number may be the number of one or more than one as required in practical implement. In a case in which the predetermined number is more than one, the determining a cycle which a present frame belongs to also involves determining the location of the present frame in the cycle.
At step 304 , it is determined whether each of subframes of the present frame is marked as a first state or a second state different from the first state according to an allocation pattern. The allocation pattern marks each subframe of each frame of the cycle as the first state or the second state. If it is determined at the step 304 that the subframe is marked as the first state, the base station is enabled to communicate with the user equipment over the subframe at step 306 . Then the method proceeds to step 308 . If it is determined at the step 304 that the subframe is marked as the second state, the base station is disabled from performing the communication only relating to the user equipment over the subframe at step 307 . The communication only relating to the user equipment dose not include the broadcasting of the system information (such as the system information in the LTE TDD system) by the base station to all the user equipments. Then the method proceeds to step 308 .
At the step 308 , it is determined whether the connection between the base station and the user equipment is over. If the connection is not over, the method returns to the step 302 to continue processing, otherwise the method ends at step 310 . With the time elapses, the corresponding present frame will change.
In the base station and the user equipment, a unified allocation pattern may be set statically. Alternatively, the user equipment may be notified by the base station of the adopted allocation pattern, for example when the user equipment is registered or the allocation pattern changes, as will be described in detail hereinafter.
The first communication may include the transmission and retransmission of the uplink data and the downlink data, exchanging of control signaling of various physical layers and high layers between the base station and the user equipment, and the like. The second communication is disabled during the first communication, and the first communication is disabled during the second communication, as will be described in detail hereinafter.
In order to maintain the normal working in the time division duplexing based on the OFDM scheme, besides the transmission of the uplink data and the downlink data, it is also necessary to transmit various uplink control information and downlink control information between the user equipment and the base station. Taking the LTE TDD system as an example, the control information may be for example the HARQ information, the CQI information, the configuration information from the base station for the user equipment to transmit the uplink data, the indication information from the base station for the user equipment to receive the downlink data, and the like. Here, the corresponding relation between the control information and the target subframe that corresponds to the control information is referred to as the control mapping relation.
In an embodiment of the base station and the method described in conjunction with FIG. 2 and FIG. 3 , the usage of the subframe for the first communication may be defined as required, for example the uplink and downlink data, the uplink and downlink control information, the broadcasting information (such as the system information in the LTE TDD system), and the control mapping relation between the subframes.
In a further embodiment of the base station and the method described in conjunction with FIG. 2 and FIG. 3 , the base station may be based on the LTE TDD scheme. According to the LTE TDD scheme, the frame may comply with one of uplink\downlink frame configurations 0 to 6 . FIG. 4 shows uplink\downlink frame configurations 0 to 6 of the LTE TDD scheme. As shown in FIG. 4 , each frame includes 10 subframes, i.e. subframe 0 to subframe 9 . The subframe marked with a symbol “D” is the downlink subframe, the subframe marked with a symbol “U” is the uplink subframe, and the subframe marked with a symbol “S” is the subframe including a switch point.
The LTE TDD scheme specifies various control mapping relations between subframes. For example, for the data transmission of one uplink\downlink subframe, the uplink transmission of the control information relating thereto should be performed over the defined uplink\downlink subframe. The allocation pattern may be set that, if the time slot of one uplink subframe is allocated to be used by the first communication, it is ensured that the time slot of the subframe which has the control mapping relation with this uplink subframe, i.e. the subframe in which there are all the control information and the retransmission data related to this uplink subframe, should also be allocated to be used by the first communication. Thus the normal performing of this uplink transmission of the first communication is ensured. Similarly, if the time slot of one downlink subframe is allocated to be used by the first communication, then it is ensured that the time slot of the subframe which has the control mapping relation with this downlink subframe, i.e. the subframe in which there are all the control information related to this downlink subframe, should also be allocated to be used by the first communication.
In the first example, the number of the frame included in the cycle is one, each frame complies with uplink\downlink frame structure configuration 0 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least the subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 2 , subframe 6 },
set 2 ={subframe 1 , subframe 7 },
set 3 ={subframe 0 , subframe 4 },
set 4 ={subframe 5 , subframe 9 }.
FIG. 5 shows a location of a subframe in a frame structure, individually defined by sets 1 to 4 in a first example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 16 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 0 of a LTE TDD scheme. In FIG. 16 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark one portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 3
2
set 3, set 4
3
set 2, set 3, set 4
4
set 1, set 2, set 3, set 4
In a second example, the number of the frame included in the cycle is one, and each frame complies with uplink\downlink frame structure configuration 1 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 2 , subframe 6 },
set 2 ={subframe 2 , subframe 5 , subframe 6 },
set 3 ={subframe 3 , subframe 9 },
set 4 ={subframe 1 , subframe 7 },
set 5 ={subframe 0 , subframe 1 , subframe 7 },
set 6 ={subframe 4 , subframe 8 }.
FIG. 6 shows a location of a subframe in a frame structure, individually defined by sets 1 to 6 in the second example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 17 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 1 of the LTE TDD scheme. In FIG. 17 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark a portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 3
2
set 2
3
set 3, set 6
4
set 3, set 4, set 5
5
set 2, set 5
6
set 2, set 3, set 6
7
set 2, set 3, set 5
8
set 2, set 3, set 4, set 6
In a third example, the number of the frame included in the cycle is one, and each frame complies with uplink\downlink frame structure configuration 2 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 2 , subframe 8 },
set 2 ={subframe 2 , subframe 4 , subframe 8 },
set 3 ={subframe 2 , subframe 5 , subframe 8 },
set 4 ={subframe 2 , subframe 6 , subframe 8 },
set 5 ={subframe 3 , subframe 7 },
set 6 ={subframe 0 , subframe 3 , subframe 7 },
set 7 ={subframe 1 , subframe 3 , subframe 7 },
set 8 ={subframe 3 , subframe 7 , subframe 9 }.
FIG. 7 shows a location of a subframe in a frame structure, individually defined by sets 1 to 8 in the third example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 18 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 2 of the LTE TDD scheme. In FIG. 18 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark a portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 1
2
set 8
3
set 1, set 5
4
set 1, set 8
5
set 2, set 3, set 5
6
set 2, set 3, set 8
7
set 2, set 3, set 4, set 8
8
set 2, set 3, set 4, set 5, set 6, set 8
In a fourth example, the number of the frame included in the cycle is one, and each frame complies with uplink\downlink frame structure configuration 3 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 0 , subframe 4 },
set 2 ={subframe 0 , subframe 4 , subframe 9 },
set 3 ={subframe 0 , subframe 3 , subframe 4 , subframe 9 },
set 4 ={subframe 0 , subframe 3 , subframe 4 , subframe 7 , subframe 9 },
set 5 ={subframe 0 , subframe 3 , subframe 4 , subframe 8 , subframe 9 },
set 6 ={subframe 0 , subframe 2 , subframe 3 , subframe 4 , subframe 8 , subframe 9 },
set 7 ={subframe 0 , subframe 1 , subframe 2 , subframe 3 , subframe 4 , subframe 8 , subframe 9 },
set 8 ={subframe 0 , subframe 2 , subframe 3 , subframe 4 , subframe 5 , subframe 8 , subframe 9 },
set 9 ={subframe 0 , subframe 2 , subframe 3 , subframe 4 , subframe 6 , subframe 8 , subframe 9 }.
FIG. 8 shows a location of a subframe in a frame structure, individually defined by sets 1 to 9 in the fourth example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 19 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 3 of the LTE TDD scheme. In FIG. 19 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark a portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 1
2
set 2
3
set 3
4
set 5
5
set 6
6
set 8
7
set 7 and set 8
8
set 7, set 8, set 9
In a fifth example, the number of the frame included in the cycle is one, and each frame complies with uplink\downlink frame structure configuration 4 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 3 , subframe 9 },
set 2 ={subframe 3 , subframe 8 , subframe 9 },
set 3 ={subframe 3 , subframe 7 , subframe 9 },
set 4 ={subframe 3 , subframe 6 , subframe 9 },
set 5 ={subframe 2 , subframe 3 , subframe 8 , subframe 9 },
set 6 ={subframe 0 , subframe 2 , subframe 3 , subframe 8 , subframe 9 },
set 7 ={subframe 1 , subframe 2 , subframe 3 , subframe 8 , subframe 9 },
set 8 ={subframe 2 , subframe 3 , subframe 4 , subframe 8 , subframe 9 },
set 9 ={subframe 2 , subframe 3 , subframe 5 , subframe 8 , subframe 9 }.
FIG. 9 shows a location of a subframe in a frame structure, individually defined by sets 1 to 9 in the fifth example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 20 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 4 of the LTE TDD scheme. In FIG. 20 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframes marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark one portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 1
2
set 2
3
set 5
4
set 6
5
set 3, set 6
6
set 3, set 4, set 6
7
set 3, set 4, set 5, set 6, set 9
8
set 3, set 4, set 5, set 6, set 7, set 8
In a sixth example, the number of the frame included in the cycle is one, and each frame complies with uplink\downlink frame structure configuration 5 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 2 , subframe 8 },
set 2 ={subframe 0 , subframe 2 , subframe 8 },
set 3 ={subframe 1 , subframe 2 , subframe 8 },
set 4 ={subframe 2 , subframe 3 , subframe 8 },
set 5 ={subframe 2 , subframe 4 , subframe 8 },
set 6 ={subframe 2 , subframe 5 , subframe 8 },
set 7 ={subframe 2 , subframe 6 , subframe 8 },
set 8 ={subframe 2 , subframe 7 , subframe 8 },
set 9 ={subframe 2 , subframe 8 , subframe 9 }.
FIG. 10 shows a location of a subframe in a frame structure, individually defined by sets 1 to 9 in the sixth example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. FIG. 21 shows an example of an allocation pattern obtained under an uplink\downlink frame configuration 5 of the LTE TDD scheme. In FIG. 21 , each line represents one example, and the lines are numbered from up to down. The numbers 0 to 9 in the row are the subframe numbers, the blocks marked with the letter “D”, “U” or “S” represent the subframe with the corresponding number, the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe. The practical allocation pattern may mark one portion or all of the other subframes as the second state. The sets on which individual examples are based are listed in the following table.
Example
Set combination
1
set 1
2
set 2
3
set 4, set 9
4
set 4, set 5, set 9
5
set 4, set 5, set 6, set 7
6
set 4, set 5, set 6, set 7, set 8
7
set 4, set 5, set 6, set 7, set 8, set 9
8
set 3, set 4, set 5, set 6, set 7, set 8
In a seventh example, the number of the frames included in the cycle is six, and each frame complies with uplink\downlink frame structure configuration 6 of the LTE TDD scheme. Furthermore, the allocation pattern marks at least subframes defined by at least one of the following sets as the first state, and marks at least one portion of the remained subframes (may be any kind of one subframe to all the subframes) as the second state:
set 1 ={subframe 2 of frame 0 , subframe 6 of frame 0 , subframe 3 of frame 1 , subframe 9 of frame 1 , subframe 4 of frame 2 , subframe 0 of frame 3 , subframe 7 of frame 3 , subframe 1 of frame 4 , subframe 8 of frame 4 , subframe 5 of frame 5 },
set 2 ={subframe 3 of frame 0 , subframe 9 of frame 0 , subframe 4 of frame 1 , subframe 0 of frame 2 , subframe 7 of frame 2 , subframe 1 of frame 3 , subframe 8 of frame 3 , subframe 5 of frame 4 , subframe 2 of frame 5 , subframe 6 of frame 5 },
set 3 ={subframe 4 of frame 0 , subframe 0 of frame 1 , subframe 7 of frame 1 , subframe 1 of frame 2 , subframe 8 of frame 2 , subframe 5 of frame 3 , subframe 2 of frame 4 , subframe 6 of frame 4 , subframe 3 of frame 5 , subframe 9 of frame 5 },
set 4 ={subframe 0 of frame 0 , subframe 7 of frame 0 , subframe 1 of frame 1 , subframe 8 of frame 1 , subframe 5 of frame 2 , subframe 2 of frame 3 , subframe 6 of frame 3 , subframe 3 of frame 4 , subframe 9 of frame 4 , subframe 4 of frame 5 },
set 5 ={subframe 1 of frame 0 , subframe 8 of frame 0 , subframe 5 of frame 1 , subframe 2 of frame 2 , subframe 6 of frame 2 , subframe 3 of frame 3 , subframe 9 of frame 3 , subframe 4 of frame 4 , subframe 0 of frame 5 , subframe 7 of frame 5 },
set 6 ={subframe 5 of frame 0 , subframe 2 of frame 1 , subframe 6 of frame 1 , subframe 3 of frame 2 , subframe 9 of frame 2 , subframe 4 of frame 3 , subframe 0 of frame 4 , subframe 7 of frame 4 , subframe 1 of frame 5 , subframe 8 of frame 5 }.
FIG. 11 shows a location of a subframe in a frame structure, individually defined by sets 1 to 6 in the seventh example, wherein the shadowed subframe is the subframe marked as the first state, and the unshadowed subframe is the other subframe.
In the LTE TDD system, it is also necessary to broadcast the system information from the base station to the user equipment. The system information includes a Main Information Block (MIB) and a System Information Block (SIB). Generally, the MIB is broadcasted in the subframe 0 , and the SIB is broadcasted in the subframe 5 . According to the resource allocation of the system, the system information may be carried on the subframe that is marked as the first state (such as the subframe 0 and the subframe 5 ), or the system information is transmitted purely on the subframe that is marked as the second state.
The LTE TDD system has more complicated control mapping relation, which is caused by the multiple kinds of frame structures of the LTE TDD system.
Specifically, the control mapping relations to which the sets relate may include the following types:
1. the mapping relation between the downlink data and the uplink ACK\NACK signal corresponding to the downlink data;
2. the mapping relation between the uplink data and the downlink ACK\NACK signal corresponding to the uplink data;
3. the mapping relation between the downlink NACK signal and the uplink retransmission data corresponding to the downlink NACK signal;
4. the mapping relation between the downlink PDCCH for configuring the uplink data transmission and the uplink data transmission corresponding to the downlink PDCCH; and
5. the mapping relation between the downlink subframe for scheduling the non-periodic CQI information and the uplink subframe for transmitting this non-periodic CQI information.
Specifically, the above control mapping relations relate to the following tables in the LTE standard: the table 5.1.1.1-1, the table 8-2, the table 9.1.2-1 and the table 10.1-1 in the TS 36.213, wherein the table 5.1.1.1-1 gives the relation between the downlink subframe for transmitting the PDCCH format 0 and the uplink subframe scheduled by this PDCCH format 0 , the table 8-2 gives the relation between the downlink subframe for receiving the downlink NACK relating to the uplink transmitted data and the uplink subframe for sending the corresponding retransmission, the table 9.1.2-1 gives the relation between the uplink subframe for sending the uplink data and the downlink subframe for receiving the HARQ information of the corresponding uplink data, and the table 10.1-1 gives the relation between the downlink subframe for receiving the data and the uplink subframe for transmitting the corresponding HARQ signal.
It should be noted that, the uplink\downlink frame structure configuration 0 has particularity, i.e., there are 6 uplink subframes and 4 downlink subframes (the subframe including the switch point is processed as the downlink subframe) in each frame. Therefore, in the control mapping relation of the uplink\downlink frame structure configuration 0 , there are particular situations which do not comply with the control mapping relations given by the above tables. For example, if the uplink subframe 2 and the uplink subframe 3 in one frame are simultaneously scheduled to transmit uplink data, the base station may allocate both the uplink subframe 2 and the uplink subframe 3 in the same downlink subframe (the subframe 6 of the previous frame). If there are uplink transmissions over both the uplink subframe 3 and the uplink subframe 4 in one frame simultaneously, the base station may transmit the HARQ signals corresponding to both the uplink subframe 3 and the uplink subframe 4 in the same downlink subframe (the subframe 0 of the next frame). The relations among the subframes 7 , 8 and 9 are similar to that among the subframes 2 , 3 and 4 .
Due to this particularity of the uplink\downlink frame structure configuration 0 , the uplink\downlink frame structure configuration 0 can not find the set without changing the present control mapping relation as other configurations. The subframe 3 and the subframe 8 are fixedly not used for the first communication for simplifying the original control mapping relation.
Because the subframe 3 and the subframe 8 may not be used for the first communication, the case in which two uplink subframes commonly correspond to one downlink subframe will not occur. Therefore, the table 5.1.1.1-1, the table 8-2, the table 9.1.2-1, and the table 10.1-1 will be performed strictly, and no original particular case will occur.
It can be seen that, according to the allocation pattern described in conjunction with the FIG. 6 to FIG. 11 , each set is defined based on the control mapping relation of the LTE TDD system within one cycle. Therefore, it is not necessary to modify the control mapping relation in the LTE TDD system. In the allocation pattern described in conjunction with FIG. 5 , the subframe 3 and the subframe 8 will not be allocated for the first communication, so that the original control mapping relation in the LTE TDD system is simplified. In practical implement, the control mapping relations of the LTE TDD system from one cycle to another cycle should be the same. Therefore, the cycle should be one frame or integral times of one frame.
In one cycle, if a set consisting of several subframes in this cycle satisfies the following conditions, this set is referred to as a closed subframe set.
1. at least one uplink subframe and one downlink subframe are included in one set;
2. if one uplink transmission is scheduled by the base station over one uplink subframe in this set, the base station must allocate this uplink transmission over one downlink subframe in this set, and the base station must feed back the HARQ signal corresponding to this uplink transmission over one downlink subframe in this set; if this uplink transmission fails according to the HARQ signal from the base station, the corresponding uplink retransmission must also be performed over one uplink subframe in this set;
3. if one downlink transmission is received by the user equipment over one downlink subframe in this set, the user equipment must transmit the HARQ signal corresponding to this down transmission to the base station over one uplink subframe in this set; and
4. if the user equipment receives one scheduling command of the non-periodic CQI information form the base station over one downlink subframe in this set, the user equipment must transmit the scheduled CQI information over one uplink subframe in this set.
In the first example to the seventh example, each of the sets is a closed subframe set.
For each configuration, there are more than one set. One of these sets or any combination thereof may define a plurality of allocation patterns. Therefore, there are different allocation patterns to be selected.
FIG. 12 is a block diagram showing an exemplary structure of a base station 1200 according to one embodiment of the present invention.
As shown in FIG. 12 , the base station 1200 includes a cycle determination device 1201 , a judgment device 1202 , a communication control device 1203 and a pattern determination device 1204 . The cycle determination device 1201 , the judgment device 1202 and the communication control device 1203 have respectively the same function as the cycle determination device 201 , the judgment device 202 and the communication control device 203 in respective embodiments described above, which will not be described in detail here.
The allocation pattern is used to mark at least subframes defined by at least one of several sets as the first state, and to mark at least one portion of the remained subframes as the second state different from the first state. The pattern determination device 1204 is adapted for determining the allocation pattern by selecting the at least one set defining a lower number of subframes including a switch point in preference, or by selecting the at least one portion including a larger number of consecutive subframes in preference. The determined allocation pattern is provided to the judgment device 1202 . The pattern determination device 1204 also notifies the user equipment of the determined allocation pattern.
FIG. 13 is a flow chart showing an exemplary procedure of a method for communication resource allocation in a base station according to one embodiment of the present invention.
As shown in FIG. 13 , the method begins from step 1300 . At step 1301 , the allocation pattern is determined. The allocation pattern is used to mark at least subframes defined by at least one of several sets as the first state, and to mark at least one portion of the remained subframes as the second state. The allocation pattern may be determined by selecting the at least one set defining a lower number of subframes including a switch point in preference, or by selecting the at least one portion including a larger number of consecutive subframes in preference. The determined allocation pattern is provided to be used by step 1304 . Furthermore, in the step 1301 , the user equipment is notified of the determined allocation pattern. The steps 1302 , 1304 , 1306 , 1307 , 1308 and 1310 have respectively the same processing as the steps 302 , 304 , 306 , 307 , 308 and 310 , which will not be described in detail here.
Relative to the ordinary uplink and downlink subframe, the amount of the effective data in the subframe including the switch point is smaller. Therefore, it is enabled to improve the utilization of the subframe resource by determining the allocation pattern by selecting the at least one set defining a lower number of subframes including a switch point.
Furthermore, by preferably selecting to include at least one portion of more consecutive subframes, the number of switching between the first communication and the second communication in the user equipment and the number of switching between enabling the first communication and disabling the first communication in the base station can be decreased, and the continuity of the second communication is improved.
In the subframe configuration adopted by the base station, there are multiple possible allocation patterns. In different allocation patterns, the number of the subframe marked as the first state and the number of the subframe marked as the second state may be different in number and proportion. Accordingly, the bandwidth requirements of the first communication and the second communication that can be satisfied by the different allocation patterns are also different. Therefore, the allocation pattern having proper proportion may be adopted according to the requirement of the services for which the first communication and the second communication are used. Before the beginning of the first communication and the second communication, or when the services for which the first communication and the second communication are used change, the allocation pattern may be determined according to the requirement fed back by the user equipment.
In a further embodiment of the base station and the method for communication resource allocation in the base station described above, the pattern determination device may be further configured to select the allocation pattern that is able to meet a bandwidth requirement, according to the bandwidth requirement of the first communication and the second communication from the user equipment. The method may further include selecting the allocation pattern that is able to meet the bandwidth requirement, according to the bandwidth of the first communication and the second communication from the user equipment. The bandwidth requirement may be represented by the bandwidth required by the first communication and the second communication, the number or the proportion of the subframes for the first communication and the second communication in the cycle, or the like.
Furthermore, it should be understood that, in the time during which the first communication is disabled, the user equipment may perform the second communication with a plurality of peripheral devices, particularly perform the second communication with individual peripheral devices based on different wireless communication schemes. In such a case, the user equipment may include a second transceiver for the second communication with the corresponding peripheral device. The control device of the user equipment may allocate the corresponding time to the second communication between the second transceiver and the individual peripheral devices.
FIG. 14 is a block diagram showing an exemplary structure of a user equipment 1400 according to one embodiment of the present invention. The user equipment 1400 may communicate with the base station in the time division duplexing manner based on the OFDM scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. Multiple frames are divided into cycles including predetermined number of frames. The allocation pattern as described above marks each subframe of each frame of the cycle as the first state or the second state different from the first state.
As shown in FIG. 14 , the user equipment 1400 includes a first transceiver 1401 , a control device 1402 and a second first transceiver 1403 .
The first transceiver 1401 may perform communication with the base station, i.e. the first communication.
The second transceiver 1403 may perform another communication with at least one peripheral device based on another wireless communication scheme, i.e. the second communication.
The control device 1402 may control the first transceiver 1401 and the second transceiver 1403 according to an allocation pattern. The control device 1402 controls the first transceiver 1401 to perform the first communication over each subframe in case of determining that the subframe is marked as the first state, and controls the second transceiver 1403 to perform the second communication with at least one peripheral device in the time period corresponding to each subframe in case of determining that the subframe is marked as the second state and is not used by the user equipment for receiving system information. For certain subframe marked as the second state, the base station may broadcast system information over this subframe. However, it may be because of that the user equipment has already successfully receive the system information and thus does not need to receive the system information again over this subframe, the user equipment is able to use the time period corresponding to this subframe for the second communication.
FIG. 15 is a flow chart showing an exemplary procedure of a method for communication control in a user equipment according to one embodiment of the present invention. The user equipment may communicate with the base station in the time division duplexing manner based on the OFDM scheme. The physical transmission resources for the communication between the base station and the user equipment are divided into a plurality of consecutive frames in the time domain, each of the frames comprises a plurality of subframes. Multiple frames are divided into cycles including predetermined number of frames. The allocation pattern as described above marks each subframe of each frame of the cycle as the first state or the second state different from the first state.
As shown in FIG. 15 , the method begins at step 1500 . At step 1502 , in case of determining that each subframe is marked as the first state, the first transceiver for the communication with the base station, i.e. a first communication, is controlled to perform the first communication over this subframe.
At step 1504 , in case of determining that the subframe is marked as the second state and is not used by the user equipment for receiving system information, the second transceiver for performing other communication with at least one peripheral device according to other wireless communication scheme, i.e. the second communication, is controlled to perform the communication with the at least one peripheral device in the time corresponding to this subframe, i.e. to perform the second communication. For certain subframe marked as the second state, the base station may broadcast system information over this subframe. However, it may be because of that the user equipment has already successfully receive the system information and thus does not need to receive the system information again over this subframe, the user equipment is able to use the time corresponding to this subframe for the second communication.
And then the method ends at step 1506 .
In a further embodiment of the user equipment and the method for communication control in the user equipment described in conjunction with FIG. 14 and FIG. 15 , the user equipment is based on the LTE TDD scheme. Multiple frames of the physical transmission resources for the communication between the base station and the user equipment are divided into cycles including a predetermined number of frames. The allocation pattern may be the allocation pattern described referring to the first to the seventh example.
In the LTE TDD system, it is also necessary to broadcast the system information from the base station to the user equipment. The system information includes a Main Information Block (MIB) and a System Information Block (SIB). Generally, the MIB is broadcasted in the subframe 0 , and the SIB is broadcasted in the subframe 5 . The system information may be carried on the subframe that is marked as the first state (such as the subframe 0 and the subframe 5 ), or the system information is transmitted purely on the subframe that is marked as the second state.
In a further embodiment of the user equipment described above, the user equipment may further include a requesting device and a pattern receiving device. The requesting device may report a bandwidth requirement of the first communication and the second communication to the base station. Accordingly, the base station may determine the allocation pattern that meets a bandwidth requirement according to the bandwidth requirement of the first communication and the second communication, and send the information about the determined allocation pattern to the user equipment. The pattern receiving device may receive the information about the determined allocation pattern from the base station.
In a further embodiment of the method for communication control in the user equipment described above, the method may further include reporting a bandwidth requirement of the first communication and the second communication to the base station; and receiving, from the base station, the information about the allocation pattern that meets the bandwidth requirement and is determined by the base station.
Those skilled in the art should know that, the devices and the steps according to the embodiments of the present invention may be embodied as for example a system, a method or a computer program product. Therefore, the present invention may be specifically implemented in the following form, i.e., may be total hardware, total software (including firmware, resident software, micro code and the like), or the combination of the software portion and the hardware portion generally referred to as “circuit”, “module” or “system” herein. Furthermore, the present invention may also be implemented in the form of computer program product that is embodied in any tangible medium of expression in which the program code available to the computer is included.
Any combination of one or more computer-readable medium may be used. The computer-readable medium may be the computer-readable signal medium or the computer-readable storage medium, and the computer-readable storage medium may be, but not limited to, for example electric, magnetic, optical, electromagnetic, infrared or semiconductor system, device, means or communication medium, or any suitable combination thereof. The more specific examples of the computer-readable storage medium may include (non-numerated list): electric connection with one or more wires, portable computer disk, hard disk, Random Access Memory (RAM), Read Only Memory (ROM), Erasable and Programmable Read Only Memory (EPROM or flash memory), optical fiber, portable Compact Disc-Read Only Memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof. In the context of this document, the computer-readable storage medium may be any tangible medium that contains or stores the programs provided to be used by or relating to the system, device, and means of instruction execution.
The computer-readable signal medium may include for example the data signal carrying computer-readable program code, transmitted in the base band or as a portion of the carrier. Such a kind of transmission signal may take any suitable form, including but not limited to the electromagnetic, the optical, or any suitable combination thereof. The computer-readable signal medium may be any kind of computer-readable medium that is different from the computer-readable storage medium and may convey, propagate, or transmit the program provided to be used by or relating to the system, device, and means for instruction execution. The program code contained in the computer-readable medium may be transmitted by using any suitable medium, including but not limited to wireless, wired, optical fiber cable, radio frequency and the like, or any suitable combination thereof.
The computer program code for performing the operation of the present invention may be wrote in any combination of one or more programming languages, and the programming languages include the object-oriented programming language, such as Java, Smalltalk, C++ and the like, and may also include the conventional procedure programming language such as “C” programming language or the similar programming language. The program code may be executed completely on the computer of the user, partially on the computer of the user, as one independent software package, partially on the computer of the user and partially on the remote computer, or completely on the remote computer or the server. In the latter situation, the remote computer may be connected to the computer of the user through any kind of networks including the Local Area Network (LAN) or the Wide Area Network (WAN), or may be connected to the external computer (for example through the Internet by using the Internet service provider).
FIG. 22 is a schematic exemplary diagram of a computer in which an apparatus and a method of the present invention are implemented.
In the FIG. 22 , the Central Processing Unit (CPU) 2201 executes various processing according to the program stored in the Read Only Memory (ROM) 2202 or the program loaded from the storage portion 2208 to the Random Access Memory (RAM) 2203 . In the RAM 2203 , the data required when the CPU 2201 executes various processing and the like are also stored as required.
The CPU 2201 , the ROM 2202 and the RAM 2203 are connected to each other via the bus 2204 . The input\output interface 2205 is also connected to the bus 2204 .
The following components are connected to the input\output interface 2205 : the input portion 2206 , including a keyboard, a mouse, and the like; the output portion 2207 , including the display such as a Cathode Ray Tube (CRT), the Liquid Crystal Display (LCD) and so on, the speaker and the like; the storage portion 2208 , including the hard disk and the like; and the communication portion 2209 , including network interface card such as LAN card, the modem and the like. The communication portion 2209 performs the communication processing via network such as Internet.
The driver 2210 is also connected to the input\output interface 2205 as required. The removable medium 2211 such as a magnetic disk, an optical disk, a magneto optical disk, the semiconductor mapping data and the like, may be mounted on the driver 2210 as required, so that the computer program read out therefrom is installed in the storage portion 2208 as required.
In a case in which the above steps and processes are implemented using software, the programs which consist the software is installed through a network such as Internet or a storage medium such as the removable medium 2211 .
It should be understood by those skilled in the art that, this kind of storage medium is not limited to the removable medium 2211 in which the program is stored and which is distributed separately from the method so as to provide the user with the program, as shown in FIG. 22 . The examples of the removable medium 2211 include magnetic disk, optical disk (including Compact Disk Read Only Memory (CD-ROM) and Digital Versatile Disc (DVD)), magnetic optical disk (including Mini-Disk (MD)), and semiconductor mapping data. Alternatively, the storage medium may be the hard disk contained in the ROM 2202 and the storage portion 2208 and the like, in which the programs are stored, and the programs are distributed to the user together with method containing the programs.
The equivalents or alternates of the corresponding structures, materials, operations and all the functionally defined means or the steps in the below claims are intended to include any structure, material or operation for performing this function in combination with the other units recited specifically in the claims. The purpose of the given description of the present invention is to illustrate and describe, but not to be exhaustive or limit the present invention to the described form. It is obvious for those skilled in the art to make many modifications and variations without deviating from the scope and the spirit of the present invention. The selection and the description of the embodiment are to explain the principle and the practical application of the present invention better, so that those skilled in that art may realize that the present invention may have various embodiments with various changes suitable for the required specific usage.
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A base station communicates with a user device in the mode of time division duplexing based on the orthogonal frequency division multiplexing scheme. The physics transmission resource used for communicating between the station and device is divided into a plurality of continuous frames in the time domain, each containing a plurality of sub-frames. The base station can include: a period determination device, for determining the period of the current frame, composed of a predetermined number of frames in a plurality of frames; a judgment device, for determining whether each sub-frame in the current frame is marked as the first or second state; a communication control device, for permitting the base station to communicate with the user device on the sub-frame when it is in the first state, forbidding communication only concerned with the user device performed by the base station on the sub-frame when it is in the second state.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to path length control apparatus (PLC) for optical devices and in particular to a physical design of the apparatus that removes the likelihood of imparted stresses on a mirror resulting in a flatter surface for reflecting a laser beam of a ring laser gyroscope (RLG).
2. Description of the Related Art
A ring laser gyroscope (RLG) is commonly used to measure the angular rotation of an object, such as an aircraft. Such a gyroscope has two counter-rotating laser light beams that move within a closed loop optical path or “ring” with the aid of successive reflections from multiple mirrors. The closed path is defined by an optical cavity that is interior to a gyroscope frame or “block.” In one type of RLG, the block includes planar top and bottom surfaces that are bordered by six planar sides that form a hexagon-shaped perimeter. Three planar non-adjacent sides of the block form the mirror mounting surfaces for three mirrors at the corners of the optical path, which is triangular in shape.
Operationally, upon rotation of the RLG about its input axis (which is perpendicular to and at the center of the planar top and bottom surfaces of the block), the effective path length of each counter-rotating laser light beam changes and a frequency differential is produced between the beams that is nominally proportional to angular rotation. This differential is then optically detected and measured by signal processing electronics to determine the angular rotation of the vehicle. To maximize the signal out of the RLG, the path length of the counter-rotating laser light beams within the cavity must be adjusted. Thus, RLGs typically include a path length control apparatus (PLC), the purpose of which is to control the path length for the counter-rotating laser light beams for maximum output signal.
FIG. 1 illustrates one such known PLC 10 for a laser block assembly (LBA) 12 of an RLG, such as that described as prior art in U.S. Pat. No. 6,515,403, herein incorporated by reference. This PLC 10 includes a piezoelectric transducer (PZT) 16 which is secured to a mirror 18 via an epoxy-based adhesive 20 . The epoxy adhesive 20 completely covers the interface (defined by a lower surface 22 of the PZT 16 and an upper surface 24 of the mirror 18 between the PZT 16 and the mirror 18 . The mirror 18 is secured to a mirror mounting surface 26 of the optical LBA 12 . The mirror 18 communicates with laser bores 32 (only partially shown) of an optical cavity 34 (only partially shown) of the LBA 12 . The bores 32 form a portion of the closed loop optical path 38 defined by the optical cavity 34 . As seen in FIG. 1 , the mirror 18 reflects counter-rotating laser light beams 40 at its respective corner of the closed loop optical path 38 .
A conventional PZT 16 ( FIGS. 2 & 3A ) is defined by a pair of piezoelectric elements 42 and 44 . The PZT 16 takes an applied voltage delivered by a regulated voltage source (not shown), in response to a signal provided by a detector (not shown) that monitors the intensity of the light beams 40 , and turns this voltage into small but precisely controlled mechanical movement in a direction perpendicular to a top surface of the PZT 16 . This mechanical movement of the PZT 16 affects translational movement of the mirror 18 , and thereby controls the laser light beam path length.
FIG. 3B illustrates a known multi-layered PZT, such as that described by U.S. Pat. No. 6,515,403, in which a stack of alternating negative and positive co-fired ceramic layers is provided. Co-fired ceramic layers are those that are “fired”, when they are made, together, as opposed to being made separately and then later bonded together. These may then form a resultant multilayered stack.
This structure may include a top layer 62 , a bottom layer 68 , and alternating negative 64 and positive 66 layers. This multi-layer PZT 16 has contacts, which are electrically connected to other layers within the multi-layer PZT 16 , formed directly on the top layer of the PZT 16 , and the regulated voltage source can be coupled directly to the PZT 16 at the top layer contacts. The multi-layer PZT 16 includes a plurality of ceramic layers 62 , 64 , 66 , 68 so as to form a stack in which each ceramic layer has first and second opposing surfaces.
The plurality of ceramic layers includes a top layer 62 at a first end of the stack having a top conductive pattern formed on its first surface. The top conductive pattern includes a negative contact and a positive contact.
The plurality of ceramic layers 62 , 64 , 66 , 68 also includes at least one poled ceramic layer 64 having a conductive pattern formed on its first surface. The plurality of ceramic layers 62 , 64 , 66 , 68 include additional poled ceramic layers 66 , 68 having alternating conductive patterns formed on the first surface thereof. In such a multi-layer configuration, the layers are more tightly coupled to the mirror since they lack extra epoxy layers. Almost all the distortion in the ceramic is directly imparted into the mirror 18 .
Sometimes, with conventional PZTs 16 in which the PLC driver is bonded directly to the transducer mirror, curvature in the mirror due to stresses or other factors may cause multimoding of the laser beam. In multi-layer PZTs 16 , this occurs more often, i.e., in approximately 30–50% of the LBAs. This is particularly true, e.g., because only thin layers 20 (such as 0.0005″ to 0.001″) of epoxy are typically used to attach the mirror 18 to the driver. This multimoding interferes with the laser mode that the LBA uses to get an accurate count data (and therefore navigation data).
The problem of multimoding is described in more detail below.
Multimoding occurs when a higher order transverse mode becomes resonant with the fundamental TEM 00 (Transverse Electro-Magnetic) mode. The fundamental TEM 00 mode is characterized by an intensity distribution, which can mathematically be described by a Gaussian function centered on the direction of propagation. Mathematically, the intensity distribution is
I
(
x
,
y
)
=
I
0
exp
[
-
x
2
+
y
2
ω
(
z
)
2
]
Here I 0 is the intensity in W/cm 2 at the center of the beam and ω is the 1/e 2 intensity radius. ω is a function of the distance, z, from a point of minimum radius called the beam waist.
Higher-order modes, designated TEM mn , where m>0 and/or n>0, have a more complicated mathematical description. Briefly, the TEM 10 mode can be described as a set of headlights, that is, two spots side-by-side. The TEM 01 is similar but rotated by 90°. The TEM 11 mode has four spots—essentially two sets of headlights, one on top of the other. Note that all three of these modes have a null point (or zero energy) at the center of the beam. This is characteristic of any mode with an odd index. Modes that have both indices (m and n) being even always have energy at the center of the beam. The mode index can be determined by counting the number of null regions along a particular direction, either x or y.
Higher-order modes have larger spatial areas than do the fundamental mode. Hence an internal body aperture can be used to against them. That is, an aperture of the correct size adds little loss to the fundamental mode, but adds measurable loss to higher-order modes whose beams are spatially offset from the beam of the fundamental mode. The higher the mode numbers, the more loss added. So, for example, in one type of device, the internal apertures add about 10 ppm loss to the fundamental mode and 100 ppm loss to the TEM 01 and TEM 10 modes.
If, however an aperture diameter were scaled to a larger RLG aperture diameter, then it would be very difficult to build any hardware, since the alignment would be very difficult to achieve with that small of an aperture (e.g., on the order of 0.032″). But a slightly larger aperture diameter provides less than 1 ppm loss for the TEM 01 and TEM 10 modes. The result is that these modes lase very well and one must attempt to reduce them with an external aperture placed in front of the LIM (Laser Intensity Monitor) sensor.
The LIM aperture discriminates against higher order modes and allows the PLC loop to lock onto the fundamental mode as it is presented to the LIM detector as the most intense mode. It is fortunate that higher order modes lase at a different frequency than does the fundamental. For example, the TEM 10 mode lases approximately mid-way between one fundamental mode and another (representing path lengths that differ by one optical wavelength). Hence if the PLC loop is controlling on a fundamental mode, the TEM 10 mode will not lase. The TEM 01 , the TEM 20 and the TEM 02 modes all are within approximately 0.1 modes from the fundamental. Again, when the loop is controlling on the fundamental mode none of these three will lase.
Thus, the lowest, higher-order transverse modes are discriminated against because they are separated in frequency from the fundamental modes, and other higher-order modes are discriminated against primarily by using the internal body aperture and secondarily by frequency separation.
The problem is that the frequency separation between the fundamental mode and any higher-order mode is a function of mirror curvature. The higher the mode indices, the stronger the function.
The wedge (the mirror having the readout detector on it—which is a second mirror distinguished from the first transducer mirror attached to the cofired driver) is flat, so this does not pose a problem. A curved third mirror's curvature is specified to a narrow range in which there are likely no problems. The piezoelectric drive transducer is nominally flat, but in fact, actually changes curvature.
Problems arise when a higher-order transverse mode has no frequency separation between itself and the fundamental mode. In that situation, the only potential solution is the aperture, and if the aperture doesn't provide sufficient discrimination (i.e., loss), then the higher order mode dominates and essentially causes error in the rate output.
There are 10 transverse modes with indices m and n under 10 which resonate with the fundamental as the transducer radius of curvature changes from −0.2 m to −2.0 m. One of these is the TEM 41 mode. Since it has one odd index, it has an intensity null at the center, so when it lases, one would expect the LIM to drop.
For co-fired multi-layer data, FIG. 9 shows an LIM plot (versus temperature) from a run that had bad rate output. Specifically, it shows an LIM v. Temperature LIM plot of LBA with 4-layered cofired driver without pads. Note the LIM spikes upon return from a hot temperature, between the range of 145° F. and 160° F.
The bad rate data was coincident with the LIM spikes observed at temperatures between 145° F. and 160° F. on the return from a hot temperature. Note that these spikes are not simply single data points, but involve a somewhat gradual decrease, followed by an increase.
FIGS. 10 and 11 show mode scans from the same gyro in the same thermal region. The FIG. 10 graph is a mode scan of LBA with 4-layer cofired ceramic. The left most 0—0 mode shows evidence of “multi-moding.” As compared to FIG. 11 , here the higher order transverse mode has moved somewhat to the right side of the mode. FIG. 11 is a graph showing a Mode Scan of LBA with 4-layer cofired ceramic. The left most 0—0 mode shows evidence of “multi-moding.”
The left most mode of FIG. 10 indicates that it is lower in intensity than the rest and that there is actually a slight drop at the center. In FIG. 11 , the same mode shows an anomaly slightly to the right of the peak. The difference between FIGS. 10 and 11 is that they were taken at different times during which the temperature was dropping. In fact, if one observed the oscilloscope during this period, one could see the anomaly move across the fundamental mode from left to right.
What appears to be happening is that in the condition of FIG. 11 , the radius of curvature of the transducer is exactly correct to allow a transverse mode to have exactly the same frequency as the fundamental; hence the transverse mode lases and decreases the intensity of the fundamental mode. It lases because the internal body aperture is not small enough to totally discriminate against this mode. Since the energy of the transverse mode is more spread out spatially than that of the fundamental, the LIM sensor receives less energy through the LIM aperture and therefore the LIM voltage drops. In the condition of FIG. 11 , the transducer curvature has changed somewhat as has the frequency separation between the transverse and the fundamental modes. The transverse mode still lases, but only when the PLC loop is detuned sufficiently.
Note that the strength of the LIM drop most probably is a function of the internal body aperture (and the beam alignment within the aperture). If the aperture was larger (and it wouldn't have to be much larger), the higher-order mode would lase more strongly, the fundamental mode would lase less strongly and the LIM would drop further. This cautions against allowing the body aperture to become much larger.
The reason the above effect more readily occurs with co-fired piezoelectric transducer drivers is because the co-fired drivers change the normal curvature of the transducer. Two reasons for this change are 1) stronger coupling between the ceramics and mirror, and 2) the increased “non-flatness” of the co-fired drivers.
SUMMARY OF THE INVENTION
The invention is directed to a piezoelectric transducer configured for use as a path length control apparatus of an optical device, comprising a void located in a central region of the piezoelectric transducer, mirror, or adhesive.
The present invention implements a physical construction of the PLC driver that removes the likelihood of imparted stresses, and therefore mirror curvature at the location where the laser beam is reflected. A voided area is provided behind the mirror in the laser beam area thus separating this area from the stresses induced by temperature, voltage and/or displacement or any other similar factor. Such a void may be implemented by a hole, a recessed area, a donut-shaped element(s) or a voided epoxy area to relax the mirror in the laser beam area. Or the mirror itself may be recessed behind the laser beam area. Thus the invention separates and relaxes the stresses imparted from the drive mechanism at the reflected laser beam area, and allows the physical motion of the mirror to provide thermal compensation and laser intensity peaking without unwanted side effects of degenerate modes. Note that the term “void” does not necessarily mean a pure vacuum or gas, but can encompass any material that achieves the separation and relaxation of stresses imparted from the drive mechanism at the reflected laser beam area. Also, the void can be provided in any combination of the above-mentioned elements, e.g., the mirror and the adhesive.
Use of a conventional PLC is different than the use of a multi-layer stack such as that described in U.S. Pat. No. 6,515,403 having a stack comprising epoxy/electrode/epoxy/ceramic/epoxy/electrode/epoxy/ceramic/epoxy/ electrode/epoxy/PWB. Such a multi-layer stack imparts significant curvature stress at the mirror center. The conventional PLC imparts less curvature stress due to a self-leveling of the drive assembly resulting from cushioning layers of epoxy. However, such a conventional PLC has increased costs and assembly associated with it and thus may not be desirable in some circumstances. Also, the conventional PLC may still impart some degree of stress in the mirror as well.
Since the laser beam is reflected from a flatter surface, laser modes that are degenerate to the TEM 00 mode are separated adequately to not interfere during operation. Nonetheless, the present invention can also be utilized with the conventional PLC to improve performance.
The inventive solution provides a much higher yield to the co-fired driver, which in turn has better performance over temperature than the conventional drivers described above (vpm over temperature and average vpm; vpm is “volts per mode”, or the amount of voltage needed to move the mirror one laser mode or wavelength; if one uses less voltage to move one mode, and one is limited in supply voltage, one gets a larger range of motion with a lower vpm driver). The inventive stress relieved co-fired driver is also a significant improvement to cost and factory space over other solutions involving additional layers. Various other approaches to the inventive solution were tried, but no other approach (including smaller aperture, adding epoxy/electrode layer, flatness of parts, preload of assembly, modulation change, drive circuitry) was able to eliminate the multi-moding.
DESCRIPTION OF THE DRAWINGS
The invention is described ingreater detail below with respect to the drawings.
FIG. 1 is a side cross-section view of a known PLC including a conventional PZT;
FIG. 2 is a simplified pictorial top view of a known PZT;
FIG. 3A is a simplified pictorial side view of a known conventional PZT;
FIG. 3B is a simplified pictorial side view of a known co-fired multi-layer PZT;
FIG. 4 is a pictorial top view of the inventive PZT having a circular-shaped void;
FIG. 5A is a pictorial side view of an inventive conventional PZT having a void extending partially through a layer of the PZT;
FIG. 5B is a pictorial side view of an inventive co-fired multi-layer PZT having a void extending partially through a layer of the PZT;
FIG. 5C is a pictorial side view of an additional embodiment of an inventive conventional PZT having the void extend through multiple layers of the PZT;
FIG. 6A is a pictorial top view of another embodiment of the inventive PZT having a donut-shaped element;
FIG. 6B is a pictorial top view of a regular polygon-shaped void of a PZT;
FIG. 6C is a pictorial side view of a possible cross-section illustrating use of the void element according to FIG. 6A ;
FIG. 6D is a pictorial side view of another possible cross-section illustrating use of the void element according to FIG. 6A ;
FIG. 7 is a pictorial side view of a PZT with attached mirror in which the void is in the epoxy layer;
FIG. 8 is a pictorial side view of a PZT with attached mirror in which the void is in a part of the mirror;
FIG. 9 is a graph showing an LIM v. Temperature LIM plot of LBA with 4-layered cofired driver without pads.
FIG. 10 is a graph showing a mode scan of LBA with 4-layer cofired ceramic; and
FIG. 11 is a graph showing a mode scan of LBA with 4-layer cofired ceramic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the invention are envisioned. The void may have a perimeter shaped as a circle, regular polygon, or a symmetrical or asymmetrical shape. The void may simple be a recessed area behind an area of the mirror at which an energy beam strikes. In one embodiment, the piezoelectric transducer has a width of between 0.1″ and 1.0″; and the void has a width of between 0.01″ and 0.4″. The piezoelectric transducer may comprise a first layer located on a top side of the piezoelectric transducer; and a second layer located on a bottom side of the piezoelectric transducer and configured to attach to a mirror, the mirror attaching on a side of the second layer opposite the first layer. In an embodiment, the thickness of the first and second layers may be between 0.01″ and 0.1″. In an embodiment, the void may have a depth such that it extends partially through the second layer. This void depth may be between 0.001″ and 0.05″. Whatever the depth, the void may extend fully through the second layer or both the first layer and the second layer. An embodiment is envisioned in which the void is a part of an attached element that attaches to a bottom side of the piezoelectric transducer. This element may have a flattened donut shape, having a void in its center. The void may also be located in an adhesive layer. Alternately, the attached element itself may reside in the adhesive layer.
The overall construction of an embodiment of the piezoelectric transducer arrangement configured for use as a path length control apparatus of an optical device may comprise a first layer located on a top side of the piezoelectric transducer; a second layer located below the first layer; an adhesive layer located adjacent to the second layer and on a side opposite the first layer, the adhesive having a void located in a central region of the arrangement; and a mirror located adjacent to the adhesive layer and on a side opposite the second layer. Alternately, this arrangement may comprise: a first layer located on a top side of the piezoelectric transducer; a second layer located below the first layer; an adhesive layer located adjacent to the second layer and on a side opposite the first layer; and a mirror located adjacent to the adhesive layer and on a side opposite the second layer, the mirror having a void that is located in a central region of the arrangement and that extends part way from a back surface of the mirror that attaches to the adhesive layer to a location within the mirror over an area of the mirror that reflects an energy beam. These embodiments will be discussed in more detail below.
An embodiment of the inventive PZT 16 is shown in FIG. 4 . FIGS. 4 , 5 A and 5 B illustrate a design similar to that shown in FIG. 2 , comprising a positive terminal 54 and a negative terminal 52 , as well as a pair of piezoelectric elements 42 and 44 (for the conventional variation) or a stack of piezoelectric elements ( 62 , 64 , 66 , 68 ). However, this embodiment also has a void 56 region/area that is roughly centered at a position generally co-linear to a perpendicular of the mirror at a point at which the laser beam 40 strikes the mirror 18 .
In the embodiment illustrated in FIG. 4 , this void 56 may be circular in shape. An exemplary embodiment might include a PZT 16 having an overall diameter of approximately 0.63″, where each of the layers 42 , 44 may be approximately 0.009″ thick. The circular void 56 may have a radius of approximately 0.06″. The actual dimensions are dependent on the amount of voltage available and the flexibility (ease of driving the mirror) of the mirror itself. One skilled in the art would be able to adjust these nominal values accordingly. The adhesive layer 20 may be a few tenths of a mil to a few mils thick, and the mirror 18 may be 0.020″ thick. These dimensions are somewhat arbitrary, but what is important is that the void is of a large enough diameter so that stresses are minimized in the region of the mirror 18 at which the laser beam 40 reflects and thus minimizes curvature.
FIG. 5A is a side view of a conventional PZT 16 with an adhesive layer 20 and mirror 18 where the void 56 has a depth that extends partially through one of the layers 44 . FIG. 5B illustrates the same configuration for a multi-layer PZT 16 in which the void 56 extends partially through one of the layers 68 . The depth of the void 56 is not critical, but it should be deep enough so that the adhesive layer 20 does not adhere the mirror 18 to the PZT 16 in the region of reflection. FIG. 5C illustrates the conventional PZT in which the void 56 extends completely through both PZT layers 42 , 44 . In both embodiments shown in FIGS. 5A and 5B , the void could extend to any depth and through any number of layers, provided there is no direct linkage between the mirror 18 (the portion in front of the laser beam 40 contact), the adhesive 20 and a layer of the PZT 44 , 68 .
FIG. 6A illustrates a PZT 16 with a donut-shaped element 57 that could look like a washer or have a torroidal shape. This central portion of the donut-shaped element 57 could have a cylindrically-shaped void ( FIG. 6C ) or it could have a rounded contour with smooth transition edges ( FIG. 6D ). There is no requirement that this element 57 be round or any other particular shape. What is important is that it has a void region that serves to separate the central part of the mirror 18 at which an energy beam is present from the rest of the assembly.
FIG. 6B illustrates a polygon-shaped void 56 . It should be understood that any symmetric, asymmetric, geometric or irregularly shaped void could be used to produce the isolating effect. It is important that the void 16 separates and relaxes the stresses imparted from the drive mechanism at the reflected laser beam area, and allows the physical motion of the mirror 18 to accommodate for thermal compensation and laser intensity peaking without the unwanted side effects of degenerate modes. The void accomplishes this because the center mirror area where the beam is reflected is free without any direct coupling from behind the mirror. The only constraints to the mirror center are along the edges of the recessed area. It effectively de-couples the ceramic imparted distortion from affecting the curvature of the mirror at the center point.
This de-coupling can also occur based on an embodiment in which the adhesive layer 20 ( FIG. 7 ) comprises a void 58 . Additionally an embodiment can include ( FIG. 8 ) a void region 59 in a portion of the mirror 18 itself, although obviously this void region 59 cannot extend through the entire thickness of the mirror.
For the purposes of promoting an understanding of the principles of the invention, reference has been made to the preferred embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art. The various aspects of the invention may be combined in any way that achieves the objectives of the invention. For example, the hexagonal void shape 56 of FIG. 6B could be present in a completely through-the-layers design 42 , 44 or a be the perimeter shape of the element 57 according to FIG. 6A .
The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional configurations, and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the present invention.
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A path length control apparatus (PLC) for a ring laser gyroscope (RLG) provides a flattened surface for reflecting a laser beam. The flattened surface is achieved by providing a void behind the mirror in the laser beam area thus separating this area from stresses induced by temperature, voltage and/or displacement.
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FIELD OF USE
This invention is in the field of stents for implantation into a vessel of a human body.
BACKGROUND OF THE INVENTION
Stents are well known medical devices that are used for maintaining the patency of a large variety of lumens of the human body. The most frequent use is for implantation into the coronary vasculature. Stents have been used for this purpose for almost twenty years. Some current stent designs such as the CORDIS BX Velocity™ stent have the required flexibility and radial rigidity to provide excellent clinical results. Yet sometimes such stents are not able to be delivered through extremely torturous or highly calcified vessels.
Many current tubular stents use a multiplicity of circumferential sets of strut members connected by either straight longitudinal connecting links or undulating longitudinal (flexible) connecting links. The circumferential sets of strut members are typically formed from a series of diagonal sections connected to curved sections forming a closed-ring, generally slotted structure. This structure expands radially outwardly as the balloon on which the stent is mounted is inflated to form the element in the stent that provides structural support for the arterial wall.
A closed-cell stent is sometimes considered a stent in which (except at the longitudinal ends of the stent) every curved section of each central circumferential set of strut members has a connection to one end of a flexible link leaving no “unconnected” central curved sections. A stent with to more than half of its central (non-end) curved sections “unconnected” can be considered to be an “open-cell” stent. A hybrid design stent is one that has fewer than half or exactly half of its central curved sections being “unconnected”.
SUMMARY OF THE INVENTION
The present invention envisions an improved flexible connecting link used in conjunction with in-phase and half-phase circumferential sets of strut members. The definitions of “in-phase” and “half-phase” which describe the orientation of adjacent circumferential sets of strut members will be given in the detailed description of the invention with the aid of several of the figures. By increasing the total length and diagonalness of the undulating connecting links, the present invention is a stent that provides increased flexibility during delivery and enhanced conformability to the shape of a curved artery when the stent is deployed into a curved vessel such as a tortuous coronary artery. By “increasing diagonalness” is meant that the end points of the flexible connecting links have an increased circumferential displacement each one from the other. That is, more diagonalness means that a line connecting the end points of a flexible links has an increased acute angle relative to a line that lies parallel to the stent's longitudinal axis.
The BX Velocity stent uses a balloon in which the folds are straight wrapped, to prevent the stent from twisting in a helical manner during deployment. By “straight wrapped” is meant the fold lines of the balloon lie generally parallel to the stent's longitudinal axis. Such helical twisting can result in significant foreshortening of the stent. The present invention stent system envisions use is of a helically wrapped balloon. By “helically wrapped” is meant that the folds of the balloon lie at an acute angle relative to a line that is parallel to the stent's longitudinal axis. When properly oriented relative to the stent, a helically wrapped balloon can cause the stent to lengthen when the balloon is inflated as compared to a foreshortening that can occur when the stent is deployed from a straight wrapped balloon.
Three embodiments of the present invention stent are disclosed herein. Two are closed-cell stent embodiments and one is an open-cell stent embodiment. The first closed-cell stent embodiment uses “N” shaped flexible links to connect the ends of the curved sections of adjacent in-phase circumferential sets of strut members. The second closed-cell stent embodiment includes at least one end-to-end spine wherein the diagonal “N” flexible links connect from the outside of the curved sections of one circumferential set of strut members to the inside of the curved sections of the adjacent circumferential set of strut members. The spine embodiments also utilize “in-phase” circumferential sets of strut members.
The open-cell stent embodiment of the present invention stent uses diagonal “N” flexible links to connect adjacent circumferential sets of strut members where only half of the curved sections are connected by a flexible link. The unconnected crowns have shorter diagonal segments so as to reduce the potential for fish-scaling during stent delivery around a bend. “Fish-scaling” is defined as the tendency of metal struts of a stent to protrude outwardly from the surface of the balloon (like a fish scale) when the pre-deployed stent is advanced through a curved coronary artery.
Although the present invention describes in-phase circumferential sets of strut members where the diagonal flexible links span one-half cycle of circumferential displacement, it is also envisioned that flexible links spanning ⅛ to 1½ cycles are also possible. These configurations of the stents will be described in detail in the detailed description of the invention with the aid of the appropriate drawings.
It is also envisioned that any of the stent designs as taught herein may be used with plastic coatings such as parylene, antithrombogenic coatings such as heparin or phosphorylcholine or anti-restenosis coatings such as paclitaxel or sirolimus.
An additional version of the non-spined, closed-cell embodiment includes two additional configurations. The first of these concepts is a specific technique for widening the diagonal sections within a circumferential set of strut members. It is desirable to taper the diagonal sections to be wider at their center, especially for the end circumferential sets of strut members. Such widening of the diagonal sections of each end circumferential set of strut members will increase the visibility of the stent ends under fluoroscopy. If the diagonal section is widened too close to the point where a curved section connects to a diagonal section of a circumferential set of strut members, this configuration will negatively affect the unbending of the curved section as the stent is deployed. This is a result of creating unwanted plastic strain in the metal if the widened region of the diagonal section is too close to the attachment point of that diagonal section to the curved section. The present invention envisions having a strut segment of uniform width for at least approximately 0.001″ between the end point of the curved section and the start of the widened taper in the diagonal section. A distance of approximately 0.002″ to 0.0003″ is more optimium.
The second of these concepts relates to the longitudinal spacing (i.e., the “gap”) between adjacent circumferential sets of strut members. The end structure of a stent is critical to stent deliverability as the leading edge of the stent must bend first as the stent mounted onto the deployment balloon is advanced through a curved artery. Assuming the flexible links for a stent are optimized to be as long and as thin as possible within the gap allowed between adjacent circumferential sets of strut members, the only way to have increased flexibility of the end flexible links is to increase the longitudinal length of the gap between each end circumferential sets of strut members and its adjacent, central circumferential set of strut members. This increased gap will permit a longer (and more flexible) link to connect each one of the two end circumferential sets of strut members to its adjacent central circumferential set of strut members.
Thus it is an object of the present invention to have a stent with circumferential sets of strut members connected each to the other by flexible links wherein a line connecting the flexible link end points that attach to each circumferential set of strut members is diagonally oriented relative to the stent's longitudinal axis.
Another object of the present invention is to have a closed-cell stent having in-phase circumferential sets of strut members with the ends of each diagonal flexible link where they are attached to the circumferential sets of strut members being situated in close proximity to the junction point of a curved section and a diagonal section.
Still another object of the present invention is to have a stent having in-phase circumferential sets of strut members with diagonal flexible links forming an end-to-end spine to prevent stent foreshortening.
Still another object of the present invention is to have an open-cell stent having in-phase circumferential sets of strut members with diagonal flexible links wherein the ends of each diagonal flexible link are connected to the circumferential sets of strut members near the junction of a curved section and a diagonal section.
Still another object of the present invention is to have a closed-cell stent having circumferential sets of strut members with diagonal flexible links wherein the diagonal sections of at least one of the circumferential sets of strut members are tapered to be wider at their center with the taper beginning placed apart from the attachment point of the diagonal sections to the curved sections.
Still another object of the invention to have a closed-cell stent with circumferential sets of strut members connected each to the other by flexible links wherein the end diagonal flexible links are longer than the flexible links elsewhere in the stent.
These and other objects and advantages of this invention will become apparent to a person of ordinary skill in this art upon reading of the detailed description of this invention including the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flat layout view of a prior art stent having out-of-phase circumferential sets of strut members connected by “N” shaped flexible links.
FIG. 2A is a flat layout view of a closed-cell embodiment of the present invention having diagonal flexible links that are connected to in-phase circumferential sets of strut members.
FIG. 2B are flat layout views of portions of three embodiments of the present invention showing different circumferential offsets between adjacent circumferential sets of strut members.
FIG. 2C are flat layout views illustrating three different types of diagonal flexible links.
FIG. 3 is a flat layout view of an embodiment of the present invention having diagonal flexible links, in-phase circumferential sets of strut members and also having two end-to-end spines to reduce stent foreshortening.
FIG. 4 is a flat layout view of an open-cell embodiment of the present invention having diagonal flexible links with in-phase circumferential sets of strut members.
FIG. 5 is a flat layout view of an alternative closed-cell embodiment of the present invention having circumferential sets of strut members with a ¼ cycle (half-phase) circumferential offset.
FIG. 6 is an enlargement of the area 70 of the stent of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a flat layout view of an embodiment of a prior art closed-cell, cylindrical stent such as that described by Fischell et al in U.S. Pat. No. 6,190,403, incorporated herein by reference. The stent 10 of FIG. 1 is shown in its pre-deployed state as it would appear if it were cut longitudinally and then laid out into a flat, two-dimensional configuration. FIG. 1 is the 2-dimensional layout view that the stent 10 would have when it is crimped onto a balloon prior to the balloon being inflated to expand the stent 10 radially outward against the wall of an artery. The stent 10 has two end sets of strut members 4 and three central sets of strut members 1 that are each connected by sets of longitudinally extending, undulating “N”-shaped flexible links 8 . The end sets of strut members 4 consist of alternating curved sections 6 that are attached to diagonal sections 5 . The central sets of strut members 1 located longitudinally between the end sets of strut members 4 consist of alternating curved sections 3 attached to diagonal sections 2 . In the prior art stent 10 , the diagonal sections 5 of the end sets of strut members 4 are shorter in length than the diagonal sections 2 of the central sets of strut members 1 . The shorter diagonal sections 5 will reduce the stiff longitudinal length of metal at the ends of the stent 10 to improve stent deliverability by reducing “fish-scaling”. The shorter longitudinal length of the end diagonals 5 will also increase the post-expansion strength of each end set of strut members 4 as compared with the strength of each central set of strut members 6 . In this prior art stent, the width of the curved sections 3 and 6 and the diagonal sections 2 and 5 are all the same. There is no variation in width within any set of strut members or between the end sets of strut members 4 and the central sets of strut members 1 .
From FIG. 1 it should be noted that the flexible links 8 are designed to accommodate one another as the stent is crimped down to allow the smallest possible outside diameter of the stent 10 as it is crimped onto a delivery balloon. The flexibility of the stent 10 is dependent on the ability of the flexible links 8 to lengthen or shorten as the stent is bent through a curved artery. Analysis of flexible link flexibility has shown that increasing the circumferential extent of the “N” flexible links 8 increases the stent's flexibility. In FIG. 1 , each circumferential set of strut members is circumferentially displaced each from the other by 180 degrees. This arrangement is defined as being “out-of-phase.” For an out-of-phase design, the adjacent curved sections of each circumferential set of strut members is straight across from the adjacent curved section. If instead of connecting from curved sections that are straight across from each other as shown in FIG. 1 , the flexible links could be connected in a more diagonal fashion, the circumferential extent of the flexible links would be longer and the stent would be more flexible.
FIG. 2A is a flat layout view of a closed-cell stent 20 which has diagonally connected flexible links with in-phase circumferential sets of strut members. The stent 20 is shown as cut from a metal tube before crimping the stent onto a balloon of a stent delivery system. The fact that the stent 20 that has circumferential sets of strut members that are “in-phase” is best illustrated by the orientation of a line connecting the points 29 . The dotted line joining the center points 29 of the curved sections 23 or 26 that are curved in the same direction would lie essentially parallel to the longitudinal axis L of the stent 20 . It can also be said that each center point 29 is not circumferentially displaced from the center point 29 of the curved section 23 or 26 of the adjacent circumferential set of strut members. It is certainly envisioned that the flexible links 8 (of FIG. 1 ) or 28 could be attached diagonally to opposing curved sections that are in-phase, out-of-phase, or anywhere in between these two states. It is also envisioned that the flexible links can be even more diagonally attached as illustrated by the 1¼ cycles connection as shown in FIG. 2C .
The stent 20 has end sets of strut members 24 located at each end of the stent 20 and eight central sets of strut members 21 connected each to the other by sets of longitudinally extending undulating diagonal flexible links 28 . The end sets of strut members 24 consist of alternating curved sections 26 and diagonal sections 25 . The central sets of strut members 21 located longitudinally between the end sets of strut members 24 consist of alternating curved sections 23 and diagonal sections 22 . In the stent 20 , the diagonal sections 25 of the end sets of strut members 24 are shorter and wider than the diagonal sections 22 of the central sets of strut members 21 . The shorter diagonal sections 25 will reduce the stiff longitudinal length of metal at the ends of the stent 20 to improve deliverability by reducing “fish-scaling”. The shorter diagonal sections 25 will also increase the post-expansion strength of the end sets of strut members 21 .
The wider diagonal sections 25 of the end circumferential sets of strut members 24 enhance the radiopacity of the ends of the stent 20 . This is particularly important because the interventional cardiologist who implants the stent can visualize the stent more accurately after emplacement at an arterial stenosis when there is clear visualization of the ends of the stent. In the stent 20 , the width of the curved sections 23 and 26 can be tapered to improve the ratio of strength to maximum plastic strain, as described in U.S. patent application Ser. No. 09/797,641 incorporated herein by reference. The curved sections 26 or 23 that connect to the ends of the diagonal flexible links 28 are, in this embodiment, displaced circumferentially by a one-half cycle.
This relationship essentially defines the relative circumferential positions of the circumferential sets of strut members for an in-phase stent configuration. That is, FIG. 2A and the left portion of FIG. 2B show that each of the circumferential sets of strut members are “in-phase” with each other. This is contrasted with the stent 10 of FIG. 1 , wherein despite the diagonal (spiral) nature of the connections of the flexible links 8 , the flexible links 8 connect to opposing curved sections 3 or 6 that have a zero cycle circumferential displacement. In other words, the present invention stents are different than the prior art stent 10 of FIG. 1 where out-of-phase adjacent circumferential sets of strut members 1 and 4 are mirror images of each other. The in-phase design of the stent 20 of FIG. 2A permits more circumferential displacement of the end point connections of the flexible links 28 to the curved sections 23 or 26 as compared with the connections for the flexible links 8 of FIG. 1 . This increased circumferential displacement of the connection points for the diagonal flexible links 28 makes them longer, and thus more easily stretched or compressed as the stent 20 is bent. Therefore, the stent 20 of FIG. 2A is envisioned to be more flexible than the stent 10 of FIG. 1 .
The stent 20 shown in FIG. 2A has five connecting diagonal flexible links 28 between each adjacent set of circumferential sets of strut members 21 or 24 . It is also envisioned that three, four, six or more than six such connecting links could also be used. The stent 20 having five flexible links is a design that is ideally suited for placement into arteries having a diameter between 2.5 and 3.5 mm. Fewer connecting links (e.g., three) with fewer cells around are typically applicable to smaller diameter vessels. Stents with more connecting links and therefore having more cells around the stent's circumference are better suited for larger vessels. This is because good scaffolding of the vessel wall is maintained when the area of each cell of the stent remains fairly constant irrespective of the stent's final diameter when expanded against the arterial wall. Thus larger diameter stents require more cells around the stent's circumference as compared to smaller diameter stents that have fewer cells around.
Although the in-phase circumferential sets of strut members 21 and 24 of the stent 20 create a one-half cycle additional circumferential displacement of the diagonal flexible links 28 as compared with the flexible links 8 of FIG. 1 , it is envisioned that circumferential displacements of one-eighth cycle or more can achieve improvement in stent flexibility through an increase in the circumferential extent of the diagonal flexible links 28 . FIG. 2B illustrates ¼, ½ and 0 cycle circumferential displacements of the adjacent circumferential sets of strut members. It should be understood that any circumferential displacement of the circumferential sets of strut members that lies between in-phase and out-of-phase is envisioned. Even circumferential displacements greater than ½ cycle (e.g., ¾ cycle) are also envisioned. A probable maximum circumferential displacement for the flexible link connection points is 1¼ cycles as shown to the left in FIG. 2C .
FIG. 2B shows alternate embodiments of the stent 20 of FIG. 2A . The stent portion on the left that is labeled C=½ CYCLE shows the ½ cycle circumferential offset of the curved sections 23 at each end of a diagonal flexible link 28 . This is identical to the stent design shown in FIG. 2A . The stent portion at the center of FIG. 2B labeled C′=¼ CYCLE shows the ¼ cycle circumferential offset of the curved sections 23 ′ that are joined by the diagonal flexible links 28 ′. The stent portion on the right that is labeled C″=0 CYCLE is identical to the prior art stent shown as stent 10 of FIG. 1 . This 0 CYCLE is an out-of-phase design stent having curved sections 23 ″ attached to flexible links 28 ″.
FIG. 2C illustrates other variations for flexible links connected to adjacent circumferential sets of strut members. Specifically, the left part of FIG. 2C shows a C′=1¼ CYCLES with a very large circumferential displacement for the end points of the flexible links 28 ′. The center portion of FIG. 2C shows a “J” type flexible link 28 J which also can be used for connecting adjacent circumferential sets of strut members. The right portion of FIG. 2C shows a very undulating form of flexible connector 28 JW which would impart a high degree of flexibility to the stent. Any of these flexible links could be designed to impart more or less flexibility to various portions of a stent.
FIG. 3 shows a stent 30 that is another embodiment of the present invention using diagonally connected “N” flexible links. The stent 30 has two end-to-end spines 48 that will reduce foreshortening when such a stent is expanded against a vessel wall. The stent 30 is, in most other ways, similar to the stent 20 of FIG. 2 in that the central and end circumferential sets of strut members 31 , 34 P and 34 D of the stent 30 are “in-phase.” The stent 30 of FIG. 3 is shown in its pre-deployed state before crimping onto a balloon. FIG. 3 shows the stent 30 as it would appear if it were cut longitudinally and then laid out into a flat, 2-dimensional configuration. The stent 30 has end sets of strut members 34 P and 34 D located respectively at the proximal and distal ends of the stent 30 and seven central sets of strut members 31 connected each to the other by sets of longitudinally extending, undulating, diagonally connected flexible links 38 A and 38 B.
The end sets of strut members 34 P and 34 D consist of alternating curved sections 36 attached to widened diagonal sections 35 . The central sets of strut members 31 located longitudinally between the end sets of strut members 34 P and 34 D consist of curved sections 33 and 44 and diagonal sections 32 and 42 . In the stent 30 , the diagonal sections 35 of the end sets of strut members 34 P and 34 D are wider than the diagonal sections 32 and 42 of the central sets of strut members 21 . The wider diagonal sections 35 of the end circumferential sets of strut members 34 P and 34 D enhance the radiopacity of the ends of the stent 30 . In the stent 30 , the width of the curved sections 33 and 36 may be tapered to improve the ratio of radial strength to maximum plastic strain when the stent is expanded.
The flexible links 38 A connect between the outside of curved sections 36 or 33 of adjacent circumferential sets of strut members 34 P, 34 D or 31 while the flexible links 38 B connect between the outside of one curved section 36 or 33 and the inside of a curved section 33 or 36 of the adjacent circumferential set of strut members. The flexible links 38 B form most of the spines 48 that run the length of the stent 30 . One key feature of the stent 30 is that the outside of every distally extending curved section 36 or 33 is attached to a flexible link. This will reduce the extent of fish-scaling of the stent 30 as the stent is advanced in a forward (i.e., distal) direction. As seen in FIG. 3 , the diagonal sections 42 that attach to the unconnected curved sections 44 are shorter that the diagonal sections 32 that connect to connected curved sections 33 of the central circumferential sets of strut members 31 . Because these diagonals 42 that attach to the unconnected curved sections 44 are shorter, the potential for fish-scaling when the stent is pulled back in the proximal direction is reduced.
FIG. 4 shows an open-cell alternative embodiment of the present invention that also has diagonal flexible links. The stent 40 of FIG. 4 is shown in its layout state as it would appear if it were cut longitudinally and then laid out into a flat, 2-dimensional configuration. As with the stents of FIGS. 2 and 3 , FIG. 4 illustrates a 2-dimensional view of how the cylindrical stent 40 would look after it is cut out of thin-walled metal tube before it is crimped onto a balloon of a stent delivery system. The stent 40 comprises end sets of strut members 54 located at each end of the stent 40 and eight central sets of strut members 51 connected each to the other by sets of longitudinally extending, undulating, diagonal flexible links 58 . The end sets of strut members 54 consist of alternating curved sections 56 E, 56 U and 56 C with diagonal sections 55 S and 55 L. The curved sections 56 E are located on the actual ends of the stent 40 . The curved sections 56 U and 56 C are so designated because the curved sections 56 C are connected to diagonal flexible links 58 while the curved sections 56 U are unconnected. The unconnected curved sections 56 U attach to shorter end diagonal sections 55 S than the connected curved sections 56 C that connect to the longer end diagonal sections 55 L. The central sets of strut members 51 located longitudinally between the end sets of strut members 54 consist of alternating curved sections 53 C and 53 U with diagonal sections 52 S, 52 M and 52 L. The curved sections 53 U and 53 C are so designated because the curved sections 53 C are connected to diagonal flexible links 58 while the curved sections 53 U are unconnected. The unconnected curved sections 53 U attach to the shortest central diagonal section 52 S while the connected curved sections 53 C connect to the longer central diagonal sections 52 M and 52 L. The advantage of having the unconnected curved sections 56 U and 53 U attach to shortest diagonal sections 55 S and 52 S is that, as the stent 40 is delivered mounted onto a delivery balloon into a curved vessel, any unconnected portion of the stent 40 can protrude outward from the balloon on which it is mounted. Thus unconnected curved sections, such as curved sections 56 U and 53 U could be caught on tight vessel blockages or on the arterial wall as the stent is advanced through curved arteries. Because the diagonal sections 55 S and 52 S are short, the extent of this phenomena called “fish scaling” is minimized.
In the stent 40 , the diagonal sections 55 S and 55 L of the end sets of strut members 54 are wider than the diagonal sections 52 S, 52 M and 52 L of the central sets of strut members 51 . The wider diagonal sections 55 S and 55 L of the end circumferential sets of strut members 54 enhance the radiopacity of the ends of the stent 40 where it is most important. In the stent 40 , the width of the curved sections 53 C, 53 U, 56 E, 56 C and 56 U may be tapered to improve the ratio of strength to maximum plastic strain. The central and end circumferential sets of strut members 51 and 54 of the stent 20 are “in-phase.” The in-phase design of the stent 40 of FIG. 4 permits more circumferential displacement for the attachment points for the flexible links 58 as compared to the stent 10 shown in FIG. 1 . The increased circumferential displacement of the diagonal flexible links 58 makes them longer and thus more easily stretched or compressed as the stent 40 is advanced through highly curved arteries. This enhances the flexibility and hence the deliverability of the stent 40 .
The open-cell stent 40 shown in FIG. 4 has four connecting diagonal flexible links 58 between each adjacent circumferential set of strut members. It is also envisioned that three, five, six or more such connecting links could also be used. Typically, the greater the diameter of the deployed stent, the greater would be the number of flexible links between each adjacent circumferential set of strut members.
The stent 60 of FIG. 5 is shown in its pre-crimped state as it would appear if it were cut longitudinally and then laid out into a flat, 2-dimensional configuration. The stent 60 has end sets of strut members 64 located at each end of the stent 60 and five central sets of strut members 61 connected each to the other by sets of flexible links 68 and 69 ; each set comprising 5 individual flexible links 78 or 79 . The end flexible links 79 that connect adjacent circumferential sets of strut members at the ends of the stent 60 are longer than the central flexible links 78 connecting all other adjacent circumferential sets of strut members. This increased length is possible because of the increased longitudinal gap G e between the adjacent circumferential sets of strut members at the end of the stent as compared with the gap G c between all central circumferential sets of strut members 61 . The increased length of the end flexible links 79 increases the flexibility at the ends of the stent during deployment in curved vessels. The shorter gap G c will place the central circumferential sets of strut members 61 closer together thereby increasing the stent's radial strength where there is the highest plaque burden in a dilated arterial stenosis.
The end sets of strut members 64 consist of alternating curved sections 66 and diagonal sections 65 . The central sets of strut members 61 located longitudinally between the end sets of strut members 64 consist of alternating curved sections 63 and diagonal sections 62 . In the stent 60 , the diagonal sections 65 of the end sets of strut members 64 are shorter and tapered to be wider than the diagonal sections 62 of the central sets of strut members 61 . The shorter diagonal sections 65 will reduce the stiff longitudinal length of metal at the ends of the stent 60 to improve deliverability. The wider diagonal sections 65 of the end circumferential sets of strut members 64 enhance the radiopacity of the ends of the stent 60 where it is most important for accurate placement of the stent relative to a stenosis that is being dilated by the stent. In the stent 60 , the width of the curved sections 63 and 66 may be tapered to improve the ratio of strength to maximum allowed plastic strain. The curved sections 66 or 63 that connect to the ends of the diagonal flexible links 79 and 78 are, in this embodiment, displaced circumferentially by a one-quarter cycle. This is the same as the central portion of FIG. 2B and is defined as a “half-phase” orientation of the circumferential sets of strut members. “Half-phase” is appropriate nomenclature because one-quarter cycle is half way between an in-phase configuration and an out-of-phase configuration.
The end circumferential sets of strut members 64 have tapered diagonal sections 65 . The tapered diagonal sections 65 and 62 are wider at their center. FIG. 6 is an enlargement of the area 70 of the stent 60 of FIG. 5 . As seen more clearly in FIG. 6 , the tapered diagonal section 65 has end straight sections 65 e and central tapered sections 65 c . The tapered section 65 c begins a distance S from the attachment point 67 of the diagonal section 65 to the curved section 66 . The regions 65 e have a uniform strut width as opposed to a changing strut width of the diagonal section 65 c and the curved section 66 . The length “S” of uniform strut width should be approximately between 0.0001″ and 0.0003″.
Various other modifications, adaptations, and alternative designs are of course possible in light of the above teachings. Therefore, it should be understood at this time that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein.
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The present invention envisions an improved flexible connecting link used in conjunction with in-phase and half-phase circumferential sets of strut members. By increasing the total length and diagonality of the undulating connecting links, the present invention is a stent that provides increased flexibility during delivery and enhanced conformability to the shape of a curved artery when the stent is deployed into a curved vessel such as a tortuous coronary artery.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International patent application PCT/EP2010/058180, filed on Jun. 10, 2010, which claims priority to foreign French patent application No. FR 0903848, filed on Aug. 4, 2009, the disclosures of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention relates to a safety priming device for ammunition using silicon micro-mechatronic systems technology.
BACKGROUND
The environment of rotating ammunition such as mortar projectiles, shells or other types of ammunition, is characterized, when they are used, by the presence of axial acceleration forces and centrifugal forces. For example, a piece of ammunition in a launcher tube or in a propelling device is subject to axial acceleration forces on leaving the tube and centrifugal forces originating from the rotation movement produced, for example, during the displacement of the ammunition in the tube, by spiral grooves in the inner wall of the tube.
Ammunition normally comprises a priming fuse of an explosive charge carried by the ammunition. The priming fuse comprises one or more safety devices to prevent the explosive charge from being activated by accident during storage or transport operations by persons.
The miniaturization, reliability and reproducibility of safety systems lead ammunition fuse designers to use safety priming devices (DSA) in micro-electro-mechanical systems (MEMS) technology.
MEMS use micromachining techniques on silicon for integrating sensor and actuator functions sometimes combined with electronics. The most common MEMS sensors are accelerometers in airbag, geophone and rate gyroscope applications.
MEMS may combine elements of mechanical, optical, electro-magnetic and electronic technology with electronics or mechanics on semiconductor substrates.
Specifiers, in the ammunition field using MEMS, call for much greater reliability in priming safeties which may sometimes offer common causes of failure.
SUMMARY OF THE INVENTION
In order to remedy the drawbacks of state of the art safety devices, the invention provides an ammunition safety priming device using silicon micro-mechatronic systems technology having at least two priming safeties intended to be deactivated by as many external independent physical events, comprising at least one movable element, along a translation axis EE′, for deactivating at least one of the priming safeties by action on said movable element of one of the physical events, the movable element being an inertial screw forming a first safety, the physical event acting on the movable element being an axial acceleration force along said translation axis EE′ of the movable element for deactivating the first safety, the axial acceleration force being caused by a translation movement of the ammunition along the same axis EE′, characterized in that it comprises a central element held in a sandwich, along a plane S perpendicular to the translation axis EE′ between an upper closure element and a lower closure element, the central element comprising an opening forming with the upper closure element and lower closure element a recess containing a slide that can slide in the recess in the plane S of the sandwich, the slide forming a second device safety, this second safety being deactivated by the presence of a lateral acceleration force perpendicular to the translation axis EE′ of the movable element caused by a rotation movement of said ammunition, the slide including a hole, with an axis VV′ perpendicular to the plane S of the sandwich, the slide being kept in position in the recess by the inertial screw inserted in the hole of the slide, the inertial screw being itself integral with the lower closure element.
Advantageously, said movable element is made of a material other than silicon, the material of the movable element being chosen from metals, plastics or ceramics.
In one embodiment of the safety priming device, the central element is in the form of a frame along a main axis XX′ having a rectangular shaped opening comprising four walls, two first walls parallel to the main axis XX′ and two second walls perpendicular to said main axis XX′, said walls forming, with a lower surface of the upper closure element and an upper surface of the lower closure element, the recess containing the rectangular parallelepiped-shaped slide, the slide being able to slide in the recess between the first two walls of the opening parallel to the main axis XX′.
In another embodiment, the slide is integral with one of the two second walls of the opening perpendicular to the main axis XX′ through the intermediary of a spring, with an axis of elasticity parallel to the main axis XX′.
In another embodiment, the circular cylinder-shaped inertial screw, with an axis of revolution CC′, comprises, from one of its two ends to the other, a stem of circular cylindrical cross-section, of the same diameter D 1 as the diameter of the hole in the slide, followed by a head of the same circular cylindrical shape but of diameter D 2 greater than the diameter D 1 to form a circular stopping edge on the circular edge of the slide hole on the side of the lower closure element.
In another embodiment, the lower closure element comprises, on the side of its upper surface, a top recess separated from a bottom recess by a separating wall in a plane parallel to the plane S of the sandwich, the top recess and bottom recess being of the same circular cylindrical shape with axes of revolution collinear with the translation axis EE′.
In another embodiment, the top recess and bottom recess of the lower closure element have the same diameter D 2 as the head of the inertial screw, the head of the inertial screw being able to slide without resistance in one or the other of the top and bottom recesses of the lower closure element.
In another embodiment, the safety priming device is configured so that, when the first and second safeties are activated, the stem of the inertial screw is inserted into the slide hole to keep it in position in the recess, the head of said inertial screw being inserted in the top recess of the lower closure element.
In another embodiment of the safety priming device, the central element, the slide, the spring and the closure elements are made of silicon and the movable element is made of steel.
A principal object of the invention lies in the production of an inexpensive, highly reliable safety priming device.
Another object of the invention lies in the use of at least one technology different from that of silicon for at least one of the priming device safeties. It is therefore sought to combine a MEMS technology using a semiconductor substrate (e.g. made of silicon) for one of the safeties, with a different technology for another safety.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with the aid of an example of embodiment of a safety priming device referring to the indexed drawings in which:
FIG. 1 a represents a side view of a safety priming device according to the invention;
FIG. 1 b represents an exploded view showing the different elements of the safety priming device in FIG. 1 a;
FIG. 2 a represents a partial view of the device in FIG. 1 a in longitudinal section;
FIGS. 2 b and 2 c show respectively a top view and a front view of an inertial screw of the device in FIG. 1 a;
FIG. 2 d represents a partial view of the device in FIG. 1 a in longitudinal section showing the lower closure element;
FIGS. 3 a , 3 b and 3 c show other partial views in longitudinal section of the device in FIG. 1 a and;
FIG. 4 shows the device in FIG. 1 b in a position with the safeties deactivated.
DETAILED DESCRIPTION
FIG. 1 a represents a side view of a safety priming device according to the invention.
FIG. 1 b represents an exploded view showing the different elements of the safety priming device in FIG. 1 a.
The safety device in FIG. 1 a comprises a central element 10 held in a sandwich along a plane S between an upper closure element 12 and a lower closure element 14 .
In this example of embodiment the elements 10 , 12 , 14 are rectangular parallelepiped-shaped.
The central element 10 , in the form of a frame along a main axis XX′, comprises a rectangular opening 20 having four walls, two first walls parallel to the main axis XX′ and two second walls perpendicular to said main axis XX′.
The walls of the opening 20 , with a lower surface 24 of the upper closure element 12 and an upper surface 26 of the lower closure element 14 , form a recess 28 containing a rectangular parallelepiped-shaped slide 30 (see FIG. 1 a ) along two planes of symmetry of the slide passing respectively through the main axis XX′ and an axis YY′ perpendicular to the main axis XX′.
The slide 30 is integral with one 36 of the two second walls of the opening 20 perpendicular to the main axis XX′ through the intermediary of a spring 46 , with an axis of elasticity parallel to the main axis XX′.
The slide 30 comprises a hole 44 , with an axis VV′ perpendicular to the plane S of the sandwich. The axis VV′ of the hole 44 is offset, on the spring 46 side, by a certain distance from the axis YY′ of the slide.
The slide 30 is kept in position in the recess 28 by an inertial screw 40 inserted in the hole 44 of the slide. The inertial screw is itself integral with the lower closure element 14 .
FIG. 2 a represents a partial view of the device in FIG. 1 a in longitudinal section along a plane P parallel to the main axis XX′ of the central element 10 and passing through the axis VV′ of the hole 44 of the slide 30 .
FIGS. 2 b and 2 c show respectively a top view and a front view of an inertial screw of the device in FIG. 1 a.
The circular cylinder-shaped inertial screw 40 , with an axis of revolution CC′, comprises, from one of its two ends to the other, a stem 50 of circular cylindrical cross-section, of the same diameter D 1 as the diameter of the hole 44 of the slide 30 , followed by a head 52 of the same circular cylindrical shape but of diameter D 2 greater than the diameter D 1 to form a circular stopping edge 54 on the circular edge 58 of the slide hole 44 on the side of the lower closure element 14 .
The stem 50 can slide freely in the hole 44 of the slide along a translation axis EE′.
FIG. 2 d shows a partial view in cross section, along the same plane P parallel to the main axis XX′, of the lower closure element 14 .
The lower closure element 14 (see FIG. 2 d ) comprises, on the side of its upper surface 26 , a top recess 60 , separated from a bottom recess 64 by a separating wall 62 in a plane parallel to the plane S of the sandwich. The top recess 60 and bottom recess 64 are of the same circular cylindrical shape with axes of revolution collinear with the translation axis EE′.
The top recess 60 and bottom recess 64 of the lower closure element 14 have the same diameter D 2 as the head 52 of the inertial screw 40 .
The head 52 of the inertial screw 40 can slide without resistance in one or other of the bottom 64 and top 60 recesses of the lower closure element 14 .
The length L of the stem 50 is slightly less than the thickness E of the movable element 30 to avoid breaking the wall 62 when producing the sandwich.
FIGS. 3 a , 3 b and 3 c show other partial views in longitudinal section of the device in FIG. 1 a.
The views in FIGS. 3 a , 3 b and 3 c are longitudinal section views along the plane P parallel to the main axis XX′ passing through the axis VV′ of the hole 44 of the slide 30 .
We shall now explain the operation of the safety priming device according to the invention by referring to FIGS. 3 a , 3 b and 3 c . The safety priming device is, for example, used in a rotating ammunition fuse. In this type of application, the safety priming device is inserted between a detonator DT and a pyrotechnic receiver RP aligned along an axis of detonation ZZ′ perpendicular to the plane S of the sandwich as shown in FIG. 1 a for activating a pyrotechnic charge for the ammunition.
The detonator DT is arranged on the side of the upper closure element 12 and the pyrotechnic receiver RP on the side of the lower closure element 14 .
The safety priming device is configured so that, when the first and second safeties are activated, the stem 50 of the inertial screw is inserted into the hole 44 of the slide 30 to keep it in position in the recess 28 , the head 52 of said inertial screw being inserted in the top recess 60 of the lower closure element 14 .
In a first phase, corresponding, for example, to a period of storage of the device (or of the ammunition comprising the safety device), represented in FIG. 3 a , the safety device is at rest; it does not undergo any acceleration.
In this first phase, the axis of detonation ZZ′ crosses a central part of the slide 30 which separates the detonator DT from the pyrotechnic receiver RP. The slide 30 is kept in position in the recess 28 of the central element 10 by the stem 50 of the inertial screw 40 inserted in the hole 44 of the slide.
The head 52 of the inertial screw 40 is inserted in the top recess 60 of the lower closure element 14 preventing any lateral displacement of the inertial screw parallel to the main axis XX′.
The inertial screw 40 is locked in translation by its head 52 inserted into the top recess 60 of the lower closure element 14 , along the axis VV′, in both opposing directions, in one direction by the wall 62 of the lower closure element 14 and, in the other opposite direction, by the circular edge 58 of the hole 44 of the slide 30 , the circular stopping edge 54 of the inertial screw 40 abutting against said circular edge 58 of the hole 44 .
In this first phase, the first safety formed by the stem 50 of the inertial screw inserted in the hole 44 of the slide to keep it in position in the recess 28 and the second safety formed by the slide 30 separating the detonator of the pyrotechnic receiver are activated.
In this first state, the detonation waves OD produced by an accidental activation of the detonator DT directed towards the pyrotechnic receiver RP are blocked or very dampened by the presence of the slide 30 between the detonator DT and the pyrotechnic receiver RP which will not be able to be activated.
In a second phase shown in FIG. 3 b , the safety priming device, fitted, for example, on the fuse of a piece of ammunition receives a transverse acceleration Acct along the axis of detonation ZZ′ and in a direction going from the lower closure element 14 towards the upper closure element 12 . The inertia of the inertial screw 40 produces a force Ft exerted through the intermediary of its head 54 on the separating wall 62 of the lower closure element 14 .
When the acceleration Acct is sufficient, the force Ft shatters said separating wall 62 releasing the inertial screw 40 in translation along the axis of detonation ZZ′, which moves into the bottom recess 64 of the lower closure element 14 . The stem 50 then exits from the hole 44 releasing the slide 30 from its locked position in the recess 28 of the central element 10 . The first safety of the device is then deactivated.
In a third phase shown in FIG. 3 b , in addition to the transverse acceleration Acct, the safety device undergoes a lateral acceleration Accl perpendicular to the translation axis EE′, for example due to a lateral displacement movement of the safety device from an initial position to another position. The slide 30 , through its own inertia, tends to maintain itself in its initial position. In this second phase, a relative displacement of the slide 30 occurs in the recess 28 .
The detection device is preferably arranged in the ammunition so as to undergo an acceleration in a direction such that the slide tends to compress the spring 46 .
The slide 30 , released in the second phase of the inertial screw 40 , moves, in the third phase, in the direction of compression of the spring 46 , freeing the space in the recess 28 between the detonator DT and the pyrotechnic receiver RP which only have as an obstacle the closure elements 12 , 14 of the central element 10 thus deactivating the second safety of the device.
FIG. 4 shows the device in FIG. 1 b in a position with the safeties deactivated. FIG. 4 shows the central element 10 and the slide 30 compressing the spring 46 during the lateral acceleration Accl.
The closure elements 12 , 14 are configured so as to transmit the detonation waves from the detonator to the pyrotechnic receiver.
In a last phase, the two safeties of the safety device being deactivated, the pyrotechnic charge of the ammunition can be activated by the activation of the detonator DT.
The manufacture of the safety priming device comprises at least steps of producing the different elements of the device made of silicon substrate and producing the inertial screw in metal.
The device is produced by assembling the sandwich comprising the metal inertial screw 40 inside the device made of silicon substrate.
For example, in an assembly process glue CI is applied onto the lower 100 and upper 102 edges of the central element 10 in the form of a frame (see FIGS. 1 a and 1 b ), then the sandwich is compressed and heated to produce the assembly. Other assembly processes can also be used, such as using ultrasound, or by pressing.
In so-called collective production, a plurality of elements of the same type, namely the central element 10 , comprising the spring 46 and the movable element 30 , the upper closure element 12 , the lower closure element 14 , can be produced collectively, each respectively on a silicon wafer. Then, after introducing inertial screws made of metal for all the devices, wafer assembly is carried out to obtain a plurality of safety priming devices. In a last step, the assembled wafers are cut up to separate the different safety devices.
The material of the movable element 40 is not restricted to metal and can be chosen from metals, plastics and ceramics. The material will be chosen according to the application and the physical phenomenon to be detected.
In practice, the safety priming device according to the invention is combined with a fuse for ammunition such as a shell or a rocket.
When a shell is propelled by its explosive charge, a first transverse acceleration Acct occurs unlocking the first inertial safety, then a lateral acceleration Accl produced by the rotation of the shell transmitted through the internal grooves of the barrel unlocking the second safety by the displacement of the slide in the movable element. Accordingly, the axis of rotation of the ammunition and the axis of the slide 30 must be offset to cause a lateral acceleration Accl sufficient to displace the slide in the recess 28 .
The safety priming device according to the invention can be used to reduce the costs of manufacturing rotating ammunition whilst achieving a high level of reliability.
The application to rotating ammunition is not restrictive and since the device according to the invention benefits from much greater reliability than state of the art devices using a single silicon technology it may also have applications in the fields previously mentioned such as airbags, geophones, rate gyroscopes and rocket stage separation trigger devices. Accordingly, an application of the invention to other fields of use may comprise more than two safeties, each of the safeties being capable of being deactivated by a different physical phenomenon.
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An ammunition safety priming device using silicon micro-mechatronic systems technology, having at least two priming safeties intended to be deactivated by as many external independent physical events, includes at least one movable element, along a translation axis, for deactivating at least one of the priming safeties by action on said movable element of one of the physical events. Said movable element is produced in a material other than silicon. The device has applications including ammunition, rocket stage separation devices, and airbags.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of U.S. Provisional Patent Application No. 61/789,043 filed Mar. 15, 2013, the disclosure of which is incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD
The present disclosure relates to fleet management systems for tracking vehicles in a fleet and, in particular, to dynamically determining the frequency with which a device reports its location to a central tracking server.
BACKGROUND
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
As mobile data and civilian location positioning systems proliferate, one widespread use of these systems is the tracking and management of mobile assets such as vehicle fleets and workforce resources. Such systems generally use a position-determining device (e.g., a Global Positioning System (GPS) receiver) associated with a mobile asset to determine the location of the asset. Using a communication channel—typically a wireless channel such as a mobile telephony channel, a mobile broadband channel, a terrestrial microwave channel, or a satellite channel—the device reports its current location to a central tracking server that tracks and manages the assets.
Owing to the mobile nature of the position-determining devices, such devices typically rely on portable power sources (e.g., batteries), rather than line power. For this reason, and because wireless communication channels are generally bandwidth constrained, there is an inherent tension between power conservation and position accuracy. Specifically, the more frequently a mobile asset reports its location, the more accurately its location will be tracked, but the greater energy resources it will consume. Generally, this tension is “resolved” by setting a tracking device to report a position on a regular interval that is a trade-off between power conservation and position accuracy.
SUMMARY
A mobile device for tracking a mobile asset reports the location of the mobile asset initially and thereafter reports the location of the mobile asset upon the occurrence of one or more pre-determined conditions. The mobile device may receive from a GPS receiver location data associated with the initial location of the mobile asset and transmit the initial location to a tracking server. Thereafter, the mobile device may continue to monitor data from the GPS receiver continuously or, to save power, only periodically. Alternatively, the mobile device may monitor sensors, such as accelerometers, compasses, and the like, other than the GPS receiver. When a reporting condition is satisfied, the mobile device may determine the current location of the mobile asset and transmit the current location of the mobile asset to the tracking server.
The reporting conditions may include receiving an indication that the mobile asset has deviated from the path of a road along which it was traveling. The reporting conditions may also include detecting a change in velocity and/or direction of the mobile asset above a pre-determined threshold. Further, the reporting conditions may include determining that the mobile asset has deviated from a predicted or assigned route. Additionally, the reporting conditions may include detecting a difference between a current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined threshold. The reporting conditions may be detected from data received from a positioning system receiver, such as a GPS receiver, data received from various sensors (e.g., accelerometers, compasses, etc.), data received from wireless networks (e.g., from mobile telephony and/or mobile internet networks).
A method is executed by a processor in a mobile device. The method is for reporting to a server a position of a mobile asset associated with the mobile device. The method includes determining a current location of the mobile asset and determining current movement data of the mobile asset. The method further includes determining a first road corresponding to the current location and movement data and receiving road segment map data corresponding to the first road. Further, the method includes transmitting to the server the first location and movement data. Still further, the method includes receiving an indication that (i) the mobile asset has deviated from the path of the first road, (ii) the velocity of the mobile asset has changed by an amount greater than a predetermined threshold, (iii) the mobile asset has deviated from a predicted or assigned route, or (iv) a difference between a current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined distance and, in response to the received indication, transmitting to the server updated location and movement data.
A computer-readable storage medium stores instructions for tracking a mobile asset, executable by a processor in a mobile device. The instructions are operable upon execution by the processor to cause the process to determine a current location of the mobile asset and determine current movement data of the mobile asset. The instructions are further operable to cause the processor to determine a first road corresponding to the current location and movement data, and to transmit to the server first location and movement data. Further, the instructions are operable to cause the processor to receive an indication that (i) the mobile asset has deviated from the path of the first road, (ii) the velocity of the mobile asset has changed by an amount greater than a predetermined threshold, (iii) the mobile asset has deviated from a predicted or assigned route, or (iv) a difference between a current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined distance; and transmit to the server, in response to the received indication, updated location and movement data.
A mobile device operable to determine the position of an associated mobile asset, and to transmit to a server information about the position of the mobile asset, includes a processor, a satellite positioning system receiver communicatively coupled to the processor and operable to receive a plurality of signals from satellites and to determine from the received signals a current position of the mobile asset, and a wireless transmitter operable to transmit data to a server via a wireless channel. The mobile device also includes a computer-readable storage medium communicatively coupled to the processor storing instructions, executable by the processor, for causing the processor to transmit to the server a current location of the mobile asset when the processor determines that (i) the mobile asset has moved from a first road to a second road, (ii) the velocity of the mobile asset has changed by an amount greater than a predetermined threshold, (iii) the mobile asset has deviated from a predicted or assigned route, or (iv) a difference between the current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined distance.
A system for tracking mobile assets comprises a server having one or more server-side computer processors coupled to one or more server-side computer readable storage media. The server-side storage media store instructions operable to cause the one or more server-side processors to receive from a plurality of mobile devices location data and movement data corresponding to each of the mobile assets, periodically calculate estimated updated location data for each of the mobile assets according to the received location data and movement data, and receive actual updated location data for each of the mobile assets at intervals determined by the mobile devices. The system also includes a mobile device that includes one or more client-side computer processors, a satellite position system receiver communicatively coupled to the one or more client-side computer processors and operable to receive a plurality of signals from satellites, and a wireless transmitter operable to transmit data to the server via a wireless channel. The mobile device also includes one or more client-side computer readable storage media communicatively coupled to the one or more client-side computer processors. The client-side storage media store instructions operable to cause the one or more client-side processors to determine a current location of the mobile asset according to data received from the satellite positioning system receiver, determine current movement data of the mobile asset according to data received from the satellite positioning system receiver, determine a first road corresponding to the current location and movement data, and transmit to the server first location and movement data. Further, the client-side storage media store instructions operable to cause the one or more client-side processors to receive an indication that (i) the mobile asset has deviated from the path of the first road, (ii) the velocity of the mobile asset has changed by an amount greater than a predetermined threshold, (iii) the mobile asset has deviated from a predicted or assigned route, or (iv) a difference between a current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined distance and, in response to the received indication, transmit to the server updated location and movement data. The server-side storage media may also store instructions operable to cause the server-side processors to determine for each mobile asset, according to the received location data for the mobile asset and a known destination for the mobile asset, a predicted or assigned route for the mobile asset. Further, the server-side storage media may store instructions operable to cause the one or more server-side processors to retrieve, for a given mobile asset, current or historical traffic data for the first road, and periodically calculate the estimated updated location data for the given device according to the received location data and movement data and also the retrieved traffic data for the first road.
A mobile device is operable to determine the position of an associated mobile asset and to transmit to a server information about the position of the mobile asset. The mobile device includes processing means, means for determining from a plurality of satellite signals a location of the mobile asset, and means for transmitting data to the server via a wireless channel. The mobile device also includes means for determining the existence of a condition indicating that an updated location of the mobile asset should be transmitted to the server and means for transmitting the updated location of the mobile asset. The means for determining the existence of the condition include means for determining that (i) the mobile asset has moved from a first road to a second road, (ii) the velocity of the mobile asset has changed by an amount greater than a predetermined threshold, (iii) the mobile asset has deviated from a predicted or assigned route, or (iv) a difference between the current location of the mobile asset and a predicted location of the mobile asset exceeds a predetermined distance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary system implementing dynamic determination of device location reporting frequency in accordance with the present description;
FIG. 2 is a block diagram depicting an exemplary mobile device implementing dynamic determination of location reporting frequency;
FIG. 3 illustrates an example of the reporting frequency of a mobile device operating according to the principles of the present description;
FIG. 4 is a flow diagram of an example method for dynamically determining device location reporting frequency which can be implemented by the device of FIG. 2 in the system of FIG. 1 ; and
FIG. 5 is a flow diagram of another example method for dynamically determining device location reporting frequency.
DETAILED DESCRIPTION
An apparatus or system operating according to the present disclosure facilitates tracking of one or more mobile assets using a device capable of determining its position and reporting the device's (and the asset's) position, with dynamically determined frequency, to a server. To this end, the mobile device transmits its location (and that of the associated asset) to a server. Throughout this description, the position of the mobile device is assumed to be the same as that of the mobile asset. Therefore, to the extent that the terms “mobile device” and “mobile asset” are used interchangeably it is because mobile device is assumed to be tied to the location of the mobile asset. It should be understood, however, that the mobile device need not be the same as the mobile asset and that, in fact, the two may be different physical entities. In any event, in contrast to prior art systems, in which the mobile device transmits the location to the server periodically—at pre-programmed intervals—the mobile device instead monitors its position and/or movement for an indication that its movement has changed in some regard or deviated from what is expected by the server. For example, the mobile device may monitor its movement or its position to determine if it has changed from one road to another, may monitor its movement or position to determine if its velocity has changed by more than a threshold amount, may monitor its location to determine if it has deviated from a predicted or assigned route, or may monitor its location to determine if a difference between its current location and a predicted location exceeds a threshold amount. If the mobile device determines that a change or deviation has occurred, then the mobile device transmits its updated location to the server.
FIG. 1 illustrates an exemplary system 100 operating according to the principles described herein. In the system 100 , a server 102 communicates via a network 104 with devices associated with a group of mobile assets 106 A-D. The mobile assets 106 A-D may be any mobile assets that the system operator wishes to track, including, for example, vehicles 106 A (e.g., automobiles, delivery trucks, aircraft, etc.), workforce assets 106 B (i.e., people), cargo 106 C, and the like. In any event, each mobile asset 106 A-D has associated with it a mobile device 110 that is operable to determine the location of the mobile device 110 (and the associated mobile asset 106 A-D) and, in some embodiments, the movement of the mobile device 110 , and to report the location (and movement) to the server 102 using the network 104 .
Each mobile device 110 generally determines its position using a positioning system receiver and, in some embodiments, a satellite positioning system receiver. The positioning system receiver can be any type of positioning system receiver, operating off of terrestrial navigation signals, satellite navigation signals, etc. Where satellite navigation signals are employed for positioning, the receiver can receive signals from the Global Positioning System (GPS) satellite constellation, the European Galileo Global Navigation Satellite System (GNSS), the Russian Global Navigation Satellite System (GLONASS), etc. For convenience, throughout the remainder of this description, the positioning system will be referred to as a GPS system, the satellites will be referred to as GPS satellites, and the positioning-system receiver operating in the mobile device 110 will be referred to as a GPS receiver. However, it should be understood that while described in terms of the GPS system, satellites, and receiver, the positioning system may use any positioning system/navigation technology, the satellites may be any orbiting space vehicle, and the receiver may be any receiver operable to receive the signals necessary to determine from the positioning system the location of the mobile device 110 .
Each mobile device 110 communicates with the server 102 using the network 104 , which may be, for example, the Internet. However, each mobile device 110 may use a wireless communication channel 112 to send data from the mobile device 110 to the network 104 . Throughout this specification, the wireless channel 112 used to relay information from the mobile device 110 , through the network 104 , to the server 102 , will be described in terms of a mobile telephony signal/system 113 , such as that generally employed by mobile phones and other devices sending telephony or data over networks owned by mobile carriers. It will be understood, though, that in some embodiments, the mobile devices 110 may communicate data to the server 102 by means of a satellite data link 114 . That is, the mobile device 110 may communicate over a data uplink 114 A to a satellite 116 which, in turn, may transmit data using a data downlink 114 B to a communication point 118 , which may transmit the data to the server 102 directly or via the network 104 . As yet another alternative, the wireless channel 112 over which the mobile device 110 communicates data to the network 104 is a terrestrial microwave link. As still another example, the wireless channel 112 may be a proprietary wireless system owned or leased by the entity tracking the mobile assets.
Generally, the mobile device 110 may be any multi-purpose mobile device, such as a smart-phone, a tablet computer, a laptop computer, a smart watch, a portable digital assistant, etc., or may be a specialized mobile device designed for the specific purpose of facilitating tracking of a mobile asset. The mobile device 110 has, at a minimum, a positioning system receiver, a transmitter operable to communicate data to the server 102 over the network 104 using the wireless channel 112 , a computer processor, a power circuit, and a variety of routines for performing various operations associated with determining the position of the device, power management, and communication of data to the server 102 . As will be described below with reference to various embodiments, the mobile device 110 may have additional features that may be used to provide additional functionality.
FIG. 2 is a block diagram of an exemplary mobile device 200 . While the mobile device 200 depicted in FIG. 2 includes many more features than the required features described above, it should be understood that the mobile device 110 need not include every one of the features depicted, and that various combinations of features will be readily apparent from the description that follows. Generally, the mobile device 200 of FIG. 2 includes an RF block 202 , a sensor block 204 , a processor block 206 , an input/output block 208 , and a power source 210 . The elements 202 - 210 may all enclosed within a single enclosure, such as when the mobile device 200 is implemented as a smart-phone.
The RF block 202 includes receiver and transmitter components of the mobile device 200 . As described above, this includes at least a positioning system receiver, such as a GPS receiver 212 , and a transmitter operable to communicate data to the server 102 over the network 104 using the wireless channel 112 , such as a mobile telephony transceiver 214 or another transmitter (or transceiver) 216 . As is generally understood, the GPS receiver 212 is operable to receive signals from multiple satellites in Earth orbit and, by comparing the signals, the GPS receiver 212 is operable, using a built-in processor or an external processor, to triangulate to determine the location of the receiver 212 . The mobile telephony transceiver 214 is operable to communicate with one or more mobile telephony networks, including, but not limited to, networks using any of the following protocols: IS-95 (CDMA), Global System for Mobile Communications (GSM), General Packet Radio Service (GPRS), cdmaOne, CDMA2000, Evolution-Data Optimized (EV-DO), Enhanced Data Rates for GSM Evolution (EDGE), Universal Mobile Telecommunications System (UMTS), Digital Enhanced Cordless Telecommunications (DECT), Digital AMPS (IS-136/TDMA), Integrated Digital Enhanced Network (iDEN), Long Term Evolution (LTE), etc. The mobile telephony transceiver 214 may be operable in the mobile device 200 to facilitate voice communications (e.g., to make phone calls) and/or to communicate data. That is, in some embodiments, the mobile telephony transceiver 214 may allow the mobile device 200 to operate as a mobile telephone and/or to transmit data to the server 102 . In other embodiments, the mobile telephony receiver 214 may facilitate only voice communications, while the other transceiver 216 may facilitate data communication to the server 102 . In still other embodiments, the mobile telephony receiver 214 may be omitted, and the other transceiver 216 may facilitate communication of data to the server 102 .
In any event, the RF block 202 may also include a wireless internet transceiver 217 (e.g., one operating according to one or more of the 802.11a/b/g/n/ac protocols). The wireless internet transceiver 217 may operate according to known principles to allow the mobile device 200 to communicate on a local network and/or to communicate via the local network to the Internet 104 . In some instances, the mobile device 200 may use wireless internet transceiver 217 to communicate data to the server 102 when an appropriate connection is available. The mobile device 200 may, therefore, use the transceivers 214 and/or 216 when the wireless internet transceiver 217 does not have a connection to the internet 104 , but may use the wireless internet transceiver 217 when a connection to the internet 104 is available through the transceiver 217 . The wireless internet transceiver 217 may also, in some embodiments, be used to scan for available wireless internet access points and, by referencing a database of locations associated with those access points, be able to provide course and/or fine location data for the mobile device 200 . This location information may be used by the mobile device 200 to assist the GPS receiver 212 or, when the GPS receiver 212 is powered down, may be used by the mobile device 200 to approximate the current location of the mobile device 200 .
The RF block 202 may also, in some embodiments, include a Bluetooth transceiver 218 . The Bluetooth transceiver 218 may allow the mobile device 200 to communicate with other, nearby devices. For example, in an embodiment in which the mobile device 200 is a stand-alone tracking device (e.g., not part of a smart-phone), the Bluetooth transceiver 218 may facilitate communication between the mobile device 200 and a smart-phone, laptop, tablet, or other device. In still other embodiments, the mobile device 200 may not include the telephony and/or other transceivers 214 and 216 , and may instead rely on an external device, with which the mobile device 200 communicates via the Bluetooth transceiver 218 , to communicate data to the server 102 via the internet 104 .
The mobile device 200 also includes the sensor block 204 , which may include one or more of an accelerometer 220 , a compass 222 , and a barometer 224 . The mobile device 200 and, more particularly, routines operating on the mobile device 200 may use data received from the sensors 220 - 224 to augment data received from the GPS receiver 212 . For example, data from the barometer 224 may help a routine operating on the mobile device 200 to determine an altitude of the mobile device 200 , which altitude may help establish whether the device is on one road or another road, for example. During periods where the GPS receiver 212 is powered down or unable to receive sufficient signals from the GPS satellites, the routines operating on the mobile device 200 may use data from the sensor block 204 to provide dead reckoning capability, and/or to detect changes in vehicle speed and/or direction, as will be described below.
The processor block 206 includes a computer processor 226 and a memory device 228 . The computer processor 226 may be a general purpose computer processor or a special purpose computer processor specially adapted to perform the functions of the mobile device 200 . The computer processor 226 is communicatively coupled to the memory device 228 , such that the computer processor 226 may retrieve instructions from the memory device 228 and store and retrieve data from the memory device 228 . The memory device 228 may store (and the processor 226 may execute) various routines 230 - 238 . For example, a routine 230 may include instructions for retrieving/receiving and processing data from the GPS receiver 212 . The routine 230 may, in some embodiments, include instructions that program the processor 226 to receive data from the GPS receiver 212 and, from the received data, determine a location of the mobile device 200 . In other embodiments (e.g., where the GPS receiver 212 includes on-board processing capability for calculating a position from the received GPS signals), the routine 230 may include instructions that program the processor 226 to receive from the GPS receiver 212 the calculated position of the mobile device 200 and perform some action with the received location, such as causing the processor 226 to transmit the location to the server 102 or causing the processor 226 to invoke another function (e.g., checking traffic, retrieving map data, performing route calculation, etc.).
The routine 230 may generally include instructions for determining and coordinating the reporting to the server 102 of the position and movement of the mobile device 200 . This may include determining whether the direction, route, speed, or other parameters of the movement of the mobile device 200 has changed relative to what the mobile device 200 and/or the server 102 is expecting and, is such a change or deviation occurs, reporting to the server 102 the updated location and/or movement parameters. The routine 230 may cause the processor 226 to receive from the GPS receiver 212 , for example, multiple consecutive locations and may, accordingly, also determine the direction of travel of the mobile device 200 and the speed at which the mobile device 200 is traveling. The routine 230 may cause the processor 226 to monitor the location and/or movement of the mobile device 200 using data from the GPS receiver 212 and/or data from the sensor block 204 , and when the speed, direction, or location changes or deviates from what the processor 226 expects, cause the processor to report the updated parameters to the server 102 .
A routine 232 may provide instructions to the processor 226 for determining map data corresponding to the location of the mobile device 200 . The routine 232 may cause the processor 226 to retrieve (from the memory 228 , from a resource on the Internet, from the server 102 , etc.) map data for an area surrounding the location of the mobile device 200 . The routine 232 may cause the processor 226 to determine a road segment, indicated in the map data, on which the mobile device 200 is located and/or traveling. In some embodiments, the routine 230 may cause the processor 226 to receive from the GPS receiver 212 more than one GPS location, and the routine 232 may use consecutive GPS locations to determine in what direction and along what road segment the mobile device 200 is moving. In other embodiments, the routine 230 may cause the processor 226 to receive from the GPS receiver 212 a single GPS location, and the routine 232 may cause the processor 226 to use data from the sensor block 204 (e.g., data from the compass 222 ) to determine the direction that the mobile device 200 is traveling. The processor 226 may use the location and the direction to determine a road segment along which the mobile device 200 is traveling, and a direction along the road segment. As will be described below, the map data and, specifically, the movement of the mobile device 200 along a road segment, may be one parameter used by the processor 226 in accordance with the routine 230 to determine whether to send updated parameters to the server 102 .
A route calculation and/or prediction routine 234 includes instructions for causing the processor 226 to determine or predict a route from the current location of the mobile device 200 to an intended destination. Often, for example, fleet management and mobile asset tracking functions include tracking vehicles or other assets as they move from one destination to another, for example, when making deliveries. The routine 234 may include instructions for receiving information about a destination (e.g., an address, intersection, coordinates, etc.) and determining a best (or at least a preferred) route from the current location of the mobile device 200 to the destination. In some embodiments, the routine 234 may include instructions for receiving from the server 102 a predetermined route to a destination, calculated by the server 102 in response to a current location transmitted to the server from the mobile device 200 .
The route calculation and/or prediction routine 234 may, in some embodiments, cooperate with a routine 236 for downloading, storing and/or predicting traffic data. The routine 236 may operate to retrieve current and/or historical traffic data for a route predicted or calculated by the routine 234 or for a route received from the server 102 . The routine 236 may cooperate with the routine 234 to find alternate routes that have less traffic, in embodiments. In some embodiments, the routine 236 may retrieve traffic data for the purpose of predicting the location and/or movement of the mobile device 200 in the absence of current location data from the GPS receiver 212 . That is, given an initial location of the mobile device 200 determined using the GPS receiver 212 , the processor 226 may use data from the route prediction and calculation routine 234 with data from the traffic routine 236 and the maps routine 232 to predict, based in part on traffic information, where the mobile device 200 is or will be at some later point.
A power management routine 238 may include instructions that cause the processor 226 to perform various power management activities. For example, in some embodiments, the routine 238 causes the processor 226 to power down the GPS receiver 212 except when the processor 226 determines (e.g., via the routine 230 ) that a new GPS position is required. The power management routine 238 may also power down other parts of the RF block 202 and/or the sensor block 204 to preserve power when the devices are not being used.
Other routines (not shown) may also be stored on in the memory device 206 including, but not limited to, routines related to an operating system or applications that may execute on the operating system. For example, where the mobile device 200 is a smart phone, an operating system and various applications running on the operating system may be stored on the memory device 208 . The routines described above are not intended to be limiting in any way and, of course, instructions described as part of one routine may be included, instead, in another routine. That is, there may be more or fewer routines than described above, and the routines described above may be combined or further divided.
Of course, the mobile device 200 may also include in the input/output block 208 various input and output devices, such as a display 240 and an input device 242 . The display 240 may be any type of display device, including (but not limited to) a touch sensitive display device. The display 240 may include or be accompanied by other output devices such as, for example, an audio output device. The input device 242 may be a touch sensitive display (e.g., the display 240 ) and/or may include a keyboard (hardware or software), a microphone (e.g., with voice recognition software), a mouse, a stylus, switches, buttons, etc.
Lastly, the mobile device includes the power source 210 . The power source 210 may be a battery, a fuel cell, a wired power source, or some combination of power sources.
Referring again, briefly, to FIG. 1 , the server 102 includes one or more processors 120 communicatively coupled to one or more memory devices 122 . The memory device 122 stores various routines for tracking the mobile devices. The routines stored on the memory device 122 may include a route calculation and/or prediction routine 124 , similar to the routine 234 described above. The routine 124 may cause the processor 120 to receive the location of a mobile device, for example, and calculate and assign to the mobile device a route to a destination. The routine 124 may also cause the processor, knowing the location of the mobile device and its destination, to predict the route that the mobile device will take. The routine 124 may use the same algorithms as the routine 234 , such that the processor 120 and the processor 226 , respectively, predict and calculate the same route when the position and destination of a mobile device are known to each.
Similarly, the memory 122 may include a routine 126 for downloading, storing and/or predicting traffic data. Like the routine 236 , the routine 126 may operate to retrieve current and/or historical traffic data for a route predicted or calculated by the routine 124 . The routine 126 may cooperate with the routine 124 to find alternate routes that have less traffic, in embodiments. In some embodiments, the routine 126 may retrieve traffic data for the purpose of predicting the location and/or movement of the mobile device 200 in the absence of current location data from the GPS receiver 212 . That is, given an initial location of the mobile device 200 determined using the GPS receiver 212 , the processor 120 may use data from the route prediction and calculation routine 124 with data from the traffic routine 126 to predict, based in part on traffic information, where the mobile device 200 is or will be at some later point.
Generally, the processor 226 , after sending initial location data calculated using data from the GPS receiver 212 , transmits to the server 102 location data of the mobile device 200 only rarely, in order to prevent unnecessary use of bandwidth and power resources. The processor 226 may monitor various parameters to determine when to send updated location and/or movement data associated with the mobile device 200 . In various embodiments, the processor 226 receives or determines one or more of several occurrences that cause the processor 226 to send an updated location of the mobile device 200 to the processor. In one embodiment, the processor 226 determines that the mobile device 200 has changed roads or road segments (e.g., the mobile asset has made a turn). In another embodiment, the processor 226 determines that the velocity of the mobile device 200 has changed significantly (e.g., by an amount greater than a predetermined threshold). In still another embodiment, the processor 226 determines that the mobile device 200 has deviated from a predicted, calculated or assigned route. In yet another embodiment, the processor 226 determines that the distance between a current location of the mobile device 200 and a predicted location of the mobile device exceeds a predetermined distance. In some embodiments, the processor 226 may send updated location information to the server 102 upon the occurrence of any one or more of the determinations. The system and method are illustrated by way of the following examples, which are not intended to be limiting.
Example 1
In an embodiment, a mobile device includes a GPS receiver and a transmitter for communicating data to a tracking server. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor of the mobile device continues to receive location information from the GPS receiver, allowing the processor to determine and monitor the speed and direction the mobile device is moving. Upon determining the speed and direction of travel of the mobile device, the processor causes the transmitter to transmit to the server the movement information (i.e., the information about the speed and direction of movement). If the mobile device slows down or accelerates by greater than 10 miles per hour (or any predetermined threshold amount), the processor causes the transmitter to send to the tracking server updated position and movement data for the mobile device.
Example 2
In an embodiment, a mobile device includes a GPS receiver, a transmitter for communicating data to a tracking server, and (1) a transceiver (which may include the transmitter) for requesting and receiving data from a map database and/or (2) a map database. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor of the mobile device retrieves (via the transceiver or from the map database) map information corresponding to the initial position. The processor of the mobile device continues to receive location information from the GPS receiver (only periodically, in some embodiments—e.g., once every 5 seconds, 10 seconds, 1 minute, etc.), allowing the processor to determine and monitor the speed and direction the mobile device is moving. The processor determines, from the position and movement data (i.e., the information about the speed and direction of movement), a road segment along which the mobile device is moving. Upon determining the speed and direction of travel of the mobile device, the processor causes the transmitter to transmit to the server the movement information. The processor continues to monitor the position and movement of the mobile device relative to the road segment. If the mobile device slows down or accelerates by greater than 10 miles per hour (or any predetermined threshold amount), or changes from the road segment to a second road segment (i.e., turns off of the road segment), the processor causes the transmitter to send to the tracking server updated position and movement data for the mobile device.
Example 3
In an embodiment, a mobile device includes a GPS receiver, a transmitter for communicating data to a tracking server, (1) a transceiver (which may include the transmitter) for requesting and receiving data from a map database and/or (2) a map database, and a routine for calculating a route. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor of the mobile device retrieves (via the transceiver or from the map database) map information corresponding to the initial position, inputting the initial position and an intended destination into the route calculation routine. The processor executing the route calculation routine returns a calculated route from the initial position to the destination. The processor transmits the route information to the tracking server. (In embodiments in which the tracking server implements a complementary route calculation routine, the mobile device need not transmit the route information to the server, because the server will be able to calculate the same route as long as it has the initial position and the intended destination.) The processor of the mobile device continues to receive location information from the GPS receiver (only periodically, in some embodiments—e.g., once every 5 seconds, 10 seconds, 1 minute, etc.), allowing the processor to determine and monitor the speed and direction the mobile device is moving. The processor determines, from the position and movement data (i.e., the information about the speed and direction of movement), a road segment along which the mobile device is moving. Upon determining the speed and direction of travel of the mobile device, the processor may cause (in some embodiments) the transmitter to transmit to the server the movement information. The processor continues to monitor the position and movement of the mobile device relative to the road segment. If the mobile device slows down or accelerates by greater than 10 miles per hour (or any predetermined threshold amount), changes from the road segment to a second road segment (i.e., turns off of the road segment), or deviates from the route calculated by the route calculation routine, the processor causes the transmitter to send to the tracking server updated position and movement data for the mobile device.
Example 4
In an embodiment, a mobile device includes a GPS receiver, a transceiver for communicating data to a tracking server and receiving data from the tracking server, and (1) a transceiver (which may include the transmitter) for requesting and receiving data from a map database and/or (2) a map database. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor receives from the tracking server a route, determined by a route calculation routine on the server, from the initial position to a destination. The processor of the mobile device retrieves (via the transceiver or from the map database) map information corresponding to the initial position, inputting the initial position and the received route. The processor of the mobile device continues to receive location information from the GPS receiver (only periodically, in some embodiments—e.g., once every 5 seconds, 10 seconds, 1 minute, etc.), allowing the processor to determine and monitor the speed and direction the mobile device is moving. The processor determines, from the position and movement data (i.e., the information about the speed and direction of movement), a road segment along which the mobile device is moving. Upon determining the speed and direction of travel of the mobile device, the processor may cause (in some embodiments) the transmitter to transmit to the server the movement information. The processor continues to monitor the position and movement of the mobile device relative to the road segment. If the mobile device slows down or accelerates by greater than 10 miles per hour (or any predetermined threshold amount), changes from the road segment to a second road segment (i.e., turns off of the road segment), or deviates from the route calculated by the route calculation routine, the processor causes the transmitter to send to the tracking server updated position and movement data for the mobile device.
Example 5
In an embodiment, a mobile device includes a GPS receiver, a transceiver for communicating data to a tracking server and receiving data from the tracking server, (1) a transceiver (which may include the transceiver above) for requesting and receiving data from a map database and/or (2) a map database, a route prediction routine and, optionally, a compass and/or one or more accelerometers. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor receives from the tracking server a route, determined by a route calculation routine on the server, from the initial position to a destination. The processor of the mobile device retrieves (via the transceiver or from the map database) map information corresponding to the initial position, inputting the initial position and the received route. The processor determines initial movement either from the GPS receiver or from a compass and one or more accelerometers, and transmits the initial movement data to the tracking server. The processor powers down the GPS receiver. The processor, executing the route prediction routine, predicts the location of the mobile device along the route according to the initial movement data. A corresponding prediction routine operating on the tracking server makes the same predictions about the location of the mobile device. The processor periodically (e.g., every minute, two minutes, five minutes, etc.) powers up the GPS receiver and determines the location of the mobile device. If the location of the mobile device differs from the predicted location of the mobile device by more than a predetermined threshold distance (or percentage or time etc.) then the processor transmits updated position and movement data to the tracking server.
Example 6
In an embodiment, a mobile device includes a GPS receiver, a transceiver for communicating data to a tracking server and receiving data from the tracking server, a transceiver (which may include the transceiver above) for requesting and receiving data related to traffic and map data and, optionally, a map database. The processor of the mobile device receives initial location information from the GPS receiver and causes the transmitter to transmit that location information to the tracking server. The processor receives from the tracking server a route, determined by a route calculation routine on the server, from the initial position to a destination. (Alternatively, the processor calculates a route by executing a route calculation routine on the mobile device.) The processor of the mobile device retrieves (via the transceiver or from the map database) map information corresponding to the initial position, inputting the initial position and the received route. The processor determines initial movement either from the GPS receiver or from a compass and one or more accelerometers, and transmits the initial movement data to the tracking server. The processor powers down the GPS receiver. The processor requests and receives information about traffic along the calculated or received route, and, cooperating with a prediction routine, predicts the position of the mobile device as the mobile device moves along the route. A corresponding set of traffic and prediction routines may be executing on the tracking server, providing to the tracking server the same predicted location of the mobile device. The processor periodically (e.g., every minute, two minutes, five minutes, etc.) powers up the GPS receiver and determines the location of the mobile device. If the location of the mobile device differs from the predicted location of the mobile device by more than a predetermined threshold distance (or percentage or time etc.) then the processor transmits updated position and movement data to the tracking server.
Turning now to FIG. 3 , a map 250 illustrates a route 252 from an initial position (not shown—beyond top left of the map 250 ) to a destination (not shown—beyond lower right of the map 250 ). A mobile device associated with a mobile asset traveling along the route 252 may determine (with the GPS receiver), and report to a tracking server (with a transmitter), the position of the mobile asset at a first time associated with the initial position. Periodically, for example at points 254 A-E, the mobile device may determine the current location of the mobile asset. At each of the times associated with the points 254 A-D, the mobile device will determine that the mobile asset is located on the assigned or calculated route, and will not send updated information to the tracking server. However, at a time associated with the point 254 E, the mobile device will determine that the mobile asset is no longer traveling along the calculated or assigned route. This will cause the processor of the mobile device to report the updated position of the mobile asset to the tracking server.
FIG. 4 is a flow diagram depicting an exemplary method 300 that may be executed by the processor 226 of the mobile device 200 . The processor 226 may determine the position of the mobile device 200 (and the mobile asset) by receiving data from the GPS receiver 212 (block 302 ). The processor 226 may also determine movement data of the mobile device by receiving additional location data from the GPS receiver 212 or by receiving data from sensors of the sensor block 204 , for example the compass 222 or the accelerometer(s) 220 (block 304 ). The processor 226 transmits the determined position and movement data to the tracking server 102 via a data connection (e.g., the mobile telephony transceiver 214 ) (block 306 ). When the processor 226 receives an indication that movement of the mobile device has changed or deviated in some way from the what the processor 226 was expecting (block 308 ), the processor updates the location (and, in some embodiments, the movement data) and transmits the updated information to the tracking server 102 (block 310 ).
FIG. 5 is a flow diagram depicting another exemplary method 320 that may be executed by the processor 226 of the mobile device 200 . The processor 226 may determine the position of the mobile device 200 (and the mobile asset) by receiving data from the GPS receiver 212 (block 322 ). The processor 226 may also determine movement data of the mobile device by receiving additional location data from the GPS receiver 212 or by receiving data from sensors of the sensor block 204 , for example the compass 222 or the accelerometer(s) 220 (block 324 ). The processor 226 determines a first road corresponding to the current location and movement data (block 326 ). Determining the first road corresponding to the current location may include retrieving map data (block 228 ) from a map database that is stored in the memory 228 , or may include retrieving map data via a data connection such as the mobile telephony transceiver 214 . The processor 226 transmits the determined position and movement data to the tracking server 102 via a data connection (e.g., the mobile telephony transceiver 214 ) (block 330 ). When the processor 226 receives an indication that movement of the mobile device has changed or deviated in some way from the what the processor 226 was expecting (block 332 ), the processor updates the location (and, in some embodiments, the movement data) and transmits the updated information to the tracking server 102 (block 334 ).
Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.
Additionally, certain embodiments are described herein as including logic or a number of components, modules, or mechanisms. Modules may constitute either software modules (e.g., code embodied on a machine-readable medium or in a transmission signal) or hardware modules. A hardware module is tangible unit capable of performing certain operations and may be configured or arranged in a certain manner. In example embodiments, one or more computer systems (e.g., a standalone, client or server computer system) or one or more hardware modules of a computer system (e.g., a processor or a group of processors) may be configured by software (e.g., an application or application portion) as a hardware module that operates to perform certain operations as described herein.
In various embodiments, a hardware module may be implemented mechanically or electronically. For example, a hardware module may comprise dedicated circuitry or logic that is permanently configured (e.g., as a special-purpose processor, such as a field programmable gate array (FPGA) or an application-specific integrated circuit (ASIC)) to perform certain operations. A hardware module may also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement a hardware module mechanically, in dedicated and permanently configured circuitry, or in temporarily configured circuitry (e.g., configured by software) may be driven by cost and time considerations. Though the application describes processors coupled to memory devices storing routines, any such processor/memory device pairing may instead be implemented by dedicated hardware permanently (as in an ASIC) or semi-permanently (as in an FPGA) programmed to perform the routines.
Accordingly, the term “hardware module” should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. As used herein, “hardware-implemented module” refers to a hardware module. Considering embodiments in which hardware modules are temporarily configured (e.g., programmed), each of the hardware modules need not be configured or instantiated at any one instance in time. For example, where the hardware modules comprise a general-purpose processor configured using software, the general-purpose processor may be configured as respective different hardware modules at different times. Software may accordingly configure a processor, for example, to constitute a particular hardware module at one instance of time and to constitute a different hardware module at a different instance of time.
Hardware modules can provide information to, and receive information from, other hardware modules. Accordingly, the described hardware modules may be regarded as being communicatively coupled. Where multiple of such hardware modules exist contemporaneously, communications may be achieved through signal transmission (e.g., over appropriate circuits and buses) that connect the hardware modules. In embodiments in which multiple hardware modules are configured or instantiated at different times, communications between such hardware modules may be achieved, for example, through the storage and retrieval of information in memory structures to which the multiple hardware modules have access. For example, one hardware module may perform an operation and store the output of that operation in a memory device to which it is communicatively coupled. A further hardware module may then, at a later time, access the memory device to retrieve and process the stored output. Hardware modules may also initiate communications with input or output devices, and can operate on a resource (e.g., a collection of information).
The various operations of example methods described herein may be performed, at least partially, by one or more processors that are temporarily configured (e.g., by software) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, such processors may constitute processor-implemented modules that operate to perform one or more operations or functions. The modules referred to herein may, in some example embodiments, comprise processor-implemented modules.
Similarly, the methods or routines described herein may be at least partially processor-implemented. For example, at least some of the operations of a method may be performed by one or processors or processor-implemented hardware modules. The performance of certain of the operations may be distributed among the one or more processors, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processor or processors may be located in a single location (e.g., within a home environment, an office environment or as a server farm), while in other embodiments the processors may be distributed across a number of locations.
The one or more processors may also operate to support performance of the relevant operations in a “cloud computing” environment or as a “software as a service” (SaaS). For example, at least some of the operations may be performed by a group of computers (as examples of machines including processors), these operations being accessible via a network (e.g., the Internet) and via one or more appropriate interfaces (e.g., application program interfaces (APIs).)
The performance of certain of the operations may be distributed among the one or more processors, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the one or more processors or processor-implemented modules may be located in a single geographic location (e.g., within a home environment, an office environment, or a server farm). In other example embodiments, the one or more processors or processor-implemented modules may be distributed across a number of geographic locations.
Some portions of this specification are presented in terms of algorithms or symbolic representations of operations on data stored as bits or binary digital signals within a machine memory (e.g., a computer memory). These algorithms or symbolic representations are examples of techniques used by those of ordinary skill in the data processing arts to convey the substance of their work to others skilled in the art. As used herein, an “algorithm” is a self-consistent sequence of operations or similar processing leading to a desired result. In this context, algorithms and operations involve physical manipulation of physical quantities. Typically, but not necessarily, such quantities may take the form of electrical, magnetic, or optical signals capable of being stored, accessed, transferred, combined, compared, or otherwise manipulated by a machine. It is convenient at times, principally for reasons of common usage, to refer to such signals using words such as “data,” “content,” “bits,” “values,” “elements,” “symbols,” “characters,” “terms,” “numbers,” “numerals,” or the like. These words, however, are merely convenient labels and are to be associated with appropriate physical quantities.
Unless specifically stated otherwise, discussions herein using words such as “processing,” “computing,” “calculating,” “determining,” “presenting,” “displaying,” or the like may refer to actions or processes of a machine (e.g., a computer) that manipulates or transforms data represented as physical (e.g., electronic, magnetic, or optical) quantities within one or more memories (e.g., volatile memory, non-volatile memory, or a combination thereof), registers, or other machine components that receive, store, transmit, or display information.
As used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Some embodiments may be described using the expression “coupled” and “connected” along with their derivatives. For example, some embodiments may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term “coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The embodiments are not limited in this context.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the description. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Still further, the figures depict preferred embodiments of a system for purposes of illustration only. One skilled in the art will readily recognize from the description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described herein
Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for a system and a process for identifying terminal road segments through the disclosed principles herein. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the spirit and scope defined in the appended claims.
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A mobile device associated with a mobile asset (and a method operating on such a mobile device) determines the location of the mobile asset and reports the location to a tracking server. To conserve power and bandwidth resources, the mobile device reports the current location and movement data of the mobile asset initially and then upon determination of the existence of one or more conditions. Potential conditions that could cause the mobile device to send an update to the server are a change from one road to another, a change in velocity or direction greater than a predetermined threshold, a deviation from an assigned or predicted route, or a difference between a current location and a predicted location.
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FIELD OF THE INVENTION
[0001] The present invention provides novel crystalline forms of aripiprazole and aripiprazole hydrochloride, processes for their preparation and pharmaceutical compositions containing them.
BACKGROUND OF THE INVENTION
[0002] Aripiprazole of formula (1):
or 7-[4-[4-(2,3-Dichlorophenyl)-1-piperazinyl]butoxy]-3,4-dihydro-2(1H)-quinolinone and its salts are useful for treating schizophrenia and their therapeutic uses were disclosed in U.S. Pat. No. 5,006,528.
[0003] Processes for the preparation of aripiprazole and its salts were described in U.S. Pat. No. 5,006,528. These processes do not produce well defined, reproducible crystalline forms.
[0004] Thus there is a need for stable and reproducible crystalline forms of aripiprazole and its salts.
[0005] We have discovered two novel crystalline forms of aripiprazole and four novel crystalline forms of aripiprazole hydrochloride. The novel forms have been found to be stable over the time and reproducible and so, suitable for pharmaceutical preparations.
[0006] Thus, the object of the present invention is to provide stable novel crystalline forms of aripiprazole, processes for preparation of the novel crystalline forms and pharmaceutical compositions containing these novel crystalline forms.
[0007] Another object of the present invention is to provide stable novel crystalline forms of aripiprazole hydrochloride, processes for preparation of the novel crystalline forms and pharmaceutical compositions containing these novel crystalline forms.
[0008] Since the novel crystalline forms of aripiprazole hydrochloride are obtained with high purity, preparation of aripiprazole via the crystalline forms of aripiprazole hydrochloride serves as a means of producing pure aripiprazole.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention, there is provided a novel crystalline form of aripiprazole, designated as Form I, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 8.7, 11.6, 16.3, 17.7, 18.6, 20.3, 23.4, 24.9 degrees. FIG. 1 shows typical Form I x-ray powder diffraction pattern.
[0010] According to another aspect of the present invention there is provided a process for preparation of the Form I of aripiprazole comprising the steps of:
a) dissolving aripiprazole in a suitable solvent; b) refluxing for about 30 minutes to 1 hour; c) cooling slowly to about 15° C. to 25° C.; d) maintaining for about 2 hour to 4 hours at about 15° C. to 25° C.; and e) filtering the solid separated.
[0016] The suitable solvent is selected from the group consisting of acetone, ethyl acetate, methanol or ethanol.
[0017] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole, designated as Form II, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 12.7, 15.1, 17.5, 18.2, 18.8, 19.5, 20.6, 21.2, 22.6, 23.3, 24.2, 24.9, 27.6, 30.0, 31.6, 35.8 degrees. FIG. 2 shows typical Form II x-ray powder diffraction pattern.
[0018] According to another aspect of the present invention there is provided a process for preparation of the Form II of aripiprazole, which comprises dissolving aripiprazole in tetrahydrofuran and vacuum drying at about 25° C. or spray drying.
[0019] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form A, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 6.2, 8.5, 11.5, 15.2, 15.5, 16.8, 17.2, 18.3, 18.9, 19.6, 20.6, 21.3, 23.4, 24.1, 24.7, 25.9, 27,5, 28.3, 28.9, 32.8 degrees. FIG. 3 shows typical Form A x-ray powder diffraction pattern.
[0020] According to another aspect of the present invention there is provided a process for preparation of the Form A of aripiprazole hydrochloride comprising the steps of:
a) dissolving aripiprazole in methanol or isopropyl alcohol; b) adding hydrochloric acid; c) maintaining for about 1 hour to 3 hours at about 15° C. to 25° C.; d) filtering the solid separated.
[0025] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form B, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 9.3, 14.8, 16.4, 17.4, 18.7, 19.7, 21.4, 21.9, 23.8, 25.1, 25.9, 29.7 degrees. FIG. 4 shows typical Form B x-ray powder diffraction pattern.
[0026] According to another aspect of the present invention there is provided a process for preparation of the Form B of aripiprazole hydrochloride comprising the steps of:
a) dissolving aripiprazole in a ketonic solvent; b) adding hydrochloric acid; c) maintaining for about 1 hour to 4 hours at about 15° C. to 25° C.; d) filtering the solid separated.
The ketonic solvent is selected from the group consisting of acetone, methyl isobutyl ketone and methyl ethyl ketone.
[0031] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form C, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 3.3, 10.3, 14.2, 14.6, 15.1, 16.4, 16.6, 19.4, 20.3, 20.8, 24.5, 24.9, 25.5, 26.4, 26.7, 28.5, 29.3, 30.1 degrees. FIG. 5 shows typical Form C x-ray powder diffraction pattern.
[0032] According to another aspect of the present invention there is provided a process for preparation of the Form C of aripiprazole hydrochloride comprising the steps of:
a) dissolving aripiprazole in an ester solvent; b) adding hydrochloric acid; c) maintaining for about 1 hour to 4 hours at about 15° C. to 25° C.; d) filtering the separated solid.
The ester solvent is selected from the group consisting of ethyl acetate, methyl acetate, ethyl formate and tert-butyl acetate.
[0037] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form D, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 9.0, 14.7, 16.4, 17.4, 19.0, 19.3, 19.8, 21.4, 23.4, 24.7, 25.4 degrees. FIG. 6 shows typical Form D x-ray powder diffraction pattern.
[0038] According to another aspect of the present invention there is provided a process for preparation of the Form D of aripiprazole hydrochloride comprising the steps of:
a) dissolving aripiprazole in tetrahydrofuran; b) adding hydrochloric acid; c) maintaining for about 2 hour to 4 hours at about 15° C. to 25° C.; d) filtering the solid separated.
[0043] According to another aspect of the present invention there is provided a pharmaceutical composition comprising crystalline Form I or Form II of aripiprazole.
[0044] According to another aspect of the present invention there is provided a pharmaceutical composition comprising novel crystalline form of aripiprazole hydrochloride.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 is a x-ray powder diffraction pattern of crystalline Form I of aripiprazole.
[0046] FIG. 2 is a x-ray powder diffraction pattern of crystalline Form II of aripiprazole.
[0047] FIG. 3 is a x-ray powder diffraction pattern of crystalline Form A of aripiprazole hydrochloride.
[0048] FIG. 4 is a x-ray powder diffraction pattern of crystalline Form B of aripiprazole hydrochloride.
[0049] FIG. 5 is a x-ray powder diffraction pattern of crystalline Form C of aripiprazole hydrochloride.
[0050] FIG. 6 is a x-ray powder diffraction pattern of crystalline Form D of aripiprazole hydrochloride.
[0051] x-Ray powder diffraction spectrum was measured on a Siemens diffractometer.
DETAILED DESCRIPTION OF THE INVENTION
[0052] According to one aspect of the present invention, there is provided a novel crystalline form of aripiprazole, designated as Form I, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 8.7, 11.6, 16.3, 17.7, 18.6, 20.3, 23.4, 24.9 degrees. FIG. 1 shows typical Form I x-ray powder diffraction pattern.
[0053] According to another aspect of the present invention, there is provided a process for preparation of the Form I of aripiprazole. Thus aripiprazole is dissolved in a suitable solvent. The suitable solvent is selected from the group consisting of acetone, ethyl acetate, methanol and ethanol. Aripiprazole obtained by a known method or crystalline Form II of aripiprazole obtained by the process described below may be used. The solution is refluxed for about 30 minutes to 1 hour. The solution is then cooled slowly to about 15° C. to 25° C. in about 1 hour and maintained for about 2 hour to 4 hours at the same temperature. The separated crystals are filtered and dried to give Form I of aripiprazole.
[0054] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole, designated as Form II, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 12.7, 15.1, 17.5, 18.2, 18.8, 19.5, 20.6, 21.2, 22.6, 23.3, 24.2, 24.9, 27.6, 30.0, 31.6, 35.8 degrees. FIG. 2 shows typical Form II x-ray powder diffraction pattern.
[0055] According to another aspect of the present invention there is provided a process for preparation of the Form II of aripiprazole, which comprises dissolving aripiprazole in tetrahydrofuran and vacuum drying at about 25° C. or spray drying.
[0056] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form A, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 6.2, 8.5, 11.5, 15.2, 15.5, 16.8, 17.2, 18.3, 18.9, 19.6, 20.6, 21.3, 23.4, 24.1, 24.7, 25.9, 27,5, 28.3, 28.9, 32.8 degrees. FIG. 3 shows typical Form A x-ray powder diffraction pattern.
[0057] According to another aspect of the present invention there is provided a process for preparation of the Form A of aripiprazole hydrochloride. Thus aripiprazole is dissolved in ethanol or isopropyl alcohol. If necessary, the solvent may be heated to effect dissolution of aripiprazole. Hydrochloric acid is added to the solution. Hydrochloric acid may be added as an aqueous solution or as a solution in any other solvent; or hydrochloric acid gas may be passed through the solution of aripiprazole. Then the contents are maintained for about 1 hour to 3 hours at about 15° C. to 25° C. and the separated crystals are filtered and dried to yield Form A of aripiprazole hydrochloride.
[0058] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form B, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 9.3, 14.8, 16.4, 17.4, 18.7, 19.7, 21.4, 21.9, 23.8, 25.1, 25.9, 29.7 degrees. FIG. 4 shows typical Form B x-ray powder diffraction pattern.
[0059] According to another aspect of the present invention there is provided a process for preparation of the Form B of aripiprazole hydrochloride. Thus aripiprazole is dissolved in a ketonic solvent. If necessary, the solvent may be heated to dissolve aripiprazole. The ketonic solvent is acetone or methyl isobutyl ketone or methyl ethyl ketone; or mixture thereof. Hydrochloric acid is added to the solution. Hydrochloric acid may be added as an aqueous solution or as a solution in any other solvent; or hydrochloric acid gas may be passed through the solution of aripiprazole. Then the contents are maintained for about 1 hour to 4 hours at about 15° C. to 25° C. and the separated crystals are filtered and dried to yield Form B of aripiprazole hydrochloride.
[0060] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form C, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 3.3, 10.3, 14.2, 14.6, 15.1, 16.4, 16.6, 19.4, 20.3, 20.6, 24.5, 24.9, 25.5, 26.4, 26.7, 28.5, 29.3, 30.1 degrees. FIG. 5 shows typical Form C x-ray powder diffraction pattern.
[0061] According to another aspect of the present invention there is provided a process for preparation of the Form C of aripiprazole hydrochloride. Thus aripiprazole is dissolved in an ester solvent. If necessary, the solvent may be heated to effect dissolution of aripiprazole. The ester solvent is selected from the group consisting of ethyl acetate, methyl acetate, ethyl formate and tert-butyl acetate. Hydrochloric acid is added to the solution. Hydrochloric acid may be added as an aqueous solution or as a solution in any other solvent; or hydrochloric acid gas may be passed through the solution of aripiprazole. Then the contents are maintained for about 1 hour to 4 hours at about 15° C. to 25° C. and the separated solid is filtered and dried to obtain Form C of aripiprazole hydrochloride.
[0062] According to another aspect of the present invention, there is provided a novel crystalline form of aripiprazole hydrochloride, designated as Form D, characterized by an x-ray powder diffraction pattern having peaks expressed as 2θ at about 9.0, 14.7, 16.4, 17.4, 19.0, 19.3, 19.8, 21.4, 23.4, 24.7, 25.4 degrees. FIG. 6 shows typical Form D x-ray powder diffraction pattern.
[0063] According to another aspect of the present invention there is provided a process for preparation of the Form D of aripiprazole hydrochloride. Thus aripiprazole is dissolved in tetrahydrofuran. Hydrochloric acid is added to the solution. Hydrochloric acid may be added as an aqueous solution or as a solution in any other solvent; or hydrochloric acid gas may be passed through the solution of aripiprazole. Then the contents are maintained for 2 hour to 4 hours at about 15° C. to 25° C. and the separated crystals are filtered and dried to produce Form D of aripiprazole hydrochloride.
[0064] The novel crystalline forms of aripiprazole hydrochloride obtained by the processes described above are very pure. So, aripiprazole with high purity can be obtained by basifying a solution of aripiprazole hydrochloride crystalline form and isolating aripiprazole from the solution by usual processes known in the art.
[0065] According to another aspect of the present invention there is provided a pharmaceutical composition comprising Form I or Form II of aripiprazole and a pharmaceutically acceptable carrier.
[0066] According to another aspect of the present invention there is provided a pharmaceutical composition comprising crystalline form of aripiprazole hydrochloride and a pharmaceutically acceptable carrier. The crystalline form may be Form A, Form B, Form C or Form D.
[0067] The forms of aripiprazole or aripiprazole hydrochloride may be formulated in a form suitable for oral administration or injection. The examples of pharmaceutical compositions are tablets, capsules, powders, suspensions, emulsions, injections and the like.
[0068] The following examples will serve to further illustrate the invention.
EXAMPLE 1
[0069] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in acetone (42 ml) and refluxed for 30 minutes. The solution is slowly cooled to 25° C. in 1 hour and maintained at 25° C. for 3 hours. The separated crystals are filtered and dried to give 1 gm of Form I of aripiprazole.
EXAMPLE 2
[0070] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in tetrahydrofuran and the solvent is removed by vacuum drying at 25° C. for 6 hours to give Form II of aripiprazole in quantitative yield.
EXAMPLE 3
[0071] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in tetrahydrofuran and the solvent is removed by spray drying at 25° C. for 6 hours to give Form II of aripiprazole in quantitative yield.
EXAMPLE 4
[0072] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in methanol (12 ml) and conc. hydrochloric acid (1 ml) is added to the solution. The contents are maintained for 2 hours at 25° C. and the separated solid is filtered to give 2 gm of Form A of aripiprazole hydrochloride.
EXAMPLE 5
[0073] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in acetone (12 ml) and conc. hydrochloric acid (1 ml) is added to the solution. The contents are maintained for 3 hours at 25° C. and the separated solid is filtered to give 1.9 gm of Form B of aripiprazole hydrochloride.
EXAMPLE 6
[0074] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in ethyl acetate (12 ml). 10% W/V HCl in ethyl acetate (4 ml) is added to the solution. The solution is maintained at 25° C. for 2 hours and the separated crystals are collected by filtration to give 2 gm of Form C of aripiprazole hydrochloride.
EXAMPLE 7
[0075] Aripiprazole (2 gm) (obtained by a process described in U.S. Pat. No. 5,006,528) is dissolved in tetrahydrofuran (12 ml) and conc. hydrochloric acid (1 ml) is added to the solution. The contents are maintained for 3 hours at 25° C. and the separated solid is collected by filtration to give 2 gm of Form D of aripiprazole hydrochloride.
EXAMPLE 8
[0076] Example 1 is repeated using Form II of aripiprazole instead of aripiprazole to give Form I of aripiprazole.
EXAMPLE 9
[0077] Example 2 is repeated using Form I of aripiprazole instead of aripiprazole to give Form II of aripiprazole.
EXAMPLE 10
[0078] Example 5 is repeated using Form I of aripiprazole instead of aripiprazole to give Form B of aripiprazole hydrochloride.
EXAMPLE 11
[0079] Example 7 is repeated using Form II of aripiprazole instead of aripiprazole to give Form D of aripiprazole hydrochloride.
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The present invention provides novel crystalline forms of aripiprazole and aripiprazole hydrochloride, processes for their preparation and pharmaceutical compositions containing them.
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BACKGROUND OF THE INVENTION
This invention relates to compositions which inhibit microbial growth. The composition consists essentially of an addition copolymer formed by reacting an olefin with sulfur dioxide.
Though the polymer is well known in the art, its use as a biocide is not. The copolymer of the present invention will inhibit microbial activity to provide sterile surfaces. It will actually kill activity on the treated surface.
The addition copolymer of the present invention consists essentially of sulfur dioxide and a monomeric olefin. This copolymer is disclosed in U.S. Pat. No. 3,820,963, but the disclosed use is for modified turbine engine fuels. U.S. Pat. No. 3,396,115 also discloses the polysulfone resin of the present invention, but for use as dry cleaning detergents. The copolymer is further disclosed in U.S. Pat. No. 3,657,200 for use as permanent sizing agents for fabrics.
The biocompatibility of the copolymers of the present invention is disclosed in U.S. Pat. Nos. 3,928,294 and 4,179,757. However, these patents do not disclose the biocidal activity of the copolymers, which is the novelty of the present invention.
Though sulfur dioxide is a known biocide, the copolymer of the present invention is not. U.S. Pat. Nos. 3,272,784 and 3,272,782 disclose copolymers of sulfur dioxide with comonomers derived from the reaction of ar-vinylidene α-haloalkyl aromatic compounds with nucleophilic reagents for use as slime-control agents. Other known sulfur-containing biocides include 1,2-dichloro-cyano-vinyl sulfides as disclosed in U.S. Pat. No. 4,238,405; aqueous liquid emulsions of bistrichloromethyl sulphone as disclosed in U.S. Pat. No. 3,996,155; 2,5-dihalophenyl-β-substituted sulfone compounds as disclosed in U.S. Pat. No. 4,206,235; arylthio sulfphone derivatives as described in U.S. Pat. No. 4,335,142; 7-(nitrogen-containing heterocyclic carbonamido) cephalosporanic acid as described in U.S. Pat. No. 3,308,120; and organic sulphones containing nitrile or carbonamide groups as described in U.S. Pat. No. 4,079,148. The advantage of the copolymers of the present invention versus the known bioactive plastic products is that they do not appear to involve a leachable species.
Silicones have also been disclosed as biocides. U.S. Pat. Nos. 3,817,739 and 3,865,728 disclose polysiloxane resins which inhibit the growth of algae on any solid, while U.S. Pat. No. 3,794,736 discloses organosilicon-substituted amines which inhibit the growth of bacteria and fungi.
Di(vinyl)alkyl polysulfides were disclosed in U.S. Pat. No. 4,438,259 as being resistant to, but not inhibiting, fungal attack.
SUMMARY OF THE INVENTION
It has been discovered in accordance with this invention that addition copolymers consisting essentially of a monomeric olefin and sulfur dioxide inhibit microbial growth as well as function as plastic materials such as wraps, packages, paints, coatings, structural members, and supports.
Thus, the invention is a method of inhibiting microbial growth by employing an addition copolymer consisting essentially of at least one mole of a monomeric olefin for each mole of sulfur dioxide; said olefin containing at least one substituent selected from the group consisting of hydrogen, chloride, and fluoride radicals.
DETAILED DESCRIPTION OF THE INVENTION
Any addition copolymer consisting essentially of at least one mole of a monomeric olefin for each mole of sulfur dioxide, said olefin containing at least one substituent selected from the group consisting of hydrogen, chloride, and fluoride radicals, can be employed for the purposes of this invention.
The addition copolymer of the present invention can be prepared by techniques well known to those skilled in the art. They can be prepared in the presence of any suitable catalyst such as a free radical source, light, peroxide, or azo nitrile. However, they are preferably prepared by solution polymerization or by suspension polymerization of the olefins with sulfur dioxide.
The solution polymerization employs specific chlorinated solvents such as chloroform, methyl chloroform, methylene chloride, mixtures thereof, or mixtures of the above with carbon tetrachloride with a minimum amount of catalyst to insure the preparation of high molecular species as is known in the art. Other solvents such as benzene and liquid sulfur dioxide can be used, however, the reaction time and rate of conversion is longer. The suspension polymerization technique uses suspending agents such as nonionic surfactants, anionic surfactants, and copolymers of alkyl styrenes with N-vinyl heterocyclic monomers.
It is preferred that the monomeric olefin employed in the copolymer of the present invention contains the unit with the general structure: ##STR1## wherein R is selected from the group consisting of hydrogen, chloride, and fluoride radicals; while X, Y and Z can be any radical. Examples of suitable radicals for X, Y and Z include hydrogen, halogens, alkyls, cycloalkyls, aryls, arylalkyls, nitriles, and carboxyalkyls, to name a few. Specific examples of suitable radicals for X, Y, and Z include chlorides, methyls, phenyls, and benzyls. It is not important for the purposes of this invention that the radicals X, Y and Z be the same. The olefin employed in the addition copolymer of the present invention can also be mixtures of the monomeric olefins just described.
Though there is no real limit on the number of carbon atoms comprising the monomeric olefin, it is preferred that it contain between 2 and 40 carbon atoms. It is further preferred that the olefin be an alpha for ease of polymerization.
Useful alpha olefins are normal (linear) alpha mono-olefins such as butene-1, hexene-1, octene-1, decene-1, dodecene-1, tetradecene-1, and the like.
Branched chain monomers are also useful to prepare the olefin polysulfones used in this invention. Examples of such monomers include 3-methyl butene-1; 2,3-dimethyl butene-1; 2,4,4-trimethyl pentene-1; 6,6-dimethyl octene-1; 4,6-dimethyl heptene-1; 2-propyl-pentene-1; 3-ethyl-2-heptene; 3,3,5,5-tetramethyl hexene-1; 6,6-diethyleicosene-1; 4,4-dimethyl octadiene-1; 3,3,5,5-tetraethyl hexene-1; 3,4-diisopropyl hexene-1; 3,5-di-t-butyl hexene-1; and the like.
If desired, selected crosslinking compounds can also be blended with the alpha olefins. Examples of such crosslinking agents include 1,7-octadiene; 1,3-butadiene; divinyl benzene; diallylcarbonate; diallyl phthalate; 1,3-cyclohexadiene; 4-methyl-1,3-pentadiene; 1,5-cyclooctadiene; 1,5,9-cyclododecatriene; 2-methyl-2,4-hexadiene; 1,11-dodecadiene; diallyl glycerol ether; diallyl phosphate; dicyclopentadiene; allyl acrylate; ethylene glycol dimethacrylate; triallyl amine; vinyl-4-allyl benzoate; diallyl ether of polypropylene glycol; and the like.
Though the polysulfones which are useful in this invention are of substantially linear molecular structure, alpha mono-olefins commercially available from cracked waxes may be employed. These contain olefins of various chain lengths both normal and branched chain α-olefins with a small amount of diolefins.
It is preferred, however, that butylene be employed as the olefin for the purposes of this invention.
The olefins of the present invention can be prepared by techniques well known to those skilled in the art. The telomers are available from the Ziegler polymerization of ethylene.
The biocides of the present invention can be employed as outdoor paints for warm, high humidity climates; post harvest crop treatment such as emulsion dipping of skinned fruits and vegetables to minimize rotting; tarps, wraps, bins, trays, coverings, etc., to minimize pest infestation of skinned fruits and vegetables; coatings for hospital surgical packs to maintain post irradiation sterility; bandages or bandage coatings to prevent infection; paints for hospital rooms, furnishings, and appurtenances to minimize sanitizer and scrubber usage and to compliment sanitizer and scrubber use; powders, dusts, liquids, or gels to inhibit or control athletes feet; powders, dusts, liquids, or gels to be used topically to prevent, inhibit, treat or control microbial infestation or infection; powders, liquids, gels, or films to impart bioactive properties to other materials by blending, coating or laminating; decorative as well as functional utility to prevent discoloration caused by microbial infestation, especially mildew staining; trough liners or interior pipe coatings to maintain good flow of water in systems where clinging wall growth would have detrimental effects; pool, pond, or storage tank liners or coatings to inhibit surface organic growth; awnings, curtains, and shades where mildew growth is undesirable; and can liners to inhibit microbial growth in paints. Other applications include those where it is desirable to inhibit the growth of algae, fungus, molds, yeasts, rusts mildew, barnacles, and bacteria. Specifically, the copolymers are active against fungi such as Penicillium glaucum, Chaetomium globosum, and Rhizopus nigricans; bacteria such as Bacterium coli, Bacterium pyocyaneum, and Aerobacteraerogenes; slimes such as slime-forming organisms which utilize caprolactam; green algae such as Stichococcus bacillaris Naegeli, Euglena gracilis Klebs, and Chorella pyrenoidosa Chick; blue algae such as Phormidium foredarum Gromont and Oscillatoria geminata Meneghini; silacaceous algae such as Phaedodactylum tricornutum Bohlin.
The apparent non-leaching activity of these polymers may permit using them to replace toxic leachable biocides which can contaminate water systems. In addition, since these polymers are not soluble in water, they should retain their activity at a near constant level for extended periods.
The copolymers can be applied together with inert solids to form dusts, or can be suspended in a suitable liquid diluent, preferably water. In place of water there can be employed organic solvents as carriers such as hydrocarbons, ketones, chlorinated hydrocarbons, esters. Examples of suitable hydrocarbons include benzene, toluene, xylene, kerosene, diesel oil, fuel oil, and petroleum naptha. Examples of suitable ketones include acetone, methyl ethyl ketone, and cyclohexane. Examples of suitable chlorinated hydrocarbons include carbon tetrachloride, chloroform, trichloroethylene, and perchloroethylene. Examples of suitable esters include ethyl acetate, amyl acetate, butyl acetate, glycol ethers such as monomethyl ether of ethylene glycol and monomethyl ether of diethylene glycol, and alcohols such as ethanol, isopropanol, and amyl alcohols.
There can also be added surface active agents or wetting agents and/or inert solids in the liquid formulations. Examples of suitable surfactants include alkyl sulfonates, alkylaryl sulfonates, alkyl sulfates, alkylamide sulfonates, alkylaryl polyether alcohols, and fatty acid esters of polyhydric alcohols.
The copolymer can also be applied via an aerosol system or as a plasticizer so long as a coherent film is formed. The copolymer can also be molded into the desired shape or object.
Now in order that those skilled in the art may better understand how the present invention can be practiced, the following examples are given by way of illustration and not by way of limitation.
EXAMPLE 1
To prepare the butene sulfur dioxide polymers, the following procedure was used. Azobisisobutyronitrile (0.0138 grams (g)) was added to a glass ampule which was then evacuated and cooled with liquid nitrogen. Butene-1 (0.5 g) and sulfur dioxide (15 g) was added by condensation. The ampule was sealed and then heated to 55° C. for 72 hours. The ampule was again cooled with liquid nitrogen and opened. The glassy polymer was dissolved in an excess of methylene chloride, precipitated with hexane and dried. An IR spectrum of the product identified it as a 1/1 copolymer of the two comonomers.
A one-inch square coupon was prepared by compression molding the polymer made above. The coupon (1/8 inch thick) was cleaned with swabs which had been dipped in 70 percent aqueous ethanol. The coupon was placed in a 37° C. incubator overnight in an individual petri dish. After drying the coupon was inoculated with 20 milliliters (ml) of a 24 hour old culture of the bacteria, Esherichia coli. Organisms were recovered at zero time with 10 ml of 0.85 percent aqueous solutions of sodium chloride. Appropriate dilutions and plate counts were made to determine that 6.8×10 7 organisms were applied to each square coupon. Forty eight hours after treatment the recoverable bacteria population on the coupon had decreased by greater than 99.999 percent. The viable count on a polystyrene control coupon had decreased only by 90 percent, after 48 hours. Most of the population decrease on the control is attributed to dehydration.
EXAMPLE 2
A terpolymer prepared as in Example 1, where 25 percent of the butene-1 is replaced with acrylonitrile, was evaluated as in Example 1. The viable count of the bacteria, Esherichia coli dropped by 99.8 percent in 24 hours. The count on the polystyrene control coupon remained the same.
EXAMPLE 3
A 50/50 mixture of butene-1 and butene-2 was used to make a polymer with SO 2 as in Example 1. The test results were essentially the same as those of Example 1, i.e., greater than 99.999 percent viable bacteria count decrease after 48 hours.
EXAMPLE 4
The polymer from Example 1 was examined for its ability to inhibit growth of the fungus, Piricularia grisea. A cleansed coupon prepared with polymer from Example 1 was placed in a petri dish which contained a culture of wet agar inoculated with Piricularia grisea. Only the underside of the coupon was exposed to the culture medium. The dish was covered and allowed to stand for two weeks at room temperature. A control coupon of polystyrene was treated in the same manner. The test coupon showed no visible fungal growth on the underside, whereas extensive growth occurred on the polystyrene control.
With the butene-sulfur dioxide polymer coupon, there was also no zone of inhibition in the culture medium indicating that the inhibition to mold growth did not take place from a leachable species but on the solid polymer surface.
A test to confirm the fungal growth inhibiting ability of these polymers was performed as follows. A coupon of the test polymer of Example 1 and a control of polystyrene were inoculated with Piricularia grisea and placed in a humid bell chamber. No growth occurred on either sample indicating that neither polymer supports the growth of this fungus. When a nutrient broth was added to each coupon, extensive fungus growth occurred on the polystyrene control but no visible growth was apparent after two weeks on the test sample. Thus, the butene-sulfurdioxide polymer appears to inhibit the growth of the fungus as well as not supporting growth.
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A method of inhibiting microbial growth by employing an addition copolymer is disclosed. The addition copolymer consists essentially of an olefin and sulfur dioxide; said olefin containing at least one substituent selected from the group consisting of hydrogen, chloride, and fluoride radicals. These compositions inhibit bacterial growth while functioning as plastic materials and can be used in coatings, packaging, paints, structural members and supports.
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[0001] This application claims the benefit of priority to International Application No. PCT/US14/67396 filed Nov. 25, 2014 which claims the benefit of priority to U.S. Application No. 61/909,682 filed Nov. 27, 2013, both applications being incorporated herein by reference.
FIELD
[0002] The following description relates to the synthesis of semiconducting polymers via the use of microreactor systems, including the synthesis of fused thiophenes and, more particularly, fused thiophene-based diketopyrrolopyrrole polymers.
BACKGROUND
[0003] Highly conjugated organic materials, due to their interesting electronic and optoelectronic properties, are being investigated for use in a variety of applications, including organic semiconductors (OSCs), field effect transistors (FETs), thin-film transistors (TFTs), organic light-emitting diodes (OLEDs), electro-optic (EO) applications, as conductive materials, as two photon mixing materials, as organic semiconductors, and as non-linear optical (NLO) materials.
[0004] Organic semiconductors (OSCs) have attracted a great amount of attention for next generation electronics due to their interesting electronic and optoelectronic properties and their advantages over inorganic semiconductors, such as processability, high mechanical flexibility, low production costs, and low weight. A number of polycyclic aromatic compounds, such as oligothiophenes, acenes, arylenes, phthalocyanenes, and polythiophenes, have been widely studied as semiconductor materials.
[0005] One promising group of compounds for use as OSCs is the fused thiophene-based polymers. These compounds have shown high mobility (up to 5 cm 2 /V·s) and high on/off ratios (up to 10 8 ). However, in order to optimize these properties and the overall quality of the material improved methods of synthesizing the polymers is necessary. The present disclosure cures this unmet need by providing methods of obtaining OSCs with improved yield, higher molecular weights and narrower molecular weight distributions.
SUMMARY
[0006] In the examples described herein, new synthetic methods are described for making fused thiophene-based polymers from fused thiophene-based tin-substituted monomer species. The synthetic methods utilize the advantages of microfluidic technology to provide improved properties for the polymers, which are advantageous in devices incorporating the polymers.
[0007] Microfluidic devices, which may be referred to as microstructured reactors, microchannel reactors, microcircuit reactors, or microreactors, (hereinafter, collectively referred to as “microreactors”) are devices in which a fluid can be confined and subjected to processing. Microreactors possessing channels ranging from microns to millimeters, have been designed and used to perform many chemical transformations. The extremely high surface area to volume ratios, high heat transfer, and reduced process volumes associated with microreactors makes them particularly suitable for “process intensification.” Microreactors can be used to assemble flow systems that maximize mass- and heat-transfer and therefore lead to major improvements in the manufacturing of compounds through a decrease in equipment size, energy consumption and waste production all while increasing production capacity. Further, as shown herein, microreactor technology provides polymers with much narrower molecular weight variations via a more precise control of reaction temperature and limiting the number of species a reactant may interact with during the reaction phase.
[0008] A first aspect comprises a process comprising the making a compound of formula (I) or formula (II):
[0000]
[0000] by reacting a compound of formula (Ia) or (IIa):
[0000]
[0000] with a compound having the formula:
[0000] (R 5 ) 3 Sn-A-Sn(R 5 ) 3
[0000] or by reacting a compound of formula (Ib) or (IIb):
[0000]
[0000] with a compound having the formula:
[0000] Z-A-Z
[0000] wherein the process is done in a microreactor and with a metal catalyst and wherein each T is independently S, SO, SO 2 , Se, Te, BR 3 , PR 3 , NR 3 , CR 3 R 4 or SiR 3 R 4 , each R 3 and R 4 is independently hydrogen, substituted or unsubstituted alkyl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, substituted or unsubstituted alkenyl, each R 1 and R 2 are, independently, substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, each R 5 is independently substituted or unsubstituted alkyl, each Z is independently Cl, Br, or I, n is an integer of 1 or more, x, m and o are independently integers of 1 or more, and each A is independently a conjugated group. In some embodiments, x is an integer from about 10 to about 200. In some embodiments, o is an integer from 1 to 5, and m is an integer from 1 to 5 and n is an integer of 2 or more. In some cases, A may be selected from the group consisting of an optionally substituted ethylene, butadiene, or acetylene. In some embodiments, A is an optionally substituted aryl. In some embodiments, A may be one selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes.
[0009] In some embodiments, the compound made by the processes described herein comprises formula (III) or formula (IV):
[0000]
[0000] wherein R 1 , R 2 , n, m, x, and o, are as described above and Ar may be one selected from the group consisting of benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes.
[0010] In some embodiments, the compound made by the processes described herein comprises formula (V):
[0000]
[0000] wherein R 1 , R 2 , n, m, x, and o are as described above.
[0011] Another aspect comprises a method of making a compound of formula (VIII) or formula (IX):
[0000]
[0000] The method may include reacting a compound of formula (Xa) or formula (XIa):
[0000]
[0000] with a compound of formula (XIIa):
[0000]
[0000] or, alternatively, reacting a compound of formula (Xb) or formula (XIb):
[0000]
[0000] with a compound of formula (XIIb):
[0000]
[0000] wherein the process is done in a microreactor with a metal catalyst and wherein the process is done in a microreactor with a metal catalyst and wherein each T is independently S, SO, SO 2 , Se, Te, BR 3 , PR 3 , NR 3 , CR 3 R 4 or SiR 3 R 4 , each R 3 and R 4 is independently hydrogen, substituted or unsubstituted alkyl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, substituted or unsubstituted alkenyl, each R 1 and R 2 are, independently, substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, each R 5 is independently substituted or unsubstituted alkyl, each Z may be independently be O, S, Se, or substituted imine, each D may be independently selected from the group consisting of Br, Cl, and I, each y is independently an integer from 0 to 5, each X′ is independently an optionally substituted C 1 -C 40 linear or branched alkyl or heteroalkyl, or H, b may be independently less than or equal to 5 and greater than or equal to 1, each B and each Ar is independently an optionally substituted conjugated species. In some embodiments, each b may be equal to 1. In some examples, each Z may be independently O, S, or substituted imines. In some embodiments, each Z is oxygen. In some cases, the optionally substituted conjugated species may be one selected from the group consisting of ethylene, butadiene, and acetylene. The optionally substituted aromatic species may be one selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes. Each R and X′ may be independently an optionally substituted C 6 -C 24 linear alkyl chain. In other embodiments, each R and X′ may be independently an optionally substituted C 13 -C 19 linear alkyl chain. The optionally substituted alkyl chain containing heteroatoms may be one selected from the group consisting of oligo(ethylene glycol), oligo(propylene glycol), and oligo(ethylene diamine). The substituted alkyl chains may include ketone, amine, ester, one or more unsaturations, halide, nitro, aldehyde, hydroxyl, carboxylic acid, alkoxy, or any combination thereof. Each x may independently be an integer from 8 to 250.
[0012] In some embodiments of the aspects above, the metal catalyst may be selected from the group consisting of Pt, Pd, Ru, and Rh.
[0013] In some embodiments of the aspects described above, the microreactor comprises a continuous-flow microreactor. In other embodiments, the microreactor comprises a microchannel-based microreactor. Additionally, the microreactors may comprise one or more heat exchange channels.
[0014] Additional features and advantages of the disclosure are set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the disclosure as described herein, including the detailed description that follows, the claims, and the appended drawings.
[0015] The claims as well as the Abstract are incorporated into and constitute part of the Detailed Description set forth below.
[0016] All publications, articles, patents, published patent applications and the like cited herein are incorporated by reference herein in their entirety.
FIGURES
[0017] FIG. 1 is an embodiment of a microreactor as embodied herein.
[0018] FIG. 2 shows an example of a microreactor as embodied herein where the microreactor comprises a low-flow reactor as used in the examples.
DETAILED DESCRIPTION
[0019] The claimed invention may be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. These example embodiments are provided so that this disclosure will be both thorough and complete, and will fully convey the scope of the claimed invention to those skilled in the art.
[0020] Before the present materials, articles, and/or methods are disclosed and described, it is to be understood that the aspects described below are not limited to specific compounds, synthetic methods, or uses as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[0021] In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings:
[0022] Throughout this specification, unless the context requires otherwise, the word “comprise,” or variations such as “comprises” or “comprising,” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
[0023] It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a fused thiophene” includes mixtures of two or more such fused thiophenes, and the like.
[0024] “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.
[0025] 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 aspect 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 aspect. 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.
[0026] The term “alkyl” refers to a monoradical branched or unbranched saturated hydrocarbon chain having a variable amount of carbon atoms, typically 1 to 40. This term is exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, t-butyl, n-hexyl, n-decyl, tetradecyl, and the like. The term “alkyl” as defined herein, unless otherwise noted, also includes cycloalkyl groups.
[0027] The term “cycloalkyl” as used herein is a non-aromatic carbon-based ring composed of at least three carbon atoms, and in some embodiments from 3 to 20 carbon atoms. Examples of cycloalkyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, etc. The term cycloalkyl group also includes a heterocycloalkyl group, where at least one of the carbon atoms of the ring is substituted with a heteroatom such as, but not limited to, nitrogen, oxygen, sulphur, or phosphorus.
[0028] The term “substituted alkyl” refers to: (1) an alkyl group as defined above, having 1, 2, 3, 4 or 5 substituents, typically 1 to 3 substituents, selected from the group consisting of alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO-alkyl, —SO-aryl, —SO-heteroaryl, —SO 2 -alkyl, SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1, 2, or 3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2; or (2) an alkyl group as defined above that is interrupted by 1-10 atoms independently chosen from oxygen, sulfur and NR a , where R a is chosen from hydrogen, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, heteroaryl and heterocyclic. All substituents may be optionally further substituted by alkyl, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, or —S(O) p R SO , in which R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2; or (3) an alkyl group as defined above that has both 1, 2, 3, 4 or 5 substituents as defined above and is also interrupted by 1-10 atoms as defined above.
[0029] The term “alkoxy” refers to the group D-O—, where D is an optionally substituted alkyl or optionally substituted cycloalkyl, or D is a group —Y—W, in which Y is optionally substituted alkylene and W is optionally substituted alkenyl, optionally substituted alkynyl; or optionally substituted cycloalkenyl, where alkyl, alkenyl, alkynyl, cycloalkyl and cycloalkenyl are as defined herein. Typical alkoxy groups are optionally substituted alkyl-O— and include, by way of example, methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, tert-butoxy, sec-butoxy, n-pentoxy, n-hexoxy, 1,2-dimethylbutoxy, trifluoromethoxy, and the like.
[0030] The term “alkylene” refers to a diradical of a branched or unbranched saturated hydrocarbon chain, having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms, typically 1-10 carbon atoms, more typically 1, 2, 3, 4, 5 or 6 carbon atoms. This term is exemplified by groups such as methylene (—CH 2 —), ethylene (—CH 2 CH 2 —), the propylene isomers (e.g., —CH 2 CH 2 CH 2 — and —CH(CH 3 )CH 2 —) and the like.
[0031] The term “substituted alkylene” refers to: (1) an alkylene group as defined above having 1, 2, 3, 4, or 5 substituents selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO-alkyl, —SO-aryl, —SO-heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1, 2, or 3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2; or (2) an alkylene group as defined above that is interrupted by 1-20 atoms independently chosen from oxygen, sulfur and NR a —, where R a is chosen from hydrogen, optionally substituted alkyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl and heterocyclic, or groups selected from carbonyl, carboxyester, carboxyamide and sulfonyl; or (3) an alkylene group as defined above that has both 1, 2, 3, 4 or 5 substituents as defined above and is also interrupted by 1-20 atoms as defined above. Examples of substituted alkylenes are chloromethylene (—CH(Cl)—), aminoethylene (—CH(NH 2 )CH 2 —), methylaminoethylene (—CH(NHMe)CH 2 —), 2-carboxypropylene isomers (—CH 2 CH(CO 2 H)CH 2 —), ethoxyethyl (—CH 2 CH 2 O—CH 2 CH 2 —), ethylmethylaminoethyl (—CH 2 CH 2 N(CH 3 )CH 2 CH 2 —), and the like.
[0032] The term “alkylthio” refers to the group R S —S—, where R S is defined as an optionally substituted alkyl or optionally substituted cycloalkyl, or D is a group —Y—W, in which Y is optionally substituted alkylene and W is optionally substituted alkenyl, optionally substituted alkynyl; or optionally substituted cycloalkenyl, where alkyl, alkenyl, alkynyl, cycloalkyl and cycloalkenyl are as defined herein.
[0033] The term “alkenyl” refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group typically having from 2 to 30 carbon atoms, more typically 2 to 10 carbon atoms and even more typically 2 to 6 carbon atoms and having 1-6, typically 1, double bond (vinyl). Typical alkenyl groups include ethenyl or vinyl (—CH═CH 2 ), 1-propylene or allyl (—CH 2 CH═CH 2 ), isopropylene (—C(CH 3 )═CH 2 ), bicyclo[2.2.1]heptene, and the like. In the event that alkenyl is attached to nitrogen, the double bond cannot be alpha to the nitrogen. The term “alkenyl” as defined herein, unless otherwise noted, also includes cycloalkenyl groups.
[0034] The term “substituted alkenyl” refers to an alkenyl group as defined above having 1, 2, 3, 4 or 5 substituents, and typically 1, 2, or 3 substituents, selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO— alkyl, —SO-aryl, —SO-heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1, 2, or 3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0035] The term “alkynyl” refers to a monoradical of an unsaturated hydrocarbon, typically having from 2 to 20 carbon atoms, more typically 2 to 10 carbon atoms and even more typically 2 to 6 carbon atoms and having at least 1 and typically from 1-6 sites of acetylene (triple bond) unsaturation. Typical alkynyl groups include ethynyl, (—C≡CH), propargyl (or prop-1-yn-3-yl, —CH 2 C≡CH), and the like. In the event that alkynyl is attached to nitrogen, the triple bond cannot be alpha to the nitrogen. The term “alkynyl” as defined herein, unless otherwise noted, also includes cycloalkynyl groups.
[0036] The term “substituted alkynyl” refers to an alkynyl group as defined above having 1, 2, 3, 4 or 5 substituents, and typically 1, 2, or 3 substituents, selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO-alkyl, —SO-aryl, —SO-heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1, 2, or 3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0037] The term “aminocarbonyl” refers to the group —C(O)NR N R N where each R N is independently hydrogen, alkyl, aryl, heteroaryl, heterocyclic or where both R N groups are joined to form a heterocyclic group (e.g., morpholino). Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0038] The term “acylamino” refers to the group —NR NCO C(O)R where each R NCO is independently hydrogen, alkyl, aryl, heteroaryl, or heterocyclic. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0039] The term “acyloxy” refers to the groups —O(O)C-alkyl, —O(O)C-cycloalkyl, —O(O)C-aryl, —O(O)C-heteroaryl, and —O(O)C-heterocyclic. Unless otherwise constrained by the definition, all substituents may be optionally further substituted by alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0040] The term “aryl” refers to an aromatic carbocyclic group of 6 to 20 carbon atoms having a single ring (e.g., phenyl) or multiple rings (e.g., biphenyl), or multiple condensed (fused) rings (e.g., naphthyl or anthryl). Typical aryls include phenyl, naphthyl and the like.
[0041] Unless otherwise constrained by the definition for the aryl substituent, such aryl groups can optionally be substituted with from 1 to 5 substituents, typically 1 to 3 substituents, selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, amino sulfonyl, aminocarbonyl amino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO— alkyl, —SO-aryl, —SO— heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0042] The term “aryloxy” refers to the group aryl-O— wherein the aryl group is as defined above, and includes optionally substituted aryl groups as also defined above. The term “arylthio” refers to the group aryl-S—, where aryl is as defined as above.
[0043] The term “amino” refers to the group —NH 2 .
[0044] The term “substituted amino” refers to the group —NR w R w where each R w is independently selected from the group consisting of hydrogen, alkyl, cycloalkyl, carboxyalkyl (for example, benzyloxycarbonyl), aryl, heteroaryl and heterocyclic provided that both R w groups are not hydrogen, or a group —Y—Z, in which Y is optionally substituted alkylene and Z is alkenyl, cycloalkenyl, or alkynyl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0045] The term “carboxyalkyl” refers to the groups —C(O)O-alkyl or —C(O)O-cycloalkyl, where alkyl and cycloalkyl, are as defined herein, and may be optionally further substituted by alkyl, alkenyl, alkynyl, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , in which R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0046] The term “cycloalkyl” refers to carbocyclic groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings. Such cycloalkyl groups include, by way of example, single ring structures such as cyclopropyl, cyclobutyl, cyclopentyl, cyclooctyl, and the like, or multiple ring structures such as adamantanyl, bicyclo[2.2.1]heptane, 1,3,3-trimethylbicyclo[2.2.1]hept-2-yl, (2,3,3-trimethylbicyclo[2.2.1]hept-2-yl), or carbocyclic groups to which is fused an aryl group, for example indane, and the like.
[0047] The term “cycloalkenyl” refers to carbocyclic groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings with at least one double bond in the ring structure.
[0048] The terms “substituted cycloalkyl” or “substituted cycloalkenyl” refer to cycloalkyl or cycloalkenyl groups having 1, 2, 3, 4 or 5 substituents, and typically 1, 2, or 3 substituents, selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO-alkyl, —SO-aryl, —SO— heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1, 2, or 3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0049] The term “halogen” or “halo” refers to fluoro, bromo, chloro, and iodo.
[0050] The term “acyl” denotes a group —C(O)R CO , in which R CO is hydrogen, optionally substituted alkyl, optionally substituted cycloalkyl, optionally substituted heterocyclic, optionally substituted aryl, and optionally substituted heteroaryl.
[0051] The term “heteroaryl” refers to a radical derived from an aromatic cyclic group (i.e., fully unsaturated) having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 carbon atoms and 1, 2, 3 or 4 heteroatoms selected from oxygen, nitrogen and sulfur within at least one ring. Such heteroaryl groups can have a single ring (e.g., pyridyl or furyl) or multiple condensed rings (e.g., indolizinyl, benzothiazolyl, or benzothienyl). Examples of heteroaryls include, but are not limited to, [1,2,4]oxadiazole, [1,3,4]oxadiazole, [1,2,4]thiadiazole, [1,3,4]thiadiazole, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, indolizine, isoindole, indole, indazole, purine, quinolizine, isoquinoline, quinoline, phthalazine, naphthylpyridine, quinoxaline, quinazoline, cinnoline, pteridine, carbazole, carboline, phenanthridine, acridine, phenanthroline, isothiazole, phenazine, isoxazole, phenoxazine, phenothiazine, imidazolidine, imidazoline, triazole, oxazole, thiazole, naphthyridine, and the like as well as N-oxide and N-alkoxy derivatives of nitrogen containing heteroaryl compounds, for example pyridine-N-oxide derivatives.
[0052] Unless otherwise constrained by the definition for the heteroaryl substituent, such heteroaryl groups can be optionally substituted with 1 to 5 substituents, typically 1 to 3 substituents selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonyl amino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO— alkyl, —SO-aryl, —SO— heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0053] The term “heteroaryloxy” refers to the group heteroaryl-O—.
[0054] The term “heterocyclic” refers to a monoradical saturated or partially unsaturated group having a single ring or multiple condensed rings, having from 1 to 40 carbon atoms and from 1 to 10 hetero atoms, typically 1, 2, 3 or 4 heteroatoms, selected from nitrogen, sulfur, phosphorus, and/or oxygen within the ring. Heterocyclic groups can have a single ring or multiple condensed rings, and include tetrahydrofuranyl, morpholino, piperidinyl, piperazino, dihydropyridino, and the like.
[0055] Unless otherwise constrained by the definition for the heterocyclic substituent, such heterocyclic groups can be optionally substituted with 1, 2, 3, 4 or 5, and typically 1, 2 or 3 substituents, selected from the group consisting of alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, amino, aminocarbonyl, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, thiocarbonyl, carboxy, carboxyalkyl, arylthio, heteroarylthio, heterocyclothio, thiol, alkylthio, aryl, aryloxy, heteroaryl, aminosulfonyl, aminocarbonylamino, heteroaryloxy, heterocyclic, heterocyclooxy, hydroxyamino, alkoxyamino, nitro, —SO— alkyl, —SO-aryl, —SO— heteroaryl, —SO 2 -alkyl, —SO 2 -aryl and —SO 2 -heteroaryl. Unless otherwise constrained by the definition, all substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, carboxy, carboxyalkyl, aminocarbonyl, hydroxy, alkoxy, halogen, CF 3 , amino, substituted amino, cyano, and —S(O) p R SO , where R SO is alkyl, aryl, or heteroaryl and p is 0, 1 or 2.
[0056] The term “thiol” refers to the group —SH.
[0057] The term “alkylthio” refers to the group —S— optionally substituted alkyl.
[0058] The term “heteroarylthio” refers to the group —S— heteroaryl wherein the heteroaryl group is as defined above including optionally substituted heteroaryl groups as also defined above.
[0059] The term “sulfoxide” refers to a group —S(O)R SO , in which R SO is an optionally substituted alkyl, aryl, or heteroaryl.
[0060] The term “sulfone” refers to a group —S(O) 2 R SO , in which R SO is an optionally substituted alkyl, aryl, or heteroaryl.
[0061] The term “keto” refers to a group —C(O)—.
[0062] The term “thiocarbonyl” refers to a group —C(S)—.
[0063] The term “carboxy” refers to a group —C(O)OH.
[0064] The term “conjugated group” or “conjugated species” is defined as a linear, branched or cyclic group, or combination thereof, in which p-orbitals of the atoms within the group are connected via delocalization of electrons and wherein the structure can be described as containing alternating single and double or triple bonds and may further contain lone pairs, radicals, or carbenium ions. Conjugated cyclic groups may comprise both aromatic and non-aromatic groups, and may comprise polycyclic or heterocyclic groups, such as diketopyrrolopyrrole. Ideally, conjugated groups are bound in such a way as to continue the conjugation between the moieties they connect.
[0065] Disclosed are compounds, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed methods and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds may not be explicitly disclosed, each is specifically contemplated and described herein. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited, each is individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these is also specifically contemplated and disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods of making and using the disclosed compositions. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination is specifically contemplated and should be considered disclosed.
[0066] In the examples described herein, new synthetic methods are described for making fused thiophene-based polymers from fused thiophene-based tin-substituted monomer species. The synthetic methods utilize the advantages of microreactor technology to provide improved properties for the polymers, which are advantageous in devices incorporating the polymers.
[0067] Generally described herein are processes comprising the synthesis of a compound of formula (I) or formula (II):
[0000]
[0000] by reacting a compound of formula (Ia) or (IIa):
[0000]
[0000] with a compound having the formula:
[0000] (R 5 ) 3 Sn-A-Sn(R 5 ) 3
[0000] Or, alternatively, by reacting a compound of formula (Ib) or (IIb):
[0000]
[0000] with a compound having the formula:
[0000] Z-A-Z
[0000] wherein the process is done in a microreactor and with a metal catalyst. As used in this embodiment, each T is independently S, SO, SO 2 , Se, Te, BR 3 , PR 3 , NR 3 , CR 3 R 4 or SiR 3 R 4 , each R 3 and R 4 is independently hydrogen, substituted or unsubstituted alkyl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, substituted or unsubstituted alkenyl, each R 1 and R 2 are, independently, substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, each R 5 is independently substituted or unsubstituted alkyl, each Z is independently Cl, Br, or I, n is an integer of 1 or more, x, m and o are independently integers of 1 or more, and each A is independently a conjugated group. In some embodiments, x is an integer from about 10 to about 200. In some embodiments, o is an integer from 1 to 5, and m is an integer from 1 to 5, and n is an integer of 2 or more. In some cases, A may be selected from the group consisting of an optionally substituted ethylene, butadiene, or acetylene. In some embodiments, A is an optionally substituted aryl. In some embodiments, A may be one selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozoles, porphyrins, carbazoles, furans, indoles, and fused thiophenes.
[0068] The reaction described above is advantageously run in a microreactor. Microreactors, as used herein, and more particularly glass, glass-ceramic and ceramic microfluidic devices (generally referred to as microstructures), are described in numerous patents and applications, for example in U.S. Pat. Nos. 7,007,709, 8,043,571, Ser. Nos. 13/266,350, 13/318,496, FR 2 821 657, WO 2005/107 937, EP 1 925 364, and US 2007/280855. The use of a microreactor flow system with good thermal control and relatively fast heat and mass transfer allows for the polymerization reactions to be run with greater heat and reaction control. The short residence times thus achievable result in high throughput and the small reaction vessels provide for less molecular weight variation. In the process, one or more working fluids confined in the microfluidic device may exchange heat with one or more associated heat exchange fluids. In any case, the characteristic smallest dimensions of the confined spaces for the working fluids are generally on the order of 0.1 mm to 5 mm, desirably 0.5 mm to 2 mm.
[0069] In some cases, the microreactor comprises microchannels. Microreactors that employ microchannels offer many advantages over conventional-scale reactors, including vast improvements in energy efficiency, reaction speed, reaction yield, safety, reliability, scalability, etc. The use of a microchannel-based device also allows the microreactor to operate as a continuous-flow reactor. The internal dimensions of the microchannels provide considerable improvement in mass and heat transfer rates. According to one embodiment of the present disclosure, a microchannel microreactor is provided. The microchannel microreactor comprises a microchannel housing comprising a plurality of channels positioned for flow (gravity, pressure, pump-assisted, etc.) and an upper microstructure disposed above the microchannel housing. The upper microstructure comprises one or more liquid feed circuits and at least one mixing cavity. The microchannel housing comprises at least one reactive passage, and the mixing cavity is in fluid communication with the reactive passage. The feed circuits each comprise at least one liquid feed inlet and at least one liquid reservoir adjacent to the mixing cavity, wherein the liquid feed is in fluid communication with the at least one liquid feed inlet. The liquid reservoir is operable to deliver a liquid feed into the mixing cavity.
[0070] An example of a microreactor for use in the reaction process is shown in FIG. 1 . Referring to the embodiment of FIG. 1 , a layer 50 of a microfluidic device may comprise at least one reactant passage 60 defined within the layer 50 . The reactant passage 60 may be defined by vertical wall structures, of which a cross-section is shown in the figure. As shown, multiple different reactant passages with various profiles may be used within the layer 50 . Moreover, while various materials are considered suitable, the layer 50 desirably may be formed of glass, glass-ceramic, ceramic, or mixtures or combinations thereof. Other materials, such as metal or polymer, may also be used if desired.
[0071] Referring again to FIG. 1 , each reactant passage 60 may comprise one or more chambers 70 , 75 disposed along a central axis 110 . In some embodiments, as shown in the figure a reactant passage 60 may comprise multiple chambers 70 , 75 arranged in succession. As used herein, “in succession” with respect to arrangement of multiple chambers means that a chamber outlet (described below) of a first chamber 70 is in fluid communication with a chamber inlet (described below) of a second chamber 75 . Though FIG. 1 depicts two chambers 70 , 75 in succession, it is contemplated to use only one chamber (not shown) or more than two chambers, such as in passage 60 a . Though two chambers are depicted in the figure, it should be understood that a reactant passage according to embodiments of the present disclosure need not be limited to four chambers.
[0072] Referring again to FIG. 1 , in some embodiments a reactant passage 60 may comprise at least one feed inlet 90 , 92 , through which fluids are introduced into the reactant passage 60 to be mixed as they flow through chambers 70 and 75 . Moreover, the reactant passage 60 may comprise at least one product outlet 94 , through which mixed fluids may leave the reactant passage 60 . As shown in FIG. 1 , the reactant passage 60 may include two inlets 90 and 92 and one outlet 94 disposed near opposite ends of the reactant passage 60 ; however, it is contemplated to include more or fewer inlets or outlets as well as to arrange the inlets and outlets at different locations on the reactant passage 60 .
[0073] Desirably, the steps in the disclosed method are performed in multiple fluidic modules, fluidically connected in series. For example, one (or more) modules is used for each of the main steps (generation of catalyst, epoxidation, quenching). Performing the reaction under continuous-flow conditions using multiple microreactor modules allows for easy optimization of the three reaction steps by performing each step in one (or more) modules well-suited to the respective step. Using such a continuous flow system with the resulting performance achievable decreases labor requirements, minimizes process volume and safety concerns, and permits continuous manufacturing of the compound, relative to competing batch techniques. With the tight thermal and process control provided in the microfluidic flow reactor, higher temperatures may be employed for epoxidation than are normally achievable, without too severe a reduction in enantioselectivity. The high temperatures allows for high yield of epoxides in short reaction times, boosting production rates. The use of a flow system also offers the possibility of easily increasing the production scale by simply “numbering-up” the number of systems. Specifically, use of Corning's Advanced-Flow™ Low Flow Reactor modules allows for potential scale-up from the low-flow modules used experimentally herein, through the G1, G2, G3 and G4 modules for a 300-fold or greater increase in production, under sufficiently similar fluid- and thermo-dynamic conditions to maintain the productivity advantages of the disclosed methods, before (external) parallelization of the reactor would be required.
[0074] In some embodiments, the compound made by the processes described herein comprises formula (III) or formula (IV):
[0000]
[0000] wherein R 1 , R 2 , m, x, and o are as described above, and Ar may be one selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes.
[0075] In some embodiments, the compound made by the processes described herein comprises formula (V):
[0000]
[0000] wherein R 1 , R 2 , n, m, x, and o are as described above.
[0076] Still another aspect comprises a method of making a compound of formula (VIII) or formula (IX):
[0000]
[0000] The method may include reacting a compound of formula (Xa) or formula (XIa):
[0000]
[0000] with a compound of formula (XIIa):
[0000]
[0000] or, alternatively, reacting a compound of formula (Xb) or formula (XIb):
[0000]
[0000] with a compound of formula (XIIb):
[0000]
[0000] wherein the process is done in a microreactor with a metal catalyst and wherein wherein the process is done in a microreactor with a metal catalyst and wherein each T is independently S, SO, SO 2 , Se, Te, BR 3 , PR 3 , NR 3 , CR 3 R 4 or SiR 3 R 4 , each R 3 and R 4 is independently hydrogen, substituted or unsubstituted alkyl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, substituted or unsubstituted alkenyl, each R 1 and R 2 are, independently, substituted or unsubstituted alkyl, substituted or unsubstituted alkenyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, alkoxy, alkylthio, acylamino, acyloxy, aryloxy, substituted or unsubstituted amino, carboxyalkyl, halogen, acyl, substituted or unsubstituted thiol, aralkyl, amino, ester, aldehyde, hydroxyl, thioalkyl, acyl halide, acrylate, carboxy, or vinyl ether, each R 5 is independently substituted or unsubstituted alkyl, each Z may be independently be O, S, Se, or substituted imine, each D may be independently selected from the group consisting of Br, Cl, and I, each y is independently an integer from 0 to 5, each X is independently an optionally substituted C 1 -C 40 linear or branched alkyl or heteroalkyl, or H, b may be independently less than or equal to 5 and greater than or equal to 1, each B and each Ar is independently an optionally substituted conjugated species.
[0077] In some embodiments, each b may be equal to 1. In some examples, each Z may be independently O, S, or substituted imines. In some embodiments, each Z is oxygen. In some cases, the optionally substituted conjugated species may be one selected from the group consisting of ethylene, butadiene, and acetylene. The optionally substituted aromatic species may be one selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes. Each R and X′ may be independently an optionally substituted C 6 -C 24 linear alkyl chain. In other embodiments, each R and X′ may be independently an optionally substituted C 13 -C 19 linear alkyl chain. The optionally substituted alkyl chain containing heteroatoms may be one selected from the group consisting of oligo(ethylene glycol), oligo(propylene glycol), and oligo(ethylene diamine). The substituted alkyl chains may include ketone, amine, ester, one or more unsaturations, halide, nitro, aldehyde, hydroxyl, carboxylic acid, alkoxy, or any combination thereof. Each x may independently be an integer from 8 to 250. In some embodiments, B or Ar is independently selected from the group consisting of an optionally substituted alkenyl. In some embodiments, each B and Ar is independently an optionally substituted aryl. In some embodiments, each B or Ar is independently selected from the group consisting of optionally substituted benzenes, pyrazoles, naphthalenes, anthracenes, pyrenes, thiophenes, pyrroles, thiozole, porphyrins, carbazoles, furans, indoles, and fused thiophenes.
[0078] In some embodiments of the aspects above, the metal catalyst may be selected from the group consisting of Pt, Pd, Ru, and Rh.
[0079] As described above, embodiments describe a series of synthetic steps. However, the methods disclosed herein are intended for purposes of exemplifying only and are not to be construed as limitations thereon. Those skilled in the art will appreciate that additional and/or other synthetic steps may be used or necessary in the synthesis of the compounds described herein. Some aspects of some embodiments may be synthesized by synthetic routes that include processes analogous to those well-known in the chemical arts, particularly in light of the description contained herein. Although specific starting materials and reagents are depicted in the schemes and discussion herein, other starting materials and reagents can be easily substituted to provide a variety of derivatives and/or reaction conditions. The starting materials are generally available from commercial sources, such as Aldrich Chemicals (Milwaukee, Wis.), or are readily prepared using methods well known to those skilled in the art (e.g., prepared by methods generally described in Louis F. Fieser and Mary Fieser, R EAGENTS FOR O RGANIC S YNTHESIS , v. 1-19, Wiley, New York (1967-1999 ed.), or B EILSIEINS H ANDBUCH DER O RGANISCHEN C HEMIE , 4, Aufl. ed. Springer-Verlag, Berlin, including supplements (also available via the Beilstein online database)). In addition, many of the compounds prepared by the methods described below can be further modified in light of this disclosure using conventional chemistry well known to those skilled in the art.
[0080] For example, precursors for the formation of the starting materials described herein may be made via conventional processes or alternatively, via microreactor-based processes. Examples of methods for forming starting materials are illustrated in Scheme 1 depicted below such that the product of Scheme 2 depicted below may be synthesized.
[0000]
Examples
[0081] Example 1 (prospective)—A prospective example of a method included herein is the synthesis described in Schemes 2 and 3 wherein the synthesis is done in a microreactor. In either case, n may be in a range of 1 to 200 or, for example, 1 to 50. For Scheme 3, each R is equivalent to R 1 , Ar is as defined herein, and Me is methyl.
[0000]
[0000]
[0082] Example 2—Scheme 4 is an example of a synthesis done via the embodied processes described herein.
[0000]
[0083] The microreactor setup comprises the following design: two solutions were pumped using a dosing lines made out of micro gear pumps (HNP mzr 7205) and mass flow controllers (Bronkhorst Coriolis mass flow controller M13). The solutions are kept under argon at all times. The reactor itself is an Advanced-Flow™ Low Flow Reactor composed out of a mixing module type LF SH and 8 residence time modules type LF R*H ( FIG. 2 ). At the reactor exit is a backpressure regulator utilized in order to increase the reaction temperature above boiling point. The reactor is dried before use by rinsing with ethanol for 2 hours. After 2 hours, the ethanol is replaced by heptane, which is replaced by toluene just prior to the experiment.
[0084] In order to aid in keeping the stoichiometric ratio between tin-FT4 and bromothienyl-DPP as close to 1:1 as possible, the two monomers are weighed into the same reservoir vessel and dissolved into chlorobenzene (toluene may also be used instead of chlorobenzene). The palladium pre-catalyst and additional phosphine ligands are dissolved into the same solvent in a separate reservoir vessel. The two solutions are carefully degassed with argon. In order to maintain these monomers in solution, it is necessary to pre-heat the combined monomers solution prior to introduction to the microreactor. The mixture is pre-heated to 60° C. to insure full dissolution and the maintenance of a solid free solution—necessary in order to maintain the stoichiometric monomer ratio and to prevent clogs in the pumps and tubing leading to the microreactor reaction plates. The monomer and catalyst feeds are then pumped at appropriate relative rates to give a 4 mol % ratio of single palladium species to monomers in the microreactor while the microreactor temperature is maintained at 160° C. The reaction is self-indicating, in that the mixed monomers are a bright pink color at temperature while the polymer is blue at low molecular weights and a dark green once full molecular weight is achieved. In this experiment material is collected from the outflow of the microreactor into an empty collection vessel and the polymer is then precipitated. However, the outflow could easily be dripped into a stirring solution of a non-solvent for the polymer that is miscible with the reaction solvent in order to induce precipitation of the polymer while solvating the residual catalyst species. Methanol mixed with acetylacetone may be used for this purpose.
[0085] It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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Synthetic processes for forming highly conjugated semiconducting polymers via the use of microreactor systems, such as microfluidic continuous flow reactors are described herein. The compounds synthesized include conjugated systems incorporating fused thiophenes and, more particularly, fused thiophene-based diketopyrrolopyrrole polymers, which are useful as organic semiconductors and have application in modern electronic devices.
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CROSS REFERENCE TO RELATED APPLICATIONS
N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
The present invention relates generally to secure or private communications, and more specifically to a system and method for providing ephemeral decryptability of documents, files, and/or messages.
In recent years, individuals and businesses have increasingly employed computer and telecommunications networks, such as the World Wide Web (WWW), to exchange messages. These networks typically include a number of intermediate systems between the source of a message and its destination, at which the message may be temporarily written to a memory and/or data storage device. Such intermediate systems, as well as the communications lines within the network itself, are often considered to be susceptible to actions of a malicious third party, which may result in messages being intercepted as they are carried through the network. For this reason, various types of data encryption have been used to secure communications through such networks. Encryption algorithms are also sometimes used to support integrity checking and authentication of received messages. Integrity checking allows the message recipient to determine whether the message has been altered since it was generated, while authentication permits the recipient to verify the source of the message.
Specific encryption algorithms are usually thought of as being either “symmetric key” or “public key” systems. In symmetric key encryption, also sometimes referred to as “secret key” encryption, the two communicating parties use a shared, secret key to both encrypt and decrypt messages they exchange. The Data Encryption Standard (DES), published in 1977 by the National Bureau of Standards, and the International Data Encryption Algorithm (IDEA), developed by Xuejia Lai and James L. Massey, are examples of well known symmetric key encryption techniques. Public key encryption systems, in contrast to symmetric key systems, provide each party with two keys: a private key that is not revealed to anyone, and a public key made available to everyone. When the public key is used to encrypt a message, the resulting encoded message can only be decoded using the corresponding private key. Public key encryption systems also support the use of “digital signatures”, which are used to authenticate the sender of a message. A digital signature is an encrypted digest associated with a particular message, which can be analyzed by a holder of a public key to verify that the message was generated by someone knowing the corresponding private key.
While encryption protects the encrypted data from being understood by someone not in possession of the decryption key, the longer such encrypted information is stored, the greater potential there may be for such a key to fall into the wrong hands. For example, key escrows are often maintained which keep records of keys. Such records may be stored for convenience in order to recover encrypted data when a key has been lost, for law enforcement purposes, to permit the police to eavesdrop on conversations regarding criminal activities, or for business management to monitor the contents of employee communications. However, as a consequence of such long-term storage, the keys may be discovered over time.
In existing systems, there are various events that may result in an encrypted message remaining stored beyond its usefulness to a receiving party. First, there is no guarantee that a receiver of an encrypted message will promptly delete it after it has been read. Additionally, electronic mail and other types of messages may be automatically “backed-up” to secondary storage, either at the destination system, or even within intermediate systems through which they traverse. The time period such back-up copies are stored is sometimes indeterminate, and outside control of the message originator. Thus, it is apparent that even under ordinary circumstances, an encrypted message may remain in existence well beyond its usefulness, and that such longevity may result in the privacy of the message being compromised.
Existing systems for secure communications, such as the Secure Sockets Layer (SSL) protocol, provide for authenticated, private, real-time communications. In the SSL protocol, a server system generates a short-term public/private key pair that is certified as authentic using a long-term private key belonging to the server. The client uses the short-term public key to encrypt a symmetric key for use during the session. The server periodically changes its short-term private key, discarding any previous versions. This renders any records of previous sessions established using the former short-term public key undecryptable. Such a system is sometimes referred to as providing “perfect forward secrecy”. These existing systems, however, provide no mechanism for setting or determining a finite “lifetime”, in terms of decryptability, for stored encrypted data or messages independent of a real-time communications session.
Accordingly it would be desirable to have a system for specifying a finite period after which stored encrypted data, such as electronic mail messages, cannot be decrypted. After such a “decryption lifetime” period expires, the encrypted data should become effectively unrecoverable. The system should provide the ability to specify such a decryptability lifetime on a per message, data unit, or file basis, independent of any particular real-time communications session. Additionally, the system should not transmit information in a manner that would permit an eavesdropper or malicious party to decrypt the information by obtaining a long term decryption key subsequent to expiration of an ephemeral key pair used in the respective encryption process.
BRIEF SUMMARY OF THE INVENTION
A system and method for providing ephemeral decryptability is disclosed. The presently disclosed system and method enables a user to encrypt a message in a way that ensures that the message cannot be decrypted after a finite period. The encrypted message that will become undecryptable after the finite period of time is referred to herein as an ephemeral message.
One or more ephemeral encryption keys are provided by an ephemerizer service or node to a party wishing to encrypt a message to be passed to a destination party. The node that provides the ephemeral service is referred to as an ephemerizer The ephemeral key or keys are each associated with an expiration time.
A first node communicates with a second node using the ephemerizer node as an “ephemerizer service”. The ephemerizer publishes a selection of ephemeral public/private key pairs, or generates ephemeral symmetric keys upon request. Each ephemeral key is associated with an expiration time. A party wishing to encrypt a message acquires one of the ephemerizer's ephemeral encryption keys with an appropriate expiration time. Alternatively, where none of the associated expiration times offered by the ephemerizer are appropriate for the message to be transmitted, the party wishing to encrypt that message may request an ephemeral key expiration time or range of expiration times, in which case the ephemerizer generates an ephemeral key having an appropriate expiration time and provides it to the requester.
Associated with each ephemeral key is a key identifier (Key Id). The Key ID is used by a client of the ephemeral service to inform the ephemerizer which key to use to decryption. If no Key ID is employed or specified, the ephemerizer may successively try to decrypt an ephemeral message using the keys available until the proper key is found. If there are only a relatively small number of keys, this method is feasible, if not optimal.
In a first illustrative embodiment in which a first node desires to transmit a message to a second node using the ephemerizer service, the second node proves knowledge of its private key by unwrapping certain information that is then forwarded to the ephemerizer. The ephemerizer then cooperates in the decryption process.
More specifically, the first node generates a first secret key and encrypts an information message intended for the second node with the first secret key. The first node then encrypts the first secret key with a public key associated with the second node and further encrypts the resulting string with an ephemeral public key having a desired expiration time to form an ephemeral key string. The first node further encrypts the ephemeral key string and the ephemeral public key with the public key associated with the second node to form an encoded key string and transmits to the second node the encrypted information message, the encoded key string and a URL that identifies the ephemerizer to be used in the decryption process.
The second node utilizes its private key to decrypt the encoded key string and additionally generates a second secret key for use in communicating with the applicable ephemerizer. The second node transmits to the ephemerizer at the ephemerizer URL the second secret key encrypted with the ephemeral public key and additionally, the ephemeral key string encrypted with the second secret key. The ephemerizer decrypts the second secret key using the applicable ephemeral private key and decrypts the ephemeral key string using the second secret key to obtain the ephemeral key string. The ephemerizer then decrypts the ephemeral key string using the ephemeral private key to obtain the first secret key that is encrypted with the second node public key. The ephemerizer then encrypts the encrypted first secret key with the second secret key and transmits the same to the second node.
The second node unwraps the first secret key received from the ephemerizer by first decrypting the string with the second secret key and then decrypting the resultant string with the second node private key to obtain the first secret key. The first secret key is used to decrypt the information message. The information message and the first secret key are deleted by the second node to prevent access to the message by an attacker who might discover the second node private key subsequent to the expiration of the respective ephemeral key pair.
In a second illustrative embodiment, the second node obtains the cooperation of the ephemerizer in decrypting the data needed to decrypt the message by proving to the ephemerizer that it possesses the private key associated with a public key that is securely associated with the encrypted data.
More specifically, in the second embodiment, the first node generates a first secret key and encrypts an information message intended for the second node with the first secret key. The first node then encrypts the first secret key with a public key associated with the second node to form an encrypted first secret key and further encrypts the encrypted first secret key and the second node public key with an ephemeral public key to form an ephemeral key string having a desired expiration time. The first node then transmits to the second node the encrypted information message, the ephemeral key string, the relevant ephemeral public key, the Key Id and information that identifies and is useful for location of the ephemerizer that is to be used in the decryption process.
The second node generates a second secret key for use in communicating with the ephemerizer. The second node then encrypts the second secret key with the ephemerizer public key to form an encrypted second secret key and encrypts the ephemeral key string with the second secret key to form an encoded key string. The second node next transmits to the ephemerizer a message that includes at least the encrypted second secret key and the encoded key string. The message that is transmitted by the second node is signed using the private key of the second node.
The ephemerizer decrypts the second secret key using the applicable ephemeral public key and then decrypts the encoded key string using the second secret key to obtain the ephemeral key string. The ephemerizer next decrypts the ephemeral key string using the applicable ephemeral private key to obtain the first secret key encrypted with the second node public key and to obtain the second node public key. The ephemerizer then verifies the signature of the second node using the second node public key obtained by decrypting the ephemeral key string. The verification of the second node signature using the second node public key assures that the second node is an authorized decryption agent for the encrypted message. Following verification of the second node signature, the ephemerizer encrypts the encrypted first secret key with the second secret key and transmits the result to the second node.
The second node unwraps the encrypted first secret key by first decrypting the string received from the ephemerizer with the second secret key and then decrypting the result with the second node private key. After obtaining the first secret key in the foregoing manner, the second node uses the first secret key to decrypt the encrypted message received from the first node. The information message and the first secret key are deleted by the second node to prevent access to the message by an eavesdropper who might otherwise discover the second node private key or the first secret key subsequent to the expiration of the respective ephemeral key pair.
Other aspects, features and advantages of the disclosed methods and systems will be apparent to those skilled in the art from the Detailed Description that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be more fully understood by reference to the following detailed description of the invention in conjunction with the drawings, of which:
FIG. 1 shows an ephemeral key pair list;
FIG. 2 is a block diagram of a system operative in a manner consistent with the present invention;
FIG. 3 depicts a block diagram of an exemplary computer system operative to perform the functions of the respective nodes and the ephemerizer depicted in FIG. 2 ;
FIGS. 4 a , 4 b and 4 c are a flow diagram that depict an exemplary method of operation of the system depicted in FIG. 2 ; and
FIGS. 5 a and 5 b are a flow diagram that depict another exemplary method of operation of the system depicted in FIG. 2 .
DETAILED DESCRIPTION
Consistent with the present invention, a system and method for providing ephemeral decryptability is disclosed which enables a user to ensure that encrypted information messages will become undecryptable after a certain point in time. In the presently described system and method, anyone that obtains access to a long term private key of an intended message recipient is unable to decrypt the information message subsequent to the expiration of the applicable ephemeral key pair.
As shown in FIG. 1 , an ephemeral key pair list 10 includes a number of ephemeral key pairs 12 . Each ephemeral key pair includes a public key 14 , a private key 16 . An expiration time 18 an a Key ID 20 are associated with each ephemeral key pair. The public key 14 of an ephemeral key pair and the associated expiration time 18 and Key Id 20 may be read by parties wishing to use an ephemeral key pair 12 . The private key 16 of each ephemeral key is accessible only to the ephemerizer 164 ( FIG. 2 ). As in conventional public key encryption techniques, data encrypted using one of the public keys 14 can only be decrypted using the private key 16 from the same ephemeral key pair. Each of the ephemeral key pairs 12 represents a promise by the publisher of the ephemeral key pair list 12 that the ephemeral key pair will be irretrievably destroyed at the associated expiration time.
Referring to FIG. 2 , the system includes a first node identified as Node A 160 , a second node that is identified as Node B 162 , and an ephemerizer 164 . Node A 160 , Node B 162 and the ephemerizer 164 are communicably coupled via a network 166 to permit communication among the nodes and the ephemerizer. The network 166 may comprise a local area network, a wide area network, a global communications network such as the Internet, a wireless or any other network suitable for communicably coupling the nodes 160 , 162 and the ephemerizer 164 . Moreover, the network 166 may include various types of networks, such as those identified above, as sub-networks within a larger network.
Nodes A 160 , Node B 162 and the ephemerizer 164 each typically comprise a computer system 170 , as generally depicted in FIG. 3 . The computer system 170 may be in the form of a personal computer or workstation, a personal digital assistant (PDA), an intelligent networked appliance, a controller or any other device capable of performing the functions attributable to the respective devices as described herein.
As depicted in FIG. 3 , the computer system 170 typically includes a processor 170 a that is operative to execute programmed instructions out of an instruction memory 170 b . The instructions executed in performing the functions herein described may comprise instructions stored within program code considered part of an operating system 170 e , instructions stored within program code considered part of an application 170 f , or instructions stored within program code allocated between the operating system 170 e and the application 170 f . The memory 170 b may comprise Random Access Memory (RAM), or a combination of RAM and Read Only Memory (ROM). The Nodes 160 , 162 and the ephemerizer 164 each typically include a network interface 170 d for coupling the respective device to the network 166 . The devices within the system may optionally include a secondary storage device 170 c such as a disk drive, a tape drive or any other suitable secondary storage device.
The operation of the system is illustrated by reference to FIGS. 2 and 4 a – 4 c . It is assumed for purposes of illustration that Node A 160 desires to send an ephemeral message to Node B 162 , that is, a message that will become undecipherable after some time. In this circumstance, Node A 160 ( FIG. 2 ) generates a first secret encryption key (SK 1 ) as depicted in step 200 ( FIG. 4 a ). The first secret encryption key has an associated decryption key. The first secret encryption key generated by Node A 160 is a temporary key and may be either a symmetric key or an asymmetric key. It is assumed for simplicity of illustration that the first secret encryption key comprises a symmetric key. As indicated in step 202 , Node A 160 next encrypts the message with the key SK 1 . Next, Node A encrypts the first secret key SK 1 with the public key (B-Public Key) of Node B 162 and encrypts the encrypted secret key SK 1 with the ephemeral public key (EPH-Public Key) to form X as illustrated in Step 204 . After encryption of the first secret key SK 1 with Node B's public key and the Ephemeral public key, as indicated in step 206 , Node A 160 transmits to Node B 162 the information message encrypted with the first secret key (SK 1 ), X and the ephemeral public key collectively encrypted with Node B's public key, the ephemeral public key and the address (URL) of the ephemerizer 164 . Node B then decrypts {X,Eph-Public Key}B-Public Key with Node B's private key to obtain X and the ephemeral public key as illustrated in step 208 . Node B 162 then generates or obtains a second secret key SK 2 for use in communicating with the ephemerizer 164 as depicted in step 210 . The second secret key SK 2 comprises a temporary key.
Node B 162 next transmits to the ephemerizer 164 the second secret key SK 2 encrypted with the ephemeral public key, X encrypted with the second secret key SK 2 and Node B's public key as illustrated in step 212 .
Following receipt of the above-identified transmission from Node B 162 , the ephemerizer 164 decrypts the second secret key (SK 2 ) using the ephemeral private key assuming that the ephemeral key has not expired as depicted in step 214 . The ephemerizer 164 next decrypts {X}SK 2 using the second secret key SK 2 to obtain X as depicted in step 216 . The ephemerizer 164 then decrypts X using the ephemeral private key (assuming that the respective ephemeral key has not expired) to obtain {SK 1 }B-Public Key as shown in step 218 .
As illustrated in step 220 , the ephemerizer 164 then encrypts {SK 1 }B-Public Key with the second secret key (SK 2 ) and sends the result to Node B 162 as depicted in step 220 . As shown in step 222 , Node B 162 then decrypts {{SK 1 }B-Public Key}SK 2 using the second secret key (SK 2 ) to obtain {SK 1 }B-Public Key. Thereafter, as illustrated in step 224 , Node B 162 decrypts {SK 1 }B-Public Key using Node B's private key to obtain the first secret key. Node B 162 then uses the first secret key to decrypt the message that was encrypted using the first secret key to obtain the unencrypted message as illustrated in step 226 . Finally, Node B 162 deletes the message, SK 1 and SK 2 to prevent another party from obtaining access to the first secret key that is needed to decrypt the message, as illustrated in step 228 . Node A 160 and the ephemerizer 164 also destroy SK 1 and SK 2 respectively, following completion of their respective tasks employing such temporary keys.
Via the above-described technique, once the first secret key is inaccessible there is no longer an ability to decrypt the encrypted information message. Moreover, once the ephemeral key expires, Node B 162 loses the ability to have to have SK 1 decrypted by the ephemerizer 164 and decryption of the encrypted information message is thwarted.
In the illustrated method the first secret key (SK 1 ) is encrypted with Node B's Public Key by Node A 160 as depicted in step 204 . Traditionally, when encrypting a message that is larger than a single RSA block with a public key, it is more efficient to encrypt the message with a secret key and to then encrypt the secret key with the respective public key. Thus, if the encryption of SK 1 with Node B's Public Key is not smaller than the ephemeral public key, it will take more than a single public key encryption operation to encrypt SK 1 . In this event, it is more efficient, rather than directly encrypting SK 1 with Node B's public key, to encrypt SK 1 with a randomly chosen secret key (SK 3 ) and to encrypt the secret key SK 3 with Node B's Public Key. In this event X={{SK 1 }SK 3 }Eph-Public Key, {SK 3 }B-Public Key. Given this optimization, Node A 160 would transmit to Node B 162 the following message:
{Message}SK 1 , {X, Eph-Public Key}SK 3 , {SK 3 }B-Public Key, Eph-URL
As a further optimization, Node A 160 may encrypt a digest of the ephemeral public key (MD(Eph-Public Key)) rather than the ephemeral public key itself and transmit the ephemeral public key as plain text. This process reduces the amount of information that needs to be encrypted with Node B's public key and reduces computational resources and time needed to perform the specified encryption. In such event the message transmitted by Node A 160 to Node B 162 in step 206 would be as follows:
{Message}SK 1 , {X, MD(Eph-Public Key)}SK 3 , {SK 3 }B-Public Key, Eph-Public Key, Eph-URL
An alternative embodiment for communication of an ephemeral message from Node B 162 to Node A 160 via a network 166 is illustrated in the flow chart of FIGS. 5 a and 5 b . In this embodiment, Node A securely conveys to the ephemerizer 164 a verification key associated with the intended recipient of the message (e.g. Node B). The verification key is used by the ephemerizer 164 to verify that the intended recipient is a proper recipient of the message. More specifically, referring to FIG. 5 a , as depicted in step 300 , Node A generates a first secret key SK 1 . The first secret key SK 1 is preferably a temporary key. As depicted in step 302 , Node A 160 encrypts a message intended for communication to Node B using the first secret key SK 1 . Subsequently, Node A calculates a value X′ that includes the first secret key (SK 1 ) encrypted with the Node B public key and also includes the Node B public key all encrypted with the ephemeral public key for the ephemerizer 164 , as illustrated in step 304 . The Node B Public Key is included to facilitate subsequent verification, by the ephemerizer 164 , of a message received from Node B and signed with the Node B private key in the circumstance in which the ephemerizer 164 is not in possession of that key.
As shown in step 306 , Node A then sends to Node B the message encrypted with the first secret key, X′, the ephemeral public key, the URL of the ephemerizer, and the applicable Key ID. The URL of the ephemerizer is included so that Node B 162 can identify the ephemerizer 164 to be used during the decryption (unwrapping) process. Node B then generates or obtains a second secret key SK 2 for use in communicating with the ephemerizer 164 as illustrated in step 308 . The second private key SK 2 is also a temporary secret key and in the illustrative embodiment is a symmetric key. Node B then sends to the ephemerizer 164 the second secret key SK 2 encrypted with the ephemeral public key and the string X′ encrypted with the second secret key SK 2 . The message transmitted to the ephemerizer 164 by Node B 162 is signed by Node B 162 using Node B's private key, all as depicted in step 310 . The ephemerizer 164 decrypts the encrypted secret key using the ephemeral private key to obtain the second secret key SK 2 as depicted in step 312 . The ephemerizer 164 then decrypts the encrypted string X′ using the second secret key SK 2 to obtain the first secret key encrypted with the Node B public key along with the Node B public key as illustrated in step 314 . The ephemerizer 164 verifies that the message is in fact from Node B 162 using Node B's public key as shown in step 316 ; i.e. that the request to unwrap the message is from an authorized decryption agent for the respective message.
The ephemerizer 164 , following verification of the signature, transmits to Node B 162 the first secret key encrypted with the Node B public key and further encrypted with the second secret key SK 2 as illustrated in step 318 . Node B 162 then decrypts the encrypted string received from the ephemerizer 164 using the temporary second secret key SK 2 to obtain the first secret key SK 1 encrypted with the Node B public key, as shown in step 320 . As illustrated in step 322 , Node B 162 then decrypts the encrypted first secret key using the Node B private key to obtain the first secret key SK 1 . Node B 162 is then able to decrypt the encrypted message received from Node A 160 using the first secret key to obtain the message in unencrypted form as depicted in step 324 .
Subsequently, as depicted in step 326 , Node B 162 deletes the decrypted message and the first and second secret keys to prevent the message from being retrieved after expiration of the relevant ephemeral key. Additionally, the Node A 160 and the ephemerizer 164 destroy secret keys SK 1 and SK 2 , respectively, when they have no further need for use of the respective keys. In the case of Node A, it may destroy SK 1 following transmission of the ephemeral message to Node B. In the case of the ephemerizer 164 , it may destroy SK 2 following transmittal of the partially decrypted encryption key to Node B 162 (i.e. following step 318 ).
Thus, in accordance with the alternative illustrated technique, the ephemerizer 164 will not cooperate in the decryption process unless the entity requesting decryption (in the illustrative embodiment Node B 162 ) proves it has the corresponding private key. More specifically, in the illustrative embodiment, the ephemerizer 164 returns the value it has decrypted using its ephemeral private key. The value being returned is encrypted with the second secret key SK 2 chosen by Node B 162 for communication with the ephemerizer 164 . In the foregoing manner, no eavesdropper or impersonator sees the first secret key encrypted with a long-term key alone absent additional encryption with the second temporary secret key SK 2 . Upon deletion of the temporary keys SK 1 and SK 2 and following the expiration of the ephemeral period, the message become undecipherable and highly secure ephemeral communication is assured.
It should be understood that the optimization techniques described with respect to FIGS. 4 a – 4 C may also be employed in connection with the alternative embodiment depicted in FIGS. 5 a – 5 b.
If a large string of information is to be encrypted, it is more efficient to encrypt the string with a secret key and to then encrypt the secret key with the appropriate public key of a public/private key pair than to encrypt the string directly with the public key. It is recognized that, although in the disclosed embodiments, the data is encrypted with a secret key that is, in turn, encrypted with the public key of the ephemerizer, the data could have been encrypted with the ephemeral public key directly. This approach is feasible if the length of the data string to be encrypted is relatively short or if processing latency does not pose a problem. Thus, it is recognized that the string may comprise information desired to be communicated to an intended recipient or alternatively a secret key used to encrypt such information.
Those skilled in the art should readily appreciate that the programs defining the functions of the present invention can be delivered to a computer in many forms; including, but not limited to: (a) information permanently stored on non-writable storage media (e.g. read only memory devices within a computer such as ROM or CD-ROM disks readable by a computer I/O attachment); (b) information alterably stored on writable storage media (e.g. floppy disks and hard drives); or (c) information conveyed to a computer through communication media for example using baseband signaling or broadband signaling techniques, including carrier wave signaling techniques, such as over computer or telephone networks via a modem. In addition, while the invention may be embodied in computer software, the functions necessary to implement the invention may alternatively be embodied in part or in whole using hardware components such as Application Specific Integrated Circuits or other hardware, or some combination of hardware components and software.
A destruction capability may be provided in a hardware device which stores at least the ephemeral decryption keys and which only allows them to be read after receiving proof of a current time prior to the expiration time, or which erases the memory in which the ephemeral decryption keys are stored at their associated expiration times or renders such decryption keys inaccessible such that they cannot be recovered, for example by powering down a volatile memory in which the ephemeral keys are stored or otherwise rendering the applicable ephemeral decryption key inaccessible.
While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Specifically, while the illustrative embodiments are disclosed with reference to messages passed between users of a computer network, the invention may be employed in any context in which messages are passed between communicating entities.
Moreover, while the embodiments are described in connection with various illustrative data structures, one skilled in the art will recognize that the system may be embodied using a variety of specific data structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.
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A method and apparatus for securely communicating ephemeral information from a first node to a second node. In a first embodiment, the first node encodes and transmits an ephemeral message encrypted at least in part with an ephemeral key, from the first node to the second node. Only the second node has available to it the information that is needed to achieve decryption by an ephemeral key server of a decryption key that is needed to decrypt certain encrypted payload information contained within the message communicated from the first node to the second node. In a second embodiment the first node transmits to the second node an ephemeral message that is encrypted at least in part with an ephemeral key. The ephemeral message includes enough information to permit the second node to communicate at least a portion of the message to an ephemeral key server and for the ephemeral key server to verify that the second node is an authorized decryption agent for the message. After verifying that the second node is an authorized decryption agent for the message, the ephemeral key server returns to the second node an encrypted decryption key that is needed to decrypt the encrypted message. The ephemeral message may comprise an encrypted decryption key that may be used after decryption of the decryption key to decrypt other encrypted information communicated to the second node.
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This application is a continuation-in-part of my copending application Ser. No. 040,129 filed Apr. 20, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to weapons of the type having a reciprocating block which recoils under the influence of an exploding shell in the chamber against a spring force holding it closed against the breech. As the breech block recoils, it picks up the spent shell casing and ejects it thus clearing the chamber to receive another shell. When the block moves forward again under the influence of a recoil spring, it picks up another shell and moves it into the chamber in position to be fired. Of particular interest are those weapons having reciprocating breech blocks that can accommodate the modern thin-jacketed shells containing a so-called "magnum" load which, when fired, generate sufficient pressure in the chamber to expand the casing and cause the weapon to jam.
2. Description of the Related Art
A .45 caliber pistol develops approximately 390 foot pounds of muzzle energy using a 185 grain bullet which will have a muzzle velocity of around 950 feet per second. This is a very popular weapon, however, it is expensive to shoot in that, at the present time at least, shells of good quality sell for somewhere between $25.00 and $30.00 for a box of fifty.
The Winchester Arms Company introduced a few years ago what is known as a .22 magnum cartridge which presently sells for only about $5.00 for a box of fifty yet, in many respects, it performs comparably to the traditional .45 caliber shell. Using only a 40 grain bullet, it develops 392 foot pounds of muzzle energy and has a 2000 foot per second muzzle velocity using a slow-burning rifle powder. Prospects are that the same cartridge filled with a fast-burning powder charge of equal size will develop muzzle energy of 2000 foot pounds and will have a muzzle velocity of 3200 to 3500 feet per second.
Unfortunately, there have been a lot of problems associated with this particular cartridge caused largely by the fact that it has a very thin-walled jacket and is quite long. What happens is that the casing cannot withstand the bore pressure and, if the block is not held securely in place against the breech for an interval that permits the pressure generated in the bore to decrease substantially, the head of the cartridge casing blows off leaving the rest of the empty jacket in the chamber since there is nothing left for the extractor to get a hold of to extract it. The next cartridge fed into the chamber either jams as it tries to enter the portion of the jacket left behind or, alternatively, the shell fires with the block only partially closed thus causing a serious and potentially very dangerous situation for the shooter. Neither of these options is acceptable and, therefore, there is a need for a solution to this problem of the head of the shell being blown off due to premature opening of the breech.
It can be shown that the pressure pulse associated with rapid burning of the powder contained within the shell casing builds almost instantaneously to a peak and then decays somewhat more slowly as the bullet leaves the muzzle and thereby creates an ever-increasing volume for the gases to expand into. There is, of course, some pressure at which the head of any cartridge will blow off if left unconfined in the chamber of the weapon. Fortunately, most cartridges are designed to withstand the pressure at which damage thereto would occur either by lessening the powder charge or increasing the strength of the shell casing or both. In some thin-jacketed shells filled with a proportionately greater powder charge like the one previously described, this is not the case and the casing can, in fact, rupture if not fully confined in the chamber until the pressure decays to a level at which it is safe to permit the block to back off and open the breech.
The so-called "recoil" of a weapon is that reactive force which causes it to move rearward as the result of the forward motion of the bullet as it exits the barrel and the pressure applied to the breech block by the rapidly-expanding gases trapped in the barrel between the bullet and its now-empty casing. Firearms, especially the handheld type, are equipped with various types of recoil-absorption mechanisms, some mechanical, others hydraulic and, in the case of certain high-powered cartridges, part of the recoil is customarily absorbed by bleeding off a portion of the muzzle pressure and conducting it to a position behind the block. Regardless of the type of recoil-absorption mechanism used, its primary function is that of a shock absorber. In automatic and semi-automatic weapons, on the other hand, the recoil-absorption mechanism is also used to perform the additional function of returning the block to its firing position covering the breech during which excursion it picks up an unfired shell and moves it into the chamber. Whatever the function or functions to be performed by the recoil-absorption mechanism in a firearm, of critical importance is always that of holding the block in place such that it holds the cartridge in the chamber for the interval required, no matter how brief, until the pressure inside the barrel has dissipated to a level at which it can be safely opened. This all-important function is adequately addressed by many recoil-absorption systems designed for use with ordinary ammunition; however, these same systems have proven to be inadequate and very dangerous when employed with thin-jacketed high-powered ammunition. Moreover, just solving the problem of holding the block closed until the muzzle pressure dissipates to a level where the breech can be safely opened is not the entire answer because its solution fails to address the remaining problem of how to best and most efficiently handle the recoil of the block without undue shock to the shooter or an overall loss in accuracy, especially in those rapid-fire firearms having one that reciprocates very quickly.
The prior art systems known to applicant for controlling the excessively high muzzle pressures generated by these modern thin-jacketed cartridges have all been based upon the principal of, first of all, not letting the muzzle pressure build up to the level at which it can damage the shell casing followed by delaying the opening of the breech in some fashion until the muzzle pressure is further reduced to a point at which the breech can be safely opened. Specifically, the muzzled pressure is limited to a level significantly below that which the powder charge would otherwise produce in a closed system by bleeding off a portion of the gas pressure ahead of the bullet as it moves toward the muzzle. While this pressure is confined, nevertheless, it expands into a volume outside the barrel thus lessening the pressure therein well below that which would exist if such an "escape" were not provided. The maximum muzzle pressure is, therefore, limited unless, of course, the by-pass system gets plugged up which, frankly, happens very quickly after only a relatively few rounds are fired.
The delay system that is used to hold the block in closed position momentarily until the muzzle pressure further dissipates to a level at which the breech can be safely opened oftentimes comprises a mechanical system of some sort that remains locked until the muzzle pressure bled off from the barrel is shunted around to open it and thus allow the block to retract. Such systems have little, if anything, to do with the absorption of the recoil, only the reduction of the excess muzzle pressure and putting it to use in delaying the opening of the breech. As a matter of fact, essentially the full impact of the recoil is transferred to the shooter through the block and mechanical system holding it closed since, for all practical purposes, nothing in the system yields and provides a shock absorbing function until most of the muzzle pressure has dissipated and its effect has already been felt. In these systems, once the block has been released, its rearward movement is usually slowed down by a conventional spring-biased recoil-absorption mechanism, however, at this point most of the damage has been done and there is very little left in the way of recoil to absorb.
The main difficulty with these systems is that they just do not work. As the powder ignites, all sorts of solid residues are generated which very quickly clog up the bleed-off system rendering it completely, or at least partially, inoperative. Moreover, as the bleed ports and passages become more and more plugged up, the muzzle pressure rises and the whole system fails to achieve that for which it was designed. These systems are most often found in rapid-fire automatic or semi-automatic weapons of the type used by the armed forces, law enforcement people and special security agencies, none of which can tolerate a weapon that cannot be relied upon. Also, the ineffectiveness of these weapons to handle the recoil properly is a major factor in their being highly inaccurate even at short range.
Other systems for handling recoil are purely mechanical and do not involve bleeding off a portion of the muzzle pressure. Some even incorporate block-opening delay mechanisms of one type or another which cooperate with the conventional spring-biased recoil absorption systems to momentarily delay the opening of the breech at which time they become wholly inoperative. As such, they have little or no effect in terms of recoil absorption for the simple reason that they permit nearly all of the reactive forces to pass directly through to the primary recoil absorption system and back to the shooter at the very time these forces are at near their maximum level. In other words, just about the time that the shooter needs the most recoil protection, the supplementary mechanical delay mechanism has ceased to function thus leaving the primary spring-biased conventional system to take care of the major portion of the recoil all by itself. Equally significant, however, is the inability of such systems to hold the block closed under the abnormally high pressures generated inside the barrel of a weapon firing the modern thin-jacketed magnum ammunition. While recoil absorption is important and a much sought-after characteristic in a firearm, especially automatic and semi-automatic ones in terms of accuracy, it is, nevertheless, subordinate to the absolute necessity for holding the breech block closed against the excessive internal pressures generated by the modern-day thin-jacketed ammunition. Insofar as applicant is aware, the only solution to this problem up to the present time involves reducing the peak pressure by bleeding off a portion of the gases generated inside the barrel and using these gases to assist the primary spring-biased recoil system in holding the breech closed until such time as it can be safely opened without blowing off the head of the shell casing.
A properly designed recoil system, whether used for high-powered thin-jacketed ammunition or conventional loads must, of necessity, take into account several other factors such as, for example, the mass and weight of the block versus the length of the weapon and the size of the spring required to bring it to a stop; the rapidity with which the block reciprocates which is also a function of its weight and the spring-bias acting to return it to closed position; the reactive forces which have to be absorbed in order to bring the block to a stop before it strikes some abutment, etc. All of these factors involve trade-offs to some greater or lesser degree but it all gets back, eventually, to initially containing the explosive forces without letting the breech open prematurely and thereafter cancelling out as best one can the reactive forces generated by the confined explosion in the barrel before they reach the shooter.
Accordingly, there is a pressing need for a gasless recoil system for use with firearms of the reciprocating breech block type that is effective for use with all types of ammunition but which is especially useful to contain those excessive forces generated in the barrel by the thin-jacketed ammunition without permitting the breech to open prematurely resulting in the weapon jamming or, worse, causing injury to the shooter. Of secondary importance, but nonetheless significant, is to design such a system which will, in addition, dampen out the reactive forces generated by the explosion inside the barrel thus improving the accuracy of the weapon and the comfort associated with firing it while, at the same time, keeping it light, compact and, in the case of rapid-fire weaponry, manageable in the sense of not firing too fast.
3. Objects of the Invention
It is, therefore, the principal object of the present invention to provide a novel and improved gasless recoil absorption system for firearms of the type employing reciprocating breech blocks.
A second objective of the invention herein disclosed and claimed is that of providing a system of the type aforementioned which is especially useful in those weapons firing thin-walled magnum cartridges.
Another object of the within-described invention is the provision of a recoil absorption system which includes both primary and secondary spring-biased subassemblies, both of which are initially operative to slow down as well as resist the reactive forces acting upon the breech block as it moves away from the breech until these forces are overcome to a degree where those which remain can be handled by the primary system alone whereupon the secondary subassembly becomes essentially inoperative.
Still another object is to provide a purely mechanical recoil absorption system which, due to its unique division of the task of overcoming the reactive forces acting upon the breech block in two or more stages, results in a much more compact yet essentially recoilless weapon having greatly increased accuracy particularly in the rapid-fire automatic and semi-automatic modes.
Yet another object is to provide an automatic weapon which is easier to handle and far more accurate than other rapid-fire weapons of the same caliber, yet, has the fire power of much larger caliber so-called "Class 3" firearms which are more commonly described as "machine guns".
A further objective is that of providing a more compact spring recoil absorption mechanism involving two or more stages of bias cooperating with one another to effectively slow down and eventually stop and reverse even a heavy breech block in a very short distance without, at the same time, shortening the recoil cycle in an automatic weapon to the degree where the rate-of-fire becomes excessive and perhaps faster than that at which the spent shell casing can be ejected and a new round picked up and inserted into the chamber without jamming.
Other objects of the invention forming the subject matter hereof include those of providing a handheld repeating weapon which is readily adapted for use with ammunition of different calibers, loads and shell casings; can be fired a round at a time, semi-automatically or automatically; and a weapon of the type aforementioned which is safe, rugged, compact, versatile, reliable, easy to use and even decorative.
SUMMARY OF THE INVENTION
The foregoing along with other objects are accomplished by the simple, yet unobvious, expedient of providing a gasless purely mechanical recoil absorption system divided into two or more stages which initially are combined and cooperate with one another to not only hold the breech block in position holding the shell in the chamber for the time interval required for the major part of the muzzle pressure to diminish to a level at which the breech can be safely opened but, in addition, continue to cooperate after the block is forced back away from the breech to slow down as well as counteract the remaining reactive forces still acting thereon during a further brief interval until those which remain fall off to a point where one or more of these stages can drop out and become essentially inoperative while the sole remaining stage absorbs whatever recoil is left. Also, after the last of the stages has functioned to stop the rearward excursion of the block and has started it back toward its firing position, the stage or stages that have dropped out recombine therewith to accelerate the block forward and thus speed up the firing cycle while, at the same time, adding the additional force therebehind needed to pick up a new shell and move it into the chamber.
By staging the recoil absorption system, several desirable ends are achieved. By combining the stages initially to hold the breech block in closed position, a very compact system results which is effective to keep the breech covered while the pressure falls to a level at which it can be safely opened even in those instances where thin-jacketed ammunition is used with magnum loads that would otherwise blow the head off the cartridge if the breech were permitted to open prematurely. Such a staged system has proven effective to handle the excessively high muzzle pressures generated by the magnum loads without having to bleed off a portion in order to prevent premature opening of the breech.
While by no means restricted in any way to use with the modern thin-jacketed ammunition carrying magnum loads, the staged, gasless recoil absorption system of the present invention is, nevertheless, especially useful in such applications and in those rapid-fire automatic weapons of the "Class 3" type which traditionally are bulky, difficult to handle and highly inaccurate. A key to the increased accuracy achievable with the staged system forming the subject matter hereof is the fact that the stages continue to cooperate and coact with one another even after the breech has been uncovered to rapidly retard the rearward movement of the block over a very short distance while simultaneously absorbing those reactive forces acting thereon to a degree where a single stage can handle what is left by itself. It is also significant to note that it is during this interval when the block is moving rearwardly most rapidly and the spent shell casing is being extracted from the chamber and ejected, that two or more of these spring-biased systems are acting together to slow down the rearward excursion of the block thus lengthening the first half of the firing cycle. Equally important is what happens on the return stroke of the block during the last half of the firing cycle. Instead of a single stage of spring bias being employed to return the block to its firing position, the stage or stages which have dropped out recombine therewith to speed the block home and provide additional impetus thereto at the very time such additional "kick" is needed to pick up a new round which is heavier than the spent cartridge case due to its powder charge and bullet and insert it into the chamber. Were it not for this staging of the recoil absorption sequence, a much heavier recoil spring would have to be used thus oftentimes speeding up the firing cycle to a degree where it becomes impossible to handle the mechanical functions of ejecting the spent shell casing and picking up a new round.
Looking at applicant's novel recoil absorption system in another way, it consists of at least five different stages of control over the movement of the block during its firing cycle, two of the control stages involving only a single spring-biased recoil subassembly functioning as it has in the past, namely, to bring the block to a stop, reverse its direction and start it back forward. In the first control stage, on the other hand, no less than three elements cooperate to hold the block closed until the muzzle pressure diminishes to a level at which the breech can be safely opened. These are, first of all, the primary spring-biased subassembly present in many, if not most, of the prior art reciprocating block weapons; applicant's secondary spring-biased subassembly which acts in concert with the first while the breech block is closed and for an interval thereafter; and, the block itself which due to its mass and its being "at rest" requires a certain amount of additional force to get it moving beyond that which is required to keep it moving. Thus, the first stage is that in which the first and second spring-biased recoil subassemblies cooperate with one another and with the mass of the block itself to hold the latter closed until the muzzle pressure has diminished to a level at which the breech can be safely opened.
The second of the control stages is that in which the block has begun to move and the initial force required to overcome its starting friction has been overcome. During this early movement, the block is also dissipating some of the energy imparted thereto by the explosion in the chamber to extract the spent shell casing. Nevertheless, it is still moving back away from the breech at its fastest rate and additional retardant force is desirable to slow it down. It is during this interval that two or more of the spring-biased recoil subassemblies act in concert with one another to slow down the movement of the block.
The third control stage is where all but one of the two or more stages which have been acting in concert with one another to slow the movement of the block to a level where a single stage can take over have dropped out of the system and become essentially inoperative while the one remaining slows the block to a stop.
The fourth stage is one in which a single spring-biased subassembly is all that is functional but acting in the opposite direction to begin returning the block to its closed position. As previously noted, the third and fourth stages are conventional and performed by almost all of the existing single stage spring-biased recoil absorption systems.
The fifth stage is, once again, unique and consists of that in which the inoperative stages become operative again to cooperate with the one that has remained active throughout the block travel to assist the latter in picking up a new unfired shell and assist it in the insertion thereof into the chamber as the block closes against the breech. As these subassemblies cooperate with one another in the manner just mentioned, the return of the block is speeded up at the point in the firing cycle when it only has the recoil system acting upon it. The net result is, of course, that the block is slowed down during the first half of the firing cycle when it is moving the fastest under the influence of the reactive forces generated within the barrel but is speeded up during the last half when it has only the recoil system acting upon it. Thus, the total cycling time will remain much the same and not be speeded up to a point where problems begin to occur, yet, the half-cycle intervals will be altered considerably in a manner which is most advantageous. Also, as will be seen presently, additional control cycles can be added by having two or more spring-biased subassemblies that drop out and become active again sequentially.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary top plan view of a rapid-fire weapon having a reciprocating breech block, the firing cycle of which is controlled in stages by two spring-biased recoil absorption systems that function together during portions of the cycle while one drops out and the other acts alone during other portions thereof;
FIG. 2 is a fragmentary top plan view much like FIG. 1 and to the same scale but differing therefrom in that the coverplate and breech block have been removed to reveal the barrel, the support for the latter, the rails atop which the breech block rides and the extractor subassembly;
FIG. 3 is still another fragmentary view to the same scale as FIGS. 1 and 2 showing the firearm in elevation with extensive portions thereof broken away and revealed in section;
FIG. 4 is a section taken along line 4--4 of FIG. 3;
FIG. 5 is a section taken along line 5--5 of FIG. 3 but to a much larger scale than the other figures;
FIG. 6 is a fragmentary top plan view, portions of which have been broken away and shown in section, revealing another embodiment of the secondary spring-biased recoil subassembly wherein three stages of recoil absorption and breech block acceleration are provided instead of just two;
FIG. 7 is a fragmentary perspective view to a somewhat larger scale showing the three stage version of FIG. 6;
FIGS. 8, 9 and 10 are fragmentary elevational views similar to FIG. 3, but to a larger scale, showing the recoil portion of the firing cycle of the three stage subassembly of FIG. 6 and 7;
FIG. 11 is a fragmentary top plan view similar to FIG. 6 but to a slightly larger scale, and also having portions broken away and shown in section, directed to another two stage spring-biased recoil absorption subassembly which differs from that of FIGS. 1-5 in that it doubles-up the spring bias exerted during the second and fifth breech block control stages;
FIG. 12 shows the last half of the firing cycle in which the breech block is accelerated forward by the two-stage subassembly of FIG. 11; and,
FIGS. 13 and 14 are fragmentary side elevational views with portions broken away to show the breech block return sequence of FIGS. 11 and 12 from the side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring next to the drawings for a detailed description of the present invention, reference numeral 10 has been chosen to broadly identify the firearm forming the subject matter hereof in its entirety while numeral 12 designates the handle housing the multi-round clip 14. A generally box-like rectangular housing or receiver indicated in a general way by reference numeral 16 is made up of front and rear endwalls 18 and 20, respectively; a bottom wall 22; right and left sidewalls 24 and 26, respectively; and, a detachable top wall or coverplate 28. Inside this receiver is housed all the functional mechanisms of the unit.
Rear wall 20 is shown provided with a cushioned bumper 20B. A block 30 is located at the front end of the housing and it together with collar 32 on the outside of front wall 18 cooperate with one another to mount the barrel 34 which passes through axially-aligned openings in these three elements as seen most clearly in FIG. 3. In FIGS. 2, 3 and 4, it can be seen that the rear end of the barrel is supported in saddle 36 which projects up through trigger slot 38 in the bottom wall 22 and forms a part of the handle subassembly. The handle 12 comprises a hollow generally elongate tubular sheath that opens into the housing through this same slot 38 in the bottom wall 22 which is widened out some to accommodate the upper end of the clip 14 as well as the shells 40 (FIGS. 1 and 3) contained therein. A handgrip 42 is shown in FIG. 3 covering the handle 12 as is customary with such firearms. The clip 14 is conventional and, of course, includes a spring-biased follower of some type (not shown) that feeds a stack of cartridges 40 one-at-a-time into position to be picked up by the advancing breech block 44 and fed into the shell chamber 46.
One of the most significant improvements present in the firearm 10 is the frame indicated broadly by reference numeral 48 which rests in the bottom of the housing 16 and provides support for the breech block 44 as well as what will be called the "secondary recoil subassembly" that has been identified in a general way by reference numeral 50 and which will be described in detail presently. This frame is held in place front and rear by pins 52 passing across between the sidewalls as shown in FIG. 3. The sides of the frame define a pair of transversely-spaced parallel rails 54 atop which the breech block rides and slides as it moves forwardly into firing position and rearwardly into retracted position during which excursion it grabs a hold of and ejects the spend cartridge case preparatory to picking up another round.
Just to the rear of the point on the bottom wall 22 of the receiver 16 where the clip 14 emerges is located the secondary recoil subassembly 50. Structurally, it can be seen seated on bottom wall 22 of the receiver between the rails 54 of the frame. It has a U-shaped yoke 56 that opens forwardly as seen in FIGS. 1 and 2. Extending across between the legs 58 of this yoke will be found pivot pin 60. Mounted upon this pivot pin 60 is a rocker arm 62. This rocker arm is mounted on pin 60 at a point between its ends for rockable movement to-and-fro between the full-line and the phantom line positions of FIG. 3 about an axis at its lower end defined by a second pivot pin 64. In this manner, the rocker arm defines a lever of the type having a fulcrum at one end thereof and one of the opposing forces located adjacent to the other end with the other opposing force located between the fulcrum and the other end of the lever. A post 66 projects rearwardly from the crossframe element 68 of the yoke 56 and it passes through an opening 70 in crossweb 72 of the frame as seen in FIG. 3. Between the rear face of the crossframe element 68 of the yoke 56 and the crossweb 72 of the frame is a compression spring 74. Movement of the rocker arm 62 between its full-line and phantom-line positions about pivot pin 64 causes the yoke to reciprocate back and forth thus alternately compressing and relaxing compression spring 74. It is significant to note that the upper end of the rocker arm is bifurcated as seen in FIGS. 1 and 2 to receive a roller 76 which rides along the rear face 78 of the block 44 and along the underside or bottom 80 thereof in a manner and for a reason which will be discussed below.
Also housed within the frame 48 between rails 54 is the trigger subassembly broadly referred to by reference numeral 82 and which includes the trigger 84 itself, the previously-identified cradle 36 that supports the rear end of the barrel, a forked sear member 86, a spring 88 and pivots 90 and 92. Trigger 84 is mounted for pivotal movement about a transverse axis between the full-line and the phantom line positions of FIG. 3 within the trigger slot 38 on pivot pin 90. In a similar manner, sear 86 is mounted for rockable movement at a point between its ends on pivot pin 92 that passes through the cradle 36. The bifurcated arms 94 of the sear extend rearwardly alongside the saddle as seen in FIG. 2 and fit into cutout portions 96 of the rails 54 of frame 48. As such, these arms when in the actuated or full-line position of FIG. 3, define continuations of the aforementioned rails 54 upon which the breech block 44 slides as it moves forward from the phantom-line position to pick up a shell from the magazine 14 and carry it forward into the shell chamber 46 where the breech block is shown in full lines. Alternately, in the cocked position of block 44 shown in phantom lines in FIG. 3, a pair of springs 88 resting in the bottom of the receiver function to bias the rear ends of the bifurcated arms upwardly and out of the plane of rails 54 (phantom line position) thus presenting transversely-spaced abutments blocking the forward movement of the block. This is also the phantom-line position of the trigger 84. When the trigger is pulled into its full-line position, the upwardly-facing ledge 98 located behind pivot pin 90 rotates counterclockwise around the latter and engages the front end of the sear thus raising its front end and lowering its rear end in opposition to the bias exerted thereon by the springs 88. As this takes place, the bifurcated arms 94 return to the full-line position shown in FIG. 3 lying in the plane of the rails 54 thereby removing the stops it provides that prevent forward movement of the breech block so that primary recoil spring 100 carried on spring-alignment rod 102 can push it forward into firing position.
As the breech block advances toward the shell chamber 46 driven by primary recoil spring 100, one of the first things that happens is that it will strip a shell 40 from the top of the magazine 14 as the longitudinally-extending rib 104 (FIGS. 3 and 5) projecting beneath the latter moves between opposed inturned tabs 106 in the top of the clip that hold the stack of shells in place against the spring-biased action of its follower that raises them up, all but the follower of which can be seen most clearly in FIGS. 1 through 3 and 5. As the top shell in the stack is stripped out of the magazine, either the follower underneath or the next shell in the stack defines a ramp which guides the shell into the chamber. The leading end of rib 104 carries the firing pin 116 which is in engagement with the head of the shell containing the primer. The breech block, advancing under the bias exerted on its rear end by both primary recoil spring 100 together with secondary recoil spring 74 which has become active in the interim, drives the firing pin into the primer contained in the head of the shell as it seats in the breech end of the barrel where the shell chamber 46 is located and stops. In so doing, of course, the shell fires in the conventional manner. It is significant to note that as the primary recoil spring 100 is extending and exerting less and less of a forwardly-propelling force against the breech block, the secondary recoil spring 74 reactivates and speeds up the return of the block into firing position.
The breech block has a longitudinally-extending opening 110 extending from end-to-end thereof as seen in FIGS. 3 and 4. The underside of this block is hollowed out part way back to form an arch-shaped pocket 112 seen most clearly in FIG. 5 which rides over and receives the top of the barrel 34 as the block advances to its full-line firing position, the firing pin 116 being positioned at the blind end of this pocket along with the rib 108 that strips the shell from the magazine and the extractors 114 and 116, seen best in FIGS. 1 and 5. Spring alignment rod 102 is loosely received in opening 110 and extends from the block 30 rearwardly all the way to the rear wall 20 of the receiver. Guiding of the block during its forward and rearward excursions is not a function of the spring alignment rod, but rather, the rails 54 and 94 in the bottom of the receiver, the sidewalls 24 and 26 of the latter and rails 118 (FIGS. 4 and 5) formed on the underside of the coverplate 28. Opening 110 is counterbored from the rear end of the block to a point spaced slightly behind its front end to enlarge same and provide a spring abutment shoulder 120 along with an annular space 122 around the spring alignment rod sized to receive primary recoil spring 100. Accordingly, as can be seen in FIG. 3, when the block moves rearwardly on its recoil stroke, the rod 102 remains fixed while the spring abutment shoulder compresses spring 100 coiled around the latter.
Digressing for a moment at this point, it is worthy of note that in those constructions where a single recoil spring-like spring 100 is used to absorb the recoil of the block, stop the latter and reverse the direction thereof before it strikes the rear endwall cushion 20B, the block would either have to be very light and have little mass, or the recoil spring would have to be very strong or very long resulting in the weapon itself being quite long. Unfortunately, especially in an automatic weapon, there is little choice left in the matter. For instance, if the block is heavy and a strong recoil spring is used to stop and reverse it in a short distance, it will cycle so rapidly that it becomes relatively impossible to extract and eject the empty shell casings and feed the unfired shells fast enough. Conversely, using a light block and a light recoil spring to stop and reverse it over a short distance not only does not solve the excessively rapid-firing problem, but more important, the block cannot withstand the muzzle pressure without blowing open prematurely. This is an especially acute problem with high power ammunition like the thin-jacketed .22 magnum cartridge.
By way of example of the above, a very popular machine gun is the so-called 9 mm UZI. It is well over 17 inches long and fires at a rate of about 650 rounds per minute. At this rate it can be controlled but requires a good deal of training to do so. Shortening the weapon to only 13 inches raised the firing rate to well in excess of 1500 rounds per minute and it could not be controlled by even an expert in rapid-fire weaponry. Accordingly, up to the present time, all such weapons having a single recoil spring use a rather massive block that travels over a long distance while the recoil is being dissipated and, therefore, an overly long weapon is the result; however, on the positive side, it is one that has a reasonable rate of fire and can be controlled.
Some mention has already been made of the rather unique problems associated with the present .22 magnum ammunition which is thin-walled and long besides using a slow burning powder. The slow burning powder becomes a factor because it is quite "dirty" when compared to fast burning powders meaning that it leaves a considerable residue inside the barrel. Space restrictions inside the barrel of a small caliber gun demand that any port for the purpose of bleeding off excess pressure be very small. The net result is that they clog up easily causing the gun to malfunction, often after firing only 30 or 40 rounds. The present inventor s two or multi-stage purely mechanical system obviates the difficulties associated with the gas-operated ones in a manner which will now be described in detail.
As previously noted, to keep the head of the .22 magnum cartridge from blowing off under the excessive muzzle pressure produced by this ammunition, it is essential that the breech remain closed until the muzzle pressure has reduced to a level far below that which ordinary thick-walled ammunition could withstand without rupturing. The inventor accomplishes this purely mechanically in accordance with the teaching of the instant invention by the simple expedient of supplementing the bias exerted by the primary recoil spring 100 with the previously-described secondary recoil subassembly while taking full advantage of the mass of the breech block itself and that additional force required to set it in motion from an "at rest" position, to hold it closed momentarily. Functionally, the roller 76 is held against the rear end of the block while it is seated against the breech holding the unfired shell therein by means of a secondary recoil subassembly spring having a spring constant selected to cooperate with the starting inertia required to get the block moving and with the primary recoil spring 100 effective to hold the block closed momentarily but long enough for the muzzle pressure to dissipiate to a level at which the head of the spent cartridge will not blow off, whereupon, the remaining pressure is still sufficient to open the block against the combined bias of both springs 74 and 100. It is noted that the cooperation between the spring forces and the force required to get the block moving are selected such that the reactive forces associated with the firing of the cartridge are insufficient to move the block away from the breech until the pressure drops to the desired level while, at the same time, leaving sufficient residual pressure in the system to retract the block against the combined force exerted by both the primary and secondary recoil absorption systems once the resting inertia of the latter has been overcome. The two acting together over a portion of the recoil stroke slow down the block considerably faster than the primary spring could do alone thus resulting in a much shorter travel of the block and a correspondingly shorter overall weapon. With the added bias of the secondary spring 74 helping to hold the block closed, a somewhat light block can be used and still retain the high muzzle pressure.
Now, another important aspect of the two-stage spring-biased recoil mechanism of the present invention is the deactivation of the entire secondary spring-biased recoil subassembly after a predetermined rearward travel of the breech block. This deactivation occurs when the roller 76 rolls off the rear end of the block and down underneath it where only minimal rolling frictional resistance is offered to its further movement. In other words, once the secondary recoil subassembly has performed its functions of initially assisting the primary one in momentarily holding the block closed until the excessive muzzle pressure has dissipated to a level where the breech can be safely opened without the shell case disintegrating and thereafter cooperates in the same way with the primary system to slow down the rearward travel of the breech block as it extracts and ejects the spent shell casing while at the same time absorbing enough of the recoil so that what remains can be absorbed by the primary system alone, then the secondary system becomes essentially inoperative and the primary system takes over. By so doing, the secondary subassembly is not functioning to return the block into firing position so quickly that it speeds up the rate of fire beyond that which can easily be accommodated and the gun controlled even though on the forward stroke of the block the secondary recoil subassembly becomes operative again to speed up the return of the block into firing position at the time it needs extra "push" to pick up a new shell and shove it into the chamber. Thus, even though the overall length of the weapon is considerably shorter than other automatic weapons using only one recoil spring, its rate of fire is no faster and it is fully controllable. As a matter of fact, while the specific reason for this is, as yet, unknown, the secondary recoil subassembly in some way cancels out much of the tendency of automatic weapons to rise as they are fired. Skilled shooters of rapid-fire weapons were able to shoot tighter groups with the unit forming the subject of the present invention than other comparable ones using the same ammunition.
It is important to note that while the two-stage recoil assembly described above has special significance in connection with the use of the .22 caliber magnum ammunition because of its thin-walled casing and large charge of powder in comparison to other .22 caliber cartridges, it also is applicable to other weapons like, for example, the aforementioned UZI which can be made much shorter, more compact and probably a good deal easier to control as well as being more accurate by adding the present secondary recoil subassembly to the conventional primary one. As a matter of fact, the staged recoil absorption system of the present invention is readily adaptable for use in more conventional firearms even shotguns, although it reaches the pinnacle of its utility on automatic weapons firing thin-walled magnum ammunition.
Of considerable practical importance, and equally applicable to other rapid-fire and weapons, otherwise, is the unique design of the gun which allows the block, the primary stage of the two-stage recoil assembly and the extractor mechanism to be taken out as a unit once the coverplate is removed. This can be done very quickly and the whole assembly replaced with a new or reconditioned one thereby placing the weapon back in operation immediately while the worn or defective parts are serviced. In combat, for example, an infantryman might even carry a spare.
The extractors 114 and 116 are mounted above the firing pin 108 alongside the insert 124 in the bottom of the block that carries the latter as seen in FIGS. 3 and 5. This insert is cylindrical and is held by a pin (not shown) within a longitudinal bore 126 running along the bottom of the block. Obviously, a broken firing pin becomes a simple matter to replace since it is an integral part of insert 124 which can be removed from the block and replaced in a minute or so.
Extractors 114 and 116 are pivotally mounted on pins 128 for movement between a spread position shown in FIG. 2 and a closed position shown in FIGS. 3 and 5. A spring 130 located in the insert normally biases the extractors into their closed position. Extractor 116 located on the side of the block opposite spent case discharge opening 132 in the right sidewall 24 of the receiver has the inside edge thereof shaped to provide a forwardly and outwardly-curved cam surface 134L (FIG. 2) that engages and rides up over the head 136 of the shell casing thus moving from its closed into its spread position. Extractor 114, on the other hand, lies adjacent to the spent case discharge opening 132 within cutout 138 (FIGS. 2 and 5) in the right side of the block and has its inside edge provided with a similar forwardly and outwardly-curved cam surface 138 that includes a notch cooperating therewith to define a hook 140. Its inclined surface 134R, like the analogous one 134L on the other extractor, rides up along the head 136 of the shell casing thus moving into its spread position when the latter enters the breech and sits in the chamber 46, however, as the breech block closes and the firing pin enters the cartridge to fire it, the hook 140 seats behind the head of the shell casing as it comes back in slightly under the influence of spring 130 and comes to rest upon the generally frustoconical surface 142 at the rear end of the barrel bordering the breech. There is just enough of the casing that extends out laterally beyond this rear end of the barrel for the hook 140 to hook behind the head 136 and pull the cartridge out of the chamber, fired or not, as the block retracts. In other words, the muzzle pressure does not back the cartridge out of the chamber into a position where the extractors can pick it up because if this were necessary, it would not be possible to eject a cartridge that had misfired. The function of the extractor 116 is to hold the head of the cartridge hooked in the hook 140 of extractor 114 when the case is pulled rearwardly and no longer confined by the chamber against sideways movement. As the block travels back on its recoil stroke with the empty case or unfired cartridge, whichever is present, the edge of the latter nearest extractor 116 will strike the front inside corner of still another inturned tab 144 atop the magazine which projects above the cartridge-retaining tabs 106. Tab 144 forms a fixed abutment which functions to cause the lefthand extractor to spread and move aside thus stripping the shell therefrom. Meanwhile, the right side of the head 136 is still hooked behind hook 140 of righthand extractor 114 which acts as a fulcrum as it continues to move rearwardly relative to the abutment defined by tab 144 and swings the shell or its case to the side and out through spent case discharge opening 132 where it unhooks and drops free, all of which is clearly revealed in FIG. 2.
In FIG. 1, it can be seen that a tension spring 146 attached at one end to ear 148 located at the front of the coverplate 28 on the underside thereof has is other end secured to block cocking lever 150. This lever extends all the way to the rear end of the receiver where it emerges through an opening 152 in the rear endwall 20 and is provided with a fingerhold 156. On the front end of this same lever adjacent to where the spring is hooked is an integrally-formed ear 158, the rear edge of which engages a forwardly-facing shoulder 160 on the side of the breech block as seen in FIG. 2. Pulling rearwardly on the cocking lever against the bias exerted by tension spring 146 causes the block to move back into its cocked phantom-line position shown in FIGS. 1 and 3 where the arms 94 of the sear 86 spring up in front of it. Once cocked in this manner, the cocking lever can be released to return forwardly into its full-line position. Movement of the cocking lever is confined to milled slot 162 in the top of the breech block and the underside of the coverplate.
A rapid-fire weapon with a barrel this short and high-powered ammunition is so noisy it cannot be fired without some sort of protection for the ears. This being the case, the particular form of the weapon illustrated in FIGS. 1, 2 and 3 shows a conventional silencer 164 attached to the barrel.
Certain other embodiments of the recoil system forming the subject matter of the present invention are shown in FIGS. 6-14 to which detailed reference will next be made. These other embodiments are both used in conjunction with a reciprocating breech block and a primary recoil absorption system of the general type already illustrated and described in detail in connection with FIGS. 1-5, inclusive; therefore, in order to avoid unnecessary duplication, these same mechanisms will not be described again although the major components thereof carry the same reference numerals assigned to them previously.
Referring next to FIGS. 6-10, a secondary recoil absorption subassembly broadly designated by reference numeral 50' has been illustrated which differs from that subassembly 50 of FIGS. 1-5 in that is consists of two successive stages of recoil absorption instead of just one. In other words, while the embodiment of FIGS. 1-5 encompassed a total of two stages of recoil absorption, one comprised of subassembly 50 and the other the primary recoil absorption subassembly, this one has a total of three, two of which are encompasses in subassembly 50 and the third being the conventional primary subassembly. An overview of FIGS. 6-10, particularly the latter three figures, will immediately reveal the fact that this embodiment effectively "doubles-up" the secondary recoil absorption subassembly and brings the breech block to a stop before reversing its direction in three successive increments instead of two. In the first, just the forwardmost and the conventional primary subassemblies are active to slow down the block at which point it is under the influence of the greatest of the reactive forces generated by the exploding cartridge. As this force diminishes in intensity, the first of the subassemblies drops out and the second becomes operative while the primary one remains active. Finally, the second of the three becomes inoperative, whereupon, the primary system takes over and finishes the job of slowing the block to a stop and reversing its direction. Then, once again, on the return stroke, the second subassembly rejoins the primary one to accelerate the block as the spring bias exerted by the latter begins to diminish and the unfired cartridge is picked up from the magazine. Next, the second drops out and the third of the three joins the first with the two now active to continue speeding the block along its way to push the shell into the chamber.
The modified secondary recoil subassembly 50' is, perhaps, most clearly revealed in FIG. 7 where it will be seen to be further subdivided into a pair of subassemblies 202 and 204 which are spaced one behind the other in the direction of breech block travel as the latter moves rearwardly. Both of these subassemblies 202 and 204 include U-shaped yokes which have been identified by reference numerals 206 and 208, respectively, and both of which open forwardly. Yoke 206 includes transversely-spaced legs 210 and 212 connected together at their rear ends by crossframe element 214 analogous to element 68 in FIG. 3. In similar fashion, yoke 208 has spaced-apart legs 216 and 218 interconnected by crossframe element 220.
Extending transversely between the free ends of the aforementioned legs of each yoke is a pivot pin 60' seen with yoke 206 and one 60" for yoke 208. Rocker arms 62' is mounted intermediate its lower and upper ends 214 and 216, respectively, on pivot pin 60' for rockable movement from its forwardmost position shown in FIGS. 6-9 and its rearwardmost position shown in FIG. 10. It will be seen in FIG. 7 that the rocker arm 62' of the rear subassembly 202 is bifurcated to receive certain elements soon to be described of the front subassembly 204. In a similar manner, the rocker arm 62" of the front subassembly 204 is mounted for rockable movement at a point intermediate its lower end 226 and upper end 228 on pivot pin 60". The movements of the latter rocker arm between its forwardmost position shown in FIGS. 6-8 and its rearwardmost one shown in FIGS. 9 and 10 is quite analogous to the movement of rocker arm 62 shown in full and phantom lines in FIG. 3.
The axes of pivotal movement of rocker arms 62' and 62" are defined by pivot pins 64' and 64", respectively, which are mounted in the bottom of the housing in position to pass through their lower ends 222 and 226 as seen in FIG. 7, once again, much in the same manner as pivot pin 64 in FIG. 3. Posts 66' and 66" project rearwardly from the crossframe elements 214 and 220, respectively, of the front and rear yokes where they pass through enlarged openings in transversely-extending spring abutments like the one shown at 72' in FIG. 6. A second such apertured abutment which receives the front post 66" is not shown, however, it is similar to the one shown at 72' in FIGS. 1, 2 and 3. Mounted between the crossframe elements of each yoke and these abutments are the compression springs 74' and 74". As alluded to previously, rocker arm 62' is bifurcated to define spaced apart legs 230 and 232 which pass alongside the post and spring of the front subassembly 204. A pin 234 extends transversely between the aforementioned legs of rocker arm 62' mounting roller 76' for rotational movement. Rocker arm 62" of the front subassembly 204, on the other hand, is shown made of one-piece construction but slotted at it upper end 228 to receive the roller 76" which is mounted on pin 238.
From a functional standpoint, the action of the front subassembly 204 is analogous to that of the single secondary subassembly 50 of FIGS. 1-5. By the same token, so is that of the rear subassembly 202 except that it performs no function in terms of holding the block closed against the breech while the muzzle pressure is degenerating to a level at which the breech can be safely opened. In other words, once the block has moved away from the breech, the retardant functions performed by subassemblies 204 and 202 are the much the same were it not for the fact that they can differ in magnitude and thus provide a dimension of breech block control that cannot be achieved using the front one and the primary system alone. Specifically, it is advantageous to have spring 74" on the front subassembly 204 a good deal stronger than spring 74' on the rear one 202. During the retraction stroke of the block, the front subassembly 204 will be active holding it closed against the breech and cooperating with the primary system to slow down and absorb the reactive forces at the time they are the greatest. Once these excessive forces have been handled and they have dropped down to a more reasonable level, then the relatively weaker back-up system defined by subassembly 202 can take over and cooperate with the primary one to finish the job. Such a "division in work" becomes even more significant on the return stroke where the final "push" necessary to propel the fresh round into the chamber requires the greatest impetus. It is at this time that subassembly 204 with its relatively stronger spring takes over the job for the weaker one 202 and, in cooperation with the primary system which at this point is even weaker, completes the firing cycle. This is not to say, of course, that subassemblies 202 and 204 cannot be alike or even that the rear one 202 cannot be stronger than the one in front, 204; however, there appear to be certain advantages in making the front one the stronger of the two.
FIGS. 8, 9 and 10 show in detail the recoil segment of the firing cycle. As already noted, front subassembly 204 is performing essentially the same function it did in the embodiment of FIGS. 1-5 in cooperation with the primary recoil absorption system while the rear subassembly 202 remains inactive. In FIG. 9, it can be seen that the front subassembly 204 has already dropped out and the rear subassembly 202 is about to take over. Finally, in FIG. 10, both subassemblies 202 and 204 of secondary system 50' have dropped out leaving the remaining recoil to be absorbed by the primary system.
Before proceeding with the second of the modifications shown in FIGS. 11-14, it should be mentioned that by merely providing a step or recess in the underside of the block such that both rollers 76' and 76" can engage it simultaneously, then the front and rear subassemblies will function on concert with one another and with the primary system rather than sequentially as shown in FIGS. 8, 9 and 10. There are, however, certain disadvantages in so doing in that, in most instances, the breech block will have to be made longer thus lengthening the entire weapon. A far better and more practical solution to providing greater recoil resistance and block slow-down at the beginning of the recoil cycle as well as accelerated shell insertion at the end thereof, all without lengthening the block, is found in the modification shown in FIGS. 11-14 to which detailed reference will now be made.
Here, instead of the secondary recoil absorption system consisting of a pair of subassemblies 204 and 202 located one behind the other as in FIGS. 6-10 so as to operate sequentially, two identical subassemblies are placed such that they both act simultaneously by pushing against the rear face of the block but, upon becoming inactive, they move over onto different faces of the latter that essentially parallel its direction of movement. As illustrated, they move from the rear over onto opposite sides of the latter. Obviously, they could do the same on the top and bottom or, conceivably the top or bottom and one side. Mounting of these subassemblies on opposite sides of the block, however, has certain advantages and is preferred in that, generally speaking, the housing can be made somewhat wider, at least in the area where the secondary recoil system is located, without interfering with other necessary elements. If, on the other hand, a part of the subassembly has to go on top of the weapon, sighting may be interfered with, etc.
This embodiment 50" includes right and left subassemblies 202' and 204', respectively, which are mounted in transversely spaced relation alongside the block 44 as opposed to one behind the other. Roller 252 mounts on rocker arm 256 which is a part of the right subassembly 202 while, in a similar fashion, roller 254 and its rocker arm 258 comprise elements of the left one 204'. Roller 252 is mounted for rotation on its arm 256 by means of pin 264 seen in FIG. 12; whereas, in a similar manner, roller 254 of the lefthand subassembly is mounted for rotation on rocker arm 258 by means of pin 266 seen in both FIGS. 12 and 14. A yoke 268 is pinned at 270 to rocker arm 256 intermediate its ends while a yoke 272 is similarly pinned to rocker arm 258 by means of pin 274. The end of rocker arm 256 opposite the mounting roller 252 is mounted for pivotal movement about a vertical axis extending along the righthand side of the block defined by pin 276. In a similar manner on the lefthand side of the block, the end of rocker arm 258 opposite that carrying roller 254 is mounted for pivotal movement on pin 278 as shown. Extending rearwardly from the crossbar portion 280 of the lefthand yoke 272 is a post 282 which is received in oversize aperture 284 in the rear wall 20' of the housing. In like manner, post 286 is fastened to the crossbar of yoke 268 in position to project rearwardly through oversize opening 288 in rear housing wall 20' as seen in FIGS. 11 and 12. This wall and the crossbar portions of the yokes define the spaced abutments for compression springs 290 and 292, respectively, that fit over the posts of the right and lefthand subassemblies 202' and 204', respectively.
The operation of both of these side-by-side subassemblies is, of course, essentially the same as that of the single one forming the subject matter of FIGS. 1-5 except that the two (202' and 204') work together to both hold the block 44 closed against the breech and to retard the initial thrust of the block as it begins to move away from the breech with the empty shell casing during the retraction stroke of the firing cycle. In like manner, these two cooperate on the return stroke of the block when it is picking up a new shell for insertion into the chamber to speed up this phase of the firing cycle. Both subassemblies, in the particular form shown, drop out at the same time during the retraction stroke and also resume their block-speed-up function simultaneously on the return stroke; however, this need not be the case and by simply changing the length of one of the rocker arms, changing the relative sizes of the rollers or relocating the pivots, or all three, one subassembly can be made to drop out and reengage at a different time than the other although it would seem that no useful purpose would be served by so doing.
This modification of FIGS. 11 through 14 is ideally suited for use in those applications like, for example, shotguns, which have a great deal of recoil, heavy shells and other complexities that oftentimes demand the extra power of two such subassemblies 202' and 204' working together that cannot be satisfactorily supplied by a single secondary spring biased recoil subassembly like that of FIGS. 1-5 equipped with a heavier spring. On the other hand, space considerations alone may dictate the use of two smaller and lighter-duty subassemblies versus a single heavy-duty one that requires more room.
Finally, those skilled in the art will readily ascertain from what has been disclosed herein that other combinations of secondary recoil absorption systems can be devised which cooperate with the primary system to control movement of the breech block during a portion of its excursion both rearwardly and forwardly while permitting the primary one to operated all by itself as it slows the block to a stop and reversed its direction.
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The present invention relates to a firearm, generally of the automatic or semi-automatic type, having a reciprocating breech block normally biased into closed position by a primary recoil absorption system including a spring, the improvement comprising providing a secondary spring-biased recoil absorption system cooperating with the primary one during a portion of the retraction stroke of the block to slow down the movement of the latter before becoming inactive while the primary system slows the block to a stop and reverses its direction and then becoming active to once again cooperate with the primary system during a portion of the return stroke of the block to speed up its return to its original position. The invention also encompasses the improved method for controlling the movement of the breech block in the aforementioned type of weapon during its firing cycle wherein such movement during its initial and final stages is supplemented and abetted by a secondary spring-biased recoil absorption system cooperating with the primary one while, at the same time, leaving the primary system solely responsible during the remainder of the cycle to stop the block and reverse its action.
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RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of co-pending U.S. patent application Ser. No. 12/883,462 filed Sep. 16, 2010.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to storage units for sets of tools that may be associated with a particular task. For example, maintenance of a particular type of vehicle may be efficiently performed if a tool set is established and organized so that all required maintenance tools are readily accessible. For such a system to be effective, the tools need to be replaced to particular locations in a dedicated storage system after each use. Proper storage of the tools may result in ready availability for successive usage.
[0003] As can be seen, there is a need for a tool storage system which can easily be employed by a user to replace tools in their proper storage location. Additionally there is a need for such a system to be adaptable to numerous variations of tool sets.
SUMMARY OF THE INVENTION
[0004] In one aspect of the present invention, a storage system for a set of tools may comprise: a box; an insert board having a tool-contact side and an image side opposite the tool contact side; and images of the tools formed on the image side of the board, the insert board being oriented in the box so that the image side of the board faces an underside of the box and so that tools placed in the box contact the tool-contact sides of the board.
[0005] In another aspect of the present invention, an insert for a tool storage box may comprise: a sheet of material having a tool-contact side and an image side, opposite the tool-contact side, and having images of tools in their respective desired locations on the image side.
[0006] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of an assembled tool storage box in accordance with an embodiment of the invention;
[0008] FIG. 2 is a perspective view of an insert of the tool storage box of FIG. 1 ; and
[0009] FIG. 3 is a schematic sectional view of a portion of the tool storage box of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0011] Various inventive features are described below that can each be used independently of one another or in combination with other features.
[0012] Broadly, embodiments of the present invention generally provide tool storage boxes and a method for producing tool storage boxes in which a graphic indicator of tool location is embedded in the box. In exemplary embodiments of the invention a desired collection of tools, for inclusion in a box, may be placed in a desired location. Images of shadows of the tools may be produced on an insert for the box in which the tools are to be stored.
[0013] Referring now to FIG. 1 , a tool storage insert 10 is illustrated with attached tools 28 . The tool storage insert 10 may be a portion of a dedicated storage box 11 which may be readily accessible on or near a vehicle (not shown) such as a specialized military vehicle (e.g., an aircraft, a tank or a truck). The insert 10 may comprise an insert board 12 and various tool holders such as spring clips 20 , a tool bracket 22 ; a strap 24 and hook and loop fasteners 26 .
[0014] Referring now to FIG. 3 , it may be seen that the insert board 12 may be transparent or translucent and may have a tool-contact side 12 - 1 and an opposing image side 12 - 2 . On its image side 12 - 2 , the insert board 12 may be printed with outlines, silouetttes or images of tools (collectively referred to herein as tool images 14 ) and tool numbers 16 . Panel text 18 may also be included. Collectively, the tool images 14 , numbers 16 and text 18 may be printed on the image side 12 - 2 of the insert board 12 . A user of the tools 28 may readily determine the proper location for each of the tools after each use by looking at the images 14 and/or the numbers 16 and text 18 , The user may also confirm that all of the tools 28 have been returned to the box 11 after completion of a task, thus assuring that none of the tools have been left inside a vehicle on which repairs have been performed. Missing tools can be readily identified by their respective empty outline and associated number 16
[0015] In an exemplary embodiment, the insert board 12 may comprise a sheet of polycarbonate having a thickness of about 0.10 inch. The board 12 may be oriented so that its image side 12 - 2 may face toward an underside 11 - 1 of the box 11 while the tool-contact side 12 - 1 may face upwardly and away from the underside 11 - 1 of the box 11 . It may be noted that the tools 28 may not come into contact with the images 14 because the images may be printed on a side opposite the tool contact side 12 - 1 . In other words, the board 12 may positioned to intervene between the tools 28 and the images 14 of the tools. Consequently, the images 14 may be protected from abrasion that might otherwise arise from repeated removal and replacement of the tools 28 in the box 11 . Thus the images 14 may remain readily visible to a user even after repeated use of the tools 28 .
[0016] In an exemplary method for producing one or more of the tool boxes 11 the following steps may be performed. In a first step, a customer may define an overall size for the box 11 and an inventory of tools 28 to be stored in the box 11 and the types of required tool holding devices 20 , 22 , 24 and/or 26 . In a second step, the customer or a fabricator of the box 11 may arrange the tools 28 and holding devices in a layout on a sheet of photosensitive material. In a third step, a shadow-like image of the layout may be made. In a fourth step, a printing mask may be produced. In a fifth step, images 14 of the tools 28 may be produced on the insert 12 using a conventional image production technique, (e.g., by reverse screen printing or laser scribing). Finally, the tool holding devices may be attached to the printed insert board 12 and the box 11 may be assembled (e.g., by adhesively attaching the insert board 12 in the box 11 ).
[0017] In optional steps, multiple sets of the tools may be delivered to a fabricator. The fabricator may produce numerous boxes and install tools into each box so that complete packaged tool sets may be delivered to a customer.
[0018] While the foregoing has been described in the context of a box 11 employing an insert board 12 on top of the underside 11 - 1 , another exemplary embodiment may comprise a translucent board 12 whose rear face is the box underside 11 - 1 and the images 14 are printed or etched within the board 12 between the underside 11 - 1 and the tool contact side 12 - 1 .]
[0019] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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Specialized tool storage boxes may be produced by defining an inventory of tools to be stored in the box. The tools may be positioned in proposed desired locations. Shadows of the tools in their respective desired locations may be produced. Image of the shadows may be produced on an insert for the tool storage box. The insert may be placed in the box so that the tools can be replaced in the desired locations after being removed from the box.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of priority to German Application No. DE 10 2006 041 808.5 filed on Sep. 6, 2006, the content of which is incorporated in its entirety herein by reference.
BACKGROUND
[0002] The present invention relates to devices for injecting, infusing, administering, delivering and dispensing substances, and to methods for making and using such devices, as well as to related peripheral, adjunct, complementary, cooperative and auxiliary devices and methods. More particularly, the present invention relates to a needle protecting device on or for devices for injecting, infusing, administering, delivering and dispensing substances.
[0003] A needle protecting device can be a fixed part of an injection device, but is typically provided for attachment to an injection device, or is detachably attached thereto. Needle protecting devices are used in the administration of substances or products, e.g. medicines, for example insulin, and can be used in self-administering, i.e. by patients who administer the relevant product themselves. The injection apparatus or devices involved can take the form of a simple syringe, including syringes which are disposed of after a single use. However, injection apparatus may be reusable, and may allow the dosage or amount of the product or substance to be administered to be set or selected. Such injection apparatus can take the form of injection pens, such as re used in diabetes therapy and, more recently, also in other therapies.
[0004] When handling injection apparatus, there is the danger of patients or medical staff injuring or sticking themselves on the point or tip of a needle, and/or infecting themselves via a stick from a used injection needle. Needle protecting devices comprising a movable needle protector have been developed to prevent this. Typically a needle protector can be moved back and forth in the longitudinal direction or along the length of the injection needle and, once used, may be automatically blocked or locked in a distal or forward protective position, such that it can no longer be moved in the proximal or rearward direction and the injection needle or at least its tip can no longer be exposed. Such needle protecting devices are for example known from WO 01/91837 A1 and U.S. Pat. No. 6,773,415 B2.
[0005] Needle protecting devices which are intended for a single use have to be mass-produced at low cost. On the other hand, they should function properly to prevent injuries and infection.
SUMMARY
[0006] It is an object of the present invention to provide a needle protector or needle protecting device that provides an optimal amount of protection and operates properly and conveniently.
[0007] In one embodiment, a needle protecting device in accordance with the present invention comprises a releaseably lockable movable needle protector.
[0008] A needle protecting device for an injection apparatus comprising an injection needle with a needle tip and a needle base beyond which the injection needle protrudes, the needle protecting device comprising a needle protector moveable from an exposing position exposing the needle tip to a protective position overlapping the needle tip, a first lock element associated with one of the needle protector or the needle base, and a second lock element associated with the other of the needle protector or the needle base, wherein, when the needle protector is in the protective position, the lock elements are in engagement preventing the needle protector from moving into the exposing position, and wherein the engagement may be non-destructively released and restored.
[0009] In one embodiment, the present invention comprises a needle protecting device for an injection apparatus comprising an injection needle with a needle tip and a needle base beyond which the injection needle protrudes, the needle protecting device comprising a needle protector moveable from an exposing position in which the needle tip is exposed to a protective position in which the protector overlaps the needle tip, a first blocking mechanism associated with one of the needle protector or the needle base, and a second blocking mechanism associated with the other of the needle protector or the needle base, wherein, when the needle protector is in the protective position, the blocking mechanisms are engaged with each other preventing the needle protector from moving into the exposing position, and wherein the engagement may be non-destructively released and/or restored.
[0010] In one embodiment of the present invention, the invention comprises a method for functionally testing a needle protecting device for an injection apparatus comprising an injection needle with a needle tip and a needle base beyond which the injection needle protrudes, the needle protecting device comprising a needle protector moveable from an exposing position in which the needle tip is exposed to a protective position in which the protector overlaps the needle tip, a first lock element associated with one of the needle protector or the needle base, and a second lock element associated with the other of the needle protector or the needle base, wherein, when the needle protector is in the protective position, the lock elements are engaged with each other preventing the needle protector from moving into the exposing position, and wherein the engagement of the lock elements may be non-destructively released and restored, the method comprising the steps of: when the needle protector is in the protective position, moving the first lock element out of the engagement using a tool, applying an external force to the needle protector thereby moving the protector in a proximal direction, and removing the external force whereby the needle protector, if functioning properly, moves into the protective position again.
[0011] In one embodiment, the present invention comprises a needle protecting device on or for an injection apparatus, which comprises an injection needle comprising a needle tip and a needle base. The needle base serves to mount the injection needle, and can be formed in a conventional way as a needle holder, into which the injection needle protrudes and which holds the injection needle fixedly, e.g. in a material lock. The injection needle protrudes beyond the needle base in a longitudinal direction, i.e., along the longitudinal length of the injection apparatus. The needle protecting device is movably connected to the needle base, and comprises a block or lock for blocking the device in a protective position.
[0012] In some embodiments, the injection needle can protrude through the needle base. In principle, however, the needle base and the injection needle can be formed in one piece. The needle protector can be moved in the distal or forward direction relative to the needle base and the injection needle, from an exposing position in which the needle tip of the injection needle protrudes beyond the needle protector into a protective position in which it overlaps the injection needle including the needle tip.
[0013] In some preferred embodiments, the needle protector is sleeve-shaped, such that it surrounds the injection needle, including the needle tip, in the protective position. In some embodiments, the needle protector forms an opaque covering around the injection needle, but can also be transparent, for example consisting of a transparent material or comprising through-holes. In principle, one or more fingers extending alongside the needle in the longitudinal direction would also be sufficient as the needle protector. The needle protector serves to protect against injury from an injection portion of the injection needle. In such embodiments, the needle protector moves in the distal or forward direction from the exposing position into the protective position.
[0014] In some embodiments, the needle protector of the present invention comprises a block or lock that comprises a first blocking or lock mechanism and a second blocking or lock mechanism. The first blocking mechanism is formed on one of the needle protector and the needle base or formed separately and connected to the relevant component. The first blocking mechanism is movably formed on or movably connected to one of the needle protector and the needle base such that it can be moved together with the one of the needle protector and the needle base, relative to the other of the needle protector and the base, and/or can also be moved relative to said one of the needle protector and the needle base. The second blocking mechanism formed on the other of the needle protector and the needle base or, if formed separately, is connected to the relevant other component. When the needle protector is in the protective position, the first blocking mechanism and second blocking mechanism are in engagement with each other, preventing the needle protector from moving in the proximal (i.e., rearward) direction. In some embodiments, the second blocking mechanism is stationary relative to the other of the needle protector and the needle base. It at least cannot be moved relative to the other of the needle protector and the needle base in the longitudinally with respect to the injection needle when the needle protector is in the protective position, thus being able to fulfil the locking function.
[0015] In accordance with some embodiments of the present invention, the blocking or lock engagement can be non-destructively released. In some embodiments, a tool is used to release it. When in blocking engagement, the blocking mechanisms prevent the needle protector from being moved into the exposing position unintentionally or by a force exerted on the needle protector from without. The protective function is thus facilitated. In some embodiments, the blocking engagement can be released by a type of manipulation which is not immediately obvious to the user. For example, at least two manipulations may be required in a certain order, one after the other. In some embodiments, the manipulation or at least one of the number of manipulations may be performed only by a tool.
[0016] In some preferred embodiments, the needle protecting device includes a spring member which charges or urges the needle protector with a spring force acting in the distal or forward direction. The spring force causes the needle protector to automatically move into the protective position after administering the product if a force overcoming the spring force is not exerted on it. The spring member is supported in the direction of the spring force on the needle protector and in the opposite direction on the needle base, either on both or on one of these components, directly or as applicable also only via one or more intermediate members. The spring member can, for example, be a pneumatic or mechanical spring or force generator. In terms of its function, it can be a pressure spring. With respect to its shape, a spiral spring may be preferred.
[0017] Before being used, the needle protector advantageously assumes an initial position in which it overlaps the injection needle including the needle tip. The needle protector is not, however, blocked or locked in the initial position, but rather can be moved into an exposing position, against the restoring force of the spring member, wherein it is entirely conceivable and also advantageous not only for the needle protector to be held in the initial position due to the spring force but also additionally for there to also be a frictional lock or advantageously a positive lock which requires a certain force to be applied in the proximal or rearward direction to overcome it. The frictional or positive lock may be released when the needle protector is charged in the proximal direction with a force such as usually occurs when the injection needle is injected into human skin. By contrast, the blocking engagement in the protective position can only be released by a force exerted on the needle protector from without by destroying at least one of the blocking mechanisms involved in the blocking engagement. In the initial position, the needle protector charged with the spring force does provide a certain but limited protective function, but can additionally serve as a blind, to remove self-administering users' fear of injecting. From the point of view of its protective function, however, it would also be possible for the needle protector to assume the exposing position before use.
[0018] In some embodiments, to enable the blocking engagement to be non-destructively released, the first blocking mechanism can be movably connected to said one of the needle protector and the needle holder, in some preferred embodiments the needle protector. The connection is such that the first blocking mechanism can move relative to the needle protector and also relative to the needle base. If the first blocking mechanism is connected to the needle protector, the connection is also designed such that the needle protector slaves the first blocking mechanism when it moves in the longitudinally with respect to the length of the injection needle.
[0019] In some embodiments, it is advantageous if a restoring spring force acts on the first blocking mechanism to counteract the movements of the first blocking mechanism relative to said one of the needle protector and the needle base. In this way, the first blocking mechanism is held in a position of equilibrium relative to said one of the needle protector and the needle base or, in the event of a deviation, is returned to the position of equilibrium. The spring member mentioned with respect to the needle protector can serve to generate the spring force for achieving equilibrium. In principle, however, a spring member can be provided for the first blocking mechanism only, either as a single spring member or in addition to the spring member which charges the needle protector with a spring force. If the same spring member acts on the first blocking mechanism and moves the needle protector into the protective position, such a spring member can act directly on the first blocking mechanism and charge the needle protector with the spring force via the first blocking mechanism.
[0020] In some embodiments, instead of forming the first blocking mechanism separately from said one of the needle protector and the needle base and movably connecting it to the relevant component in a joint or by a number of joints, a movable first blocking mechanism may be formed in one piece with the relevant component, wherein its ability to move is enabled by shaping it appropriately. In another alternative, the first blocking mechanism and the relevant component are formed separately from each other and connected to each other in a material lock. When the first blocking mechanism is formed in one piece or fixedly connected in a material lock, a restoring spring force which acts on the first blocking mechanism is based on dimensional elasticity. The first blocking mechanism can thus, for example, be elastically pliable. In some preferred embodiments, a first blocking mechanism is formed separately and connected in a joint to said one of the needle protector and the needle base. Such a first blocking mechanism can advantageously be rigid, i.e. inflexible, in its own right.
[0021] In some preferred embodiments, a needle protecting device in accordance with the present invention features a blocking portion which surrounds the needle protector or is surrounded by the needle protector. At least when in blocking engagement, the blocking mechanisms are within the axial length of the blocking portion. One of the needle protector and the blocking portion surrounds the blocking mechanisms in blocking engagement, at least when the needle protector is in the protective position, and in this way protect them from being accessed laterally. Neither of the blocking mechanisms in blocking engagement is visible from the side, such that the method of operation of the blocking is at least not immediately obvious to the user. Since the spatial arrangement is very tight and the injection needle is arranged centrally, the user cannot easily act on the blocking mechanisms in the longitudinally relative to the injection needle using a finger to release their blocking engagement. Rather, a specific tool is required to release the engagement, which in some preferred embodiments can be a straight or, as applicable, a bent rod. To release the blocking engagement or lock, the tool is moved through a distal or forward opening in the needle protector or the blocking portion and, at least substantially in the longitudinal direction of the injection needle, into the region of the blocking portion, and brought to bear on one of the blocking mechanisms. The blocking engagement can be released by pressing the tool at least substantially in the longitudinal direction of the injection needle against one of the blocking mechanisms, e.g., the first blocking mechanism. Other manipulations on the blocking mechanisms in blocking engagement are not required. The blocking mechanisms are formed accordingly and can be moved relative to each other in blocking engagement. Enabling them to be released by the action of pressure in the longitudinal direction facilitates automatic functional testing, such that this can advantageously be performed in a short period of time and with low demands on precision in positioning the needle protecting device to be tested or in controlling the movement which the tool or needle protector has to perform relative to the respective other component.
[0022] In some preferred embodiments, the first blocking mechanism is connected to said one of the needle protector and the needle base such that it can be tilted or pivoted. In accordance with some preferred embodiments, the first blocking mechanism may only exhibit the degree of freedom of an ability to tilt or pivot about one tilting or pivoting axis relative to said one of the needle protector and the needle base, wherein the relevant axis is stationary relative to said one of the needle protector and the needle base. As applicable, the first blocking mechanism can also be able to tilt or pivot about a number of axes relative to said one of the needle protector and the needle base. The axis or, as applicable, number of axes is/are advantageously not parallel to the injection needle, but rather extend/s transverse to the injection needle. In some preferred embodiments, the axis or number of axes is/are perpendicular to the injection needle and extend radially with respect to the injection needle. The injection needle is at least substantially straight, and at least sufficiently straight that it can be injected into and through human skin by a pressure force.
[0023] In a further development of the present invention, a needle protecting device in accordance with the present invention includes a third blocking mechanism which is formed together with the second blocking mechanism on the other of the needle protector and the needle base, or is connected to the relevant component. In this respect, the statements made regarding the second blocking mechanism also apply similarly to the third blocking mechanism. In a top view onto the cited tilting or pivoting axis, the second blocking mechanism and the third blocking mechanism are arranged on different sides of said axis, i.e. one to the left and the other to the right of the axis. The second blocking mechanism and third blocking mechanism each form a stopper for the first blocking mechanism. These stoppers are offset with respect to each other longitudinally relative to the length of the injection needle. When the needle protector is in the protective position, the first blocking mechanism is in pressing contact with at least one of the other two blocking mechanisms. If a force acting in the direction of the exposing position is exerted on the needle protector, the first blocking mechanism tilts or pivots in accordance with the axial offset which the other two blocking mechanisms exhibit with respect to each other, in pressing contact with the other of said two blocking mechanisms, such that the first blocking mechanism then abuts against both other blocking mechanisms.
[0024] In other developments of the present invention, an unblocking mechanism may be provided which forms another stopper for the first blocking mechanism. This stopper faces away from the stopper formed by the second blocking mechanism. In some preferred embodiments, the needle protecting device thus includes three stoppers, two of which point in the same direction, while the third points in the opposite direction. The stoppers can point in the proximal (rear) or distal (front) direction, i.e. with respect to a direction along the length of the injection needle or an injection device to which the needle is attached. If the first blocking mechanism is formed on or connected to the needle protector, such that it is slaved by its axial movements, the stoppers formed by the second blocking mechanism and third blocking mechanism point or extend in the distal direction, and the stopper formed by the unblocking mechanism accordingly points in the proximal direction. If the first blocking mechanism can be tilted about a tilting axis pointing transverse to the longitudinal direction of the injection needle, it is advantageous for the second blocking mechanism to have a smaller distance, as measured longitudinally, from the stopper of the third blocking mechanism than from the stopper of the unblocking mechanism. By arranging the stoppers in this way, the first blocking mechanism can perform tilting movements of different amplitudes, depending on the movement direction of the needle protector.
[0025] In some preferred embodiments, the second blocking mechanism is formed by a protrusion which projects transversely relative to the longitudinal axis of the needle, from a surface area of the needle protecting device, for example from the needle protector or from the above-mentioned blocking portion. The third blocking mechanism may be formed by another protrusion which projects from the surface area, likewise transversely relative to the needle. If the needle protecting device also features the unblocking mechanism, the latter may be formed by a protrusion which projects from the same surface area or, as applicable, from another surface area generally across the axis of the injection needle.
[0026] The present invention enables the proper functioning of the needle protecting device to be verified or tested at the end of the production process, thus encompassing a method of such testing. An advantage of the testing method of the present invention is that the needle protecting devices can be used properly after having been verified or tested, since the blocking engagement can be non-destructively released and/or restored. Accordingly, a method for testing the proper method of operation of the needle protecting device is also a subject of the present invention
[0027] In one embodiment, for testing, the first blocking mechanism is moved out of the blocking engagement by a tool when the needle protector is in the protective position, and the needle protector is moved in the proximal (rear) direction by an external force, such that the needle tip protrudes beyond the needle protector. The needle protector is moved into the exposing position. The needle protector is then relieved of the external force and moves back in the distal (forward) direction. In the course of the movement in the distal direction, the blocking mechanisms pass back into blocking engagement, if functioning properly. It is possible to test that the blocking engagement has been restored by again applying an external force while omitting the manipulation performed using the tool. The testing method advantageously also includes this testing step.
[0028] If the needle protector assumes a non-blocked, distal initial position before the needle protecting device is used, some preferred embodiments of the testing method in accordance with the present invention include other steps preceding the steps mentioned above. In a first step of the testing method in such a further development, the needle protector is moved by an external force out of the distal, forward initial position, into the exposing position or at least in the direction of the exposing position and is relieved of the external force in the exposing position or, as applicable, earlier, such that it moves into the protective position. In a following step, the blocking engagement which is automatically set by this is released using the tool, as described.
[0029] When needle protecting devices in accordance with the present invention are serially produced, they can advantageously each be subjected to the testing method directly following their assembly, i.e. they are tested in-line with their assembly. In such method embodiments, an additional holder for holding, in a defined way, the respective needle protecting device to be tested is not required, since an assembly holder could be used to hold the devices, in a defined way, for testing. If the devices are tested by a holder provided especially for this purpose, they can still simply be automatically passed from the assembly holder—if the devices are assembled automatically—to the testing holder. In principle, however, off-line testing is also possible, wherein the needle protecting devices are first assembled and only later—as applicable, after intermediate storage or transport—tested for proper functioning. Off-line testing, however, may require each needle protecting device which is to be tested to be picked up again by the testing device or a holder associated with the testing device. In some embodiments of the method, testing by hand may also be feasible both for in-line and off-line testing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 depicts one embodiment of a needle protecting device in accordance with the present invention comprising a needle protector, in a distal, initial position;
[0031] FIG. 2 depicts the needle protecting device of FIG. 1 , with the needle protector in a distal, protective position;
[0032] FIG. 3 depicts the needle protector in a perspective view;
[0033] FIG. 4 depicts the needle protector in a longitudinal section;
[0034] FIG. 5 depicts an embodiment of a first blocking mechanism of the needle protecting device, in a perspective view; and
[0035] FIGS. 6-10 depict the needle protecting device in various operational positions.
DETAILED DESCRIPTION
[0036] FIG. 1 shows a needle protecting device in an initial position before an injection. The needle protecting device includes and/or is coupled to an injection needle 1 and a needle base which serves to position and attach the injection needle 1 . The needle base comprises a flat bottom 2 and a central holding region 3 projecting from the bottom 2 in a distal direction. The injection needle 1 protrudes through the holding region 3 , such that it protrudes beyond the needle base in the distal direction and in the proximal direction. The holding region 3 holds the injection needle 1 fixedly, such that it cannot move axially. The injection needle 1 is a cannula, i.e. a hollow needle.
[0037] The needle protecting device also includes a sleeve structure 4 which surrounds the needle base. The needle base is inserted into the sleeve structure 4 and connected to the sleeve structure 4 such that it cannot move in the longitudinal direction of the injection needle 1 , relative to the sleeve structure 4 . The needle base and the sleeve body 4 could, in principle, be formed from one piece. The sleeve structure 4 forms a attaching portion, proximal to the needle base 2 , for attaching the needle protecting device to the distal end of an injection apparatus. The injection apparatus may be an injection pen such as is known from diabetes therapy and from other therapies, for example administering osteoporosis preparations or growth hormones. The needle protecting device can be detachably clipped onto the injection apparatus and, for this purpose, comprises a number of latching mechanisms 6 , distributed in the circumferential direction, in its attaching portion. The attaching portion surrounds a connecting portion of the injection needle 1 , which protrudes beyond the needle base in the proximal direction, at least up to a proximal needle tip. When attached onto the injection apparatus, the connecting portion of the injection needle 1 penetrates a sealing membrane which seals a distal end of a reservoir, for example a medicine ampoule. Once this membrane has been penetrated, the hollow volume of the injection needle 1 is fluidically connected to the reservoir.
[0038] The sleeve structure 4 surrounds the holding region 3 of the needle base distal to the bottom 2 , and protrudes slightly beyond the holding region 3 in the distal direction.
[0039] Other parts of the needle protecting device are a needle protector 7 which can be moved along the injection needle 1 relative to the needle base and the sleeve structure 4 , a spring member 10 which charges the needle protector 7 in the distal direction with a spring force, and a blocking means for blocking the needle protector 7 in a distal protective position. FIG. 1 , however, shows the needle protecting device in an initial state in which the needle protector 7 assumes a distal initial position relative to the needle base and in particular the injection needle 1 . The needle protector 7 can be moved out of the initial position in the proximal direction relative to the needle base, against the restoring spring force of the spring member 10 . The needle protector 7 comprises a sleeve portion which surrounds the distal, forward needle portion of the injection needle 1 which protrudes distally beyond the needle base and the sleeve structure 4 . The sleeve portion of the needle protector 7 protrudes through a distal opening in the sleeve structure 4 . A flange 5 which protrudes inwards onto the injection needle 1 is formed on the distal end of the sleeve structure 4 . The flange 5 guides the needle protector 7 axially and linearly and also forms an axial translational stopper up to which the needle protector 7 can be maximally moved in the distal direction due to the spring force of the spring member 10 . In its initial position, however, the needle protector 7 does not axially abut against the flange 5 but is rather held in a different way, namely by a part of the locking structure.
[0040] The locking structure, lock or lock system (which also may be referred to as a blocking mechanism or blocking means) includes a first blocking mechanism 11 which is connected to the needle protector 7 such that it can be moved together with or also relative to the needle protector 7 . The first blocking mechanism 11 exhibits one degree of freedom of movement relative to the needle protector 7 , namely an ability to rotate about an axis K which is not parallel to the longitudinal axis L or injection needle 1 . The axis K points radially with respect to the longitudinal axis L or injection needle 1 and forms a tilting axis for the first blocking mechanism 11 which is connected to the needle protector 7 such that it can tilt about the tilting axis K. The blocking mechanism also includes a second blocking mechanism 12 and a third blocking mechanism 13 . The blocking mechanisms 12 and 13 are formed by protrusions which project inwards, i.e. in the direction of the central longitudinal axis L, from the sleeve body 4 . The blocking mechanisms 12 and 13 are offset with respect to each other in the longitudinal direction of the injection needle 1 and are arranged on different sides of the tilting axis K. In the representation in FIG. 1 , the second blocking mechanism 12 is arranged to the right of the tilting axis K and the third blocking mechanism 13 is arranged to the left of the tilting axis K. The second blocking mechanism 12 is also arranged distal to the third blocking mechanism 13 .
[0041] In the initial state shown in FIG. 1 , the blocking mechanisms 12 and 13 form axial stoppers for the first blocking mechanism 11 on their rear side respectively pointing in the proximal direction. The axial offset between these rear stoppers is selected such that the first blocking mechanism 11 cannot, within the scope of its ability to tilt, be moved out of the initial position in the distal direction, past the blocking mechanisms 12 and 13 .
[0042] The lock system also includes an unblocking mechanism 14 which is likewise formed by a protrusion and projects inwardly from the sleeve structure 4 . The unblocking mechanism 14 is arranged on the same side as the third blocking mechanism 13 with respect to the tilting axis K and is offset with respect to it in the proximal direction. Another protrusion on the side of the second blocking mechanism 12 , proximal to it, is not formed. The unblocking mechanism 14 only protrudes inwards far enough that it does form a stopper for the first blocking mechanism 11 on its front side pointing in the distal direction, but the first blocking mechanism 11 cannot tilt out of the stopper contact and be moved past the unblocking mechanism 14 in the proximal direction when the needle protector 7 moves in the proximal direction. The first blocking mechanism 11 does protrude into a gap between the blocking mechanism 13 and the unblocking mechanism 14 , however the blocking mechanism 13 likewise only projects from the sleeve body 4 far enough that the first blocking mechanism 11 can tilt out of the stopper contact with the unblocking mechanism 14 .
[0043] FIG. 2 shows the needle protecting device in an end state, once used. In the end state, the needle protector 7 assumes a distal protective position in which the blocking mechanism locks it, such that it cannot be moved in the proximal (rearward) direction by an external force. The blocking mechanisms 12 and 13 each form a stopper for the first blocking mechanism 11 , pointing in the distal direction, on their front side. The axial distance between these two stoppers is dimensioned such that when an attempt is made to move the needle protector 7 in the proximal direction, the first blocking mechanism 11 passes into stopper contact with the blocking mechanism 12 and, while maintaining this stopper contact, tilts into a stopper contact with the blocking mechanism 13 . Due to the stopper contact on both sides, the first blocking mechanism 11 cannot pass the two blocking mechanisms 12 and 13 in the proximal direction, such that the needle protector 7 is blocked in the protective position. The two stoppers of the blocking mechanisms 12 and 13 which act when the needle protector 7 is in the protective position exhibit at least substantially the same distance from each other in the longitudinal direction L as the two stoppers formed on the rear sides of the blocking mechanisms 12 and 13 , which prevent the needle protector 7 from being able to move from the initial position shown in FIG. 1 into the protective position. The blocking mechanisms 12 and 13 , in co-operation with the first blocking mechanism 11 , thus block the needle protector 7 in the proximal direction in the protective position and in the distal direction in the initial position.
[0044] FIGS. 3 and 4 show the needle protector 7 in a perspective view and in a longitudinal section. The needle protector 7 comprises the sleeve portion mentioned, which already surrounds the injection needle 1 when the needle protecting device is in its initial state and protrudes at least up to the height of the needle tip and, in some embodiments, beyond the needle tip in the distal direction. The sleeve portion is formed as an opaque, hollow-cylindrical covering. A flange 8 which projects radially outwards is formed on the proximal end and in the example embodiment encircles the longitudinal axis L, but could in principle also be formed by flange pieces spaced from each other in the circumferential direction, or as applicable a single flange piece only. The flange 8 , together with the flange 5 of the sleeve structure 4 , forms a pair of stoppers which co-operate to limit the movement by the needle protector 7 in the distal direction, i.e. which determine the most distal end position which the needle protector 7 can assume relative to the sleeve structure 4 and the needle base. The needle protector 7 also includes two attaching mechanisms 9 which project from the sleeve portion in the proximal direction. The attaching mechanisms 9 serve to connect the needle protector 7 to the first blocking mechanism 11 in a joint.
[0045] FIG. 5 shows the first blocking mechanism 11 in a perspective view. The blocking mechanism 11 comprises a disc-shaped base body 11 a , two attaching mechanisms 11 b and two rotational blocks 11 c which are formed with the base body 11 a in one piece. The rotational blocks 11 c are each in guiding engagement with an assigned axial guide of the sleeve structure 4 , said engagement preventing rotational movements of the first blocking mechanism 11 and thus rotational movements of the needle protector 7 about the longitudinal axis L. In this exemplary embodiment, the rotational blocks 11 c protrude slightly beyond the base body 11 a , transverse to the longitudinal direction L. The two assigned guides of the sleeve structure 4 are axial grooves, but could, for example, also be axial ribs which project inwardly on the inner surface area of the sleeve structure 4 . In the case of projecting ribs, the rotational blocks 11 c could also be replaced with recesses. A single rotational block is in principle sufficient. However, rotational blocks arranged offset with respect to each other in the circumferential direction about the longitudinal axis L, such as for example the rotational blocks 11 c which are offset exactly or at least substantially by 180° with respect to each other in the circumferential direction, may more securely prevent rotational movements relative to the sleeve structure 4 . When connected to the needle protector 7 , the attaching mechanisms 9 of the needle protector 7 and the attaching mechanisms 11 b of the first blocking mechanism 11 form a rotary joint with each other, with the tilting axis K as the joint axis. The attaching mechanisms 11 b form the shaft of the rotary joint and the attaching mechanisms 9 form the socket of the rotary joint. The blocking mechanism 11 is shown in a position of equilibrium with respect to the axes L and K, in which it is held by the spring member 10 when installed. The tilting axis K then constantly points radially with respect to the longitudinal axis L. In said position of equilibrium, the base body 11 a forms a tilting arm both to the left and to the right of the tilting axis K. One of the two tilting arms is in stopper contact with the blocking mechanism 12 in the protective position, and the other tilting arm is in stopper contact with the blocking mechanism 13 in the protective position. As shown by way of example in FIGS. 3 and 4 , the attaching mechanisms 9 are divided parallel to the longitudinal axis L, such that each of the attaching mechanisms 9 forms two socket arms next to each other in the longitudinal direction L which can be elastically bent away from each other such that the first blocking mechanism 11 can be inserted via its two attaching mechanisms 11 b , and the attaching mechanisms 9 elastically snap together with the attaching mechanisms 11 b . For this purpose, corresponding recesses are formed in the base body 11 a on both sides of the attaching mechanisms 11 b , which the attaching mechanisms 9 enter when being connected and which can latch together with the attaching mechanisms 11 b . The base body 11 a also comprises a central passage, extending in the longitudinal direction L, for the holding region 3 of the needle base.
[0046] The method of operation of the needle protecting device is explained below on the basis of the sequence shown in FIGS. 6 to 10 , wherein FIGS. 6 and 10 correspond to FIGS. 1 and 2 .
[0047] The needle protecting device reaches the user sterilely packaged, in the initial state. The user removes the packaging parts of the sterile packaging and places the needle protecting device, in its initial state, on the distal end of the injection apparatus, such that the connecting portion of the injection needle 1 penetrates the sealing membrane of the product reservoir and the fluid connection to the hollow volume of the injection needle 1 is established.
[0048] The user places the injection apparatus, with the needle protector 7 in the initial position, onto the skin at the desired injection point and presses the injection apparatus against the skin in the distal direction, whereby the needle protector 7 experiences a force acting in the proximal direction and begins to move in the proximal (rearward) direction relative to the injection apparatus and the needle base. The spring member 10 counteracts the movement with its spring force. In the first phase of the movement, the first blocking mechanism 11 —which, when the needle protector 7 is in the initial position, is still in stopper contact with the front side of the unblocking mechanism 14 —tilts into the angular position shown in FIG. 7 and ultimately passes the unblocking mechanism 14 . Additional pressure causes the needle protector 7 to be moved into the exposing position shown in FIG. 8 , against the force of the spring member 10 . In the exposing position, the needle protector 7 has completely entered the sleeve body 4 . The spring force of the spring member 10 holds the first blocking mechanism 11 in its position of equilibrium, in which the left-hand and right-hand tilting arm of the blocking mechanism 11 point not only perpendicular to the tilting axis K but also at least substantially perpendicular to the longitudinal axis L. The central holding portion 3 of the needle base protrudes through the blocking mechanism 11 . The injection portion of the injection needle 1 protrudes beyond the sleeve structure 4 and the needle protector 7 in the distal direction. The freely protruding length of the injection needle 1 is advantageously dimensioned such that the needle tip penetrates into the subcutaneous tissue.
[0049] Once the product has been administered, the user draws the injection needle 1 out of the tissue. Once the external force has been removed, the needle protector 7 moves back in the distal (forwardly) direction due to the force of the spring member 10 .
[0050] FIG. 9 shows the needle protecting device in the course of its movement in the distal direction, at the moment in which the first blocking mechanism 11 passes the blocking means. In a first phase of the movement, the first blocking mechanism 11 is completely free from the other blocking mechanisms 12 and 13 and the unblocking mechanism 14 . At the end of this first phase, the blocking mechanism 11 passes into stopper contact with the unblocking mechanism 14 , such that it “catches” or lodges in the stopper contact and the tilting arm on the other side of the tilting axis K, which faces the second blocking mechanism 12 , tilts forwards in the distal direction. The axial distance between the stopper formed on the rear side by the unblocking mechanism 14 and the rear side of the blocking mechanism 12 is dimensioned such that the first blocking mechanism 11 , in stopper contact with the unblocking mechanism 14 on the opposite side, can tilt distally in front of the blocking mechanism 12 and pass it. Once the blocking mechanism 11 has passed the blocking mechanism 12 , it slips out of the stopper contact with the unblocking mechanism 14 and then also passes the third blocking mechanism 13 .
[0051] FIG. 10 shows the needle protecting device in its end state, in which the needle protector 7 assumes its distal protective position. The movement by the needle protector in the distal direction is limited by the pair of stoppers 5 , 8 . In the end state, the first blocking mechanism 11 assumes its position of equilibrium again and exhibits its greatest extent as measured radially with respect to the longitudinal axis L. The rear side of the first blocking mechanism 11 then faces the front sides of the blocking mechanisms 12 and 13 . Pressure exerted on the needle protector 7 in the proximal direction can only cause the first blocking mechanism 11 to tilt simultaneously into stopper contact with the blocking mechanism 12 and the unblocking mechanism 14 , and the needle protector 7 to thus be blocked securely in the protective position. In this state, the user can detach the needle protecting device from the injection apparatus, secure against pricking injuries, and dispose of it. Once a new needle protecting device has been attached, the injection apparatus is ready for the next injection.
[0052] The sleeve structure 4 forms a part of the locking system, not only in the form of the blocking mechanisms 12 and 13 and the unblocking mechanism 14 ; it is also accorded the function of protecting the blocking and unblocking mechanisms 11 to 14 from being accessed from the side. In fulfilling this protective function, the sleeve structure 4 forms a blocking portion which circumferentially envelops the entire blocking means and in which the blocking mechanisms 12 and 13 and the unblocking mechanism 14 are formed. It is also advantageous for the flange 5 which projects inwards to be formed circumferentially, as in the example embodiment, such that there is also no possibility of manipulation through the gap between the sleeve structure 4 and the needle protector 7 . The user has no direct access to the blocking mechanisms 12 and 13 ; when the needle protector 7 is in the protective position, the user cannot even see the blocking mechanisms 12 and 13 . The method of operation of the blocking means is therefore not immediately obvious, making it even more difficult to manipulate.
[0053] A needle protecting device in accordance with the present invention allows complete functional testing in the production process. When tested, the completely assembled needle protecting device is triggered, as described above for an injection, i.e. it is transferred from the initial state shown in FIG. 6 to the end state shown in FIG. 10 . Testing may be performed by hand, but, in some preferred embodiments of the testing method, is performed automatically by tensing the needle protecting device by using a holding means, i.e. exerting axial pressure on the needle protector 7 in the region of the sleeve structure 4 and by a gripper or plunger, such that it moves from the initial position to the exposing position and, once the pressure is relieved, moves in the distal direction into the protective position. Once this cycle is complete, an elongated, rod-shaped tool is—likewise, possibly automatically—moved through the needle protector 7 in the longitudinal direction L up to the first blocking mechanism 11 , such that it contacts the first blocking mechanism 11 on the side opposite the blocking mechanism 12 . A pressure acting in the proximal direction is exerted on the blocking mechanism 11 by the tool. The pressure is sufficiently large that the spring force of the spring member 10 is overcome, and the blocking mechanism 11 tilts out of its position of equilibrium as established by the spring member 10 and can pass the blocking mechanisms 12 and 13 in the proximal direction. During this tilting movement, there is no stopper contact between the blocking mechanism 11 and blocking mechanism 12 , i.e. the needle protector 7 is pressed in the distal direction by the spring member 10 via the blocking mechanism 11 until it abuts the flange 5 , far enough that the first blocking mechanism 11 is free from the second blocking mechanism 12 . Accordingly, “air” exists in the axial direction between the two blocking mechanisms 11 and 12 . The needle protector 7 can optionally be held in stopper contact with the flange 5 by a gripping means, to prevent the blocking mechanism 11 from being able to be pressed into stopper contact with the blocking mechanism 12 by the pressure of the tool, before the first blocking mechanism 11 has passed the third blocking mechanism 13 . If the blocking mechanism 11 , still in contact with the tool, has passed the blocking mechanism 13 in the course of its tilting movement, the needle protector 7 is moved by applying an external force in the proximal direction, until the blocking mechanism 11 has also passed the blocking mechanism 12 . As soon as this has occurred, the tool is retracted such that the blocking mechanism 11 , thus relieved, can move back into its neutral position of equilibrium due to the spring force of the spring member 10 , and assumes the position shown in FIG. 6 , i.e. the needle protecting device is once again in the initial state.
[0054] Embodiments of the present invention, including preferred embodiments, have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms and steps disclosed. The embodiments were chosen and described to provide the best illustration of the principles of the invention and the practical application thereof, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
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A needle protecting device on or for an injection apparatus comprising an injection needle with a needle tip and a needle base beyond which the injection needle protrudes, the needle protecting device including a needle protector moveable from an exposing position in which the needle tip is exposed to a protective position in which it overlaps the needle tip, a first blocking mechanism connected to or formed in one piece with one of the needle protector or the needle base, and a second blocking mechanism connected to or formed in one piece with the other of the needle protector or the needle base, wherein, when the needle protector is in the protective position, the blocking mechanisms are engaged with each other preventing the needle protector from moving into the exposing position, and wherein the engagement may be non-destructively released and/or restored.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims under 35 U.S.C. §119 priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/855,631, filed May 20, 2013 in the United States, and is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to building construction, and particularly to a drywall tapering device for tapering the ends of drywall sheets so that butt joints can be covered by paper tape and joint compound, eliminating unsightly butt joints.
2. Description of the Related Art
Drywall has largely replaced plaster and lath in the construction and remodeling of homes and offices, such as in the construction of interior walls or ceilings. Sheets or panels of drywall, conventionally supplied as 4′×8′ or 4′×16′ sheets, are fastened to the wall studs or ceiling joists, either vertically or horizontally, by drywall nails or screws. The elongated 8′ or 16′ sides are formed with tapered edges so that paper tape can be placed in the tapered recesses of adjoining panels and secured with joint compound to form a smooth joint that is hardly noticeable when painted. However, when the wall or ceiling is longer than eight feet, it can be necessary to place two or more panels end-to-end, forming a butt joint. The ends of drywall panels are either tapered or not tapered. Typically, butt joints are simply covered with joint compound and smoothed by sanding. Over time, however, the joint can spread slightly as the studs and joists expand and contract in response to thermal stress, resulting in ridges or gaps forming along the seam of the butt joint.
Thus, a drywall tapering device addressing the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The drywall tapering device has a drive roller and two idler rollers extending from the front face of a frame in a triangular configuration with the drive roller above the idler rollers. The drive roller has an annular groove defined around its base and tapers in diameter from wide to narrow as the roller extends from the base to its free end. The butt end of a drywall panel is supported against an elongate track. The frame is clamped over the butt end and the track, a spring-biased adjustment screw assembly being used to clamp the drive roller against the butt end with the track engaging the groove. A drill grips a mandrel extending from the drive roller and causes the drive roller to rotate and ride along the track, forming a tapered recess in the butt end of the drywall, the idler rollers following below the track.
Two drywall panels having tapered recesses formed in this manner can be placed end-to-end and taped with drywall tape and joint compound to form a smooth, secure seam.
The drive roller is rotatably mounted in a mounting tube that is vertically slidable in a slot defined in the frame. The mounting tube has front and rear annular disks disposed against the front and rear faces of the frame to constrain the tube to slide in the slot. A stud having a compression spring coaxially disposed around its shank is positioned below the rear annular disk. A threaded bolt extends through the top of the frame, and a knob is mounted on the free end of the threaded bolt. The opposite end of the threaded bolt bears against the rear annular disk, pressing the rear annular disk against the compression spring to fix the height of the drive roller. The height of the drive roller can be adjusted by using the knob to screw the threaded bolt into and out of the frame, thereby clamping the drive roller against drywall panels, such as of a conventional thickness, e.g., ½ inch, ⅝ inch, etc.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a drywall tapering device according to the present invention.
FIG. 2 is a side view of the drywall tapering device shown in FIG. 1 .
FIG. 3 is a rear view of the drywall tapering device shown in FIG. 1 .
FIG. 4 is a front view of the drywall tapering device shown in FIG. 1 .
FIG. 5A is a perspective view of a system for tapering drywall according to the present invention.
FIG. 5B is a detailed side view of the drywall tapering device and the track in the system for tapering drywall shown in FIG. 5A .
FIG. 6A is a top view of a butt joint.
FIG. 6B is a top view of a seam joint formed by a factory tapered butt end and a tapered butt end created by a drywall tapering device and a system for tapering drywall according to the present invention.
Unless otherwise indicated, similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-5B , a drywall tapering device 100 is shown. The drywall tapering device 100 includes a frame 102 and channel or slot 104 defined on the frame 102 . As shown in FIGS. 1-4 , the slot 104 can extend through the frame 102 to form a cut-out region. Communicating with the slot 104 of the frame 102 is a drive roller 112 . The drive roller 112 includes an annular groove 114 defined around its base. The annular groove 114 is situated around the perimeter of the drive roller 112 and is adapted to receive a lip 202 of a track 200 , as shown in FIG. 5B . By receiving the lip 202 , the drive roller 112 and the frame 102 of the drywall tapering device 100 can be moved linearly along the track 200 in a controlled manner. In addition to the annular groove 114 , the drive roller 112 has a shape that includes a circumferential taper 116 extending from the annular groove 114 towards a front edge 118 at the distal end of the drive roller 112 . The taper 116 is formed by a decrease in diameter along the length of the drive roller 112 from wide at the base to narrow at the distal end. As shown in FIGS. 1-513 , the taper 116 of the drive roller 112 forms a generally frustoconical shape or any suitable shape that fits the user's needs. This taper 116 of the drive roller 112 can allow for a corresponding tapered butt end, such as the tapered edge 606 b shown in FIG. 6B , to be formed on an end of a sheet, panel, board, or web 208 when the sheet 208 is placed beneath the drive roller 112 and the frame 102 of the drywall tapering device 100 is moved along the edge of the sheet of material 208 .
In order to facilitate movement of the drywall tapering device 100 , the drywall tapering device includes a drive attachment 122 extending from the rear 120 of the drive roller 112 as shown in FIGS. 2 and 3 . The drive attachment 122 assists in moving the frame 102 across the track 200 by communicating with a drive mechanism 124 . In this embodiment, the drive attachment 122 can be an elongate mandrel for selective coupling with the drive mechanism 124 , the drive mechanism 124 selectively gripping the mandrel 122 and rotating the drive roller 112 . Desirably, the drive mechanism 124 can be a cordless power drill, such as having a ½ inch bit, as exemplarily shown in FIG. 5A . Other examples of drive mechanisms include, but are not limited thereto, power tools, pneumatic tools, manual tools, or any instrument that can be selectively coupled to the drive attachment 122 and rotate the same. Rotation of the drive roller 112 facilitates concurrent movement of the drive roller 112 and the frame 102 of the drywall tapering device 100 along the track 200 while the drive roller 112 forms a tapered edge on the desired butt end of the sheet 208 .
The drive roller 112 can be adjustably positioned along the slot 104 of the frame 102 by a controller 106 in order accommodate various thicknesses of sheets 208 . The drive roller 112 is rotatably mounted in a mounting housing 111 configured to vertically slide inside the slot 104 . In this instance, the mounting housing 111 is constructed as a mounting tube with the drive attachment 122 extending outwardly from the back of the mounting housing 111 . Desirably, the diameter of the mounting housing 111 is about the same as the width of the slot 104 so that the mounting housing 111 can be received in the slot 104 with minimal tolerances which can help to minimize undesirable rotation of the mounting housing 111 within the slot 104 . Also, the diameter of the mounting housing 111 can be constructed with a diameter larger than the width of the slot 104 so that diametric opposing sides can be ground, milled, or molded to form guide faces or surfaces 111 a of the mounting housing 111 . The guide faces 111 a can permit the mounting housing 111 to fit and slide within the slot 104 and can provide an abutment surface to assist in preventing relative rotation of the mounting housing 111 therein.
The mounting housing 111 also includes a front annular disk 109 a and a rear annular disk 109 b disposed thereon, the front and rear annular disks 109 a , 109 b being spaced apart from each other so as to straddle the frame 102 therebetween. When installed, the annular disks 109 a , 109 b are disposed on opposite sides of the frame 102 and thereby can assist in preventing undesirable axial movement of the mounting housing 111 with respect to the frame 102 . This arrangement constrains movement of the mounting housing 111 to slide in the slot 104 . The front annular disk 109 a and the rear annular disk 109 b can be construed as stabilizing members, since they confine positioning and movement of the drive roller 112 .
In the embodiment of FIGS. 1-5B , as illustrated, the front annular disk 109 a and the rear annular disk 109 b have been shown to be of unequal thickness where the rear annular disk 109 b is thicker than the front annular disk 109 a . The thicker rear annular disk 109 b can provide a sturdy base for receiving the mounting housing 111 . Moreover, the thicker rear annular disk 109 b can provide a sturdy structure for interaction with the controller 106 .
In order to facilitate the vertical adjustment of the drive roller 112 , the controller 106 includes a biasing mechanism such as a stud 110 having a compression spring 110 a coaxially disposed around its shank. The stud 110 and the compression spring 110 a are positioned below the rear annular disk 109 b in order to vertically support the rear annular disk 109 b . The stud 110 can extend into the rear annular disk 109 b to an extent as can insure proper alignment of the drive roller 112 and additionally can prevent rotation of the mounting housing 111 . An adjustment mechanism, such as a threaded bolt 108 a , extends through the top of the frame 102 , and a knob 108 is mounted on the free end of the threaded bolt 108 a . The opposite end of the threaded bolt 108 a bears against the rear annular disk 109 b , pressing the rear annular disk 109 b against the compression spring to 110 a to fix the height of the drive roller 112 . The height of the drive roller 112 can be adjusted by using the knob 108 to screw the threaded bolt 108 a into and out of the frame 102 , thereby clamping the drive roller 112 against one of the butt ends of the sheet 208 . The threaded bolt 108 a can also extend, at least partially, into the rear annular disk 109 b . As shown in FIGS. 1-4 , the knob 108 can be a four pronged handle or any other common attachment, such as a wheel or lever that can assist the user in manipulating the controller 106 .
The frame 102 also includes a plurality of idler rollers 126 disposed below the drive roller 112 forming a gap 128 where a butt end of the sheet 208 can be inserted between the drive roller 112 and the idler rollers 126 , such as where the butt end of the sheet 208 can be inserted between the drive roller 112 and the track 200 with the idler rollers 126 positioned to an underside 204 of the track 200 , as best seen in FIGS. 1 , 2 , 4 and 5 B. Each idler roller 126 is also desirably provided with an annular groove 124 proximate the base thereof. The annular grooves 124 on the idler rollers 126 function similarly to the annular groove 114 on the drive roller 112 . In that regard, the annular grooves 124 are configured to engage the bottom portion of the lip 202 as best seen in FIG. 5B . The disposition of the drive roller 112 and the idler rollers 126 form a generally triangular configuration. In use, the plurality of idler rollers 126 can follow, for example, along the underside 204 of the track 200 as best shown in FIGS. 5A and 5B when the frame 102 is moved along the track 200 forming the tapered butt end on the sheet 208 . Placement of the plurality of idler rollers 126 along the underside 204 of the track 200 allows for the drywall tapering device 100 to be further secured to the track 200 , and the annular grooves 124 are vertically aligned with the annular groove 114 on the drive roller 112 so that a relatively secure, accurate and properly aligned engagement can be maintained throughout the operation of the drywall tapering device 100 , such as can enhance the efficiency of the process of forming a tapered edge, as for example, on the sheet 208 . Additionally, by placing the plurality of idler rollers 126 along the underside 204 of the track 200 , when downward pressure is applied onto the drive roller 112 which would also be applied onto the sheet of material 208 and onto the track 200 , the plurality of idler rollers 126 will be forced up and can come into further contact with the underside 204 of the track 200 . This can allow the downward pressure applied to the drive roller 112 to be applied along the end of the sheet 208 to be tapered while the drywall tapering device 100 is traveling along the track 200 and across the sheet 208 . This downward force applied by the drive roller 112 onto one of the ends of the sheet 208 allows for the formation of a tapered edge thereon.
Referring to FIG. 5A , the system for tapering drywall 500 includes a table 206 where both the track 200 and the table 206 are adapted to receive the sheet 208 . The table 206 can be formed from any common components, including a plurality of horses and a plurality of pipes over welded struts connected together by a plurality of brackets, for example. The track 200 can be secured to the table 206 by any common securing mechanisms, including brackets or braces, among others. By using this type of configuration and components in the system for tapering drywall 500 , the table 206 and track 200 can be assembled and disassembled relatively easy and quickly. This can allow for the system for tapering drywall 500 to be assembled and disassembled by the user at a job site.
In use, the user places the sheet 208 onto the table 206 and the track 200 . In this instance, the sheet 208 is a drywall panel of a conventional thickness, e.g., ½ inch, ⅝ inch, etc. It is to be understood that the drywall tapering device 100 can also be used on compressible webs where a taper can be formed. The user aligns the butt end to be tapered by the drywall tapering device 100 onto the track 200 behind the lip 202 , the lip 202 forming a fence for alignment of the butt end of the sheet 208 . In the embodiment shown, the lip 202 is desirably an elongate, vertical bar extending above and below the horizontal portion of the track 200 . This configuration permits the top part of the lip 202 to engage the annular groove 114 of the drive roller 112 while the bottom part of the lip 202 can engage the annular groove 124 on the idler rollers 126 . The user then places the annular groove 114 of the drywall tapering device 100 in communication with the lip 202 of the track 200 , which also facilitates mutual communication between the lip 202 and the annular grooves 124 . The user connects the drive mechanism 124 to the drive attachment 122 of the drywall tapering device 100 to selectively move the drywall tapering device 100 across the butt end of the sheet 208 to be tapered. Movement of the drywall tapering device 100 across the butt end the sheet of material 208 compresses and forms the new tapered edge, such as tapered edge 606 b shown in FIG. 6B . Depending on the user's needs, the user can adjust the vertical position of the drive roller 112 to accept different thicknesses of sheets 208 by manipulating the controller 106 of the drywall tapering device 100 which can selectively position the drive roller 112 along the slot 104 of the drywall tapering device 100 .
Referring to FIGS. 6A and 6B , a butt joint 600 a and a seam joint 600 b are shown. The butt joint 600 a is formed when a factory tapered edge 604 a is placed adjacent to a non-factory tapered edge 606 a . The butt joint 600 a can form bulges or unevenness when tape and compound are placed within the butt joint 600 a and therefore should be avoided as being typically undesirable. In comparison, as shown in FIG. 6B , a seam joint 600 b is formed when a factory tapered edge 604 b is placed adjacent to a tapered edge 606 b that was reworked or formed by the drywall tapering device 100 and the system for tapering drywall 500 . The seam joint 600 b can allow for taping and compound to be filled into the seam joint 600 b without typically leaving a bulge or unevenness in the wall, and thereby can allow for a smooth and even surface in the wall or ceiling, for example.
It is to be understood that the present invention encompasses a variety of alternatives. Though the specification describes forming one butt end on a sheet for tapering, the drywall tapering device 100 can be used to form tapered butt ends on any desired one or more sides of the sheet 208 . Additionally, the drywall tapering device 100 can be constructed from any sturdy materials such as steel, plastic, composites, combinations thereof and the like. Furthermore, the drywall tapering device 100 can form tapers without the track 200 where the front face of the frame 102 forms a sufficient alignment surface for the sheet 208 to be tapered and the idler rollers 126 provide sufficient support for the drywall tapering device 100 to travel along the end of the sheet 208 to be tapered.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The drywall tapering device has a drive roller and two idler rollers extending from the front face of a frame in a triangular configuration with the drive roller above the idler rollers. The drive roller has an annular groove defined around its base and tapers in diameter from wide to narrow as the roller extends from the base to its free end. The butt end of a drywall panel is supported against an elongate track. The frame is clamped over the butt end and the track, a spring-biased adjustment screw assembly being used to clamp the drive roller against the butt end with the track engaging the groove. A drill grips a mandrel extending from the drive roller and causes the drive roller to rotate and ride along the track, forming a tapered recess in the butt end of the drywall, the idler rollers following below the track.
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BRIEF DESCRIPTION OF THE INVENTION
This invention relates generally to micromachined fluid control devices, such as valves and pumps. More particularly, this invention relates to a thermally conductive boiler controlled by a heat source positioned outside of the boiler chamber.
BACKGROUND OF THE INVENTION
Micromachined devices (also called micromechanical devices or microelectro-mechanical devices) are small (micron scale) machines that are constructed using semiconductor processing techniques. Micromachines include a variety of devices, such as fluid control devices (e.g., valves and pumps), motors, and gear trains analogous to conventional macroscale machinery. As used herein, the term micromachine refers to any three-dimensional object that is at least partially constructed in reliance upon semiconductor processing techniques.
FIG. 1 illustrates a micromachined valve 20 constructed in accordance with the prior art. The valve 20 includes three major components: a heat insulating substrate 22, a deformable membrane 24, and a fluid routing substrate 26. The heat insulating substrate 22 may be formed of Pyrex, while the deformable membrane may be formed of silicon. A working fluid 28 is positioned in a void formed between the heat insulating substrate 22 and the deformable membrane 24. A thin-film heater 30 is formed on the heat insulating substrate 22. More particularly, as shown in FIG. 1, the thin-film heater 30 is attached to an interior surface of the valve 20. An electrical contact 32 and an electrical feedthrough 34 are used to supply current to the thin-film heater 30. Although not shown for the purpose of simplicity, at least one additional contact and electrical feedthrough are also used. FIG. 1 also shows a seal cap 36 which may be used to deliver the working fluid 28 into the valve 20.
The deformable membrane 24 is positioned on a pedestal 38 and carries a valve seat 40. The valve seat 40 rests over a valve opening 42. Thus, the apparatus of FIG. 1 represents a normally closed valve. That is, the valve of FIG. 1 is closed when no power is applied to it.
FIG. 2 illustrates the valve of FIG. 1 in an open state after power is applied to it. When current is applied across the thin-film resistor 30, the working fluid 28 is heated and subsequently expands, thereby deforming the deformable membrane 24. As a result, fluid can pass through the valve opening 42, as shown with arrow 44.
Those skilled in the art will recognize a number of shortcomings associated with the apparatus of FIGS. 1 and 2. First, the prior art device is relatively slow because it is relatively time-consuming to heat the working fluid 28 with the thin-film heater 30. In addition, the prior art device is relatively expensive to manufacture and test. A significant portion of this expense is associated with the thin-film heater 30. The thin-film heater 30 is inherently expensive to manufacture. Testing of the thin-film structure is difficult because of the position of the thin-film heater in the interior of the valve. Furthermore, it is relatively expensive to provide a thin-film heater with refined temperature and current control capabilities.
In view of the foregoing, it would be highly desirable to provide an improved micromachined fluid control device. Such a device should provide improved speed in controlling the temperature of the working fluid. In addition, such a device should be relatively inexpensive to manufacture and test.
SUMMARY OF THE INVENTION
The apparatus of the invention is a micromachined boiler with a thermally conductive housing that has a housing exterior surface and a housing interior surface. The housing interior surface defines an interior void that has a fluid positioned within it. A heat source is incorporated with the housing exterior surface. The heat source selectively generates heat that is conducted through the thermally conductive housing so as to selectively expand the fluid in a predetermined manner. A load resistor may be positioned within the thermally conductive housing. Current may be driven through the load resistor in a predetermined manner to further control the selective expansion of the fluid.
The method of the invention includes the step of enclosing a working fluid within a micromachined boiler with a thermally conductive housing. The thermally conductive housing is subsequently heated to control the expansion of the working fluid within the micromachined boiler. Current may be selectively driven through a load resistor positioned within the thermally conductive housing to control the expansion of the working fluid within the micromachined boiler.
The combination of the thermally conductive boiler housing and externally positioned heat source provides rapid proportional control of the working fluid within the boiler. The heat source of the invention is relatively easy to assemble. The position of the heat source also facilitates testing. The heat source may be implemented as a low-cost, externally mounted controller. Alternately, the heat source may be integrally formed within the boiler. In either embodiment, the heat source is an external heat source since it is external to the interior of the boiler chamber. The thermally conductive housing efficiently exploits all thermal energy associated with the heat source.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a prior art valve that uses internal heating of a working fluid to control the valve state.
FIG. 2 illustrates the prior art valve of FIG. 1 in an open state.
FIG. 3 illustrates a micromachined fluid control apparatus in accordance with an embodiment of the invention.
FIG. 4 is an enlarged cross-sectional view of a micromachined fluid control apparatus in accordance with an embodiment of the invention.
FIG. 5 illustrates an electrical circuit corresponding to the apparatus of FIG. 4.
FIG. 6 is an enlarged cross-sectional view of a micromachined fluid control apparatus in accordance with another embodiment of the invention.
FIG. 7 illustrates an electrical circuit corresponding to the apparatus of FIG. 6.
FIG. 8 is an enlarged cross-sectional view of a micromachined fluid control apparatus in accordance with another embodiment of the invention.
FIG. 9 illustrates an electrical circuit corresponding to the apparatus of FIG. 8.
FIG. 10 is an enlarged cross-sectional view of a micromachined fluid control apparatus in accordance with another embodiment of the invention.
FIG. 11 illustrates an electrical circuit corresponding to the apparatus of FIG. 10.
FIG. 12 illustrates a micromachined fluid control apparatus in accordance with another embodiment of the invention.
Like reference numerals refer to corresponding parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 illustrates a micromachined fluid control apparatus 50 in accordance with an embodiment of the invention. The apparatus 50 includes a micromachined boiler 52. The micromachined boiler 52 includes a thermally conductive housing that defines an interior void (shown in subsequent figures). A heat source 54 is incorporated with the exterior of the micromachined boiler 52. The heat source 54 may either be a discrete device attached to the boiler 52, as shown in FIG. 3, or it may be a device integrated into the boiler. In either embodiment, the heat source is external to the interior chamber defined by the boiler. Heater bond wires 56 are attached to the heat source 54.
The micromachined boiler 52 is preferably positioned on an insulating substrate 58, which may have a fluid seal cap 60. The insulating substrate may be formed of Pyrex. A deformable membrane 62 is attached to the insulating substrate 58. By way of example, the deformable membrane 62 may be formed of silicon. A fluid routing substrate 65 is attached to the deformable membrane 62. The deformable membrane 62, the fluid routing substrate 65, and the insulating substrate 58 may be of the type known in the art. The invention is directed toward the micromachined boiler 52 and its associated heater 54. Those skilled in the art will appreciate that any number of valve configurations or other external devices may be utilized in connection with the disclosed boiler 52.
The micromachined boiler 52 is formed of a thermally conductive material. As used herein, the term thermally conductive material refers to a material with a thermal conductivity of at least 40 W/m K, preferably at least 80 W/m K. The invention has been implemented with a silicon micromachined boiler 52. In this embodiment, standard semiconductor processing techniques are used to fabricate individual halves of the boiler cylinder. As discussed below, a load resistor may be formed within the individual halves of the cylinder, or may be placed at the interface between the halves. The load resistor may be an implanted device, a thin-film device, or the like. The individual halves are sealed to form a closed chamber.
The external heater 54 provides a resistive heat source. Preferably, the external heater 54 includes a control circuit to reduce heat output from the heater 54 when the heat output reaches a predetermined temperature. Alternately, the external heater 54 includes a control circuit to reduce current flow through the heater 54 when the current flow reaches a predetermined value. By way of example, the external heater 54 has been implemented with a MC7805 integrated circuit sold by Motorola, Inc., Schaumburg, Ill.
Those skilled in the art will recognize a number of benefits associated with the apparatus of FIG. 3. First, the boiler 52 is completely formed from a thermally conductive material. Thus, any heat associated with the heater 54 is conveyed to the working fluid within the boiler 52. This results in rapid heating of the working fluid. Observe that with the apparatus of FIGS. 1 and 2, the thin-film heater 30 is formed on an insulating substrate 22.
The apparatus 50 of FIG. 3 is also advantageous because it uses an externally positioned heater 54. A discrete external heater provides a low-cost implementation. An integrated external heater provides a compact and efficient implementation.
The operation and benefits of the invention are more fully appreciated with reference to FIG. 4. FIG. 4 is an enlarged cross section of the "normally open" embodiment of the device. The figure illustrates the boiler 52, which defines a boiler chamber 61. A working fluid 63 is positioned within the chamber 61. In the embodiment of FIG. 4, a load resistor 64 is positioned within the wall of the boiler 52.
A voltage input bond pad 66 is positioned on the insulating substrate 58. A voltage input bond wire 68 extends from the bond pad 66 to the top of the heater 54. A ground bond pad 70 is also positioned on the insulating substrate 58. Ground bond wires 72 are attached to the boiler 52 and the heater 54. A ground plane 74 is formed on the top of the boiler 52. An output bond wire 78 extends from the top of the heater 54 to an output lead 80, which is electrically linked with the load resistor 64.
FIG. 5 illustrates an electrical circuit corresponding to the device of FIG. 4. FIG. 5 illustrates the voltage input bond wire 68 being applied to the heater 54. The output bond wire 78 from the heater is connected to the load resistor 64, which is connected to ground at its other end. The heater 54 is also grounded via the ground bond wire 72. The input voltage applied from node 68 is applied to the heater 54, causing the heater to generate resistive heat, which is conducted to the working fluid 63. Resistive heat is also generated by the load resistor 64.
The applied heat causes the working fluid 63 to expand. As a result, the deformable membrane 62 distends to block the output port 84 of the fluid routing substrate 64. Control of the working fluid 63 provides proportional control of the valve. Those skilled in the art will appreciate that the boiler of the invention can be used with any number of fluid control paths, valves, or pumps. The configuration of FIG. 4 is solely provided by way of example.
FIG. 6 illustrates another embodiment of the micromachined boiler of the invention. The apparatus of FIG. 6 does not include a load resistor. Instead, a load transistor 92 is provided. The transistor is used as a load and a secondary heating source. The load transistor 92 allows dynamic output loading. The transistor 92 may be mounted onto the boiler 54, manufactured into the boiler 54, or mounted remotely.
The boiler 90 of FIG. 6 encloses a working fluid 63. The boiler 90 is positioned on an insulating substrate 58. A voltage input bond pad 66 is positioned on the substrate 58. A voltage input bond wire 68 extends from the bond pad 66 to the top of the heater 54. A ground bond pad 70 is also positioned on the substrate 58. Ground bond wires 72 extend to the ground plane 74, the load transistor 92, and the heater 54. The load transistor 92 is connected to a control input pad 94 via a control input bond wire 96. An output bond wire 78 links an output node of the heater 54 to the load transistor 92.
FIG. 7 illustrates an electrical circuit corresponding to the device of FIG. 6. An output node of the heater 54 is connected to the load transistor 92. The control input bond wire 96 is attached to the gate or base of the transistor 92. In this embodiment, the heater 54 provides heat to the working fluid, as does the transistor 92.
FIG. 8 illustrates another embodiment of the invention. In this embodiment, the boiler 100 includes an internal load resistor 64 and an externally mounted transistor 102. FIG. 9 is a schematic corresponding to the device of FIG. 8. A control input bond wire 104 is attached to the gate or base of transistor 102. A transistor output lead 106 is electrically connected to the load resistor 64. Thus, in this embodiment, the transistor 102 is used as a power control device, allowing for fast, efficient heating.
FIG. 10 illustrates still another embodiment of the invention. In this embodiment, the boiler 120 includes a set of heat transfer fins 122 positioned within the boiler interior chamber. The heat transfer fins 122 improve the heat transfer characteristics of the device. A separate resistor input lead 124 is provided in this embodiment to establish separate control of the load resistor 64. FIG. 11 illustrates an electrical schematic corresponding to the device of FIG. 10.
FIG. 12 illustrates a boiler 130 in which the heater 54 is integral with the boiler housing. Bond wires 132 are used to establish the required electrical connections. The device of FIG. 12 operates consistently with the previously disclosed embodiments of the invention.
The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. In other instances, well known circuits and devices are shown in block diagram form in order to avoid unnecessary distraction from the underlying invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with 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.
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A micromachined fluid control apparatus includes a micromachined boiler with a thermally conductive housing that has a housing exterior surface and a housing interior surface. The housing interior surface defines an interior void that has a fluid positioned within it. A heat source is incorporated with the housing exterior surface. The heat source selectively generates heat that is conducted through the thermally conductive housing so as to selectively expand the fluid in a predetermined manner. A load resistor may be positioned within the thermally conductive housing. Current may be driven through the load resistor in a predetermined manner to further control the selective expansion of the fluid.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/355,491, filed Feb. 16, 2006. The disclosure of the above application is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to wireless networks, and more particularly to implementing multiple access points in a single device.
BACKGROUND OF THE INVENTION
Referring now to FIG. 1 , an internetwork 10 is shown that includes a first subnetwork 12 , a second subnetwork 14 , and a connection 16 to a distributed communications system 18 , such as the Internet. First subnetwork 12 includes a plurality of wireless stations 20 - 1 , 20 - 2 , . . . , 20 - n that are associated with a first wireless access point (AP_A) 22 . Second subnetwork 14 includes a plurality of wireless stations 24 - 1 , 24 - 2 , . . . , 24 - m that are associated with a second wireless access point (AP_B) 26 . AP_A 22 and AP_B 26 communicate with a switch 28 that routes data packets between first network 12 , second network 14 and distributed communications system 10 .
Internetwork 10 is of typical construction in that AP_A 22 and AP_B 26 each include, in pertinent part, a media access controller (MAC) and a physical layer module (PHY) to form and communicate data packets over the wireless channel.
SUMMARY OF THE INVENTION
A wireless network device includes a first media access controller (MAC) that generates a first output signal, a second MAC that generates a second output signal, and a communication channel. The communication channel includes a baseband processor in communication with a radio frequency transmitter and selectively transmits one of the first output signal and the second output signal.
In other features the wireless network device includes a switch that routes one of the first output signal and the second output signal to the communication channel in accordance with a select signal. The communication channel generates a clear channel assessment signal that is communicated to the first MAC and the second MAC and determines when the first and second output signals can be generated.
In other features an arbitration circuit determines which of the first output signal and the second output signal is transmitted by the communication channel. The determination is made based on a priority relationship between the first MAC and the second MAC. The first MAC and the second MAC generate respective first and second request signals that are communicated to the arbitration module. The first and second request signals indicate that the respective one of the first and second MACs desires to generate its respective one of the first and second output signals.
In other features the arbitration module generates a first drop signal that is communicated to the first MAC and generates a second drop signal that is communicated to the second MAC. The first MAC and the second MAC each include a queue for data to be output through their respective first and second output signals. The first MAC and second MAC flush the data from their respective queue upon receiving their respective one of the first drop signal and the second drop signal.
In other features the communication channel is otherwise compliant with at least one of the Institute of Electrical and Electronics Engineers (IEEE) standards 802.11, 802.11a, 802.11b, 802.11g, 802.11h, 802.11n, 802.16, and 802.20 and the Bluetooth standard issued by the Bluetooth Special Interest Group (SIG).
A wireless network device includes first media access controller (MAC) means for generating a first output signal, second MAC means for generating a second output signal, and communication channel means including baseband processor means for communicating a selected one of the first and second output signals to radio frequency transmitting means for transmitting a radio-frequency modulated carrier based on the selected one of the first and second output signals.
In other features the wireless network device includes switch means for routing the selected one of the first and second output signals to the communication channel means in accordance with a select signal. The communication channel means generates a clear channel assessment signal that is communicated to the first MAC means and the second MAC means and determines when the first and second output signals can be generated.
In other features the wireless network device includes arbitration means for determining which of the first output signal and the second output signal is transmitted by the communication channel means. The determination is made based on a priority relationship between the first MAC means and the second MAC means. The first MAC means and the second MAC means generate respective first and second request signals that are communicated to the arbitration means. The first and second request signals indicate that the respective one of the first and second MAC means desires to generate its respective one of the first and second output signals.
In other features the arbitration means generates a first drop signal that is communicated to the first MAC means and generates a second drop signal that is communicated to the second MAC means. The first MAC means and the second MAC means each include queue means for queuing data to be output through their respective first and second output signals. The first MAC means and second MAC means flushes the data from their respective queue means upon receiving their respective one of the first drop signal and the second drop signal.
In other features the communication channel means is otherwise compliant with at least one of the Institute of Electrical and Electronics Engineers (IEEE) standards 802.11, 802.11a, 802.11b, 802.11g, 802.11h, 802.11n, 802.16, and 802.20 and the Bluetooth standard issued by the Bluetooth Special Interest Group (SIG).
A method for generating a transmit signal in a wireless network device includes providing a first media access controller (MAC) that generates a first output signal in accordance with a first wireless network protocol, providing a second MAC that generates a second output signal in accordance with a second wireless network protocol, transmitting the first data packets and the second data packets from a common transmitter.
In other features the method includes generating a select signal and routing one of the first and second output signals to the transmitting step in accordance with the select signal. The method also includes receiving a wireless network signal, generating a clear channel assessment signal that indicates one of the receiving and transmitting steps are executing; and generating the first and second output signal based on the clear channel assessment signal.
In other features the method includes determining which of the first and second output signals is transmitted during the transmitting step based on a priority relationship between the first and second output signals. The method includes generating first and second request signals associated with respective ones of the first and second output signals, and asserting respective ones of the first and second request signals in association with generating the respective ones of the first and second output signals.
In other features the method includes generating first and second drop signals associated with respective ones of the first and second output signals, maintaining first and second queues for data to be included in respective ones of the first and second output signals, and flushing a respective one of the first and second queues in response to a respective one of the first and second drop signals.
In other features the transmitting step is otherwise compliant with at least one of the Institute of Electrical and Electronics Engineers (IEEE) standards 802.11, 802.11a, 802.11b, 802.11g, 802.11h, 802.11n, 802.16, and 802.20 and the Bluetooth standard issued by the Bluetooth Special Interest Group (SIG).
In other features the first wireless network protocol is different from the second wireless network protocol. The first wireless network protocol includes an ad-hoc networking protocol and the second wireless network protocol includes an infrastructure mode protocol.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a functional block diagram of an internetwork of the prior art;
FIG. 2 is a functional block diagram of an improved internetwork;
FIG. 3 is a functional block diagram of a system-on-chip (SOC);
FIG. 4 is a flowchart of a method for controlling access to a communication channel of the SOC;
FIG. 5A is a functional block diagram of a high definition television;
FIG. 5B is a functional block diagram of a vehicle control system;
FIG. 5C is a functional block diagram of a cellular phone; and
FIG. 5D is a functional block diagram of a set top box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term module, circuit and/or device refers to an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or or suitable components that provide the described functionality. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. It should be understood that steps within a method may be executed in different order without altering the principles of the present invention.
Referring now to FIG. 2 , an improved internetwork 50 is shown. Internetwork 50 includes a networked appliance 52 that communicates with a first subnetwork 54 , a second subnetwork 56 , and a distributed communications system 58 , such as the Internet. In an example configuration, networked appliance 52 can be an audio/visual entertainment system. In the example configuration, first subnetwork 54 communicates real-time control data between remote control devices and second subnetwork 56 provides a wireless access point (WAP) to distributed communications system 58 . First subnetwork 54 and second subnetwork 56 can be configured to use different network modes. For example, first subnetwork 54 can be configured in an ad-hoc mode, and second subnetwork 56 can be configured in an infrastructure mode.
Wireless networking protocols that may be used with first subnetwork 54 and second subnetwork 56 include the Institute of Electrical and Electronics Engineers (IEEE) standards 802.11, 802.11a, 802.11b, 802.11g, 802.11h, 802.11n, 802.16, and 802.20. First subnetwork 54 and second subnetwork 56 can also be operated as personal area networks such as Bluetooth. A Bluetooth standard is published by the Bluetooth Special Interest Group (SIG). The aforementioned standards are hereby incorporated by reference in their entirety.
First subnetwork 54 includes a plurality of wireless stations (STAs) 60 - 1 , 60 - 2 , . . . , 60 - n , referred to collectively as STAs 60 , that are associated with a first media access controller (MAC 1 A) 62 . Second subnetwork 56 includes a plurality of wireless stations 64 - 1 , 64 - 2 , . . . , 64 - m , referred to collectively as STAs 64 , that are associated with a second media access controller (MAC 1 B) 66 .
STAs 60 and 64 communicate with MAC 1 A 62 and MAC 1 B 66 through a communication channel 67 that includes an RF module 68 and a baseband processor 70 . An arbitration module 72 allows MAC 1 A 62 and MAC 1 B 66 to transmit through the single communication channel 67 as described below. MAC 1 A 62 , MAC 1 B 66 , arbitration module 72 , and baseband processor 70 can be implemented as part of a system-on-chip (SOC) 74 .
MAC 1 A 62 and MAC 1 B 66 communicate with distributed communications system 58 through a third MAC 76 , PHY 78 , and a network switch 80 . PHY 78 and switch 80 can be compatible with a copper and/or fiber-optic Ethernet connection. In one embodiment, PHY 78 and switch 80 are compatible with a 100-BASET Fast Ethernet (FE) connection. MAC 76 and PHY 78 can also be implemented on SOC 74 , which can also include other components as will be described later.
Networked appliance 52 can also include a first central processor unit (CPU 1 ) 82 and memory 84 . Memory 84 stores computer programs such as operating systems and/or applications for operating networked appliance 52 . CPU 1 82 executes the computer programs stored in memory 84 . CPU 1 82 also includes a network link 86 that communicates with network switch 80 . Network link 86 allows CPU 1 82 to communicate with SOC 52 , first subnetwork 54 , second subnetwork 56 , and distributed communications system 58 .
Referring now to FIG. 3 , SOC 74 is shown in additional detail. SOC 74 can include a second central processor unit (CPU 2 ) 100 that communicates with MAC 1 A 62 , MAC 1 B 66 , and MAC 76 through an internal bus 102 . CPU 2 100 routes data packets between MAC 1 A 62 , MAC 1 B 66 , and MAC 74 and is associated with memory 104 that stores one or more computer programs related to routing the data packets.
Arbitration module 72 provides flow control logic for data packets transmitted from an OUT1 port of MAC 1 A 62 and an OUT2 port of MAC 1 B 66 . Arbitration module 72 includes a switch module 106 that receives data packets from OUT 1 and OUT 2 and selectively communicates one of them to an output 112 in accordance with a select signal 108 . An arbitration logic circuit 110 selects the MAC 1 A 62 and MAC 1 B 66 that gets access to communication channel 67 and generates select signal 108 accordingly. In one embodiment, arbitration logic circuit 110 determines priority between MAC 1 A 62 and MAC 1 B 66 according to a predetermined hierarchy. For example, arbitration logic circuit 110 can be configured to give priority to MAC 1 A 62 over MAC 1 B 66 .
Arbitration module 72 generates a first clear channel assessment signal CCA 1 and a second clear channel assessment signal CCA 2 . The CCA1 signal is applied to MAC 1 A 62 and the CCA2 signal is applied to MAC 1 B 66 . The signals CCA 1 and CCA 2 change state (such as go low) to indicate the MAC 1 A 62 and MAC 1 B 66 that has access to communication channel 67 and change state (such as go high) to indicate that communication channel 67 is unavailable to the respective MAC 1 A 62 and MAC 1 B 66 .
A first OR-gate 114 generates the CCA1 signal. First OR-gate 114 includes a first input that receives a CCA1′ signal from arbitration logic circuit 110 and a second input that receives a CCA signal 116 from baseband module 70 . Arbitration logic circuit 110 drives the CCA1′ signal high when MAC 1 A 62 is granted access to communication channel 67 and drives the CCA1′ signal low when MAC 1 A 62 is not granted access to communication channel 67 . Baseband module 70 drives CCA signal 116 high when communication channel 67 is busy transmitting or receiving and drives CCA signal 116 low when communications channel 67 is clear.
A second OR-gate 118 generates the CCA 2 signal. Second OR-gate 118 includes a first input that receives a CCA2′ signal from arbitration logic circuit 110 and second input that receives CCA signal 116 from baseband module 70 . Arbitration logic circuit 110 drives the CCA2′ signal high when MAC 1 B 66 is granted access to communication channel 67 and drives the CCA2′ signal low when MAC 1 A 62 is not granted access to communication channel 67 .
In general, second OR-gate 118 drives the CCA2 signal high when MAC 1 A 62 is granted permission to transmit over communication channel 67 and drives CCA 2 low after MAC 1 A 62 finishes transmitting. First OR-gate 114 drives the CCA1 signal high when MAC 1 B 66 is granted permission to transmit over communication channel 67 and drives CCA 1 low after MAC 1 B 66 finishes transmitting.
MAC 1 A 62 and MAC 1 B 66 include respective internal transmit queues and assert respective request signals REQ 1 and REQ 2 when their respective queue contains data to be transmitted. The REQ1 and REQ2 signals are applied to arbitration logic circuit 110 . Upon receiving an asserted REQ1 or REQ2 signal, arbitration module 72 executes methods that are described below. A first method ( FIG. 4 ) determines whether one of MAC 1 A 62 and MAC 1 B 66 may access communication channel 67 . A second method (FIG. 5 ) determines whether arbitration logic circuit 110 should instruct MAC 1 A 62 and/or MAC 1 B to flush its respective queue and thereby drop the packet (dropped packets can be retried and/or re-sent according to a selected wireless protocol). Arbitration logic circuit 110 generates a DROP1 signal that is communicated to MAC 1 A 62 and generates a DROP2 signal that is communicated to MAC 1 B 66 . The DROP1 and DROP2 signals are asserted to indicate that the respective one of MAC 1 A 62 and MAC 1 B 66 should flush the data packet from its respective queue. MAC 1 A 62 and MAC 1 B simultaneously receive data from communication channel channel via an RX port 118 that is driven by baseband module 70 .
Referring now to FIG. 4 , a method 150 is shown for determining which of MAC 1 A 62 and MAC 1 B 66 is granted access to communication channel 67 . Method 150 can be executed by a central processing unit and/or or a logic circuit included in arbitration logic circuit 110 . Method 150 is executed when MAC 1 A 62 and/or MAC 1 B 66 asserts its associated request signal REQ 1 , REQ 2 .
Control begins in block 152 and proceeds to decision block 154 . In decision block 154 , control determines whether REQ 1 and REQ 2 are being asserted simultaneously. If not, control branches to block 156 and clears CCA 1 ′ if MAC 1 A is requesting or clears CCA 2 ′ if MAC 1 B is requesting. Control then proceeds to block 158 sets the CCAx′ signal of the non-requesting MAC 1 x so that it does not transmit while the requesting MAC 1 x is transmitting. Control then exits through exit block 160 .
Returning now to decision block 154 , if MAC 1 A and MAC 1 B are simultaneously requesting to send then control branches to block 162 . In block 162 control clears CCA 1 ′ if MAC 1 A has higher priority than MAC 1 B. If MAC 1 A has lower priority than MAC 1 B then control clears CCA 2 ′. Control then proceeds to block 164 and asserts the DROPx signal associated with the non-requesting MAC 1 x , thereby causing it to flush its queue. Control also sets the CCAx′ signal of the non-requesting MAC 1 x so that it does not transmit while the requesting MAC 1 x is transmitting. Control then exits through exit block 160 .
Referring now to FIGS. 5A-5D , various exemplary implementations of the present invention are shown. Referring now to FIG. 5A , the present invention can be implemented in a high definition television (HDTV) 420 . The present invention may implement and/or be implemented in a WLAN interface 429 . The HDTV 420 also includes signal processing and/or control circuits, which are generally identified at 422 , that communicate with the WLAN interface 429 . The signal processing and/or control circuits 422 also communicate with mass data storage 427 .
The HDTV 420 receives HDTV input signals in either a wired or wireless format and generates HDTV output signals for a display 426 . In some implementations, signal processing circuit and/or control circuit 422 and/or other circuits (not shown) of the HDTV 420 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other type of HDTV processing that may be required.
The mass data storage 427 stores data in a nonvolatile manner such as optical and/or magnetic storage devices. At least one of the magnetic storage devices may be a mini hard disk drive (mini HDD) that includes one or more platters having a diameter that is smaller than approximately 1.8″. The HDTV 420 may be connected to memory 428 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The HDTV 420 also may support connections with a plurality of WLANs via a WLAN network interface 429 .
The HDTV 420 may include a power supply and/or power conditioning circuit 423 that applies power to the other components of the HDTV 420 .
Referring now to FIG. 5B , the present invention may implement and/or be implemented in a WLAN interface 448 of a vehicle 430 . The WLAN interface 448 communicates with one or more vehicle control systems, mass data storage of the vehicle control system and/or a power supply 433 . In some implementations, the vehicle control systems include a powertrain control system 432 that receives inputs from one or more sensors such as temperature sensors, pressure sensors, rotational sensors, airflow sensors and/or any other suitable sensors and/or that generates one or more output control signals such as engine operating parameters, transmission operating parameters, and/or other control signals.
The vehicle control systems may also include other control systems 440 of the vehicle 430 . The control systems 440 may likewise receive signals from input sensors 442 and/or output control signals to one or more output devices 444 . In some implementations, the control system 440 may be part of an anti-lock braking system (ABS), a navigation system, a telematics system, a vehicle telematics system, a lane departure system, an adaptive cruise control system, a vehicle entertainment system such as a stereo, DVD, compact disc and the like. Still other implementations are contemplated.
The powertrain control system 432 may communicate with mass data storage 446 that stores data in a nonvolatile manner. The mass data storage 446 may include optical and/or magnetic storage devices for example hard disk drives (HDDs) and/or DVDs. At least one of the magnetic storage devices may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The powertrain control system 432 may be connected to memory 447 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The powertrain control system 432 also may support connections with a plurality of WLANs via WLAN network interface 448 . The control system 440 may also include memory 447 .
Referring now to FIG. 5C , the present invention can be implemented in a cellular phone 450 that may include a cellular antenna 451 . The present invention may implement and/or be implemented in WLAN interface 468 . The WLAN interface 468 communicates with either or both signal processing and/or control circuits, which are generally identified in FIG. 5C at 452 . The cellular phone 450 may also include mass data storage 464 and/or a power supply 453 . In some implementations, the cellular phone 450 includes a microphone 456 , an audio output 458 such as a speaker and/or audio output jack, a display 460 and/or an input device 462 such as a keypad, pointing device, voice actuation and/or other input device. The signal processing and/or control circuits 452 and/or other circuits (not shown) in the cellular phone 450 may process data, perform coding and/or encryption, perform calculations, format data and/or perform other cellular phone functions.
The cellular phone 450 may communicate with the mass data storage 464 to store data in a nonvolatile manner such as on optical and/or magnetic storage devices for example hard disk drives (HDDs) and/or DVDs. At least one of the magnetic storage devices may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The cellular phone 450 may be connected to memory 466 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage.
Referring now to FIG. 5D , the present invention can be implemented in a set top box 480 . The present invention may implement and/or be implemented in a WLAN interface 496 , which communicates with either or both signal processing and/or control circuits generally identified at 484 . The control circuits 484 can also communicate with mass data storage 490 of the set top box 480 and/or a power supply 483 . The set top box 480 receives signals from a source such as a broadband source and outputs standard and/or high definition audio/video signals suitable for a display 488 such as a television and/or monitor and/or other video and/or audio output devices. The signal processing and/or control circuits 484 and/or other circuits (not shown) of the set top box 480 may process data, perform coding and/or encryption, perform calculations, format data and/or perform any other set top box function.
The set top box 480 may communicate with mass data storage 490 that stores data in a nonvolatile manner. The mass data storage 490 may include optical and/or magnetic storage devices for example hard disk drives (HDDs) and/or DVDs. At least one of the magnetic storage devices may be a mini HDD that includes one or more platters having a diameter that is smaller than approximately 1.8″. The set top box 480 may be connected to memory 494 such as RAM, ROM, low latency nonvolatile memory such as flash memory and/or other suitable electronic data storage. The set top box 480 also may support connections with a plurality of WLANs via a WLAN network interface 496 . Still other implementations in addition to those described above are contemplated.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
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A network appliance includes a first media access controller with a first transmit queue storing one or more data packets to be transmitted to a first wireless device. A second media access controller includes a second transmit queue storing one or more data packets to be transmitted to a second wireless device. A baseband processor communicates with the first and the second media access controllers. An arbitration module arbitrates access of the first and second media access controllers to the baseband processor based on whether the first and second transmit queues have data packets to be transmitted to the first and second wireless devices, respectively. When both have data packets to be transmitted, the arbitration module instructs the first or second media access controller to flush any data packets stored in the first or second transmit queue so that transmission of a flushed data packet can be re-tried.
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This application is a continuation of application Ser. No. 800,758 filed Nov. 22, 1985, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to document copying devices and particularly to sheet-feeding mechanism for advancing, seriatim, the individual sheets from a stack of sheets to be copied.
The stack of sheets is placed on a holder, and the mechanism automatically feeds the bottom-most sheet onto the copier, on demand, as the copier operates.
In the past, sheet-feeding mechanisms have generally been large, bulky, and heavy, supported to one side of the copying surface on or adjacent the frame of the copier, with complicated drive-mechanism to interact between the sheet-feeder and the copier when the sheet-to-be-copied is advanced to the copy position of the copier.
This application is one of a group of four simultaneously filed: Ser. No. 800,756 now U.S. Pat. No. 4,632,376; Ser. No. 800,757 now U.S. Pat. No. 4,674,738; Ser. No. 800,962 abandoned in favor of Ser. No. 078,456 now abandoned, and Ser. No. 800,758 abandoned in favor of the present application. Applicant has also filed corresponding applications in Japan, Korea, Taiwan and the European Patent Office. The European application was published June 3, 1987 as No. 224,171A.
SUMMARY OF THE PRESENT INVENTION
In the present invention, the document feeder is a compact, box-like unit which rests directly upon the glass plate copying surface of the copy machines. It can be used with copiers having a stationary copying surface or those having a reciprocating copying surface It is to be understood that the copying machines, which may be well-known office copiers, facsimile, or electronic mail copiers, (as well as the copies which are made thereby), are not a part of this invention.
The document feeder has a cover which also functions as a tray-support for the documents to be copied When the operator chooses to use the document feeder, the box is placed directly upon the glass plate of the copy machine and the cover is raised into an inclined support-position for the documents.
The set of documents to be copied is placed face-up on the inclined support with tho first page on the top, and with the bottom (or last) page of the document, as it rests on the tray, coming into contact with a feed roller of the feeder.
Upon command, the feed roller rotates to remove the bottom sheet of the document from the tray support and (in cooperation with a drive-wheel) transfers it face-down onto the glass plate of the copier.
After the document has been copied, and while the copier is re-cycling, the drive wheel reverses direction, removes the document from the glass plate and transfers it face-up into a document-receiving tray.
During the next cycle, the drive wheel reverses and brings the next sheet from the stack of documents onto the glass plate, and the sequence is repeated.
After all the sheets have been copied, the documents may be removed from the receiving tray, the document support can be lowered to its position as a cover for the feeder, and the feeder may be removed from the copy machine.
The copier discharges the newly-made copy face-up into its copy-receiving tray and, therefore, the new set of copies are in order, when finished, with the top page on top.
Inasmuch as the newly-prepared copies, as well as the re-stacked set of copied documents are discharged from the copier face-up, all copies and documents are in proper sequence with the first page at the top of the stack and re-stacking is not required.
The document feeder of the present invention is light-weight, simple and uncomplicated and can be manufactured inexpensively and sold at a reasonable price. It can be used with a copier by an inexperienced operator and does not need a skilled service person for installation or operation.
The principle object of the present invention is to provide a document feeder which is small, compact, high-speed, easily transported, lightweight, and inexpensive.
A further object of the present invention is to provide a document feeder which can be used with any standard and well-known copy machine having either a stationary glass plate or a reciprocating glass plate.
Another object is to provide a low-cost feeder which can be easily connected to the copier so that the operation of the feeder may be automatically controlled from the control panel of the copier.
With the above and other objects in view, more information and a better understanding of the present invention may be achieved by reference to the following detailed description.
DETAILED DESCRIPTION
For the purpose of illustrating the invention, there is shown in the accompanying drawings a form thereof which is at present preferred, although it is to be understood that the several instrumentalities of which the invention consists can be variously arranged and organized and that the invention is not limited to the precise arrangements and organizations of the instrumentalities as herein shown and described.
In the drawings, wherein like reference characters indicate like parts:
FIG. 1 is a top perspective view of the document feeder of the present invention.
FIG. 2 is another top perspective view of the document feeder of the present invention with the document support tray in elevated position.
FIG. 3 is a schematic side elevational view of the document feeder showing the sheet-path through the feeder mechanism.
FIG. 4 is a plan view of the document feeder on a copier, showing a flange to cover the unused portion of the glass and to position the document feeder.
FIG. 5 is a schematic illustration of the sheet-advancing feed wheels.
FIG. 6 is a schematic illustration of the forces acting on the sheets.
FIG. 7 is a greatly enlarged diagram of the frictional forces acting upon the sheets.
FIG. 8 is a schematic illustration of an alternate feed/sheet separator mechanism.
FIG. 9 is a schematic drawing of the power-train or drive-mechanism of the present invention.
FIG. 10 is a side elevation of a section as shown generally at 10--10 of FIG. 9.
FIG. 11 is a fragmentary cross-section shown generally at 11--11 in FIG. 4.
FIG. 12 is an illustration of a prior-art feeder.
FIG. 13 is a vertical schematic drawing of one form of paper-stop.
FIG. 14 is a vertical schematic view of another form of paper-stop.
FIG. 15 is a vertical cross-sectional view of one form of drive-wheel taken along lines 15--15 of FIG. 9.
FIG. 16 is a cross-sectional view taken generally along line 16--16 of FIG. 15.
FIG. 17 is a fragmentary front elevational view of a light-weight pivot arm for a paper-stop.
FIG. 18 is a vertical sectional view taken generally along line 18--18 of FIG. 17.
In the present invention, a feeder 21 of generally box-like configuration has a body 22 and a top 23 (shown open at 23-a and closed at 23-b) The body 22 has a bottom 24 which is a generally rectangular frame having side portions 25 and an opening 26-a (FIGS. 4 & 11).
The bottom portion 24 is designed to be placed upon the glass plate of a copy machine, but supported above the copier glass to provide a thin space 26-a of appropriate size between glass and feeder for a document to be received therein.
The top 23 is pivoted at 23-c so that it can tilt to the position shown in FIGS. 2 and 3, and thus provide an inclined document-support 23-a for a stack of documents 28.
As many as twenty or more documents can be supported face-up on the tray 23-a and the bottom sheet 30 of the stack of documents 28 comes into contact with a feed roller 31, disposed along a generally central line of the stack of documents. This arrangement eliminates drive wheels and separators near the edges of the documents which, in many cases, may be damaged or wrinkled or otherwise rendered unsuitable for easy separation and feeding of the documents.
The preferred embodiment may be inter-connected with the copier in such a way that the required few watts of the low-voltage power and timing (logic) may be derived directly from the copier. Alternatively, the feeder of the present invention may have its own logic. Power may be supplied from a wall outlet mounted transformer, the copier, or rechargeable batteries. If desirable, the unit can be powered by a dry-cell battery arrangement which would provide the lowest cost of a non-interfaced design.
Additionally, the size of the trays and supports and guides may be appropriately chosen for U.S.-size paper, or for the international size (DIN-A4) used generally elsewhere around the world, or legal-size paper (81/2"×13" or 81/2"×14").
Because the feeder can be easily removed from the copier, the copier can be used without the automatic document feeder of the present invention.
After the document feeder 21 of the present invention is placed upon the copier 102 in alignment with the registration edge 118, and the tray 23 is elevated to support-position 23-a, the stack 28 of sheets to be copied is placed upon the tray 23, face-up. The feeder 21 is resting on the copier glass 112 and positioned by flange 100.
When the copy machine is started, the document feeder is also actuated, either by its own power and logic (in synchronism with the copier) or as instructed by the power and logic of the copier if connected thereto. Then the feed wheel 31 is caused to rotate in the direction of the arrow 32, moving the bottom sheet 30 from the stack 28 arOund the periphery of the wheel 51 and onto the top of the glass plate 112 in the thin space 26-a until it reaches the stop or abutment 34. At this moment, the sheet is in position to be copied and the copying takes place.
The drive wheels on the main shaft 70 are a pair (or more) of wheels 44 and a center wheel 51. The wheel 51 is rubber so as to provide a strong pull on the paper when it is in the bite between the wheel 51 and the cooperating wheel 55 These wheels are relatively firm and the force between wheels 51 and 55 is high enough to pull the document 30 from the stack and overcome the drag of the feed/separation rollers 31 and 37. The wheels 44 are larger in diameter than wheel 51 and very soft, such as the foam rubber used in upholstery padding. The larger diameter allows the wheels 44 to touch the glass, while the wheel 51 does not. The wheels 44 move the paper, without skewing, on-to and off-of the glass and, as only a single sheet is being moved, the force can be low. Wheels 44 may be about 6" apart.
After the copying is finished, the drive wheels 44 and 51 are caused to rotate in the opposite direction (as shown by the arrow 35) and the sheet which was on the copier glass is driven around the drive wheels 44 and 51 (in direction of arrow 46) and deposited in the receiving tray 36.
With a center feed and separator, a center set of pull-out rollers 51 and 55 is needed, and it is preferred to have them driven at a speed faster than the feed from roller 31, and to have a one-way clutch 43 on the feed roller shaft 74 so it will turn freely as the sheet is pulled through the drive. If there is a document in the bite of rollers 51 and 55, these rollers pull the tail of the document through the bite of rollers 31 and 37, causing rollers 31 and 37 to roll at a higher speed than if driven by the motor 120, (as allowed by the one-way clutch 38).
The feeder drive is reversed by the reversal of the power polarity to the motor 120. All of the system then goes in the reverse direction EXCEPT that beyond the one-way drive 43. These parts (shafts 74 and 72, rollers 31 and 37, gear-train 122, and the slip clutch 38) are driven directly by the motor 120 in the feed direction through the one-way drive, but not in the reverse direction. The reverse roller system is a very good way to feed one and only one sheet even when the documents in the stack are of different weights and have different surface finishes. Many of the common feed systems do not work satisfactorily as a bottom feeder because of the weight and drag of the documents above the sheet to be fed. This drag also causes multi-feeds.
One or more separation rollers 37, as shown particularly in FIGS. 3, 6, 7, and 9 operate to insure that only the bottom-most sheet 30 in the stack 28 is fed into the copying position.
The principle is simple, elegant and has wide tolerance, as shown particularly in FIGS. 6 and 7. If one assumes likely values of 300 g. of force between the feed roller 31 and separation rollers 37, a coefficient of friction of 1.2 for rubber to paper, or rubber to rubber, and a coefficient of 0.3 for paper to paper, the drive force of the feed roller 31 on the bottom of the bottom sheet 30 is 300×1.2=360 g. If two sheets are in the bite of the rollers 31 and 37, the force between them is still 300 g., but as the friction coefficient is only 0.3, the friction force is only 300 g.×0.3=90g. If the one-way clutch 38 is set to give a maximum force on the paper of any value from 90 g. to 359 g., the system will function. Assume that the clutch is set to slip at 200 g. force tangent to the surface of roller 37, the friction force of the paper and roller is 360 g., but the force on the paper is limited to 200 g. Therefore, when one document is being fed, the top roller 37 will roll on the paper and slip on the shaft 72. With two or more sheets, the sheet on the side of the drive wheel 31 is acted upon by a net drive of 360-90 g.=270 g., and the sheet(s) not in contact with the drive roller 31 are acted upon by a force of 90-200=-110 g. (the negative sign shows that the force is in the reverse direction, i e., up and to the right) as shown in FIGS. 6 and 7 and the upper sheet(s) move back out of the bite. With one sheet in the ite, the net drive is 360 g.-200 g.=160 g. and the sheet is driven forward. With no paper in the bite, the feed roller 31 drives the retard roller 37 in the direction of arrow 61.
Other feed/separation systems which may be used are a high coefficient of friction feed roller 39 with a moderate coefficient retard member 62 as shown in FIG. 5, or the wheel-and-fence system shown in FIG. 8. Here the extra sheets are not pushed back, but they are kept from feeding forward.
Other well-known feed/separator systems could also be used, such as a sticky-tape system marketed by the 3M Company.
The sheet 30 is slid onto the glass 112 with the two spaced guide-rollers 44 to prevent skewing. The drive should be light enough to move the paper until it hits the end stop 34. The rollers can slip on the paper if the normal force is low, or a weak drive may be used, such as weak motor or another slip clutch.
A gate 45 is placed in the path so that when the sheet is returned by the reversal of the rollers 44 and 51, the paper is directed to the stacking tray 36 in direction of arrow 46.
A photocell and light 48 indicates when there is a sheet in position at the stops 34.
The photocell 48 may be a mechanical switch so that the light of the copier does not affect it. It may not be needed because the motor 120 can be driven long enough to be certain that the paper is at the stop 34. But it is preferred to have such a signal so that the logic knows that the paper is at the stop readied to be copied. The switch can also be used to indicate when the last sheet had been fed. The logic would be arranged so that when there is no signal two seconds after a FEED, a "beep" is sounded, and a light is illuminated to advise the operator to pick up the documents and/or to stop the copier.
With one drive motor 120 powering all the automatic document feeder on the in-feed, there is a need to stop the feeding after the sheet has reached the registration stop 34, and before the next sheet has reached the gate area 45. If the feed motion is stopped too soon, the first sheet will not be registered on the glass; if too late, the lead edge of the second sheet will hit the first sheet as it exits, or it will have pushed down the gate so that the exiting of the first sheet is not diverted into the stacking area 46. Either way there will be a jam.
To solve these problems, the surface speed of the main drive rollers 55 and 44 must be much faster than the surface speed of the feed roller 31 Furthermore, the switch 48 detects the lead edge of the sheet as it is near the end of its path which is the registration end stop 34.
The preferred design has a thin steel stripper 49 resting on the glass 112 to strip the sheet from the glass when the rollers 44 and 51 rotate in direction of the arrow 35. The edge of the stripper 49 on the glass 112 must be sharp so the edge of the paper does not stub against it. The sharp edge may be guarded when the tray 23 is folded or when the entire feeder 21 is lifted from the glass of the copier 102.
The logic of the feeder can either be in the copier when the feeder and copier are connected, or in the feeder where there is no electrical interface. In the case where the feeder has all the logic there may be a photocell 136 near the center of the bottom 24, or at an edge or corner, to detect the motion of the copier scan lamp. The photocell 136 will then note the passage of the light from the copier scan lamp, and soon after the light passes the center of the feeder, the copying is completed, and it is time to remove one sheet from the glass and put on the next sheet. Some copiers keep the lamp "ON" for the backstroke, some do not. With the lamp "ON" on the backstroke, the feeder would be set to respond to every other light signal.
For some uses, it will be desirable to keep the sheet on the glass while several copies are made. Thus, if four copies of a three-page document are needed, the three-page document 28 is placed face-up in the tray 23-a and, with an interfaced unit, the copier would be set for "4 copies" and the "Print" button pushed. This would cause the interfaced feeder to feed the last document from the stack onto the glass. The copier would then make the four copies and on the backstroke between the fourth and fifth copies, the sheet would be removed and the next sheet put on the glass. Thereafter, the four copies are made, the documents are changed, and more copies are made. At the end, the top sheet is removed from the glass and placed in the stacking area 36, face-up, and on top.
The outer main drive rollers 44 are made of a very soft material so that their interference with the glass causes only the light force needed to move the paper but not so much as to cause excessive drag. The center roller 51 is of a smaller diameter so it does not touch the glass. The difference in diameter may cause paper stress as the paper curves around the curved path defined by 121.
In the improved design shown in FIG. 15, the shaft 220 is driven by a spline 221 which matches and fits the internal spline 222 of the hub 223 secured to shaft 70 by set screw 224. The left end of shaft 220 is free to move vertically but not horizontally as confined by fixed guides 225 of bearing plate 226 mounted on side frame 53. Also extending from 226 are ribs 227 which limit the axial motion of shaft 220.
Rollers 44 and roller 51 can be the same diameter, and rollers 44 rest on the paper, or the glass 112 if there is no paper there The force is light, as determined by the weight of the part, and/or a spring load There is a gap between the bottom of roller 51 and the paper or glass The roller rubber tires 44 may be solid, strong material as the load on the paper is not determined by the deflection on the material.
The action of the feeder of the present invention may be better understood by the following description:
During the FEED operation, as the bottom sheet 30 of the set of documents 28 is separated and fed to the glass 112, the motor 120 through gears 122 drives the system in the direction of the arrows 32, 61 and 50 on rollers 31, 37 and 51, respectively. Roller 55 is driven by roller 51 and always rolls with it. Sheet 30 is moved to the lower left in FIG. 3 as the friction of roller 31 on the sheet 30 is higher than the slip-clutch setting of the retard roller 37. When the lead edge of sheet 30 hits the top side of gate 45, it pushes it down and moves into the bite of the rollers 51/55. These rollers are turning at a higher surface speed than the sheet as driven by wheel 31, and have a greater pulling force. They thus pull the sheet out of the rollers 31/37 causing roller 31 to turn faster than it would have been driven. The document is curved around by guides 121 and stripper 49 onto the copier glass 112. It passes under the rollers 44 which are in light contact with the glass near the edges of the sheet. They move the sheet through the thin space 26-a between the glass 112 and the bottom plate 24 of the feeder 21 until the leading edge of the sheet hits the end stop 34. The rollers 44 have such a light drive on the sheet that they slip until the motor stops, as signaled by the electric-eye switch 48. The document is now positioned on the copier glass and the copies can be made.
During the TAKE-OFF operation, the motor 120 reverses and the shaft 70 drives rollers 44 and 51 in the direction of arrow 35 in FIG. 3. Since the rollers 44 are in contact with the sheet, the sheet is driven to the left in FIG. 3 and diverted by the sharp edge of stripper 49 into the bite of rollers 51/55. As the gate is normally in the position shown in FIG. 3, the sheet is guided in direction of arrow 46 into the stacking tray 36.
A feeder of the type described will feed one sheet and, as the end of that sheet exits the feed/separation rollers 31/37, the next sheet will start to feed. The sheets would be touching head to tail, but in the present invention, when the first sheet reaches the main drive rollers, it is pulled faster than it was fed. This faster down-stream feed will create a gap between the tail of the first sheet and the lead edge of the next. This gap will be larger if the main drive pull overcomes the drag of the feed roller. The one-way clutch 38 on the drive shaft 72 allOws it to drive, but as the first sheet is pulled faster than the drive, the drive roller 31 is free to turn faster. The gap between the tail of the first sheet and the lead edge of the next sheet, and thus the speed difference, must be enough that the first sheet is moved to the registration stop 34 before the next sheet, which starts to feed when the tail of the first is pulled from the feed rollers, reaches the gate area.
More than the theoretical gap must be allowed as the motor coast will move the lead edge of the second sheet. Also, allowance must be made for possible imperfect separation where the second speed is pulled into the feed/separation bite 31/37.
For some copiers, it will be preferred to have a long spring stripper 49 so that it extends under the left edge of a sheet 30 when on the glass 112. Thus the stripping of the sheet from the glass is not needed, because the left end was not resting on the glass. This will be best on copiers which do not copy that edge of the document, and thus the end of stripper 49 will not be seen on the copy.
When there is already a sheet on the glass, the TAKE-OFF operation precedes the FEED operation.
As shown in FIG. 9, the motor 120 drives a belt 123. This belt drives shafts 70 and 74 in the FEED direction. Due to the pulley and roller sizes, the surface speeds of the rollers 44 and 51 are much greater than that of the roller 31. When the motor is reversed, only shaft 70 is driven directly by the motor due to the one-way clutch 43 on shaft 72.
While a reflective photoswitch can be used for the paper switch 48, this requires electronics and could be confused by the bright light of the copier. A mechanical switch is preferred.
The novel design is for a very light force paper switch which rests on the glass This requires a flag having a close tolerance as the paper is thin and weak and may be very close to the glass. The freedom of the flag to rest on the glass under the effect of gravity and/or spring pressure, in spite of mechanical tolerance of the parts or their warpage, is novel.
Two embodiments of the switch are shown in FIG. 13 and FIG. 14. The standard snap switch 201 is operated by the pivoted metal flag 203 which is pivoted on shaft 205 which is welded to the flag and is free to move vertically in slots 207 in the fixed holder 209. It is shown in its home position at 203 and in its deflected position as 204. The sketch also shows the bevel 208 on the bottom of the flag so that a sheet of paper does not get under the flag This design assures that the sharp edge of the flag is lightly on the glass, but free to move in response to the edge of the paper. The flag is returned to its normal position by the spring of the switch.
As the paper hits the flag with a considerable velocity, and as the flag needs to move with the paper and along the glass, there is sometimes a tendency for the flag to hop up and for the paper to slide under. This mode of failure can be eliminated by a light spring force downward on the flag, shown as springs 206.
FIG. 14 shows an alternate design which can be used where added headroom is available. The spring of the switch both returns the flag and adds the downward spring force needed on the flag.
FIGS. 17 and 18 show another design wherein the feet 210 and 211 of the flag 212 are pivoted at 213 so that the bottom of the feet always slide the glass plate and prevent the sheet from slipping beneath the flag.
FIG. 10 illustrates the gears connecting shafts 74 and 72. The shaft 72 turns slower than shaft 74, as shown by the gear train 124. This saves power and permits use of a smaller motor. A belt can also be used. The shafts 72 and 74 are driven in the same direction as shown by arrows 50. Roller 37 is loaded against roller 31 with a known and constant force. This can be caused by a built-in interference of the rollers, depending on the softness of the rollers, or the bending of the shafts, to determine the force The ends of shaft 72 may be guided in slots 52 in frame 53 (as shown in FIGS. 5 and 9) and loaded with a light spring (not shown) in direction of arrow 54.
FIG. 4 and 11 shows the feeder 21 on a copier 102 with a control panel 104, a cover 110, and a registration edge 108 and 118 around glass 112. The feeder 21 is positioned to insure that the document, when on the glass 112 and at the stops 34, is where the copier needs the document to be located for a proper copy to be made. A flange 100 fits between the lower edges of the feeder 21 and the edge 108 to hold the feeder in place, to block the light, and to provide a white surface on the copier glass.
EXAMPLE
In the present invention, the lead edge of the first sheet moves about 2" from the feed/separator rollers 31/37 and is then gripped by the pinch of the main shaft roller 51 and its idler roller 55. The main roller pulls the sheet from the feed/separator bite, aided by the one-way clutch 38 With the customary 11" long paper, the main roller must move the lead edge of the paper about 13" to reach the registration stop; i.e., the 11" length and an added 2" around the main drive roller which gets the tail of the sheet on the glass. This motion must be done as the next sheet, which is being fed by the feed/separator rollers, moves toward the gate area. The next sheet can move about 3/4" before there is any interference.
Thus, using the above figures, the limiting case for the minimum excess speed of the main drive over the feed drive is that the main drive must move the paper 13" before the lead edge of the next sheet moves 3/4" past the feed roller. The feed roller will not start to feed the second sheet until the tail of the first sheet has been pulled free of the roller, assuming the separation is perfect. Thus the main drive must move the first sheet the 2" to the registration edge before the second sheet moves the 3/4" to the gate area. The main drive must be over 2.7 times as fast as the feed. (Ratio=2/.75=2.6666 . . . )
In this embodiment with 0.75" diameter feed roller, a 1.4" diameter main drive roller, and a belt drive with a speed ratio of 3.33 faster main drive to feed drive, the main drive ratio is 6.2: i.e., comfortably over the minimum and allowing for motor coast and the occasional imperfect separation where the next sheet may be dragged by the first. The advance of the second sheet past the feed roller is about 0.6" with a quick-stop circuit on the motor. (As a check, the calculated motion with a 6.2 ratio is 2/6.2=0.32". The paper feed speed, before the main drive pulls the sheet, is about 6" per second at the normal 36 v. This suggests a delay of the quick-stop relay and the stopping of the motor of 46 ms, a reasonable number.)
It is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes hereof, and it is therefore desired that the present embodiments be considered in all respects as illustrative, and therefore not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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A document feeder is disclosed which can be used with glass-top copy machines. It fits such copiers, having either a stationary or a moving sheet-support. It is small, light-weight, compact and portable. It feeds the bottom-most page first from a face-up stack of sheets, and re-stacks the copied sheets, face-up, with the bottom sheet at the bottom of the new stack. It operates in excess of 25 copies per minute.
Drive wheels feed the document-to-be-copied onto the copier glass and, when the wheels are reversed, remove the document from the glass into a stacking area. The removal of a document from the glass and the placement of the next document onto the glass occur during the non-copying time of the continuously-running copier. The feed/separation act upon the center of the documents.
The copier can derive its driving force and energy from the copier or can have its own independent power source.
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FIELD OF THE INVENTION
[0001] The present invention relates to a sensor for determining a physical, biological or physiological parameter of an object to which the sensor is attached to, the sensor comprising a degradable adhesive.
[0002] The present invention also relates to the removal of the sensor from the object.
BACKGROUND OF THE INVENTION
[0003] After an installation of an object comprising a vessel-like or a pipe-like structure, for a subsequent passing of a fluid through the pipe structure or vessel structure, it may be beneficial to be able to determine whether there is a fluid flow present within the pipe-structure or vessel-structure as intended. E.g. when installing a pipe and subsequently connecting the pipe for obtaining a fluid flow, information whether the desired flow is present within the pipe-structure is beneficial for determining whether the installation was successful.
[0004] In the context of medical applications, for example after a transplantation procedure, medical personnel may be required to monitor a patient, in particular with regard to whether the patient's body is accepting a transplanted organ and/or whether the medical procedure was successful with regard to the transplantation itself, e.g., it may be required to monitor whether a transplanted organ is sufficiently circulated by bodily fluids. This may be done by determining from outside the body whether an object is fluid circulated, e.g. by determining its color or a by manual determination of fluid pulsation or fluid flow.
[0005] However, an according time to time manual check is a non-continuous monitoring procedure as well as comprises only an indirect manual determination thus a considerable risk remains that an according determination may be unsuccessful or that a non-flow condition may be detected too late for correction.
[0006] E.g. recognizing too late, that an implanted organ is not sufficiently circulated by fluid, may result in serious complications, e.g. even the abandonment of the organ by the host's body.
[0007] Thus, there may be a need for a sensor for determining a physical, biological or physiological parameter, in particular for continuously determining said parameter, which sensor furthermore may be easily removable, e.g. without an additional procedure.
[0008] Document U.S. Pat. No. 7,244,251 describes a surgical drain comprising a sensor for monitoring a condition of an anatomical side of fluid emitted from the side where the surgical drain is placed. The surgical drain is mechanically fixed to the anatomical side by an anchor element.
SUMMARY OF THE INVENTION
[0009] Accordingly, a sensor for determining a physical, biological or physiological parameter according to the independent claims is provided.
[0010] Preferred embodiments of the present invention may be derived from the dependent claims.
[0011] The present invention relates to monitoring or determining a physical, biological or physiological parameter like for example a temperature, e.g. a local temperature, or a further parameter, like a flow parameter of a fluid within a vessel of an object. The sensor may be attached to the object by a degradable adhesive and may be removed from the object by an induced degrading or a timed degrading of the degradable adhesive or a part thereof.
[0012] These and other aspects of the present invention will become apparent from and elucidated with reference to the embodiments described hereinafter.
[0013] Exemplary embodiments of the present invention will be described below with reference to the following drawings.
[0014] The illustration in the drawings is schematic. In different drawings, similar or identical elements are provided with similar or identical reference numerals.
[0015] The figures are not drawn to scale however may depict qualitative proportions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1 a - c show exemplary embodiments of a sensor for determining a biological or physiological parameter according to the present invention;
[0017] FIGS. 2 a - d show further exemplary embodiments of a sensor for determining a biological or physiological parameter according to the present invention;
[0018] FIGS. 3 a - c show an exemplary embodiment of determining a fluid flow employing a heat pulse according to the present invention;
[0019] FIGS. 4 a - d show exemplary embodiments of components of a degradable adhesive according to the present invention;
[0020] FIG. 5 shows an exemplary embodiment of a method of removing a sensor from an object according to the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0021] The sensor according to the present invention may be employed for determining or measuring a biological, physical or physiological parameter, in particular of the object in the vicinity of the attachment region where the sensor is arranged at the object.
[0022] E.g., in case of a flow sensor, the sensor may be considered to constitute a thermal flow sensor. For example, an array of temperature determining elements, e.g. thermocouples, in particular e.g. two, four, six, eight or more temperature determining elements, may be located at defined positions with a heating element in the center or middle between the temperature determining elements, in particular with one half of the number of temperature determining elements on each side of the heating element, for example linearly arranged.
[0023] The sensor may be attached to an object or a vessel and within the object or vessel, a fluid may be arranged. The sensor may be employed for determining a flow within the fluid, e.g. water within a pipe or blood within a blood-vessel. The heating element may constitute a heat source for locally heating the object. Depending on a flow velocity of the fluid in a vessel, a temperature may be induced to the object and thus the fluid, with temperature determining elements adapted for determining a local temperature of the object, which temperature determining elements are located upstream and downstream of the heating element. The temperature determining elements may determine a local temperature, which may be compared for determining a temperature difference. An according temperature difference may indicate a fluid flow within the vessel.
[0024] In case there is no substantial temperature difference between the temperature determining elements located upstream and downstream of the heating element, a condition with no fluid flow may be assumed within a vessel. On the other hand, in case there is a temperature difference, a fluid flow may be assumed.
[0025] Also by employing temperature determining elements both upstream and downstream of the heating element, a flow direction may be determined. E.g. in case there is a temperature difference determinable with temperature determining elements located upstream and downstream of the heating element, since a heat source is provided to the fluid within the vessel by the heating element, the temperature determining element that determines an increased temperature versus a further temperature determining element on the other side of the heating element, which may determine a lesser temperature, may be considered to be downstream of the heating element with respect to a flow direction within the vessel.
[0026] Also, a fluid flow within a vessel may be determined by measuring a flow dependent cooling of the heating element using temperature determining elements such as thermocouples, resistors or transistors. In this case, a single sensor element e.g. a single temperature determining elements or thermocouple, may be arranged in the vicinity of the heating element.
[0027] A certain amount of energy may be applied to the heating element, possibly defining a supposed resulting temperature of the heating element. In case the thermocouple arranged in the vicinity of the heating element is determining a temperature different from the temperature the heating element is supposed to comprise due to the supplied energy, a fluid flow may be indicated. The amount of fluid flow may be directly related to the amount of temperature difference between the supposed temperature the heating element should have due to the energy provided and the actual measured temperature of the heating element by the sensor element.
[0028] An according method may be more robust with regard to variations in the wall thickness of a vessel containing the fluid. Preferably, the sensor in particular the heating element may be operated in a constant temperature mode for avoiding excessive heating of both the object the sensor is attached to and the fluid within the vessel.
[0029] E.g., the heating element and the at least one sensor element may be provided with a feedback loop for maintaining the temperature of the heating element at a constant pre-set value. The power dissipating in the heating element to maintain the constant temperature level may be a measure for the flow of a fluid within the vessel. Also, in a constant temperature mode, an overheating may be controlled, thus avoided, e.g. for avoiding unwanted premature degradation of a degradable adhesive, which degradable adhesive may be a temperature degrading adhesive.
[0030] Furthermore, a fluid flow may be determined by the “time-of-flight” of a heat pulse provided by the heating element to the object and/or the vessel, which heat pulse may be determined by a sensor element located spaced apart from the heating element, e.g. again up- and downstream of the heating element with respect to the vessel of the object the sensor is attached to.
[0031] E.g., a heat pulse is provided to the object and thus the vessel, which heat pulse is subsequently determined at one sensor element only of at least two sensor elements located upstream and downstream of the heating element, a fluid flow may be assumed and also a flow direction may be determinable. In case no temperature difference between the at least two sensor elements located upstream and downstream of the heating element or even no temperature change at all may be determinable by the sensor element, a non-flow situation may be assumed.
[0032] The sensor for determining a biological, physical or physiological parameter may be attached to the object and/or the vessel by a degradable adhesive. The sensor may preferably be flexible for attachment to a flexible object or vessel, e.g. by employing circonflex technology, e.g. for fabrication of sensors on a biocompatible flexible carrier like parylene. Further, the sensor may be provided with a biocompatible layer like poly(chloro-p-xylylene) (Parylene C) or poly(p-xylylene) (Parylene N) or poly-dimethylsiloxane (PDMS).
[0033] The determined or measured parameter may be transferred to a monitoring unit, e.g. for continuously monitoring the parameter either by a wired connection or by a wireless connection. The sensor may also comprise anti-biofouling agents, e.g. silver, in particular silver particles.
[0034] For attachment of the sensor to the object, a biodegradable adhesive may be employed, e.g. comprising a mixture of degradable thiol monomers, non-degradable thiol monomers and polyethylene glycol-diallyl ether. Also, the sensor may be attached to the object by employing as adhesive a polymer such as acrylate polymers, e.g. poly(glycerolcosebacate)-acrylate with enzymes induced. With induced enzymes, the polymer may be biodegradable so that after a defined period, e.g. days to weeks, the sensor may be detaching itself from the object by degrading the adhesive characteristics of the degradable adhesive.
[0035] Also, the sensor may be attached to the object by a biodegradable adhesive such as lactate. A controlled degradation of the adhesive may be provided by the heating element or a further heater element integrated in the sensor, in particular in the area of the degradable adhesive.
[0036] In particular, a two-layer adhesive may be employed. First, the sensor may be provided with a removable element or removable coating or a degradable element or degradable coating, for example a hot melt coating, e.g. based on an ethylene-vinyl acetate (EVA) copolymer modified with a tackifyer, e.g. a wax or hot melt wax, to optimize its melting temperature, which may be preferably below 80° C. The adhesion of the coated sensor to the object may employ an adhesive as described earlier. In case the sensor is to be detached from the object, the removable component may for example be melted, e.g. by heating the sensor by the heating element or the further heater element. A remaining adhesive component or adhesive element, e.g. a thiol-ene adhesive, may remain attached to the object or vessel, however may bio-degrade slowly afterwards.
[0037] The hot melt component may also be heated employing a laser source as a heating element or a heater element, in particular while employing a dye material adapted for a preferred absorption of laser energy of a particular wavelength emitted by the laser element for conversion into heat. Accordingly, the laser source may be considered to be a heating element or heater element for providing heat for melting the hot melt component of the degradable adhesive.
[0038] Furthermore, instead of providing a heating element and at least one sensor element for determining a temperature, also a sound transducing element, in particular an ultrasound transducing element, i.e. an element adapted for both emitting and receiving acoustic waves, or dedicated sound generating and sound receiving elements, as the at least one sensor element, adapted for determining a sound pressure level and/or a frequency, may be employed.
[0039] E.g., an acoustic transducer or ultrasound transducer may be provided instead of or with the heating element or heater element. Further acoustic transducers may be arranged as sensor elements, thus an array of acoustic transducer elements, e.g. two or three acoustic transducer elements, may be employed for determining a flow parameter. For example by employing two acoustic transducers, one acoustic transducer may emit an acoustic pulse with the other acoustic transducer receiving the acoustic pulse, e.g. an ultrasound pulse. Accordingly, a time of flight and frequency or frequency difference between the emitted and received acoustic pulses may be determinable. The array of two acoustic transducers may subsequently reverse their individual operation mode, thus the transducer previously employed for providing the acoustic pulse may now determine a time of flight, intensity and/or frequency of an acoustic pulse emanated from the respective other transducer element. In case there is a time of flight difference or frequency difference between the individual modes of operation, a fluid flow may be assumed as well as a flow direction in accordance with the physical principle of the Doppler effect.
[0040] The transducer or the array of transducers may also be used to operate as transmitting element(s) and receiving element(s) of the sound pulses, in particular ultrasound pulses. In case one transducer or an array of transducer is located at one position and one transducer or an array transducer is located at another position, the time between transmitting the ultrasound pulse and receiving the ultrasound pulse, i.e. the time of flight, may be t 0 in case there is no fluid flow, depending on the distance between the transducers or the transducer arrays. In case a time t 1 between transmitting the ultrasound pulse and receiving the ultrasound pulse is t 1 >t 0 or t 1 <t 0 , a fluid flow may be assumed as well as a fluid flow direction detected.
[0041] In case an array of at least three acoustic transducers is employed, the center transducer may provide an acoustic pulse, which acoustic pulse is subsequently determined or detected by both transducer elements located upstream and downstream of the central transducer. Again, by employing the Doppler effect or determining the time of flight, a fluid flow may be determinable as well as a flow direction, however in this case with only one acoustic pulse provided.
[0042] In case it is decided that the sensor is to be detached from the object, the degradable adhesive may be intentionally degraded by induced degradation, e.g. by heat, and the sensor may be removed by pushing or pulling it out, e.g. employing wires attached to the sensor element for a wired connection.
[0043] Now referring to FIGS. 1 a - 1 c, exemplary embodiments of a sensor for determining a biological, physical or physiological parameter according to the present invention are depicted.
[0044] FIG. 1 a shows an exemplary embodiment of a sensor 2 comprising two sensor elements 4 as well as a heating element 6 arranged in between the sensor elements 4 . Both the sensor elements 4 and the heating element 6 are arranged on a flexible carrier element 3 , e.g. employing the circonflex technology. Both sensor elements 4 as well as the heating element 6 are connected employing wire 12 for providing energy to the heating element 6 as well as for receiving a determined physiological, physical or biological parameter, e.g a local temperature, by each of the sensor elements 4 . Wire 12 may be connected to an external unit for controlling the sensor 2 , in particular heating element 6 , as well as for analyzing information received from sensor elements 4 .
[0045] Now referring to FIG. 1 b, a further exemplary embodiment of a sensor 2 is depicted.
[0046] Sensor 2 of FIG. 1 b comprises again heating element 6 and a single sensor element 4 arranged in the vicinity or within heating element 6 . A wire 12 is connecting both the heating element 6 and the sensor element 4 with an external unit, which is not depicted. By employing sensor element 4 , a cooling of heating element 6 may be determinable, and thus a fluid flow within an object to which sensor 2 may be attached to.
[0047] Now referring to FIG. 1 c, possible locations of a degradable adhesive 8 a,b according to an exemplary embodiment of the present invention is depicted.
[0048] Attached to one side of carrier element 3 , three areas of a degradable adhesive 8 a,b are depicted. Degradable adhesive 8 b is arranged in the vicinity of heating element 6 while two areas of degradable adhesive 8 a are arranged on either side of heating element 6 on the opposing side of carrier element 3 . It may be also be conceivable to omit degradable adhesive element 8 a completely, thus attaching the sensor to an object only employing degradable adhesive 8 b. By employing heating element 6 or a further heater element, a possible heat degradable adhesive 8 b or a hot melt degradable adhesive 8 b may be influenced such that the adhesive characteristics of the degradable adhesive 8 b are altered so that a detachment of the sensor 2 from an object may be achievable.
[0049] Now referring to FIGS. 2 a - d, further exemplary embodiments of a sensor for determining a biological, physical or physiological parameter according to the present invention are depicted.
[0050] In FIG. 2 a, sensor 2 is arranged in the vicinity of object 10 , exemplarily a vessel 10 , as depicted in FIG. 2 a. The carrier element is preferably round or convex, e.g. vessel shaped for attaching sensor 2 to object 10 . Sensor 2 in FIG. 2 a exemplarily comprises four sensor elements 4 arranged in two pairs on each side of heating element 6 , one pair arranged upstream and one pair arranged downstream of heating element 6 with regard to a flow of a fluid 14 within vessel 10 . However, it may also be conceivable to employ only two sensor elements 4 , one on each side of heating element 6 , as depicted in FIG. 1 a.
[0051] Heating element 6 may be adapted to provide a temperature T to object 10 in the vicinity of heating element 6 . Thus, heating element 6 may be considered to be heating object 10 to temperature T or at least employing temperature T. Accordingly, by sensor elements 4 , a temperature, in particular a local temperature T 1 and/or T 2 may be determinable and thus a temperature difference ΔT 1 as well as ΔT 2 between the temperature of the heating element 6 and the respective sensor elements 4 . In case T 1 substantially equals T 2 , thus ΔT 1 equals ΔT 2 , a non-flow condition within vessel 10 may be assumed. In case e.g. T 2 is larger than T 1 , possibly nearing or equaling T, a fluid flow 14 may be assumed within vessel 10 . E.g., in case T 2 is larger than T 1 , a flow 14 from heating element 6 in the direction of the sensor elements measuring the higher temperature T 2 , thus, with regard to FIG. 2 a, a flow from top to bottom may be assumed.
[0052] With regard to FIG. 2 b, sensor 2 is attached to object 10 comprising a vessel in which vicinity sensor 2 is attached to object 10 . In FIG. 2 b exemplary a sensor element in accordance with FIG. 1 b is employed. However, as with all exemplary embodiments described herein, all sensors described may be employed equally.
[0053] By wire 12 , energy may be provided to heating element 6 for generating a constant temperature. In case vessel 10 ,to which sensor 2 is attached to, comprises a fluid flow 14 , a cooling of heating element 6 may occur, which cooling or temperature difference may be determinable by sensor element 4 , arranged in a vicinity of heating element 6 . E.g. in case a fluid flow 14 is present in object 10 , heating element 6 may be cooled more than would be the case if no fluid flow 14 is present within object 10 . Thus, e.g. by providing a constant temperature via heating element 6 , sensor element 4 may determine a temperature, which is smaller than a temperature in case no fluid flow 14 would be present.
[0054] In FIG. 2 c, heating element 6 is embodied as a laser source. Energy for producing laser light of a defined wavelength is provided by wire 12 . Degradable adhesive 8 may comprise a dye that is adapted to the wavelength of laser source 6 for a preferred absorption of laser energy and thus heating of the degradable adhesive 8 .
[0055] Thus, in case of a hot melt degradable adhesive 8 , heating element 6 incorporated as a laser source 6 , may heat the degradable adhesive such that it may be detached from an object 10 , not depicted in FIG. 2 c. In FIG. 2 c the laser source 6 and the heating element 6 are substantially identical elements. However, it may also be conceivable that sensor 2 comprises a heating element 6 as well as a further laser source both of which may be operated independently by wire 12 . Also, laser source 6 may be adapted for providing light at at least two different wavelengths. One wavelength may be adapted to a dye of the degradable adhesive 8 for removal of the sensor, thus an operation as a heater element, while a further wavelength may be employed for an operation as a heating element, thus for the heating of object 10 .
[0056] In FIG. 2 d, an implementation of sensor 2 comprising acoustic transducers is depicted. In FIG. 2 d exemplary three acoustic transducers 15 a - 15 c, e.g. ultrasound transducer, are depicted. In FIG. 2 d exemplary acoustic transducer 15 b is adapted for emanating ultrasound, while acoustic transducers 15 a and 15 c are adapted for receiving acoustic sound waves 16 emanating from acoustic transducer 15 b.
[0057] Sound emanating from acoustic transducer 15 b may comprise a defined wavelength. In case a fluid flow 14 is present, due to the physical principle of the Doppler effect, the frequency of the received acoustic wave by transducer 15 a may be larger than the frequency of emitted acoustic wave from transducer 15 b, which again may be larger than the frequency received by transducer 15 c. Accordingly, by a frequency difference, a fluid flow 14 as well as the direction of fluid flow 14 and also a fluid flow velocity, may be determinable. Sensor 2 may also only comprise two acoustic transducers 15 a, 15 b in a dual reverse configuration, e.g. requiring both acoustic transducers to emanate an acoustic wave consecutively with the respective other acoustic transducer receiving the acoustic wave. In case there is a frequency difference between the received frequencies, a flow of fluid 14 as well as the direction and velocity may be determined.
[0058] Now referring to FIGS. 3 a - c, an exemplary embodiment of determining a fluid flow employing a heat pulse according to the present invention is depicted.
[0059] In FIG. 3 a, substantially a sensor 2 according to FIG. 1 a is attached to a vessel 10 employing a degradable adhesive 8 . Sensor 2 comprises two sensor elements 4 a,b arranged upstream and downstream with regard to a possible fluid flow 14 within vessel 10 . Heating element 6 may provide a temperature pulse, thus a sudden increase in temperature, which may be substantially temporary or also a long-term increase, with the sensor elements 4 a,b subsequently determining a possible temperature increase within their field of measurement, thus a possible local temperature increase.
[0060] With regard to FIG. 3 b, which depicts a no flow scenario, a heat pulse is provided by heating element 6 at time t 0 . Subsequently at time t 1 both sensor elements 4 a,b determine an increase in temperature lasting until t 2 . Accordingly, the temperature pulse provided by heating element 6 may be considered to spread uniformly in both directions towards sensor element 4 a as well as 4 b. Thus, it may be assumed that no fluid flow 14 is present within vessel 10 .
[0061] With regard to FIG. 3 c, only one sensor element, here sensor element 4 a, is detecting a temperature increase at t 1 . Temperature increase T 1 is only be determined at sensor element 4 a, thus indicating a fluid flow 14 in the direction from sensor element 4 b to heating element 6 to sensor element 4 a within vessel 10 .
[0062] Now referring to FIGS. 4 a - 4 d, exemplary embodiments of components of a degradable adhesive according to the present invention are depicted.
[0063] FIG. 4 a depicts an example of a degradable tetrathiol, pentaerythritol tetrakis(3-mercaptopropionate), FIG. 4 b depicts an example of a degradable dithiol, glycol dimercaptopropionate, FIG. 4 c depicts an example of a non-degradable dithiol, 2,2′-(ethylenedioxy) diethanediol and FIG. 4 d depicts an example of a polyethylene glycol diallyl ether.
[0064] The monomers may be mixed in a molar concentration of allyl groups and thiol groups, which are equal. A ratio between a degradable and a non-degradable thiol may determine the degradation rate of an adhesive, which may be, after curing of the adhesive, between 1 and 25 days for 0 mol-% and 15 mol-% of non-degradable thiols, respectively.
[0065] For curing, a small amount of initiator needs to be added, typically 0.2 wt-% 1-[4-(2-hydroxyethoxy)-phenyl]-2-hydroxy-2-methyl-1-propane-1-one (Irgacure 2959—CIBA). The adhesive may be a liquid at room temperature and may be cured by 100 s exposure to UV light using a waveguided 365 nm mercury lamp with
[0000]
100
mW
cm
2
.
[0066] Now referring to FIG. 5 , an exemplary embodiment of a method of removing a sensor from an object according to the present invention is depicted.
[0067] FIG. 5 shows a method 30 for removing a sensor from an object comprising employing 32 a heating element 6 for providing a heat source, wherein the heat source is adapted for degrading a degradable adhesive 8 . A sensor 2 according to the present invention is detached 34 from an object 10 by the degradation of the degradable adhesive 8 . The sensor 2 is subsequently removed 36 from the object 10 , e.g. by pulling sensor 2 , employing wire 12 .
[0068] It should be noted that the term “comprising” does not exclude other elements or steps and that “a” or “an” does not exclude a plurality. Also, elements described in association with different embodiments may be combined.
[0069] It should also be noted, that reference numerals in the claims shall not be construed as limiting the scope of the claims.
LIST OF REFERENCE NUMERALS:
[0000]
2 Sensor
3 Carrier element
4 a,b Sensor element
6 Heating element/laser source
8 a,b Degradable adhesive
10 Object/vessel
12 Wire
14 Flow of fluid
15 a - c Ultrasound transducer
16 Sound waves
30 Method of removing a sensor from an object
32 STEP: employing a heating element
34 STEP: detaching a sensor from an object
36 STEP: removing the sensor.
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The present invention relates to determining or measuring a biological, physical or physiological parameter of an object ( 10 ) by a sensor ( 2 ). It may be beneficial to constantly monitor or determine a biological, physical or physiological parameter of an object ( 10 ) by a sensor ( 2 ), subsequently allowing for a preferred removal of the sensor ( 2 ) from object ( 10 ) when the monitoring is no longer required. Accordingly, a sensor ( 2 ) is provided, e.g. a flow sensor, employing a degradable adhesive ( 8 ) for attachment of the sensor ( 2 ) to the object ( 10 ). The degradable adhesive ( 8 ) may be degradable e.g. by time, by exposure to a certain measure, e.g. induced heat, or substance for detaching the sensor ( 2 ) from the object ( 10 ) for subsequent removal of the sensor ( 2 ).
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TECHNICAL FIELD
[0001] The present invention relates to a cancer cell inhibitory drug, particularly to a cancer stem cell inhibitory drug, and a cancer stem-cell detection probe.
BACKGROUND ART
[0002] At present, as a general cancer therapy, e.g., radiation therapy, chemotherapy, immunotherapy and surgical (excision) therapy are mentioned. The chemotherapy is a method for suppressing cancer by use of an anticancer therapeutic agent made of various types of low-molecular compounds.
[0003] The therapy using an anticancer therapeutic agent is directed to reduce the size of a solid tumor. However, the most part of a tumor is occupied by differentiated cancer cells which no longer have a function as a cancer stem cell and it is pointed out in a general anticancer agent treatment that the differentiated cancer cells are only targeted to reduce the size thereof.
[0004] Cancer has cells having nature of stem cells, called cancer stem cells.
[0005] The cancer stem cells, which were first identified in 1997 in an acute myeloid leukemia, are now increasingly found in various types of cancers including solid cancers, and recently, a new way of thinking, called “cancer stem cell hypothesis” that cancer would be developed from cancer stem cells as an origin, has been proposed (NPL 1).
[0006] According to the hypothesis, even though the most part of cancer cells are killed or excised out by applying the aforementioned therapy, if a very small number of self-reproducible cancer stem cells remain, recurrence and metastasis conceivably occur. In short, it is considered that recurrence and metastasis are caused by the remaining small amount of cancer stem cells. Accordingly, if cancer stem cells can be targeted and completely eradicated, it is expected to develop a useful therapy for preventing metastasis and recurrence of cancer.
[0007] It is pointed out that some of the cancer stem cells acquire drug resistance to an anticancer therapeutic agent (NPL 2).
[0008] At present, as a low-molecular compound for use in detection of cancer stem cells and as a therapeutic agent, a compound containing radioactive Cu-ATSM is known (PTL 1). However, the radioactive compound may affect normal cells. Therefore, when a radioactive compound is used, safety becomes a matter of concern. In addition, it is also pointed out that cancer stem cells may develop strong resistance to radiation.
[0009] In the circumstances, it has been desired to develop a drug inhibiting cancer stem cells and a compound capable of detecting cancer stem cells.
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Patent Application Laid-Open No. 2010-013380
Non Patent Literature
[0000]
NPL 1: Carcinogenesis, Vol. 26, p.p. 703-711, 2005
NPL 2: Nature Review Cancer, Vol. 5, p.p. 275-284, 2005
NPL 3: Journal of the American Chemical Society, Vol. 133, p.p. 6626-6635, 2011
NPL 4: Dye and Pigments, Vol. 71, p.p. 28-36, 2005
NPL 5: Organic & Biomolecular Chemistry, Vol. 9, p.p. 4199-4204, 2011
SUMMARY OF INVENTION
Technical Problem
[0016] Cancer stem cells have high resistance to radiation therapies and chemotherapies conventionally used and are causual cells from which cancer growth, recurrence and metastasis occur. Up to present, where cancer stem cells are present cannot be clearly detected. This was a issue remaining unsolved. To completely cure cancer, it has been strongly desired to detect cancer stem cells and develop a drug inhibiting cancer cells, in particular, cancer stem cells.
Solution to Problem
[0017] The present inventors intensively made studies with a view to solving the aforementioned problem. As a result, they found that a compound represented by the following general formula (1) has an inhibitory effect on cancer cells and is selectively taken into particularly cancer stem cells among the cancer cells and inhibits them. Based on the finding, the present invention was accomplished.
[0018] Furthermore, the compound of the present invention has a luminescence property. Owing to this, the position of cancer cells can be identified (determined) by detecting luminescence of the compound selectively taken into cancer cells. Based on the finding, the present inventors arrived at the present invention. Note that, in the specification, luminescence includes fluorescence and phosphorescence. Since the compound of the present invention is taken into particularly cancer stem cells in a high ratio, cancer stem cells can be selectively detected.
[0019] More specifically, the compound of the present invention contains a compound represented by general formula (1):
[0000]
[0020] In general formula (1), R 1 and R 2 each independently represent an alkyl group, a carboxylalkyl group, an alkoxycarbonylalkyl group or an alkylcarbonyloxyalkyl group; R 3 to R 10 each independently represent a hydrogen atom, an alkyl group, an aryl group, an alkoxy group, a halogen atom, an alkoxysulfonyl group, a N-alkylsulfamoyl group, an alkyloxycarbonyl group, a carbamoyl group or a N-alkylcarbamoyl group; R 3 and R 4 , R 5 and R 6 , R 7 and R 8 , and R 9 and R 10 may be each independently cyclized to form a benzene ring; X 1 − represents an anionic group; Y 1 is a group including *1, *2 and *5 and represents any one of the followings: *1-S-*5-*2, *1-O-*5-*2, *1-C(—R 11 ,—R 12 )-*5-*2, and *1-*5-CH═CH-*2, where R 11 and R 12 each independently represent an alkyl group, and R 11 and R 12 may bind together to form a ring; Y 2 is a group including *3, *4 and *6 and represents any one of the followings:
[0021] *4=*6-S-*3, *4=*6-O-*3, *4=*6-C(—R 51 ,—R 52 )-*3, *4=*6-CH═CH-*3, and *4=CH—CH=*6-*3, where R 51 and R 52 each independently represent an alkyl group and R 51 and R 52 may bind together to form a ring; and a group including A to carbon atoms represented by *5 and *6 is represented by general formula (2) or (3).
[0000]
[0022] (In general formula (2), R 13 to R 15 each independently represent a hydrogen atom, an alkyl group or an aryl group; and n represents an integer of 0 to 2, and in general formula (3), R 16 represents a hydrogen atom, a phenyl group, a thiol group, an alkoxy group, an aryloxy group or a halogen atom; and R 17 and R 18 each independently represent a hydrogen atom, an alkyl group or an alkyloxycarbonyl group).
Advantageous Effects of Invention
[0023] Owing to the compound provided by the present invention, growth suppression, cellular division suppression, metastasis suppression, functional inhibition and cytocidal action of cancer cells can be mediated even in sites where cancer cells are overlooked by surgical excision and hardly excised out. More specifically, the present invention provides a cancer cell inhibitory drug. Further, of the cancer cells, particularly against cancer stem cells, these effects are significantly exerted. Furthermore, cancer stem cells can be easily detected and the site of the cancer stem cells can be accurately determined. More specifically, the present invention provides a cancer stem-cell detection probe.
DESCRIPTION OF EMBODIMENTS
[0024] Now, embodiments of the present invention will be described below.
[0025] A cancer cell inhibitory drug of the present invention, particularly, a cancer stem-cell inhibitory drug which is selectively taken into cancer cells, particularly, into cancer stem cells, thereby inhibiting cancer stem cells, and a cancer stem-cell detection probe will be described; however, the present invention is not limited to these.
[0026] Cancer Cell Inhibitory Drug
[0027] The cancer cell inhibitory drug refers to a composition having functions of suppressing growth, cellular division, metastasis and function of cancer cells and killing cancer cells. Furthermore, cancer cells can be detected and observed by measuring luminescence of the compound of the present invention.
[0028] A compound according to the present invention contains a compound represented by general formula (1).
[0029] Regarding compound represented by general formula (1)
[0000]
[0030] In general formula (1), R 1 and R 2 each independently represent an alkyl group, a carboxylalkyl group, an alkoxycarbonylalkyl group or an alkylcarbonyloxyalkyl group; R 3 to R 10 each independently represent a hydrogen atom, an alkyl group, an aryl group, an alkoxy group, a halogen atom, an alkoxysulfonyl group, a N-alkylsulfamoyl group, an alkyloxycarbonyl group, a carbamoyl group or a N-alkylcarbamoyl group; R 3 and R 4 , R 5 and R 6 , R 7 and R 8 , and R 9 and R 10 may be each independently cyclized to form a benzene ring; X 1 − represents an anionic group; Y 1 is a group including
[0031] *1, *2 and *5, and represents any one of the followings:
[0032] *1-S-*5-*2 (exemplified in compounds 1 to 12, 29, 39 and 42),
[0033] *1-O-*5-*2 (exemplified in compounds 13 to 19, 23, 28, 33, 38, 41, 44, 56 and 57),
[0034] *1-C(—R 11 ,—R 12 )-*5-*2 (exemplified in compounds 20 to 22, 24 to 27, 30 to 32, 37, 40, 43, 49 to 55 and 58), and
[0035] *1-*5-CH═CH-*2 (exemplified in compounds 34 to 36 and 45 to 48),
[0036] where R 11 and R 12 each independently represent an alkyl group, R 11 and R 12 may bind together to form a ring;
[0037] Y 2 is a group including *3, *4 and *6 and represents any one of the followings:
[0038] *4=*6-S-*3 (exemplified in compounds 1 to 12, 29, 34, 39 and 42),
[0039] *4=*6-O-*3 (exemplified in compounds 13 to 19, 23, 28, 33, 35, 38, 41, 44, 56 and 57),
[0040] *4=*6-C(—R 51 , —R 52 )-*3 (exemplified in compounds 20 to 22, 24 to 27, 30 to 32, 36, 37, 40, 43, 49 to 55 and 58),
[0041] *4=*6-CH═CH-*3 (exemplified in compounds 45, 47 and 48) and
[0042] *4=CH—CH═*6-*3 (exemplified in compound 46),
[0043] where R 51 and R 52 each independently represent an alkyl group and R 51 and R 52 may bind together to form a ring; and a group including A to carbon atoms represented by *5 and *6 is represented by general formula (2) or (3):
[0000]
[0044] In general formula (2), R 13 to R 15 each independently represent a hydrogen atom, an alkyl group or an aryl group; and n represents an integer of 0 to 2, in general formula (3), R 16 represents a hydrogen atom, a phenyl group, a thiol group, an alkoxy group, an aryloxy group or a halogen atom; and R 17 and R 18 each independently represent a hydrogen atom, an alkyl group or an alkyloxycarbonyl group.
[0045] In general formula (1), examples of the alkyl group represented by R 1 and R 2 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0046] In general formula (1), examples of the carboxylalkyl group represented by R 1 and R 2 include, but are not particularly limited to, a carboxylmethyl group, a carboxylethyl group and a carboxylpropyl group.
[0047] In general formula (1), examples of the alkoxycarbonylalkyl group represented by R 1 and R 2 include, but are not particularly limited to, a methoxycarbonylmethyl group, a methoxycarbonylethyl group, an ethoxycarbonylethyl group, a butoxycarbonylethyl group and a methoxycarbonylpropyl group; and examples of the alkylcarbonyloxyalkyl group include, but are not particularly limited to, a methylcarbonyloxymethyl group, an ethylcarbonyloxymethyl group, an ethylcarbonyloxyethyl group, an ethylcarbonyloxybutyl group and a propylcarbonyloxymethyl group.
[0048] In general formula (1), examples of the alkyl groups represented by R 3 to R 10 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0049] In general formula (1), examples of the aryl groups represented by R 3 to R 10 include, but are not particularly limited to, a phenyl group, a 2-bromophenyl group, a 3-bromophenyl group, a 4-bromophenyl group, a 2-methoxyphenyl group, a 3-methoxyphenyl group, a 4-methoxyphenyl group, a 2-thiomethylphenyl group, a 3-thiomethylphenyl group, a 4-thiomethylphenyl group and a naphthyl group.
[0050] In general formula (1), examples of the alkoxy groups represented by R 3 to R 10 include, but are not particularly limited to, a methoxy group, an ethoxy group, a propoxy group and a butoxy group.
[0051] In general formula (1), examples of the halogen atoms represented by R 3 to R 10 include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
[0052] In general formula (1), examples of the alkoxysulfonyl groups represented by R 3 to R 10 include, but are not particularly limited to, a methoxysulfonyl group and an ethoxysulfonyl group.
[0053] In general formula (1), examples of the N-alkylsulfamoyl groups represented by R 3 to R 10 include, but are not particularly limited to, a N-methylsulfamoyl group, a N-ethylsulfamoyl group, a N,N-dimethylsulfamoyl group and a N,N-diethylsulfamoyl group.
[0054] In general formula (1), examples of the alkyloxycarbonyl groups represented by R 3 to R 10 include, but are not particularly limited to, a methyloxycarbonyl group, an ethyloxycarbonyl group, a propyloxycarbonyl group and a butyloxycarbonyl group.
[0055] In general formula (1), examples of the N-alkylcarbamoyl groups represented by R 3 to R 10 include, but are not particularly limited to, a N-methylcarbamoyl group, a N-ethylcarbamoyl group, a N,N-dimethylcarbamoyl group and a N,N-diethylcarbamoyl group.
[0056] R 3 to R 10 in general formula (1) each independently represent preferably a hydrogen atom, a halogen atom, a phenyl group or an alkoxy group, and more preferably a hydrogen atom or a phenyl group.
[0057] In general formula (1), examples of the anionic group represented by X 1 − include, but are not particularly limited to, a chloride ion, a bromide ion, an iodide ion, a sulfate ion, a nitrate ion, a methanesulfonate ion, a p-toluenesulfonate ion, a tetrafluoroborate ion and a hexafluorophosphate ion.
[0058] In general formula (1), examples of the alkyl groups represented by R 11 , R 12 , R 51 and R 52 in Y 1 and Y 2 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group and a 2-ethylhexyl group. R 11 and R 12 are favorably the same; however they may differ. R 51 and R 52 are favorably the same; however they may differ.
[0059] In general formula (1), R 11 and R 12 or R 51 and R 52 may bind together to form an aliphatic ring such as a cyclohexane ring and a cyclopentane ring.
[0060] In general formula (2), examples of the alkyl groups represented by R 13 to R 15 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0061] In general formula (2), examples of the aryl groups represented by R 13 to R 15 include, but are not particularly limited to, a phenyl group, a 2-bromophenyl group, a 3-bromophenyl group, a 4-bromophenyl group, a 2-methoxyphenyl group, a 3-methoxyphenyl group, a 4-methoxyphenyl group, a 2-thiomethylphenyl group, a 3-thiomethylphenyl group and a 4-thiomethylphenyl group.
[0062] In general formula (3), examples of the thiol group represented by R 16 include a methanethiol group, a butanethiol group and a benzenethiol group. Alternatively, the thiol group represented by R 16 may be a phenylthio group.
[0063] In general formula (3), examples of the alkoxy group represented by R 16 include a methoxy group, an ethoxy group, a propoxy group and a butoxy group.
[0064] In general formula (3), examples of the aryloxy group represented by R 16 include a phenoxy group and a phenoxy group which may have a substituent.
[0065] In general formula (3), examples of the halogen atoms represented by R 16 include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
[0066] In general formula (3), examples of the alkyl groups represented by R 17 and R 18 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0067] In general formula (3), examples of the alkyloxycarbonyl groups represented by R 17 and R 18 include, but are not particularly limited to, a methyloxycarbonyl group, an ethyloxycarbonyl group, a propyloxycarbonyl group and a butyloxycarbonyl group.
[0068] Regarding compound represented by general formula (4) As a favorable compound of the present invention, a compound represented by general formula (3) can be mentioned.
[0000]
[0069] In general formula (4), R 19 and R 20 each independently represent an alkyl group, a carboxylalkyl group, an alkylcarbonyloxyalkyl group or an alkoxycarbonylalkyl group; and R 21 to R 28 each independently represent a hydrogen atom, an alkyl group, an aryl group, an alkoxy group, a halogen atom, an alkoxysulfonyl group, a N-alkylsulfamoyl group, an alkyloxycarbonyl group or a N-alkylcarbamoyl group. R 21 and R 22 , R 23 and R 24 , R 25 and R 26 and R 27 and R 28 may be each independently cyclized to form a benzene ring; R 29 to R 31 each independently represent a hydrogen atom, an alkyl group or an aryl group; and m represents an integer of 0 to 2. X 2 − represents an anionic group; and Y 3 and Y 4 each independently represent an oxygen atom, a sulfur atom or an alkylene group and the alkylene group may have a substituent being alkyl group. If the alkylene group has two or more substituents being alkyl groups, they may bind together to form an aliphatic ring.
[0070] In general formula (4), examples of the alkyl group represented by R 19 and R 20 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0071] In general formula (4), examples of the carboxylalkyl group represented by R 19 and R 20 include, but are not particularly limited to, a carboxylmethyl group, a carboxylethyl group and a carboxylpropyl group.
[0072] In general formula (4), examples of the alkoxycarbonylalkyl group represented by R 19 and R 20 include, but are not particularly limited to, a methoxycarbonylmethyl group, a methoxycarbonylethyl group, an ethoxycarbonylethyl group, a butoxycarbonylethyl group and a methoxycarbonylpropyl group.
[0073] Examples of the alkylcarbonyloxyalkyl group include, but are not particularly limited to, a methylcarbonyloxymethyl group, an ethylcarbonyloxymethyl group, an ethylcarbonyloxyethyl group, an ethylcarbonyloxybutyl group and a propylcarbonyloxymethyl group.
[0074] In general formula (4), examples of the alkyl groups represented by R 21 to R 28 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0075] In general formula (4), examples of the aryl groups represented by R 21 to R 28 include, but are not particularly limited to, a phenyl group, a 2-bromophenyl group, a 3-bromophenyl group, a 4-bromophenyl group, a 2-methoxyphenyl group, a 3-methoxyphenyl group, a 4-methoxyphenyl group, a 2-thiomethylphenyl group, a 3-thiomethylphenyl group, a 4-thiomethylphenyl group and a naphthyl group.
[0076] In general formula (4), examples of the alkoxy groups represented by R 21 to R 28 include, but are not particularly limited to, a methoxy group, an ethoxy group, a propoxy group and a butoxy group.
[0077] In general formula (4), examples of the halogen atoms represented by R 21 to R 28 include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
[0078] In general formula (4), examples of the alkoxysulfonyl groups represented by R 21 to R 28 include, but are not particularly limited to, a methoxysulfonyl group and an ethoxysulfonyl group.
[0079] In general formula (4), examples of the N-alkylsulfamoyl groups represented by R 21 to R 28 include, but are not particularly limited to, a N-methylsulfamoyl group, a N-ethylsulfamoyl group, a N,N-dimethylsulfamoyl group and a N,N-diethylsulfamoyl group.
[0080] In general formula (4), examples of the alkyloxycarbonyl groups represented by R 21 to R 28 include, but are not particularly limited to, a methyloxycarbonyl group, an ethyloxycarbonyl group, a propyloxycarbonyl group and a butyloxycarbonyl group.
[0081] In general formula (4), examples of the N-alkylcarbamoyl groups represented by R 21 to R 28 include, but are not particularly limited to, a N-methylcarbamoyl group, a N-ethylcarbamoyl group, a N,N-dimethylcarbamoyl group and a N,N-diethylcarbamoyl group.
[0082] R 21 to R 28 in general formula (4) each independently represent preferably a hydrogen atom, a halogen atom, a phenyl group or an alkoxy group, and more preferably a hydrogen atom or a phenyl group.
[0083] In general formula (4), examples of the alkyl groups represented by R 29 to R 31 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0084] In general formula (4), examples of the aryl group represented by R 29 to R 31 include, but are not particularly limited to, a phenyl group, a 2-bromophenyl group, a 3-bromophenyl group, a 4-bromophenyl group, a 2-methoxyphenyl group, a 3-methoxyphenyl group, a 4-methoxyphenyl group, a 2-thiomethylphenyl group, a 3-thiomethylphenyl group and a 4-thiomethylphenyl group.
[0085] In general formula (4), examples of the anionic group represented by X 2 − include, but are not particularly limited to, a chloride ion, a bromide ion, an iodide ion, a sulfate ion, a nitrate ion, a methanesulfonate ion, a p-toluenesulfonate ion, a tetrafluoroborate ion and a hexafluorophosphate ion.
[0086] In general formula (4), Y 3 and Y 4 each independently represent an oxygen atom, a sulfur atom or an alkylene group and the alkylene group may have a substituent being alkyl group. If the alkylene group has two or more substituents being alkyl groups, they may bind together to form an aliphatic ring.
[0087] Examples of the alkylene group herein include, but are not particularly limited to, a methylene group, an ethylene group, a propylene group, a butylene group, a pentylene group, a hexylene group and a 2-ethylhexylene group. Examples of the aliphatic ring to be formed include, but are not particularly limited to, a cyclohexane ring and a cyclopentane ring.
[0088] The compounds represented by general formula (4) in the present invention are mostly commercially available and can be purchased and also synthesized in the same manner as in known methods (for example, NPL-3).
[0000]
[0089] In the above compounds (A) to (D), R 19 to R 31 , X 2 − , Y 3 , and Y 4 are the same as defined in R 19 to R 31 , X 2 − , Y 3 and Y 4 in compounds (A) to (D) in general formula (4). Furthermore, R in compound (A) represents an alkyl group such as a methyl group and an ethyl group.
[0090] More specifically, a compound represented by general formula (4) where m represents 0 is obtained by coupling compound (A), compound (C) and compound (D). A compound represented by general formula (4) where m represents 0 to 2 is obtained by coupling compound (B), compound (C) and compound (D).
[0091] Examples of the coupling method are not particularly limited. For example, a method of using compound (A) where m represents 0 will be described below as an embodiment.
[0092] The use amount of compound (C) in a coupling step relative to compound (A) (1 mole) is 0.1 to 1.2 times by mole, preferably 0.5 to 1.1 times by mole, and more preferably 0.8 to 1.0 times by mole.
[0093] The use amount of compound (D) in a coupling step relative to compound (A) (1 mole) is 0.1 to 2 times by mole, preferably 0.5 to 1.5 times by mole, and more preferably 0.8 to 1.2 times by mole.
[0094] The compound (C) and compound (D), which are not limited, may be the same or different; however, they are preferably the same compounds in view of process. The use amount of compound (C) and compound (D) relative to compound (A) (1 mole) when they are the same compounds, is 0.1 to 3 times by mole, preferably 0.5 to 2 times by mole, and more preferably 0.8 to 1.5 times by mole.
[0095] The coupling step can be performed in the absence of a solvent; however, it is favorably performed in the presence of a solvent. The solvent is not particularly limited as long as it is not involved in a reaction. Examples of the solvent include ester solvents such as methyl acetate, ethyl acetate, isopropyl acetate and butyl acetate; nitrile solvents such as acetonitrile, propionitrile and benzonitrile; aromatic solvents such as benzene, toluene, xylene, ethylbenzene, chlorobenzene and mesitylene; ether solvents such as diisopropyl ether, methyl-tert-butyl ether and tetrahydrofuran; alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol; ketone solvents such as acetone and methylethyl ketone; dimethylformamide (DMF), dimethylsulfoxide (DMSO), water and acetic acid. Preferably, alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol, water and acetic acid, and more preferably e.g., ethanol, iso-propyl alcohol and diethylene glycol and acetic acid are mentioned. Furthermore, two or more types of solvents can be used in combination and the mixing ratio of solvents used in combination can be determined at discretion.
[0096] The use amount of reaction solvent in the coupling step relative to compound (A) falls within the range of 0.1 to 1000 times by weight, preferably 0.5 to 500 times by weight, and more preferably 1.0 to 150 times by weight.
[0097] The reaction temperature in the coupling step falls within the range of −80 to 250° C., preferably −20 to 200° C., and more preferably 10 to 170° C. The reaction is generally completed within 24 hours.
[0098] In the coupling step, if an acid or a base is added as necessary, the reaction swiftly proceeds. The acid to be used is not particularly limited. Examples of the acid include inorganic acids such as hydrochloric acid, sulfuric acid and phosphoric acid; organic acids such as p-toluenesulfonic acid, formic acid, acetic acid, propionic acid, trifluoroacetic acid and acetic anhydride; strongly acidic ion exchange resins such as Amberlite (Rohm and Haas) and Amberlyst (Rohm and Haas); and inorganic acid salts such as ammonium formate and ammonium acetate. More preferably, an inorganic acid salt such as ammonium formate or ammonium acetate, and more preferably ammonium acetate is mentioned. The use amount of acid relative to compound (A) (1 mole) is 0.001 to 50 times by mole, preferably 0.01 to 10 times by mole, and more preferably 0.1 to 5 times by mole.
[0099] Specific examples of the base to be used in the coupling step include metal alkoxides such as potassium tert-butoxide, sodium tert-butoxide, sodium methoxide and sodium ethoxide; organic bases such as piperidine, pyridine, 2-methylpyridine, dimethylaminopyridine, diethylamine, triethylamine, isopropylethylamine, sodium acetate, potassium acetate, 1,8-diazabicyclo[5,4,0]undec-7-ene (hereinafter, simply referred to as DBU) and ammonium acetate; organic bases such as N-butyllithium and tert-butylmagnesium chloride; and inorganic bases such as sodium borohydride, metallic sodium, sodium hydride and sodium carbonate. Preferably, potassium tert-butoxide, sodium methoxide, sodium ethoxide, piperidine, dimethylaminopyridine, sodium acetate and ammonium acetate; and more preferably sodium methoxide, piperidine, sodium acetate and ammonium acetate are mentioned. The use amount of base as mentioned above relative to compound (A) (1 mole) is 0.1 to 20 times by mole, preferably 0.5 to 8 times by mole, and more preferably 1.0 to 4 times by mole.
[0100] After completion of the reaction, a reaction product is diluted with water or precipitated with an acid such as hydrochloric acid to obtain a compound represented by general formula (4).
[0101] To the obtained compound, isolation/purification methods generally used for organic compounds can be applied. For example, a reaction solution is acidified with an acid such as hydrochloric acid to precipitate a solid substance. The solid substrate is separated by filtration, neutralized with e.g., sodium hydroxide and concentrated to obtain a crude product. The crude product is further purified by e.g., recrystallization using e.g., acetone or methanol, or a column using silica gel. The crude product can be highly purified by employing these methods alone or in combination with two or more.
[0102] Regarding compound represented by general formula (5) As a preferable compound of the present invention, a compound represented by general formula (5) can be mentioned.
[0000]
[0103] In general formula (5), R 34 and R 35 each independently represents an alkyl group, a carboxylalkyl group or an alkoxycarbonylalkyl group; and R 36 to R 43 each independently represent a hydrogen atom, an alkyl group, an aryl group, an alkoxy group, a halogen atom, an alkoxysulfonyl group, a N-alkylsulfamoyl group, an alkyloxycarbonyl group or a N-alkylcarbamoyl group. R 36 and R 37 , R 38 and R 39 , R 40 and R 41 and R 42 and R 43 may be each independently cyclized to form a benzene ring. R 44 represents a hydrogen atom, a phenyl group, a thiol group, an alkoxy group, an aryloxy group or a halogen atom; and R 45 and R 46 each independently represent a hydrogen atom, an alkyl group or an alkylcarbonyloxy group. X 3 − represents an anionic group; and Y 5 and Y 6 each independently represent an oxygen atom, a sulfur atom or an alkylene group and the alkylene group may have substituents being alkyl groups which may bind together to form an aliphatic ring.
[0104] In general formula (5), examples of the alkyl group represented by R 34 and R 35 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0105] In general formula (5), examples of the carboxylalkyl group represented by R 34 and R 35 include, but are not particularly limited to, a carboxylmethyl group, a carboxylethyl group and a carboxylpropyl group.
[0106] In general formula (5), examples of the alkoxycarbonylalkyl group represented by R 34 and R 35 include, but are not particularly limited to, a methoxycarbonylmethyl group, a methoxycarbonylethyl group, an ethoxycarbonylethyl group, a butoxycarbonylethyl group and a methoxycarbonylpropyl group; and in general formula (5), examples of the alkyl groups represented by R 36 to R 43 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0107] In general formula (5), examples of the aryl groups represented by R 36 to R 43 include, but are not particularly limited to, a phenyl group, a 2-bromophenyl group, a 3-bromophenyl group, a 4-bromophenyl group, a 2-methoxyphenyl group, a 3-methoxyphenyl group, a 4-methoxyphenyl group, a 2-thiomethylphenyl group, a 3-thiomethylphenyl group, a 4-thiomethylphenyl group and a naphthyl group.
[0108] In general formula (5), examples of the alkoxy groups represented by R 36 to R 43 include, but are not particularly limited to, a methoxy group, an ethoxy group, a propoxy group and a butoxy group.
[0109] In general formula (5), examples of the halogen atoms represented by R 36 to R 43 include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
[0110] In general formula (5), examples of the alkoxysulfonyl groups represented by R 36 to R 43 include, but are not particularly limited to, a methyl sulfonate group and an ethyl sulfonate group.
[0111] In general formula (5), examples of the alkylsulfamoyl groups represented by R 36 to R 43 include, but are not particularly limited to, a monomethylamide sulfonate group, a monoethylamide sulfonate group, a dimethylamide sulfonate group and a diethylamide sulfonate group.
[0112] In general formula (5), examples of the alkylcarbonyloxyalkyl groups represented by R 36 to R 43 include, but are not particularly limited to, a methylcarbonyloxymethyl group, an ethylcarbonyloxymethyl group, an ethylcarbonyloxyethyl group, an ethylcarbonyloxybutyl group and a propylcarbonyloxymethyl group.
[0113] In general formula (5), examples of the N-alkylcarbamoyl groups represented by R 36 to R 43 include, but are not particularly limited to, a N-methylcarbamoyl group, a N-ethylcarbamoyl group, a N,N-dimethylcarbamoyl group and a N,N-diethylcarbamoyl group.
[0114] R 36 to R 43 in general formula (5) each independently represent preferably a hydrogen atom, a halogen atom, a phenyl group or an alkoxy group, and more preferably a hydrogen atom or a phenyl group.
[0115] In general formula (5), examples of the thiol group represented by R 44 include a mercaptomethyl group, a mercaptobutyl group and a mercaptophenyl group. Alternatively, the thiol group represented by R 44 may be a phenylthio group.
[0116] In general formula (5), examples of the alkoxy group represented by R 44 include a methoxy group, an ethoxy group, a propoxy group and a butoxy group.
[0117] In general formula (5), examples of the aryloxy group represented by R 44 include a phenoxy group and a phenoxy group which may have a substituent.
[0118] In general formula (5), examples of the halogen atom represented by R 44 include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
[0119] In general formula (5), examples of the alkyl group represented by R 45 and R 46 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0120] In general formula (5), examples of the alkyloxycarbonyl groups represented by R 45 and R 46 include, but are not particularly limited to, a methyloxycarbonyl group, an ethyloxycarbonyl group, a propyloxycarbonyl group and a butyloxycarbonyl group.
[0121] In general formula (5), examples of the anionic group represented by X 3 − include, but are not particularly limited to, a chloride ion, a bromide ion, an iodide ion, a sulfate ion, a nitrate ion, a methanesulfonate ion, a p-toluenesulfonate ion, a tetrafluoroborate ion and a hexafluorophosphate ion.
[0122] In general formula (5), examples of the alkylene groups represented by Y 5 and Y 6 include, but are not particularly limited to, a methylene group, an ethylene group, a propylene group, a butylene group, a pentylene group, a hexylene group and a 2-ethylenehexyl group. Examples of the alkyl group serving as a substituent of an alkylene group include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group and a butyl group.
[0123] The compounds represented by general formula (5) in the present invention are mostly commercially available and can be purchased and also synthesized in the same manner as in known methods (for example, NPL-4).
[0000]
[0124] In compounds (E) to (G), R 35 to R 44 , X 3 − , Y 5 , and Y 6 are the same as defined in R 35 to R 44 , X 3 − , Y 5 , and Y 6 in compounds (E) to (G) in general formula (5).
[0125] More specifically, a compound represented by general formula (5) can be obtained by coupling compounds (E) to (G). Examples of the coupling method are not particularly limited. For example, a method described below is mentioned as an embodiment.
[0126] The use amount of compound (F) in a coupling step relative to compound (E) (1 mole) is 0.1 to 1.2 times by mole, preferably 0.5 to 1.1 times by mole, and more preferably 0.8 to 1.0 times by mole.
[0127] The use amount of compound (G) in a coupling step relative to compound (E) (1 mole) is 0.1 to 2 times by mole, preferably 0.5 to 1.5 times by mole, and more preferably 0.8 to 1.2 times by mole.
[0128] The compound (F) and compound (G), which are not limited, may be the same or different; however, they are preferably the same compounds in view of process. The use amount of compound (F) and compound (G) relative to compound (E) (1 mole) when they are the same compounds, is 0.1 to 3 times by mole, preferably 0.5 to 2 times by mole, and more preferably 0.8 to 1.5 times by mole.
[0129] The coupling step can be performed in the absence of a solvent; however, it is favorably performed in the presence of a solvent. The solvent is not particularly limited as long as it is not involved in a reaction. Examples of the solvent include ester solvents such as methyl acetate, ethyl acetate, isopropyl acetate and butyl acetate; nitrile solvents such as acetonitrile, propionitrile and benzonitrile; aromatic solvents such as benzene, toluene, xylene, ethylbenzene, chlorobenzene and mesitylene; ether solvents such as diisopropyl ether, methyl-tert-butyl ether and tetrahydrofuran; alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol; ketone solvents such as acetone and methylethyl ketone; dimethylformamide (DMF), dimethylsulfoxide (DMSO), water and acetic acid. Preferably, alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol, water and acetic acid, and more preferably e.g., ethanol, iso-propyl alcohol and diethylene glycol and acetic acid are mentioned. Furthermore, two or more types of solvents can be used in combination and the mixing ratio of solvents used in combination can be determined at discretion.
[0130] The use amount of reaction solvent in the coupling step relative to compound (E) falls within the range of 0.1 to 1000 times by weight, preferably 0.5 to 500 times by weight, and more preferably 1.0 to 150 times by weight.
[0131] The reaction temperature in the coupling step falls within the range of −80 to 250° C., preferably −20 to 200° C., and more preferably 10 to 170° C. The reaction is generally completed within 24 hours.
[0132] In the coupling step, if an acid or a base is added as necessary, the reaction swiftly proceeds. The acid to be used is not particularly limited. Examples of the acid include inorganic acids such as hydrochloric acid, sulfuric acid and phosphoric acid; organic acids such as p-toluenesulfonic acid, formic acid, acetic acid, propionic acid, trifluoroacetic acid and acetic anhydride; strongly acidic ion exchange resins such as Amberlite (Rohm and Haas) and Amberlyst (Rohm and Haas); and inorganic acid salts such as ammonium formate and ammonium acetate. More preferably, an inorganic acid salt such as ammonium formate or ammonium acetate, and more preferably ammonium acetate is mentioned. The use amount of acid relative to compound (E) (1 mole) is 0.001 to 50 times by mole, preferably 0.01 to 10 times by mole, and more preferably 0.1 to 5 times by mole.
[0133] Specific examples of the base to be used in the coupling step include metal alkoxides such as potassium tert-butoxide, sodium tert-butoxide, sodium methoxide and sodium ethoxide; organic bases such as piperidine, pyridine, 2-methylpyridine, dimethylaminopyridine, diethylamine, triethylamine, isopropylethylamine, sodium acetate, potassium acetate, 1,8-diazabicyclo[5,4,0]undec-7-ene (hereinafter, simply referred to as DBU) and ammonium acetate; organic bases such as N-butyllithium and tert-butylmagnesium chloride; and inorganic bases such as sodium borohydride, metallic sodium, sodium hydride and sodium carbonate. Preferably, potassium tert-butoxide, sodium methoxide, sodium ethoxide, piperidine, dimethylaminopyridine, sodium acetate and ammonium acetate; and more preferably sodium methoxide, piperidine, sodium acetate and ammonium acetate are mentioned. The use amount of base as mentioned above relative to compound (E) (1 mole) is 0.1 to 20 times by mole, preferably 0.5 to 8 times by mole, and more preferably 1.0 to 4 times by mole.
[0134] After completion of the reaction, a reaction product is diluted with water or precipitated with an acid such as hydrochloric acid to obtain a compound represented by general formula (5).
[0135] To the obtained compound, isolation/purification methods generally used for organic compounds can be applied. For example, a reaction solution is acidified with an acid such as hydrochloric acid to precipitate a solid substance. The solid substrate is separated by filtration, neutralized with e.g., sodium hydroxide and concentrated to obtain a crude product. Furthermore, the crude product is purified by e.g., recrystallization using e.g., acetone or methanol, or a column using silica gel. The crude product can be highly purified by employing these methods alone or in combination with two or more.
[0136] Regarding compound represented by general formula (6) As a preferable compound of the present invention, a compound represented by general formula (6) can be mentioned.
[0000]
[0137] In general formula (6), R 49 and R 50 each independently represent an alkyl group, a carboxylalkyl group, an alkylcarbonyloxyalkyl group or an alkoxycarbonylalkyl group. X 4 − represents an anionic group.
[0138] In general formula (6), examples of the alkyl group represented by R 49 and R 50 include, but are not particularly limited to, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group.
[0139] In general formula (6), examples of the carboxylalkyl group represented by R 49 and R 50 include, but are not particularly limited to, a carboxylmethyl group, a carboxylethyl group and a carboxylpropyl group.
[0140] In general formula (6), examples of the alkoxycarbonylalkyl group represented by R 49 and R 50 include, but are not particularly limited to, a methoxycarbonylmethyl group, a methoxycarbonylethyl group, an ethoxycarbonylethyl group, a butoxycarbonylethyl group and a methoxycarbonylpropyl group; and examples of the alkylcarbonyloxyalkyl group include, but are not particularly limited to, a methylcarbonyloxymethyl group, an ethylcarbonyloxymethyl group, an ethylcarbonyloxyethyl group, an ethylcarbonyloxybutyl group and a propylcarbonyloxymethyl group.
[0141] In general formula (6), examples of the anionic group represented by X 4 − include, but are not particularly limited to, a chloride ion, a bromide ion, an iodide ion, a sulfate ion, a nitrate ion and a methanesulfonate ion.
[0142] The compounds represented by general formula (6) in the present invention are mostly commercially available and can be purchased and also synthesized in the same manner as in known methods (for example, NPL-5).
[0000]
[0143] In compounds (H) to (J), R 49 , R 50 and X 4 − are the same as defined in R 49 , R 50 and X 4 − in compounds (H) to (J) in general formula (6).
[0144] More specifically, a compound represented by general formula (6) can be obtained by coupling compounds (H) to (J). Examples of the coupling method is not particularly limited. For example, a method described below is mentioned as an embodiment.
[0145] The use amount of compound (I) in a coupling step relative to compound (H) (1 mole) is 0.1 to 1.2 times by mole, preferably 0.5 to 1.1 times by mole, and more preferably 0.8 to 1.0 times by mole.
[0146] The use amount of compound (J) in a coupling step relative to compound (H) (1 mole) is 0.1 to 2 times by mole, preferably 0.5 to 1.5 times by mole, and more preferably 0.8 to 1.2 times by mole.
[0147] The compound (I) and compound (J), which are not limited, may be the same or different; however, preferably the same compounds in view of process. The use amount of compound (I) and compound (J) relative to compound (H) (1 mole) when they are the same compounds, is 0.1 to 3 times by mole, preferably 0.5 to 2 times by mole, and more preferably 0.8 to 1.5 times by mole.
[0148] The coupling step can be performed in the absence of a solvent; however, it is favorably performed in the presence of a solvent. The solvent is not particularly limited as long as it is not involved in a reaction. Examples of the solvent include ester solvents such as methyl acetate, ethyl acetate, isopropyl acetate and butyl acetate; nitrile solvents such as acetonitrile, propionitrile and benzonitrile; aromatic solvents such as benzene, toluene, xylene, ethylbenzene, chlorobenzene and mesitylene; ether solvents such as diisopropyl ether, methyl-tert-butyl ether and tetrahydrofuran; alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol; ketone solvents such as acetone and methylethyl ketone; dimethylformamide (DMF), dimethylsulfoxide (DMSO), water and acetic acid. Preferably, alcohol solvents such as methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, butyl alcohol and diethylene glycol, water and acetic acid, and more preferably e.g., ethanol, iso-propyl alcohol and diethylene glycol and acetic acid are mentioned. Furthermore, two or more types of solvents can be used in combination and the mixing ratio of solvents used in combination can be determined at discretion.
[0149] The use amount of reaction solvent in the coupling step relative to compound (H) falls within the range of 0.1 to 1000 times by weight, preferably 0.5 to 500 times by weight, and more preferably 1.0 to 150 times by weight.
[0150] The reaction temperature in the coupling step falls within the range of −80 to 250° C., preferably −20 to 200° C., and more preferably 10 to 170° C. The reaction is generally completed within 24 hours.
[0151] In the coupling step, if an acid or a base is added as necessary, the reaction swiftly proceeds. The acid to be used is not particularly limited. Examples of the acid include inorganic acids such as hydrochloric acid, sulfuric acid and phosphoric acid; organic acids such as p-toluenesulfonic acid, formic acid, acetic acid, propionic acid, trifluoroacetic acid and acetic anhydride; strongly acidic ion exchange resins such as Amberlite (Rohm and Haas) and Amberlyst (Rohm and Haas); and inorganic acid salts such as ammonium formate and ammonium acetate. More preferably, an inorganic acid salt such as ammonium formate or ammonium acetate, and more preferably ammonium acetate is mentioned. The use amount of acid relative to compound (H) (1 mole) is 0.001 to 50 times by mole, preferably 0.01 to 10 times by mole, and more preferably 0.1 to 5 times by mole.
[0152] Specific examples of the base to be used in the coupling step include metal alkoxides such as potassium tert-butoxide, sodium tert-butoxide, sodium methoxide and sodium ethoxide; organic bases such as piperidine, pyridine, 2-methylpyridine, dimethylaminopyridine, diethylamine, triethylamine, isopropylethylamine, sodium acetate, potassium acetate, 1,8-diazabicyclo[5,4,0]undec-7-ene (hereinafter, simply referred to as DBU) and ammonium acetate; organic bases such as N-butyllithium and tert-butylmagnesium chloride; and inorganic bases such as sodium borohydride, metallic sodium, sodium hydride and sodium carbonate. Preferably, potassium tert-butoxide, sodium methoxide, sodium ethoxide, piperidine, dimethylaminopyridine, sodium acetate and ammonium acetate; and more preferably sodium methoxide, piperidine, sodium acetate and ammonium acetate are mentioned. The use amount of base as mentioned above relative to compound (H) (1 mole) is 0.1 to 20 times by mole, preferably 0.5 to 8 times by mole, and more preferably 1.0 to 4 times by mole.
[0153] After completion of the reaction, a reaction product is diluted with water or precipitated with an acid such as hydrochloric acid to obtain a compound represented by general formula (6).
[0154] To the obtained compound, isolation/purification methods generally used for organic compounds can be applied. For example, a reaction solution is acidified with an acid such as hydrochloric acid to precipitate a solid substance. The solid substrate is separated by filtration, neutralized with e.g., sodium hydroxide and concentrated to obtain a crude product. Furthermore, the crude product is purified by e.g., recrystallization using e.g., acetone or methanol, or a column using silica gel. The crude product can be highly purified by employing these methods alone or in combination with two or more.
[0155] Now, compounds (1) to (60) will be shown below as preferable examples of the compounds according to the present invention; however, the present invention is not limited to the following examples.
[0000]
[0156] The compounds of the present invention are favorably emitted by light upon irradiation with excitation light of 350 to 800 nm in wavelength.
[0157] The compounds of the present invention is characterized in that growth suppression, cellular division suppression, metastasis suppression, functional inhibition and cytocidal action of cancer cells are mediated by taking a compound selectively into the cancer cells. Further, cancer cells can be detected and observed by measuring luminescence of the compound of the present invention.
[0158] The compounds of the present invention may be used alone or in combination with two types or more for cancer inhibition, and may be used in combination with a known anti-cancer drug(s).
[0159] In the present invention, an effect is selectively exerted particularly on cancer stem cells among cancer cells.
[0160] Cancer Stem Cells
[0161] In the specification, the cancer stem cells refer to cancer cells having properties of the stem cells. The stem cells refer to cells having two functions, i.e., self-replication ability and pluripotency (ability to differentiate into various types of cells).
[0162] Applicable Cancer
[0163] Examples of the cancer to be inhibited by the compound of the present invention include, but are not particularly limited to Examples of the cancers include breast cancer, brain tumor, stomach cancer, prostatic cancer, pancreatic cancer, lung cancer, large bowel cancer, small intestine cancer, colon cancer, rectal cancer, esophagus cancer, duodenal cancer, tongue cancer, pharyngeal cancer, liver cancer, endometrium cancer, uterine cervix cancer, renal cancer, bile duct cancer, ovarian cancer, bladder cancer, skin cancer, blood vessel cancer, salivary gland cancer, thyroid cancer, parathyroid gland cancer, nasal cavity cancer, paranasal sinus cancer, penile cancer, infant solid cancer, malignant lymphoma, malignant melanoma, retina sarcoma, testicular tumor, myeloma, sarcoma, blood vessel fibroma and leukemia. Preferably, e.g., pancreatic cancer, prostatic cancer and leukemia are mentioned. Particularly, applicable cancers may include cancer stem cells or cells originated from cancer stem cells.
[0164] Test Subject
[0165] Examples of the subject used in a test for checking whether a compound of the present invention suppresses a cancer or not include, but are not particularly limited to, vertebral animals including bony fish such as Takifugu (Japanese pufferfish), Takifugu niphobles , green spotted pufferfish ( Tetraodon nigroviridis ), killifish and zebra fish, amphibians such as Xenopus , birds such as fowl and quail, and mammalians such as human, monkey, chimpanzee, calf, horse, pig, dog, cat, mouse, rat, guinea pig, hamster and rabbit; small animals such as rat, mouse and hamster; and large animals such as goat, pig, dog, cat, calf and horse, monkey, chimpanzee and human. Favorably, e.g., human, mouse, rat, dog and cat are mentioned.
[0166] When a compound of the present invention is used as a medicinal drug, various types of dosage forms can be selected depending upon the administration route. Examples of dosage forms that can be used include liquid, syrup, fine granule, granule, tablet, capsule, pasting medicine and drug delivery system (DDS) such as liposome.
[0167] The administration method of a compound of the present invention is not limited and oral or parenteral administration may be used. Examples of the administration method that can be used include exposure to a living body (e.g., liquid); administration such as oral, intravascular (through e.g., a vein or an artery), peroral, sublingual, intrarectal, intraperitoneal, dermal, subcutaneous, intracutaneous, intravesical, tracheal (via bronchia), intraocular and intranasal administrations; and injection, spray and application into ear or the like.
[0168] A compound of the present invention, if necessary, may contain pharmacologically or pharmaceutically acceptable additives such as a moisturizer, a surface tension moderator, a thickener, a pH moderator, a pH buffer, a preservative, an antibacterial agent, a sweetening agent, a flavor, a solubilizer, a solubilizing agent, a coating agent and a binder.
[0169] The dose of the compound of the present invention is appropriately determined depending upon a purpose for therapy or prophylaxis, and conditions such as sexuality, age, weight of a test subject, an administration route, and degree of a disease.
[0170] Transplant Model Animal
[0171] Generally, it is difficult to monitor behavior of metastatic cancer by culturing cells. Thus, in the present invention, in order to monitor behavior of metastatic cancer, particularly, a transplant model animal can be used.
[0172] Examples of the cancer-cell transplant model animal applicable to the present invention include, but are not particularly limited to, vertebral animals including bony fish such as Takifugu (Japanese pufferfish), Takifugu niphobles , green spotted pufferfish ( Tetraodon nigroviridis ), killifish and zebra fish, amphibians such as Xenopus , birds such as fowl and quail, mammalians such as human, monkey, chimpanzee, calf, horse, pig, dog, cat, mouse, rat, guinea pig, hamster and rabbit, and birds such as fowl and quail; small animals such as rat, mouse and hamster; and large animals such as goat, pig, dog, cat, calf and horse, monkey and chimpanzee. Favorably, e.g., mouse, rat, dog and cat are mentioned.
[0173] Of these, e.g., immunodeficiency mice and rats, are often generally used in an initial study. In this case, it is necessary to maintain an environment by use of e.g., a clean room in the period (usually, at least 3 to 6 months) during which the study is carried out. In addition, extraordinary labor cost for management during this period is required.
[0174] For the reason, among these biological samples, zebra fish is particularly preferably used in view of cost and speed (usually at least a week). Zebra fish has been recently and already recognized as a third model animal which comes next to mice and rats in the United States and the United Kingdom. It has been elucidated that, the entire genomic sequence of zebra fish has a 80% homology to that of a human and the number of genes of zebra fish is virtually the same as that of a human. Furthermore, development and structure of major organs/tissues are mutually quite resembled. Since a process from differentiation of a fertilized egg to formation of each part (organ such as heart, liver, kidney and digestive tube) can be observed through a transparent body, it is particularly preferable to use zebra fish (the inside of which can be observed non-invasively) for screening as a model animal.
[0175] Furthermore, zebra fish lay about 200 or more fertilized eggs per time. Since zebra fish having the same genetic background are obtained, zebra fish is advantageous for screening.
[0176] The method for administering a compound of the present invention is not particularly limited; however, a cancer cell inhibitory drug may be suspended in the form of a complex with an appropriate surfactant or in the form of an emulsion in breeding water. Alternatively, the cancer cell inhibitory drug may be mixed in feed or food and orally or parenterally (e.g., injection) administered.
[0177] Cancer Stem Cell Detection Probe
[0178] Since the compound of the present invention can be used for selective detection of cancer stem cells, it can be suitably used as a cancer stem-cell detection probe. More specifically, the present invention encompasses a cancer cell detection probe.
[0179] The ratio of the compound of the present invention particularly taken into cancer stem cells among the cancer cells is large. Thus, cancer stem cells can be selectively detected. Detection and confirmation of behavior of cancer stem cells by the present invention can be carried out all in vitro, ex vivo or in vivo.
[0180] A method for detecting, by use of a compound of the present invention, which is not particularly limited as long as it has no effect upon cancer stem cells, is a method for capturing state and change of a biological sample as an image. For example, visible light, near infrared light or infrared light is applied to cancer stem cells and an image is visually observed by e.g., a camera or CCD, namely, visible light observation, near infrared light observation and infrared light observation are mentioned. Alternatively, observation by a laser microscope; fluorescence observation in which excitation light is applied to a biological sample from an excitation-light source and fluorescence emitted from the biological sample is observed by a fluorescent endoscope or the like; observation by a fluorescent microscope; observation by a fluorescent endoscope; observation by a confocal fluorescence microscope; or observation by a multiphoton excitation fluorescence microscope is mentioned. Alternatively, narrow-band light observation; colight interference tomogram observation (OCT) or observation by a soft X ray microscope is mentioned. Particularly, fluorescence observation is favorable.
[0181] The wavelength of light for exciting a compound of the present invention varies depending upon the compound represented by general formula (1) and the wavelength of the excitation light is not particularly limited as long as a cancer cell detection probe of the present invention efficiently emits fluorescent light.
[0182] The wavelength is preferably, 200 to 1010 nm, more preferably 400 to 900 nm, and more preferably 480 to 800 nm. When light within a near infrared region is used, the wavelength that is used is preferably 600 to 1000 nm, and more preferably 680 to 900 nm, which is also excellent in permeability through a living body.
[0183] The source of excitation light for exciting a compound of the present invention is not particularly limited and various types of laser light sources can be used. Examples of these laser light sources include a dye laser light source, a semiconductor laser light source, an ion laser light source, a fiber laser light source, a halogen lamp, a xenon lamp and a tungsten lamp. Alternatively, if various types of optical filters are used, a favorable excitation wavelength can be obtained and fluorescence alone can be detected.
[0184] As described above, in the state where a compound of the present invention present within cancer stem cells is allowed to emit light by applying excitation light to an individual biological organism, if the cancer stem cells can be photographed, a luminescent site can be easily detected. Furthermore, if an image in light field, which is obtained by applying visible light, is combined with a fluorescent image, which is obtained by applying excitation light, with the help of an image processing unit, cancer stem cells can be more specifically observed. Furthermore, if a confocal microscope is used, a sectional optical image can be favorably obtained. Furthermore, a multiphoton excitation fluorescence microscope, since it is highly permeable to a deep portion and a spatial resolution, is favorably used for observing inside a tissue.
EXAMPLES
[0185] Now, the present invention will be more specifically described below by way of Examples. These are specific Examples for further deep understanding of the present invention and should not be construed as limiting the invention.
Example 1
[0186] Production Examples of the compounds of the present invention will be shown.
[0187] Production of Compound (1)
[0000]
[0188] Under a nitrogen atmosphere, to a solution of compound (A1) (0.61 g (2.0 mmol)) in anhydrous acetic acid (10 mL), a compound (B1) (0.20 g (1.0 mmol)) and anhydrous sodium acetate (0.16 g (2.0 mmol)) were added and stirred at 100° C. for one hour. After completion of the reaction, while the reaction solution was cooled, saturated saline (100 mL) was gently added dropwise to cool the reaction solution to room temperature. Furthermore, the reaction solution was extracted twice with dichloromethane (50 mL) and dried over anhydrous sodium acetate. Thereafter, the organic layer was concentrated under reduced pressure. The residue was purified by silica gel chromatography and the purified product was recrystallized from diethyl ether to obtain the compound (1) (0.29 g (yield 59%)). The desired product was confirmed by 1 H nuclear magnetic resonance spectroscopic analysis (ECA-400, manufactured by JEOL Ltd.) and LC/TOF MS (LC/MSD TOF, manufactured by Agilent Technologies).
[0189] Production of Compound (40)
[0000]
[0190] Under a nitrogen atmosphere, to a solution of compound (A2) (0.48 g (2.2 mmol)) in anhydrous acetic acid (10 mL), a compound (B2) (0.32 g (1.0 mmol)) and anhydrous sodium acetate (0.25 g (3.0 mmol)) were added and stirred at 100° C. for one hour. After completion of the reaction, while the reaction solution was cooled, saturated saline (100 mL) was gently added dropwise to cool the reaction solution to room temperature. Furthermore, the reaction solution was extracted twice with dichloromethane (50 mL) and dried over anhydrous sodium acetate. Thereafter, the organic layer was concentrated under reduced pressure. The residue was purified by silica gel chromatography and the purified product was recrystallized from diethyl ether to obtain the compound (40) (0.38 g (yield 54%)). The desired product was confirmed by 1 H nuclear magnetic resonance spectroscopic analysis (ECA-400, manufactured by JEOL Ltd.) and LC/TOF MS (LC/MSD TOF, manufactured by Agilent Technologies).
[0191] Production of Compound (46)
[0000]
[0192] Under a nitrogen atmosphere, to a solution of compound (A3) (0.90 g (3.0 mmol)) in anhydrous acetic acid (15 mL), a compound (B3) (0.29 g (1.5 mmol)) and anhydrous sodium acetate (0.29 g (3.5 mmol)) were added and stirred at 100° C. for 1.5 hours. After completion of the reaction, while the reaction solution was cooled, saturated saline (100 mL) was gently added dropwise to cool the reaction solution to room temperature. Furthermore, the reaction solution was extracted twice with dichloromethane (50 mL) and dried over anhydrous sodium acetate. Thereafter, the organic layer was concentrated under reduced pressure. The residue was purified by silica gel chromatography and the purified product was recrystallized from diethyl ether to obtain the compound (46) (0.46 g (yield 64%)). The desired product was confirmed by 1 H nuclear magnetic resonance spectroscopic analysis (ECA-400, manufactured by JEOL Ltd.) and LC/TOF MS (LC/MSD TOF, manufactured by Agilent Technologies).
[0193] Furthermore, commercially available products were purchased or 32 types of compounds shown in Table 1 were obtained by a production method according to any one of the aforementioned Production Examples. The structures of these compounds were confirmed by an analyzer in the same manner as mentioned above.
Example 2
[0194] Measurement of Fluorescent Property of Compound
[0195] A 5 μM DMSO solution of each of the compounds shown in the following Table 1 was prepared. The excitation wavelength and fluorescence wavelength of the compound were measured by a FL4500 spectrofluorometric measuring machine manufactured by Hitachi High-Technologies Corporation.
[0000]
TABLE 1
Excitation
Fluorescence
Compound
wavelength λex
wavelength λem
Compound 1
485
575
Compound 4
563
569
Compound 5
560
628
Compound 7
344
381
Compound 10
586
615
Compound 11
354
469
Compound 14
491
510
Compound 16
474
509
Compound 17
492
511
Compound 18
492
510
Compound 20
516
602
Compound 21
473
564
Compound 22
553
570
Compound 24
496
569
Compound 26
684
710
Compound 27
650
675
Compound 28
589
614
Compound 30
643
662
Compound 34
638
661
Compound 35
571
620
Compound 37
650
770
Compound 40
819
825
Compound 43
797
816
Compound 45
665
681
Compound 46
679
715
Compound 47
615
637
Compound 49
830
831
Compound 50
831
833
Compound 54
774
800
Compound 55
688
715
Compound 59
804
520
Compound 60
670
696
Example 3
[0196] Confirmation on Cancer Cell Inhibitory (Growth Suppressive) Action Against Pancreatic Cancer Cells
Experimental Example 1
[0197] Human pancreas cancer cells, KLM-1, were pre-cultured in RPMI1640 medium containing 10% FBS at 37° C. in a 5% CO 2 ambient. Thereafter, 4,000 cells were seeded per well of a 96-well plate and further cultured for 24 hours. Subsequently, Compound (1) was added to the medium so as to obtain a final concentration of 10 μg/mL and cultured at 37° C. for 24 hours in a 5% CO 2 ambient. The cultured cells were analyzed for viable cell count according to CellTiter-Glo Luminescent Cell Viability Assay (manufactured by Promega KK.). As a reference, the number of cells cultured in a medium containing a 0.1% dimethylsulfoxide solution (hereinafter, simply referred to as DMSO) in place of a medium containing Compound (1), in the aforementioned operation, was regarded as 100.
Experimental Examples 2 to 23
[0198] Viable cell count was analyzed in the same manner as in Experimental Example 1 except that Compound (1) of Experimental Example 1 was changed to another compounds shown in Table 2.
Comparative Examples 1 to 4
[0199] Viable cell count was analyzed in the same manner as in Experimental Example 1 except that Compound (1) was changed to comparative compounds 1 to 4.
[0000]
[0200] Viable cell counts of Experimental Examples 1 to 23 and Comparative Examples 1 to 4 were analyzed to obtain growth rates. The results are shown in Table 2. Evaluation of cancer cell inhibition against the pancreatic cancer cells (KLM-1) (growth suppression) was made based on the following criteria. Note that the growth rate used in Examples refers to the rate (expressed by percentage) of viable cell count after culture relative to the number of cells at the initiation of cell culture.
[0201] A: Cancer cell growth rate is less than 20% (cancer cell inhibitory (growth suppressive) effect is extremely high)
[0202] B: Cancer cell growth rate is 20% or more and less than 50% (cancer cell inhibitory (growth suppressive) effect is high)
[0203] C: Cancer cell growth rate is 50% or more (cancer cell inhibitory (growth suppressive) effect is low)
[0204] Table 2
[0000]
TABLE 2
Cancer
cell growth
Compound
rate (%)
Evaluation
Experimental Example 1
Compound 1
31.9
B
Experimental Example 2
Compound 4
3.1
A
Experimental Example 3
Compound 5
6.4
A
Experimental Example 4
Compound 7
13.0
A
Experimental Example 5
Compound 10
13.5
A
Experimental Example 6
Compound 11
5.0
A
Experimental Example 7
Compound 16
2.0
A
Experimental Example 8
Compound 20
1.2
A
Experimental Example 9
Compound 21
38.2
B
Experimental Example 10
Compound 24
6.5
A
Experimental Example 11
Compound 26
8.6
A
Experimental Example 12
Compound 27
6.0
A
Experimental Example 13
Compound 30
18.8
A
Experimental Example 14
Compound 31
30.5
B
Experimental Example 15
Compound 34
26.6
B
Experimental Example 16
Compound 35
29.7
B
Experimental Example 17
Compound 37
4.8
A
Experimental Example 18
Compound 40
14.1
A
Experimental Example 19
Compound 43
35.6
B
Experimental Example 20
Compound 45
28.5
B
Experimental Example 21
Compound 46
16.7
A
Experimental Example 22
Compound 47
8.6
A
Experimental Example 23
Compound 49
12.0
A
Comparative Example 1
Comparative
87.0
C
compound 1
Comparative Example 2
Comparative
86.0
C
compound 2
Comparative Example 3
Comparative
93.0
C
compound 3
Comparative Example 4
Comparative
75.0
C
compound 4
[0205] As is apparent from Table 2, the compounds of the present invention have a high cancer cell inhibitory (growth suppressive) effect against the pancreatic cancer cells (KLM-1), compared to the comparative compounds.
Example 4
[0206] Observation on Cancer Cell Inhibitory (Growth Suppressive) Action Against Prostatic Cancer Cells
Experimental Example 24
[0207] Prostatic cancer cells, PC-3, were pre-cultured in RPMI1640 medium containing 10% FBS at 37° C. in a 5% CO 2 ambient. Thereafter, 4,000 cells were seeded per well of a 96-well plate and further cultured for 24 hours. Subsequently, Compound (1) was added to the medium so as to obtain a final concentration of 10 μg/mL and cultured at 37° C. for 24 hours in a 5% CO 2 ambient. The cultured cells were analyzed for viable cell count according to Cell Titer-Glo Luminescent Cell Viability Assay (manufactured by Promega KK.). As a reference, the number of cells cultured in a medium containing a 0.1% dimethylsulfoxide solution (hereinafter, simply referred to as DMSO) in place of a medium containing Compound (1), in the aforementioned operation, was used as 100.
Experimental Examples 25 to 36
[0208] Viable cell count was analyzed in the same manner as in Experimental Example 24 except that Compound (1) of Experimental Example 24 was changed to each compound shown in Table 2.
Comparative Examples 5 to 8
[0209] Viable cell count was analyzed in the same manner as in Experimental Example 24 except that Compound (1) of Experimental Example 24 was changed to each of Comparative compounds 1 to 4, to obtain growth rates.
[0210] Note that the growth rate used in Examples refers to the rate (expressed by percentage) of viable cell count after culture relative to the number of cells at the initiation of cell culture. The results are shown in Table 3. Evaluation criteria are the same as in the above experiments. A cancer cell growth rate exceeding 100% indicates that cells are grown.
[0211] Cancer cell inhibition (growth suppression) against prostatic cancer cells (PC-3) was evaluated based on the following criteria.
[0212] A: Cancer cell growth rate is less than 20% (cancer cell inhibitory (growth suppressive) effect is extremely high)
[0213] B: Cancer cell growth rate is 20% or more and less than 50% (cancer cell inhibitory (growth suppressive) effect is high)
[0214] C: Cancer cell growth rate is 50% or more (cancer cell inhibitory (growth suppressive) effect is low)
[0215] Table 3
[0000]
TABLE 3
Cancer cell
growth
Compound
rate (%)
Evaluation
Experimental Example 24
Compound 1
13.8
A
Experimental Example 25
Compound 4
19.5
A
Experimental Example 26
Compound 5
15.0
A
Experimental Example 27
Compound 7
15.3
A
Experimental Example 28
Compound 11
4.3
A
Experimental Example 29
Compound 16
8.4
A
Experimental Example 30
Compound 20
13.1
A
Experimental Example 31
Compound 24
10.0
A
Experimental Example 32
Compound 27
7.7
A
Experimental Example 33
Compound 43
12.3
A
Experimental Example 34
Compound 46
17.7
A
Experimental Example 35
Compound 47
13.8
A
Experimental Example 36
Compound 49
5.3
A
Comparative Example 5
Comparative
105
C
compound 1
Comparative Example 6
Comparative
68.0
C
compound 2
Comparative Example 7
Comparative
101
C
compound 3
Comparative Example 8
Comparative
88.3
C
compound 4
[0216] As is apparent from Table 3, the compounds of the present invention have a high cancer cell inhibitory (growth suppressive) effect against the prostatic cancer cells (PC-3), compared to comparative compounds.
Example 5
[0217] Observation on Cancer Stem-Cell Selective Inhibitory Action Against Chronic Myelocytic Leukemia Cells
Experimental Examples 37
[0218] Human chronic myelocytic leukemia cells, K562, were pre-cultured in RPMI1640 medium containing 10% FBS at 37° C. in a 5% CO 2 ambient. Then, a fraction containing 80% or more of cancer stem cells was extracted by use of a cancer stem cell marker, ALDEFLUOR reagent (manufactured by VERITAS Corporation) and FACSAria flow cytometry (manufactured by Nippon Becton, Dickinson and Company). Subsequently, Compound (16) was added to the medium so as to obtain a final concentration of 0.05 μg/mL and cultured at 37° C. for 24 hours in a 5% CO 2 ambient. The cultured cells were analyzed for viable cell count according to CellTiter-Glo Luminescent Cell Viability Assay (manufactured by Promega KK.). As a reference, the number of cells cultured in a medium containing a 0.1% dimethylsulfoxide solution (hereinafter, simply referred to as DMSO) in place of a medium containing Compound (1), in the aforementioned operation, was used as 0.1. Note that hereinafter, an ALDEFLUOR reagent positive fraction (deemed as cancer stem cells) is represented by ALDH (+), whereas an ALDEFLUOR reagent negative fraction (not deemed as cancer stem cells) is represented by ALDH (−), in some cases.
Experimental Examples 38 to 70
[0219] The same operation as in Experimental Example 37 was repeated except that Compound (16) in Experimental Example 37 was changed to the other compounds and final concentrations shown in Table 3 were used and viable cell counts were separately analyzed.
Comparative Examples 9 to 16
[0220] The same operation as in Experimental Example 37 was repeated except that Compound (16) in Experimental Example 37 was changed to Imatinib (manufactured by NOVARTIS), which is a general anticancer drug, and comparative compounds shown in Table 3 and final concentrations shown in Table 3 were used and viable cell counts were separately analyzed.
[0221] The results of Experimental Examples 37 to 70 and Comparative Examples 9 to 16 are collectively shown in Table 4. Further, the growth suppressive effect of cancer stem cells was evaluated based on the following criteria. Note that the growth rate in Examples is a value obtained by dividing viable cell count after culture by the number of cells at the initiation time of culture.
[0222] A: The growth rate of ALDH (+) is less than 0.5 (growth suppressive effect against cancer stem cells is extremely high)
[0223] B: The growth rate of ALDH (+) is 0.5 or more and less than 0.95
[0224] (growth suppressive effect against cancer stem cells is high)
[0225] C: The growth rate of ALDH (+) is 0.95 or more (no growth suppressive effect against cancer stem cells)
[0226] Furthermore, superiority evaluation of cancer stem cells was evaluated by comparing cancer stem cells to cancer cells based on the following criteria.
[0227] A: The value of the growth rate of ALDH (+)/the growth rate of ALDH (−) is less than 0.8 (selective inhibitory effect against cancer stem cells is extremely high)
[0228] B: The value of the growth rate of ALDH (+)/the growth rate of ALDH (−) is 0.8 or more and less than 0.95 (selective inhibitory effect against cancer stem cells is high)
[0229] C: The value of the growth rate of ALDH (+)/the growth rate of ALDH (−) is 0.95 or more
[0230] (no selective inhibitory effect against cancer stem cells)
[0000]
TABLE 4
Growth
ALDH(+)
suppression
Superiority
Compound
Amount of dye
ALDH(+)
evaluated
ALDH(−)
ALDH(+)/ALDH(−)
evaluation
Experimental Example 37
35
0.05
μg/ml
0.67
B
0.87
0.77
A
Experimental Example 38
35
0.5
μg/ml
0.43
A
0.66
0.66
A
Experimental Example 39
35
1
μg/ml
0.44
A
0.49
0.90
B
Experimental Example 40
16
0.05
μg/ml
0.68
B
0.78
0.87
B
Experimental Example 41
16
0.5
μg/ml
0.36
A
0.52
0.70
A
Experimental Example 42
16
1
μg/ml
0.16
A
0.34
0.47
A
Experimental Example 43
24
0.05
μg/ml
0.61
B
0.75
0.81
B
Experimental Example 44
24
0.5
μg/ml
0.39
A
0.63
0.61
A
Experimental Example 45
24
1
μg/ml
0.19
A
0.39
0.48
A
Experimental Example 46
27
10
μg/ml
0.07
A
0.13
0.56
A
Experimental Example 47
32
10
μg/ml
0.09
A
0.29
0.32
A
Experimental Example 48
21
10
μg/ml
0.27
A
0.41
0.66
A
Experimental Example 49
1
10
μg/ml
0.45
A
0.52
0.87
B
Experimental Example 50
34
10
μg/ml
0.48
A
0.67
0.72
A
Experimental Example 51
35
10
μg/ml
0.55
B
0.80
0.69
A
Experimental Example 52
5
10
μg/ml
0.71
B
0.90
0.79
A
Experimental Example 53
33
10
μg/ml
0.83
B
1.00
0.84
B
Experimental Example 54
56
10
μg/ml
0.42
A
0.65
0.65
A
Experimental Example 55
57
10
μg/ml
0.55
B
0.68
0.81
B
Experimental Example 56
58
10
μg/ml
0.70
B
0.85
0.82
B
Experimental Example 57
14
10
μg/ml
0.38
A
0.49
0.77
A
Experimental Example 58
17
10
μg/ml
0.04
A
0.13
0.30
A
Experimental Example 59
17
1
μg/ml
0.69
B
0.79
0.87
B
Experimental Example 60
18
10
μg/ml
0.04
A
0.13
0.29
A
Experimental Example 61
22
10
μg/ml
0.22
A
0.29
0.75
A
Experimental Example 62
28
10
μg/ml
0.30
A
0.43
0.69
A
Experimental Example 63
28
1
μg/ml
0.65
B
0.77
0.83
B
Experimental Example 64
54
10
μg/ml
0.07
A
0.13
0.50
A
Experimental Example 65
55
10
μg/ml
0.04
A
0.11
0.33
A
Experimental Example 66
59
10
μg/ml
0.02
A
0.10
0.22
A
Experimental Example 67
59
1
μg/ml
0.14
A
0.21
0.67
A
Experimental Example 68
60
10
μg/ml
0.04
A
0.12
0.34
A
Experimental Example 69
50
10
μg/ml
0.05
A
0.12
0.42
A
Experimental Example 70
51
10
μg/ml
0.03
A
0.11
0.27
A
Comparative Example 9
Imatinib
0.12
μg/ml
0.74
B
0.51
1.47
C
Comparative Example 10
Imatinib
0.24
μg/ml
0.59
B
0.40
1.48
C
Comparative Example 11
Imatinib
0.35
μg/ml
0.48
A
0.32
1.51
C
Comparative Example 12
Imatinib
0.47
μg/ml
0.36
A
0.22
1.63
C
Comparative Example 13
Imatinib
0.59
μg/ml
0.31
A
0.11
2.80
C
Comparative Example 14
Comparative compound 1
1
μg/ml
1.00
C
0.94
1.06
C
Comparative Example 15
Comparative compound 2
1
μg/ml
0.99
C
1.21
0.82
C
Comparative Example 16
Comparative compound 3
1
μg/ml
1.09
C
1.38
0.79
C
[0231] Note that, in the cases of Comparative Examples 14 to 16, ALDH (+) is close to almost 1. This indicates that no suppressive effect is obtained. In contrast, a numerical value of 1 or more as an ALDH (−) value indicates that the number of cancer cells increases.
[0232] As is apparent from Table 4, it is confirmed that the compounds of the present invention has a selective inhibitory effect against cancer stem cells. More specifically, when a general anticancer agent, Imatinib, was used, an inhibitory effect against general cancer cells was observed; however, no inhibitory effect was confirmed when comparative compounds were used.
Example 6
[0233] Confirmation of Cancer Stem-Cell Selective Staining to Chronic Myelocytic Leukemia Cells
Experimental Examples 71 to 73
[0234] The cells cultured for 24 hours in each of Experimental Examples 39, 42 and 45 were subjected to nuclear staining with Hoechest33342 (manufactured by Dojindo Laboratories) and a fluorescent image observed under AXIOVERT200M inverted fluorescent microscope (manufactured by Carl Zeiss) was photographed. The ratio of ALDH (+) cells stained and the ratio (percentage) of ALDH (−) cells stained in each compound are shown in Table 5.
[0000]
TABLE 5
Selective staining of
Compound
ALDH(+)
ALDH(−)
cancer stem cells
Example 71
35
82.5
21.4
ALDH (+) cells are
selectively stained
Example 72
16
99.5
18.6
ALDH (+) cells are
selectively stained
Example 73
24
81.2
28.6
ALDH (+) cells are
selectively stained
[0235] As is apparent from Table 5, it is found that the compound of the present invention selectively stains cancer stem cells (ALDH (+)) than general cancer cells (ALDH (−)).
Example 7
[0236] Confirmation of Inhibitory Action in Cancer Stem Cells Transplanted Animal
Experimental Example 74
[0237] From cell strain K562-KOr, which is a strain of human chronic myelocytic leukemia cells having fluorescent protein Kusabira-Orange constantly expressed, a fraction (ALDH (+)) containing 80% or more of cancer stem cells was extracted by use of a cancer stem cell marker, ALDEFLUOR reagent (manufactured by VERITAS Corporation) and FACSAria flow cytometry (manufactured by Nippon Becton, Dickinson and Company). The ALDH (+) fraction and a ALDH (−) fraction of general cancer cells were transplanted separately to zebra young fish (MieKomachi lineage, 2 days after fertilization) and the fish were raised in a 32° C. environment. Furthermore, 24 hours after transplantation, Compound (16) was added to breeding water so as to obtain a final concentration of 0.5 μm and fish were raised for two days in a 32° C. environment.
[0238] Cells transplanted to the zebra young fish were observed under MZ16F fluorescent stereoscopic microscope (manufactured by Leica Microsystems) and a fluorescent image of the cells after 24 hours was photographed and then fluorescent intensity was quantified.
[0239] As a reference, the fluorescent intensity of cells, which were cultured in the same operation method as above in a medium containing a 0.1% DMSO solution in place of Compound (16), was used.
Comparative Example 17
[0240] The numerical value of fluorescent intensity was obtained from a fluorescent image taken in the same manner as in Experimental Example 74 except that Compound (16) of Experimental Example 74 was changed to Imatinib.
[0241] The inhibition rates of ALDH (+)/ALDH (−) cell transplanted to zebra young fish in Experimental Example 74 and Comparative Example 17 are shown in Table 6. The inhibition rate herein was obtained according to the expression: 100×(1−F1/F0), where the fluorescent intensity of cells when a test substance was added is represented by F1, and the fluorescent intensity of cells when a reference substance (DMSO) was added is represented by F0.
[0000]
TABLE 6
Growth
Compound
ALDH(+)
ALDH(−)
suppression rate
Example 74
16
95.0
82.0
ALDH(+) is high
Comparative
Imatinib
60.0
80.0
ALDH(−) is high
Example 17
[0242] As is apparent form Table 6, it was confirmed that the size of tumor (fluorescent region) is small compared to the case where neither compound nor Imatinib was administered. Particularly, in the group in which the compound of the present invention is administered, it was confirmed that an effect of suppressing a tumor size is preferentially obtained in a cancer stem cell (ALDH (+)) transplanted model animal.
Example 8
[0243] Confirmation of Cancer Metastasis Suppressive Effect in Cancer Cell Metastatic Foci (Region within 300 to 450 μm from a Transplanted Tumor)
Experimental Example 75
[0244] From cell strain K562-KOr, in which KLM1 cells have fluorescent protein Kusabira-Orange constantly expressed, a fraction (ALDH (+)) containing 80% or more of cancer stem cells was extracted with ALDEFLUOR reagent (manufactured by VERITAS Corporation) and FACSAria flow cytometry (manufactured by Nippon Becton, Dickinson and Company). The extracted KLM1-KOr cells were transplanted to zebra young fish (MieKomachi lineage, 2 days after fertilization) and the fish were raised in a 32° C. environment. Furthermore, 24 hours after transplantation, Compound (26) (745 μmol/KgBW) was administered to yolk sac.
[0245] 72 hours later, cells transplanted to the zebra young fish were observed under MZ16F fluorescent stereoscopic microscope (manufactured by Leica Microsystems) and a fluorescent image of the region within 300 to 450 μm from a transplanted tumor was photographed and then fluorescent intensity was quantified.
[0246] As a reference, the fluorescent intensity of cells, which were cultured in the same operation method as above in a medium containing a 0.1% DMSO solution in place of Compound (26), was used.
Comparative Examples 18 and 19
[0247] Fluorescent images were photographed in the same manner as in Experimental Example 26 except that Imatinib and Dasatinib were respectively used in place of the compound (26) in Experimental Example 75.
[0248] The cancer cell inhibition rates of metastatic foci of cancer cells (in the region within 300 to 450 μm from a transplanted tumor) transplanted to zebra young fish in Experimental Example 75 and Comparative Examples 18 and 19 are shown in Table 6.
[0249] The inhibition rate herein was obtained according to the expression: 100×(1−F1/F0), where the fluorescent intensity of cells when a test substance was added is represented by F1, and the fluorescent intensity of cells when a reference substance (DMSO) was added is represented by F0.
[0250] The growth suppressive effect in metastatic foci (region within 300 to 450 μm from a transplanted tumor) of cancer stem cells was evaluated based on the following criteria.
[0251] A: Inhibition rate is 70 or more
[0252] (growth suppressive effect against metastatic foci (region within 300 to 450 μm from a transplanted tumor) of cancer stem cells is extremely high)
[0253] B: Inhibition rate is 50 or more and less than 70
[0254] (growth suppressive effect against metastatic foci
[0255] (region within 300 to 450 μm from a transplanted tumor) of cancer stem cells is high)
[0256] C: Inhibition rate is less than 50
[0257] (growth suppressive effect against metastatic foci
[0258] (region within 300 to 450 μm from a transplanted tumor) of cancer stem cells is low)
[0000]
TABLE 7
Inhibition
Compound
rate
Evaluation
Example 75
26
80
A
Comparative
Imatinib
60
B
Example 18
Comparative
Dasatinib
36
C
Example 19
[0259] As is apparent from Table 7, it was confirmed that the cancer stem-cell inhibition drug of the present invention has a higher metastasis suppressive effect than known anticancer agents used as comparison.
INDUSTRIAL APPLICABILITY
[0260] The compound provided by the present invention is useful as a cancer cell inhibitory drug. Furthermore, owing to the cancer cell inhibitory drug provided by the present invention, growth suppression, cellular division suppression, metastasis suppression, functional inhibition and cytocidal action of cancer cells, particularly cancer stem cells, can be mediated. In addition, cancer stem cells can be easily detected and the site of cancer stem cells can be accurately specified. The compound of the present invention is expected to widely contribute to the medical industry.
[0261] This application claims the benefit of Japanese Patent Application No. 2012-236977, filed Oct. 26, 2012, which is hereby incorporated by reference herein in its entirety.
|
An object of the present invention is to provide a cancer cell inhibitory drug, particularly a cancer stem-cell inhibitory drug, or a cancer stem-cell detection probe. The present invention provides a cancer cell inhibitory drug comprising at least one compound represented by general formula (1) as an active ingredient
| 2
|
FEDERALLY SPONSORED RESEARCH
[0001] Nonapplicable.
SEQUENCE LISTING OR PROGRAM
[0002] Nonapplicable.
BACKGROUND
[0003] 1. Field of the Invention
[0004] This invention relates to innovative processes used to dye textile materials, to dye and fortify rubber materials prior to and after product formation, and to color and revitalize plastic prior to and after product formation. Because it employs a particular chemical bonding system, it should be considered useful on a wide selection of natural and synthetic organic polymers and organic chain polymers to achieve a broad range of desired effects, among them, but not limited to, mildew resistance, sizing, creation of printable or paintable surfaces, glazing, sheen, artistic coloring effects, UV protection, abrasion resistance, and many more.
[0005] 2. Prior Art
[0006] Textile dyeing has been done for thousands of years; the process has almost always involved the application of a pigment or dye in solution which, when heated and applied to a textile, would allow the colorant (dye or pigment) to seat itself in the fibres of the textile material. An after-process of curing using heat is employed to fix the colorants and to regularize the color dispersion and to dry the dyed end-product, thereby allowing the colorant to be as fixed to the textile as possible. This general approach has been used since dyes and pigments were derived from natural sources such as shellfish through the era where coal-tar derivatives were used and through the era where synthetic dyes and pigments were developed, which is the current state of the art. Chemically different coloring solutions and varying degrees of heat are required for the different classes of fibres: cellulosic, polyester, amide, aramide, for example. Different equipment is also required to apply those processes: highly-pressurized kettles, heated dye troughs, pre-wash baths, finishing ranges which can be anywhere from one roller of 36″ diameter to ranges fully two stories high and several hundred feet in length, etc. Some textile materials, such as polypropylene, Kevlar, Nomex, Teflon, etc remain resistant to the above processes and were, until now, considered undyeable. In most textile manufacturing facilities, the bottleneck which limits the amount of available finished goods occurs in the processing department (which includes the dyeing processes). One way of alleviating that bottleneck is to send raw textile goods (yarn, fabric, etc) to a dyehouse, that is, another company who will contract dye yarn or fabric if the end-user does not have dye kettles, continuous dye ranges. or other proper equipment and expertise of their own. This contract-dyeing is employed by a great percentage of textile manufacturers. This invention will address some of the problems inherent in the aforementioned state-of-the-art processes, provide dyes for fibres previously considered undyeable, save costs when compared with current methods, and greatly streamline the process of dyeing while yielding a finished dyed product as good or better than that produced by means currently employed. Note that the terms used relative to textile applications in the descriptions herein are known and understood by persons conversant with current textile treatment procedures.
[0007] Among existing active patents and applications, none could be found which describe a complete dyeing system with a process which is novel in both concept and execution as compared with current practices used in the textile industry. The nearest relevant related art falls into several categories: (A) Dyeing for Special Fabric Effects: U.S. Pat. No. 8,523,957 Arioglu, et al is concerned with cellulosic fibres (cotton denim and blends); U.S. Pat. No. 7,201,780 Schoots Apr. 10, 2007 is limited to cotton or cotton blends dyeing; Application 20060282957 Schoots Dec. 21, 2006 is an improvement on his previous patent, similar processes described; U.S. Pat. Nos. 4,740,214 and 5,330,540 McBride et al both deal with specific dye effects (mottled or hammered appearance and pattern dyeing) in which heat is used; U.S. Pat. Nos. 4,622,040 and 4,622,041 and 4,622,042 Nichols Nov. 11, 1986 describe three methods of dyeing tufted nylons for carpets; U.S. Pat. No. 4,397,650 Gregorian, et al deals with dyestuffs added to a foamed composition for specialized effects (carpets). (B) Stimulation of Dye Bath to Encourage Penetration: U.S. Pat. Nos. 4,270,236 and 4,329,146 Zurbuchen et al; U.S. Pat. Nos. 7,740,666 and 7,674,300 and 8,182,552 Janssen, et al; U.S. Pat. No. 8,182,712 Maekawa, et al; U.S. Pat. No. 8,439,982 and Application 20120047665 Yager all refer to exotic stimulants to improve dye penetration such as electrophoresis, superheated steam, electric current, magnetoheological fluid, ultrasonic vibration, microwaves and are not dye systems per se, but system enhancers. (C) Additives for Dye Penetration and Fixatives: U.S. Pat. No. 4,065,254 Buhler, et al; U.S. Pat. No. 5,833,720 Kent et al; U.S. Pat. No. 5,984,979 Bella, et al; U.S. Pat. No. 6,296,672 Barfoed, et al; U.S. Pat. No. 6,544,297 Liu et al; U.S. Pat. No. 4,065,254 Buhler et al; U.S. Pat. No. 3,953,168 Fabbri, et al; U.S. Pat. No. 6,389,627 Annen; U.S. Pat. No. 6,676,710 Smith, et al; and Applications 20120309077 Sachdev; 20100047531 Baum, et al; 20090158534 and 20090255064 Jungen et al describe additives to to heated dyebaths to enhance dye penetration and attachment such as oleylamines, bioscouring enzymes, enzyme catalysts, alkali solutions, supercritical fluid carbon dioxide, diazonium salts, etc, and are adjuncts to presently standard dye systems. (D) Dye Methods for Specific Situations: U.S. Pat. No. 7,398,660 Shalev, et al requires heat and specially-designed apparatus for application; U.S. Pat. No. 5,512,062 Fuller et al uses heat (under 100 degrees C.) for carpet dyeing; U.S. Pat. No. 4,816,035 Craycroft, et al involves heating (below 280 degrees F.), rinsing and at least two stages of heating; Application 20110083283 Valldepras-Morell, et al refers to recycled dye baths and uses heat to dye a limited range of fibres; Application 20040194234 Bartl, et al describes a process for use on non-wovens which requires heat (150-240 degrees C.) and treatment times of 15 seconds to 60 minutes.
[0008] In the area of rubber coloring, the literature is sparse. U.S. Pat. No. 6,036,998 Calvo et al refers to a paint application to the outer surface of rubber, not a true dye of the rubber itself, and requires heat; U.S. Pat. No. 5,296,284 Durham describes a pigment used to make inks and paints for rubber application; Applications 20140338809 Nakamura and 20140360645 Takashi, et al describe adding color to tires by affixing a separate rubber piece of a different color to black tires (The present inventor has spoken with the assignee of these applications and they do not have a product or process which will accomplish what the process of this application will); Applications 20020119314 and 20020128366 Coffey are pigment coatings using heat for application, not dyes, for use on recycled tires used in playgrounds, road surfaces, soil additives, and landscaping mulch. These processes are different from the process described in this application in that they require heat to apply, are not intrinsic dyes, and are used on rubber materials which do not require close performance tolerances with respect to stretch, modulus, recovery, etc, which means these processes could not be used on, for example, rubbers used as textile elastomers. The present invention will not greatly change the performance characteristics of rubbers that have functions more sophisticated than the end-uses specified in the prior art.
[0009] As concerns applications for coating and/or coloring plastics, U.S. Pat. No. 7,361,702 Schwalm, et al, U.S. Pat. No. 6,716,905 Bremser, et al, U.S. Pat. No. 6,653,394 Meisenburg, et al and U.S. Pat. No. 6,534,588 Locken, et al are primarily for OEM automotive paint use as UV inhibitors, free radical inhibitors, etc. The present inventor has dealings with the assignee of the foregoing patents and has been assured there is no BASF product which functions like the present invention. U.S. Pat. No. 5,029,870 Concepcion, et al describes a golf ball coating which is a paint/primer and sealant 2-step process, and is not a dye. Application 20150004424 Kruesemann, et al, is also a base coat/sealant 2-step application for OEM automobile paint which requires heat to address “jetness” of blacks and UV protection by using pigments (also a BASF Application). U.S. Pat. No. 4,487,855 Shih, et al is primarily concerned with styrene plastics, is aqueous-based, and is used in the liquid latex form and requires heat (at room temperature this process would take from 1-35 days to complete). Applications 20060124017 and 20060258784 Adam, et al requires sophisticated plastics manufacturing apparatus with a good deal of heat and are for use in a pre-extrusion (i.e., pellet form) state. Applications 20140342100 Valeri, 20140057115 Treadway, and U.S. Pat. No. 5,618,619 Petrmichl, et al are for use primarily as abrasion-resistant coatings in optical products and require heat in application. Similarly, U.S. Pat. No. 7,960,031 and Application 20110073171 Pickett, et al, require heat to provide UV protection, abrasion resistance, etc. U.S. Pat. No. 8,877,295 Chilla is for a primer and color coat (2 steps) for auto plastics and requires heat. U.S. Pat. No. 4,210,565 Emmons has a multi-purpose coating, uses heat in a multi-step application process. Application 20130243962 Lomoelder, et al describes a coating, solvent-based, for use on OEM automobile finishes and uses heat for curing (up to 80 degrees C.); see also German Patent Application DE 10 2012204298.9 Mar. 19, 2012. This application presents options reminiscent of U.S. Pat. No. 6,177,496 Luzon, especially in the use of diisocyanate variations. This last mentioned Patent is distinct from the present invention because it refers to coatings used for various purposes, not intrinsic dyes, but coatings which may carry colors; it also differs in that there are no surface preparations necessary for the vast majority of uses of the present invention. As the present invention does not require heat, it is distinct from nearly every reference in the sources; furthermore, there was no mention of use of these coatings as “plastics revitalizers,” that is, a coating which will bring a plastic surface back to as good, or in many cases, better than original appearance while at the same time providing a cleaner for that surface, a protective layer, and, if desired, a color. These advantages are gained by a one-wipe application at room temperature, air dried, with no need for heat curing.
SUMMARY
[0010] This invention relates to the use of formulations and their variations and derivatives for the purposes of (a) dyeing the broad range of textile classes of fibres, for example, but not limited to, cellulosic, polyesters, polypropylenes, cottons, rayons, amides, aramides, etc without the use of heat; (b) dyeing and fortifying rubber, natural and synthetic, whether in the pre-formed state or the finished product state without substantially changing the elastomeric functions of rubber, such as, but not limited to, stretch, recovery, modulus, etc when used in products where the stretching is critical and in those products in which the ability of rubber to stretch and recover is not as critical; © applying the same group of related formulations to revitalize and/or color plastics before and after product formation; (d) applying the same formulations to polymers for the purpose of carrying a broad range of additives such as, but not limited to, UV protection, polyvinyl acetates (PVA) and other sizing agents, glazing, abrasion resistance, mercerizing, mildew resistance, stain resistance, weather protection, flame resistance, agents to promote printability and printability, agents to promote artistic coloring effects, and many more, with or without dyes or pigments.
DRAWINGS
[0011] Nonapplicable.
DETAILED DESCRIPTION
[0012] This invention involves the application a specific group of formulations to organic polymers such as, but not limited to, textiles, natural and synthetic rubbers, plastics, etc. There are a broad number of uses given, but, in the inventor's opinion, they should be grouped under one application because the basic formulation will accomplish any of the uses listed in the Field of the Invention; the adjustments made to the formulations to address specific circumstances in different industries are relatively minor and would be employed to make this invention more useful to specific circumstances in particular application situations. The reason these formulations are so adaptable is that they chemically bond with natural and synthetic polymers in a way not seen before by the manufacturers of the aforementioned materials and products, yet do not alter the original character of the material treated. That one could be able to apply a solvent-based formulation to, for example, natural and synthetic rubber, without changing the performance characteristics of those materials, and, in fact, increasing the usable lifespan of that material, and dyeing it at the same time, was not accomplished for functions listed in this application until this invention. Similarly, textiles and plastics retain their original characteristics, visually and functionally, excepting, of course, for the color when the formulations are used as a dye carrier.
[0013] One base formulation which will accomplish the foregoing, though it should not be considered unique because of the large number of possible additions, quantity adjustments, component substitutions, etc as preferred for optimizing effects in different tasks, is given:
[0000] Solvent aliphatic hydrocarbons 40-85% Alkyd resin compound including: 07-35% Petroleum distillates (>=10-<30%) Ethanol, 2-propoxy-(>=01-<5%) Nonane (<1%) Light Aromatic Solvent Naphtha compound including: 05-15% Trimethylbenzene 1,2,4-(>=30-<40%) Trimethylbenzene 1,3,5-(>=5-<10%) Xylene (>=1.5-<5%) Cumene (>=1.5-<5%) Diethylbenzene (>=1.5-<5%) N-Methyl-2-pyrrolidone (NMP)) 01-05% 2 Butanone Oxime 0.5-1.5% Cobalt Octoate 6 or 12% .01-1% Calcium Naphthenate .05-.3% Zirconium Octoate .2-.8%
Note: While the Alkyd resin compound should be made to specifications which suit the intended use, a user should also be aware that Arkema, Inc supplies a product, Chempol 818-0237 (and some variations), which may be acceptable for some uses, and saves the user additional compounding costs. Similarly, Nexeo Solutions, Inc of Columbus, Ohio supplies a product Hi-Sol 10 (and some variations) which may serve for the Light Aromatic Solvent Naphtha compound in certain cases.
First Embodiment
[0014] The process which accomplishes the aforementioned results as concerns plastics and their revitalization and coloring is as follows: The formulation given above, when applied by a wiping agent, for example, but not limited to, cloth, paper, roller, spray, or other means, or applied by, for example, but not limited to, dipping, full immersion, etc will impart a revitalization, which is defined as a chemically-bound coating which returns plastics to original or better than original condition. By revitalization to a potentially better-than-original condition, the inventor claims that the sheen produced is better than the original sheen in many cases, minor abrasions are removed, weathering effects are reversed, and an extra protective layer is provided as well. Plastics, over time, lose sheen, suffer UV degradation, are worn by weathering, are affected by plasticizer degradation, experience abrasion and other detrimental effects of aging. No pre-treatment of the surfaces, aside from the removal of obvious surface dirt is required in the great majority of cases, but there may be cases where pre-treatment for purposes of mechanical adhesion may be helpful for optimal results. The process for coloring plastics is the same as the revitalization process, except that the formulations include dyes or pigments and these processes may be used prior to (i.e., in pellet form) or after product formation.
[0015] Because of the vast number of plastics available, it is not possible for the inventor to claim this process works on all plastics, but the following example should assure the user that the process works on a very wide range of plastics: On the average passenger automobile, there are at least twelve (12) different types of plastics and at least six (6) different types of rubber. The base formulation described herein has been used on (exterior) molding, roof racks, bumpers, cowling, mirror housings, mud flaps, wheelwell guards, door handles, step treads, headlight lenses, tires, windshield wipers, etc; (interior) dashboards, consoles, door panels, window seals, seats, steering wheel column, weatherstripping, wire insulation, etc; (under the hood) air intake, battery compartment, fan cowling, rubber hosing, hose sleeves, brake fluid reservoir, etc. All items treated were wiped (cloth) once by hand with the same base formulation without a prep stage, as the formulation has an inherent cleaning aspect due to the Aliphatic hydrocarbon content. The applications were air-dried. Current retail products which claim some similar results are basically waxes, polishes, and cleaners. None are used as universally as this invention (never under the hood, for example) and are effective, as a general rule, for a week or two. The treatments applied as described above are nearing two (2) years with, in most cases, less than 10% degradation.
[0016] The above example is given as a specific set of applications for purposes of illustration, but these formulations will also apply to the broad range of plastics including, but not limited to, construction materials, outdoor furniture, appliances, wire, etc, etc. This invention may also be used to treat sheet plastic, for example, but not limited to, polyvinyl acetate (PVA), polyvinyl chloride (PVC), Polypropylene, etc when the user intends to color the sheeting or to provide a surface which will accept water-based inks and be printable with the same presses used to print paper. Because the process uses no heat, the potential for sheeting application should have no thickness restrictions. End uses may include, but not be limited to, product packaging, signage, advertisement materials, road signs, etc.
Second Embodiment
[0017] The process which accomplishes the results described concerning natural and synthetic rubber are the same as described for textiles in the Third Embodiment; as in that application, no pre-treatment should be used. Simple contact at room temperature or in a wide range of outdoor temperatures (for example, 32 degrees to 110 degrees F.) is enough to ensure the chemical bond which allows the results described in an earlier section. According to major suppliers of rubber, this is the first time rubber has been able to be dyed after it has been made into a product without changing the general performance characteristics of those rubbers. For example, hevea rubber made for use as a textile elastomer (as used in bungee cords, waistbands, suspenders, and hundreds of other products), in this case 34 gauge rubber thread (which has a useful life expectancy of approximately 2 years, according to the manufacturer), was treated with this invention with dye included. The result was a dyed rubber which retained its original performance characteristics (stretch, recovery, modulus, etc), and would be as useful today in standard applications as during its intended lifespan. This sample was treated fifteen (15) years ago; this indicates that a certain aspect of longevity of usefulness has been introduced by this invention (what the inventor calls “fortification,” which is distinct from other processes such as vulcanization).
[0018] Coloration and fortification of rubber may also be achieved prior to product forming if the user includes this invention with colorants (dyes and pigments) in the solid or liquid states of rubber prior to product formation. This invention may also be used to color carbon black before it is included in the compound mix, ensuring a better “jetness” to the black through the entire body of the finished product. Other methods are used to color carbon black, but they are, by their own description, “paints”; this invention introduces a penetration dye or pigment coloring. The alternative methods are recommended for use on rubber products where there is no need for retention of performance characteristics, such as in tires recycled for use as playground and road surfaces. In some cases, for example, but not limited to, when the flash point of the formulation is of concern to the end user, this invention may be applied to carbon black when used in rubber and plastics compounding, prior to inclusion in the product compound.
Third Embodiment
[0019] This invention, when used in textile processing applications, represents a complete departure from the conceptual approaches and practices used today and through most of the history of textiles. Throughout the history of textiles, several basic steps were required to continuously dye fabrics: (A) a preparation in solution of colorants, distinct for different fibres; (B) a basin or tank, preferably heated, for goods to pass through and absorb colorant chemicals; © Squeeze rollers to eliminate excess colorant liquid; (D) a finishing range consisting of a series of large cylinders injected with steam which cures the dyestuffs, regularizes their dispersement, and dries the fabric. Other equipment may be present as well, for example, pre-dye treatment baths, heat ovens for drying, etc, but the basic principle remains the same, and is, more or less, universally used today. Package yarn dyeing and finished goods dyeing are done using the same basic steps, but using equipment more appropriate to the product being processed, such as pressurized heated kettles, skein dyeing apparati, etc. Improvements on this system have been on the order of (1) chemically improved dyestuffs, (2) improved equipment for processing, such as the introduction of electricity and more sophisticated machinery, (3) more efficient means for delivering goods through processing, (4) computer-assisted dye formulation and testing, and others, but the necessary basic procedures remained unchanged.
[0020] This invention streamlines those procedures radically while producing a product result equal to or better in terms of quality of dyeing. The equipment needed for the invention is (A) a dye bath exactly as used previously, but without heat, and, (B) a connected “wicking cabinet,” which is described as a simple stainless steel box of appropriate size (somewhat similar to what is known to the trade as a steam box, but without the steam), which has been fitted with horizontal stainless rods, as many as are appropriate for a given type of production.
[0021] The goods to be processed, for example, but not limited to, 72″ broad fabrics or multiple ends of 2″ narrow fabrics, are run through the dye bath as has been done for centuries, but in this case without heat. It is preferred, indeed recommended, by the inventor that no pre-dye treatment be applied to textile goods, with the single exception of monofilament amides, polyesters, etc because of the content of plasticizers and their tendency to migrate to the surface; multi-filament yarns of these same materials need no pre-treatment as the plasticizer migration is spread over a much larger surface area and has no practical effect on the application of this invention. As only simple contact with the formulations described herein is necessary to ensure dye penetration, the goods may be run a fast as the feeding machinery (for example, but not limited to, creels, beams, fabric rolls, etc) will allow. In trials we have not found a fabric (see list of potentially dyeable fabrics elsewhere in this description) which required more than a one (1) second immersion time, including US Military Spec Mil-W-4088 Type XXVI, which is one of the heaviest and densest nylon webbing commonly used by the US government. All fabrics dyed were dyed fully through, and because this system is based on molecular correspondence, the dyeing has very even dispersion. The goods being processed, once through the dye bath and without being subjected to squeeze rollers (used traditionally to squeeze out unattached dyestuff liquid), enter the wicking cabinet and travel over and around the stainless rods (as many as are deemed necessary for a particular product) for the purposes of “drying” the goods, which is really a process to promote evaporation of the parts of the formulation which conveyed the dyestuffs to the fabrics, but are no longer part of the dyed material. In some cases, the wicking cabinet may be enhanced by a dry-air heat application, similar to a common clothes dryer (for example, but not limited to, 130-140 degrees F. or 55-60 degrees C.); this possible heat addition is not for for curing or “seating” dyes, as that has been done earlier in the process, but only to encourage faster evaporation of elements no longer necessary in the finished product. Products dyed with this invention may be air-“dried” at room temperature if preferred.
[0022] Some advantages of this invention to the user are:
The base formulation given, with solvent-based dyes or pigments added, will dye any of the common fibre types, for example, but not limited to: cellulose-based (cottons, rayons, jutes, hemps, etc); polyesters; polyamides (nylon 6, nylon 6.6, Conex, etc); polypropylenes; polyaramides (Kevlar, Nomex, etc); PTFE fluoropolymers (Teflon, etc); Endumax and others. The same formulation will dye all of these fibres, including blends and combinations of these fibres, but the user is encouraged to adjust the formula to optimize specific desired outcomes if necessary. This is the first process which (1) dyes all these above fibres with one formulation; (2) dyes materials previously considered to be undyeable in the fibre or fabric state, such as Kevlar, Conex, Teflon, Nomex, Polypropylene, and others, and because of the type of chemical bonding, fibres yet to be developed may enjoy the benefits of this invention; (3) dyes without using heat, which means there is no shrinkage, no fibre destruction (as with, for example, polypropylene, which melts at 340 degrees F./171 degrees C.); (4) allows the manufacturer the freedom to not have to distinguish woven, knitted, braided, purchased, and/or non-woven goods which were intended as finished goods in white or natural and those intended for dyeing (greige goods) because greige goods are prepared to account for shrinkage in the dye process due to the heat used (between 3 and 10% in many cases). There is no shrinkage in the present process because there is no heat. Products which are difficult to dye by traditional means because of heat alteration in the dyeing and curing processes, such as, but not limited to, lightweight fabrics, sheer fabrics, non-wovens, embossed fabrics, delicate embroideries, tufted articles, etc can be processed easily using this invention. Products which are not flat or nearly flat, such as, but not limited to, ropes, cords, cord-edged fabrics, braids, tassel fringes, ball fringes, laces, trimming treatments for home furnishing and apparel products, etc can be processed easily using this invention because there are no squeeze rollers and no finishing (curing and drying) range. As the immersion time is less than one (1) second, and because there are no after-curing processes, materials may be run as fast as one's loading and take-up machinery will allow. Traditionally, there are speed-of-run limits imposed by the (1) weight and density of the material (limiting dye infusion), and (2) the physical limitations of the large steam cylinders (called “cans”) to rotate any faster than a few yards per minute in the curing part of the process. Traditionally, the compensation to achieve volume production is (in the case of narrow goods) to run multiple ends of a product at the same time. This invention also allows multiple ends in the same circumstances, but with one (1) second immersion time and no finishing range, the user can expect to increase his processing time by a factor of four (4) to ten (10) times, possibly more, producing a commensurate amount of finished goods. The color preparation (dyes or pigments) is as follows: Into a beaker of measured formulation add a measured percentage of dyestuff and mix the solution at room temperature. Dip a small sample of the material to be dyed into the solution and that is the exact color which will emerge as a result of processing. Traditional dyeing methods require much more expertise because (1) different fibres require different dyebath configurations before the colorant is added; (2) the changes imparted by multiple heat applications change the effects of color depth, dispersion, etc, which require a fair amount of expertise which is usually provided by a dyemaster who employs a combination of science, art, and experience to produce a desired color. This invention requires only the ability to understand how primary and secondary colors combine to make the full spectrum. The introduction of this invention will allow a manufacturer, processor, distributor, importer, etc of any size to be his own dyer; a circumstance, because of the cost and operation of necessary machinery, the necessity of scientific knowledge, and other factors, which was not previously considered practical. The essential equipment necessary to perform the processes of this invention already exist in a manufacturing facility using traditional processing machinery (specifically, the dyebath tank), or can be adapted from existing equipment used for other purposes (specifically, the wicking chamber, which is just a stainless steel box of suitable size with stainless steel bars inside). The material loading apparatus (creels, beams, greige goods containers) and the collection apparatus (winders, blockers, beams, collection containers) are all standard items in a textile mill. If a user had never done dye processing previously, a serviceable version of equipment to do this process could probably be installed for approximately $10,000 US as compared with the cost of a finishing range alone, which can cost anywhere from $10,000 US (for a 1-can set-up) to several million dollars (for ranges fully two stories high and several hundred feet in length). The formulations are solvent-based, and, although aqueous-based dye solutions are preferred currently, chiefly due to health and environmental concerns, it can be argued that the formulations and processes associated with this invention are actually preferable to aqueous methods in that they are more friendly to the environments affected. The primary environment is inside the processing plant; traditionally, workers have been exposed to the evaporating elements released into the air as the dyeing, curing, and drying are taking place, which is why dyehouses are densely humid atmospheres. That humidity includes not only the aqueous base of the colorant material, but also the dyestuff chemicals, fixatives, and any number of other additives which may have been added. This invention is solvent-based, and is applied by, as described in a prior section, a quick immersion into a dyebath which is closed to the air, then through closed passages through to the wicking chamber, which is also a closed unit and has a hose vent, similar to a clothes dryer, except that it has “scrubber” filters, which remove anything undesirable from being released into the air (the secondary environment) outside the facility. There are types of catalytic convertors which may be adapted for similar purposes. This would greatly improve the in-plant conditions of the workers without releasing anything dangerous to the environment. At the end of a processing run using traditional technology, the excess dyebath liquid (now waste) is dumped into drains which carry this waste to the sewer system and on to the treatment facilities. While this is an improvement on the time-honored dump-it-in-the-river or pour-it-in-the-holding tank or open-air cistern, the accepted modern solution is not ideal either. By contrast, this invention is 99+% usable, as all colors will eventually go to black or can be made black by adding black colorants; no dye “liquor” is thrown out. The inventor says 99+% usable because there is inevitably some lint or detritus from the processed material which ends up in the dye liquor. This is removed by filtering through mesh, cheesecloth, or similar means and the dye liquor is “as good as new.” This detritus is well under 1% of the total volume and can be disposed of as solid waste. The fact that this invention can dye cottons, delicate fabrics, and be strained through cheesecloth speaks to the relatively benign nature of this invention. Suggested personal safety protection include eye protection, rubber (nitrile) gloves, and otherwise standard work clothes. An ancillary environmental benefit to this invention is the savings involved in not having to power (which is provided, often, by fossil fuels) the traditional equipment which provide the heat treatments necessary to process goods currently. Savings involved in energy costs, labor and overhead costs (because of the significantly increased yields), the inventory reduction costs (as this system is simpler to load, use, and change), and the reduced amount of manufacturing space necessary to use this invention are not insignificant. The processes described herein have had to do with products in solid colors; striped patterns and other color designs can be achieved by running yarn through this same process, formulations, and equipment for dyeing (known as “slash dyeing” when applied to yarn) before those yarns are sent through looms, knitters, braiders, rope-making equipment, etc and made into finished fabrics. As for products intended for printing, a pass through the process of this invention, in base (clear) form or with dyes or pigments will leave a surface which may be printed using water-based inks on standard paper presses, which is much more economical than using, for example, but not limited to, sublistatic (paper transfer) printing. In a more general sense, this invention may be useful to an importer of, as an example, men's polo shirts, which must be ordered at least 90 days before they are to be offered on retail shelves. This means the colors, the distribution of colors over sizes (small through 5XL, commonly) and the quantities of units of each must be pre-determined a season ahead of the retail sale date. If these shirts were all brought in as whites (or “blanks,” as they may be called), and dyed to color as needed, the turnaround time would be greatly reduced and it would give the supplier more freedom to supply preferred colors (as opposed to slower-selling colors) along with other advantages of what might be called “flexible” (as opposed to “fixed”) inventory. This principle would be applicable to thousands of other products as well. This invention may also be useful in areas with limited water resources, such as the northern coast of Africa, large parts of the Mideast, parts of Asia, etc and geographic locations with less sophisticated water treatment systems.
CONCLUSIONS, RAMIFICATIONS, AND SCOPE
[0034] The inventor has reason to believe this invention represents an approach to textile processing which, in conception and execution, has not been seen before in that industry. This conclusion is derived from his own 30 years of experience in the field, and the valued opinions of many other persons, company owners and executives, processing engineers, research and development personnel, material suppliers, etc who are significant in the textile industry and who are associated with the leading companies in these fields. It is not enough that this invention be simply different from established approaches; to be useful, it must present, ideally, a more simplified approach, a more universally applicable approach, a more cost-effective approach, additional options for production methods, improved products, and it must produce results equal to or better than those produced before this invention. The inventor believes this has been accomplished with additional benefits, such as the ability to dye fibres and fabrics which had heretofore been considered undyeable and, arguably, some better options as concerns the environment relative to manufacturing practices. The advantages it presents for other industries, among them the rubber and plastics industries mentioned herein, are more in the nature of providing options which were not formerly available.
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A method for: (1) The application of solvent-based resin formulations to various forms and classes of textile fibres, fabrics, and finished goods which, when dyes or pigments are included, will impart color to textile materials; (2) The application of the formulations to various forms of rubbers, natural and synthetic, in the pre-formed state or subsequent to forming a finished product which will impart color and fortification; (3) The application of the same group of formulations to revitalize plastic surfaces and impart color to plastics prior to and subsequent to forming finished products; (4) The application of the same formulations to polymers for the purpose of carrying additives for purposes such as, but not limited to, sizing, mildew resistance, UV protection, glazing, creation of printable or paintable surfaces, artistic coloring effects, abrasion resistance, stain resistance, mercerizing, and many more, with or without dyes or pigments included.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the use of sand art techniques for fabricating novelty items, amusement devices, craft kits, toys and other artistic and decorative products, items and devices. More particularly, the invention relates to articles and products using shaped and sized flexible resilient containers in which colored sand is placed.
[0002] Sand art has become a popular craft enjoyed by both children and adults. It requires placing sand, preferably of various colors, in a translucent container. Thus, flowable small particulate matter, such as colored sand or other particles of material for creating and fashioning visible patterns within an object such as a bottle, a bowl, a lamp base and other translucent objects, are known in the prior art.
[0003] It is also known in the prior art to utilize small particulate media or materials such as beads, crystals and beans to fill flexible bags such as bean bags, as lounging spots or for tossing toys, etc.
[0004] However, the prior art does not disclose the use of sand art, or a similar craft, for placing particulate material, such as sand of the like, having a plurality of colors within a flexible container made of a translucent material. The prior art also fails to disclose a sand art system, or similar craft, where sand is placed within a flexible translucent container along with other fill materials, such as sponges, clay, pipe cleaners, and the like.
[0005] The present invention addresses the shortcomings of the prior art by providing a sand art system and method where a particulate material having multiple colors is placed within a flexible translucent container.
[0006] The prior art also does not disclose a sand art system including support materials such as flexible elongate support members (e.g., pipe cleaners or the like), or materials such as clay positioned in a flexible container along with particulate material to maintain the shape of the flexible container. Further, the prior art does not disclose a sand art system including fillers such as sponges or polyurethane foam inserted along with sand within a flexible container.
SUMMARY OF THE INVENTION
[0007] In a preferred embodiment, an article comprising a flexible container defining a cavity is provided. The flexible container includes a translucent material. Particulate material having a plurality of colors is arranged within the cavity of the flexible container whereby the flexible container displays a desired design and has a desired three-dimensional size and shape.
[0008] Preferably, the particulate material comprises a first sand having a first color and a second sand having a second color. Other particulate materials, include, but are not limited to, beads and the like. In addition, the particulate material may comprise a combination of materials made of different colors. Other fill materials may be arranged within the flexible container along with the particulate material. Examples of other fill materials include sponge material and pliable material (such as clay, pipe cleaners or any other type of flexible elongated member and the like).
[0009] In a preferred embodiment, the cavity of the flexible container may have a first section and one or more additional sections. Preferably, the first section includes a larger volume than any one of the other sections. While the specific shape of the flexible container is not intended to be limited, examples of preferred shapes include that of a hand, various animals, and an infinite variety of other objects and things.
[0010] The flexible container may have at least one sealable opening in communication with the cavity. Preferably, an object is arranged within the at least one sealable opening after all desirable fill materials have been arranged within the cavity. Thus, the fill materials would be precluded from being easily removed from the flexible container. The object arranged within the sealable opening may form a base on which the flexible container rests. In a preferred embodiment, the base may comprise a piggy-bank. In other embodiments, the base may comprise a cup. It should be understood that the scope of the present invention is not intended to be limited by the type of object used to seal the flexible container after the particulate material, or any other fill material, is placed therein.
[0011] Thus, one aspect of the present invention relates to a shaped and sized flexible resilient container made of a translucent material, in which relatively small or fine particulate colored materials, such as colored sand or beads, are placed.
[0012] It is another aspect of the present invention to utilize a flexible plastic container which can be filled by a sand art technique using particulate matter to form a desired three-dimensional object or thing.
[0013] It is another aspect of the present invention to provide a method utilizing a sand art technique for creating a filled and formed flexible container having an artistic and decorative design.
[0014] Additional objects, advantages and features of the present invention will become apparent from the detailed description which follows below, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a perspective view of a preferred embodiment of the present invention illustrating a translucent flexible container in the shape of a hand filled with various colored sand and other materials.
[0016] [0016]FIG. 2 is a cross-sectional view of the present invention taken along line 2 - 2 of FIG. 1.
[0017] [0017]FIG. 3 is a perspective partially cut-away view of a second embodiment of the present invention illustrating a translucent flexible container in the shape of an animal having accessories thereon.
DETAILED DESCRIPTION
[0018] [0018]FIGS. 1 and 2 illustrate a preferred embodiment of the invention as an article generally designated 10 comprising a flexible resilient container 12 having a cavity defined by inner wall 14 . The flexible container 12 is in the shape of a human hand, in which the cavity 16 defined by inner wall 14 has been filled with materials to give the flexible container 12 the three-dimensional shape as shown. The hand-like shape of the flexible container 12 has only been selected for purposes of illustration. Those skilled in the art will readily recognize that the flexible container 12 can take any desired shape, form or size. For example, the shape of an animal, an automobile, a person, a toy, a building, and an indefinite number of other objects, without departing from the scope, purpose and objects of the present invention.
[0019] The flexible container 12 is preferably a translucent material made from polymer, copolymer, block-copolymer, resin, rubber, glass or the like. Vinyl is one of many suitable materials. Such materials are well known, and shaped articles made of these materials, such as vinyl or rubber gloves, are easily purchasable in the commercial marketplace. Alternatively, the flexible translucent container 12 made of these materials can be fabricated into any desired shape, form and size by methods which are also well known to those skilled in the art. In the present invention, the flexible container 12 is made of a translucent material in order to enable any design formed within the cavity 16 to be visible in the finished product. The design may be as simple as a combination of colored sand 34 , or may be more complex by forming a recognizable pattern or the like.
[0020] The flexible container 12 has at least one opening 18 which communicates with the cavity 16 . This provides means for filling the cavity 16 with the various materials for imparting the three-dimensional appearance to the particular shape or forms selected for the flexible container 12 . When all of the spaces and areas of cavity 16 are filled, a closure object 20 is inserted into the opening 18 to seal or to prevent the materials within the cavity 16 from escaping.
[0021] Filling of the cavity 16 is preferably accomplished by positioning the opening 18 above, or at a higher point, than the remaining portions of the flexible container member 12 . The desired materials are then placed through the opening 18 for expanding the flexible container 12 into its three-dimensional form. Thus, in the illustrated hand-shape form of the flexible container 12 shown in FIG. 1, the flexible container 12 may be placed in an inverted position where the opening 18 is readily accessible for facilitating placement of fill materials into cavity 16 .
[0022] The materials to be placed through the opening 18 may vary depending on the size, shape and other factors selected for the flexible container 12 . Preferably, such materials will include particulate materials such as sand 34 , beads or the like. The sand 34 or beads are preferably colored as one more aspect of the invention relates to filling of the translucent flexible container 12 with multiple colors of sand 34 , beads or the like. Clay 36 will have the effect of providing additional pliability and stability to the finished product 10 , as will be described below.
[0023] The filling of the colored sands 34 or colored regularly or irregularly shaped beads or crystalline materials may be done in accordance with sand art techniques depending on the desired design. Thus, the fill materials can be selected to provide different colored layers or using different colors in various sections. Accordingly the fill materials will not only provide the desired three-dimensional shape of the flexible container 12 but will also provide a desired design, which will be visible by reasons of the translucent material from which the flexible container 12 is made.
[0024] Additionally, clay 36 or other pliable material such as pipe-cleaner 38 like structures may be used to fill the flexible container 12 . For example, clay 36 may be placed within the finger sections of the flexible container 12 .
[0025] Particulate materials, such as colored sand 34 or colored shaped beads or crystals are also used to fill the main cavity chamber (i.e., a palm portion 22 of the hand) and the sub-chambers (i.e., the finger portions 24 , 26 , 28 , 30 and 32 of the hand). The main chamber may be considered a first section of the cavity 16 and the sub-chambers may be considered second sections thereof. The multiple colored sand 34 enables designs to be formed, which will be visible through the translucent three-dimensional form of the shaped flexible container 12 .
[0026] Where the size of the main or sub-chambers of the cavity 16 permits, fillers such as sponges 40 may be added so that smaller quantities of particulate materials such as colored sands 34 or regularly or irregularly shaped beads or crystals will be used to fill the cavity 16 of the flexible container 12 .
[0027] By reference to FIGS. 1 and 2, the cavity 16 formed in the hand-shaped flexible container 12 has the palm section 22 and a plurality of elongated finger sections as at 24 , 26 , 28 , 30 and 32 , continuous with and in communication with the palm section 22 . When the flexible container 12 is in the inverted position so that the opening 18 is accessible, the desired fill materials can be readily placed into the respective finger sections 24 , 26 , 28 , 30 and 32 . Thus, as shown in the cross-sectional view of FIG. 2, clay 36 is arranged within one of the finger sections 24 , 26 , 28 , 30 and 32 .
[0028] Further, as shown in FIGS. 1 and 2, after the finger sections 24 , 26 , 28 , 30 and 32 have been filled to expand the finger portions into their three-dimensional form, the palm section 22 may be partially filled in the center section with a filler member, such as a sponge 40 or a piece of polyurethane foam, and then particulate matter such as colored sand 34 or beads.
[0029] As also shown in the cross-sectional view of FIG. 2, the completed article 10 may include an elongated and pliable pipe cleaner 38 . In particular, the pipe cleaner 38 may be arranged within the finger sections 24 , 26 , 28 , 30 and 32 along with the various types of colored sand 34 and clay (or other pliable material) 36 . The pipe cleaner 38 and clay 36 , may add the desired degree of stability or pliability to the completed sand art article 10 .
[0030] When all of the filling materials are arranged within the cavity 16 including the palm section 22 and the associated finger sections 24 , 26 , 28 , 30 and 32 , the closure object 20 is placed into the opening 18 so as to close and seal the opening 18 and prevent the filling materials from escaping out of cavity 16 when the flexible container 12 is placed in the upright position to provide the completed appearance of the hand shape or other selected shape.
[0031] The closure object 20 can be so formed that it will act as a base, which supports the associated flexible container 12 .
[0032] By reference to FIG. 1 showing the three-dimensional form of the hand-shaped flexible container 12 , designs as at 42 , 44 and 46 are printed, stamped or adhesively attached to the exterior surface of the container 12 . Such designs are clearly visible as well as the designs formed within the container 12 , which are visible through the translucent material of which the flexible container 12 is formed.
[0033] An alternate embodiment of the present invention is shown in FIG. 3. The particulate filled article 110 of FIG. 3 is similar to the article 10 of FIGS. 1 and 2. The only differences are in the shape of the article and the base member. In particular, the article 110 of FIG. 3 is in the shape of a dog. The accessories such as eyes 150 , a nose 152 , and a mouth 154 , have been pasted or printed thereon to complete the face of the dog. This embodiment is intended to provide an example how the flexible container 112 of the present invention can assume the shape of substantially any animal, object, etc.
[0034] It should be appreciated in alternate embodiments, that the opening into the flexible container may be arranged at various locations, and may comprise multiple openings. Thus, the opening need not be arranged in the vicinity of base 120 .
[0035] As also illustrated in FIG. 3, a base member 120 is arranged within what would have otherwise been an opening in the flexible container 112 . The base member 120 serves the dual purpose of closure to prevent fill materials within flexible container 112 from escaping from the associated cavity (not shown), and performing a stable base on which the flexible container 112 can rest. The base member 120 of FIG. 3 is shown in the form of a piggy bank.
[0036] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A particulate-filled article and method of creating the article is disclosed. The article includes a flexible container and is filled with at least one type of particulate material. Other materials such as pliable solid materials and sponge-like materials may be arranged within a cavity of the article along with the particulate material. The particulate materials may be various colored sands or other particulate materials. A method of fabricating the article is also disclosed.
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The invention herein described was made in the course of or under a contract or subcontract thereunder with the Department of Defense.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,812,082 teaches a compliant polyimide having high thermal-oxidative stability in addition to recoverable elongation. The primary disadvantage of the compliant polyimide taught in the patent is that the prepolymer must be dissolved in a solvent prior to application to the intended surface. Thus, in order to leave the polyimide in a workable state during the application, a solvent must be added which will reduce the amount of solid resin being applied. Therefore, when a polyamide-acid precursor is applied to the intended surface, the precursor must be exposed to heat for a predetermined period of time in order to remove the solvent from the precursor. After the solvent is removed, the precursor is then heated to the temperature of imidization. Because the solvent makes up a large percentage of the precursor composition, additional considerations are required if a certain weight of resin solids is desired in the final product, viz, a second application may be required or a larger initial application may be required. In any case, the solvent removal frequently leads to voided structures and precludes use of the polyimide resin.
SUMMARY OF THE INVENTION
The present invention proposes a polyimide having high thermal-oxidative stability and recoverable elongation which may be applied to a surface as 100 percent resin solids. Briefly, the polyimides according to this invention are prepared by reacting a bis(furfurylimide) with a bis(maleimide) via a Diels-Alder reaction. A bis(furfurylimide) is prepared by reacting two moles of maleic anhydride with one mole of a diisocyanate or a diamine terminated aliphatic ether. The bis(furfurylimide) reacts with the bis(maleimide) to form an alicyclic endooxy linkage between the aliphatic ether and the aromatic radical contributed by the dianhydride. This endooxy link chain is characterized by a high degree of workability in the absence of the usual solvent vehicle, and it is cured to a compliant polyimide by the application of heat, which drives off water of aromatization from the endooxy structure. A cross-linked polyimide can be effected by partially substituting a tetraamine or a tetraisocyanate terminated aliphatic ether and by heat treatment of the aromatized polymer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Polyaliphatic ethers suitable for use in the present invention may be terminated with either functional amine or functional isocyanate groups. The aliphatic groups in these ether compounds may be either alkylene, alkylidene, haloalkylene, or oxyalkylene having one to six carbon atoms between the oxygen atoms. Substituent groups on the carbon atoms may comprise halogens or oxygen atoms. Molecular weights of these compounds can range from 400 to 10,000, with 500 to 5,000 molecular weight being preferred for most applications. The proportion of the polyaliphatic ether may range from about 2 percent to about 98 percent by weight of the polyimide product depending on the molecular weight of the ether and the desired properties of the polyimide product. Expressed in mole ratios, the functionally terminated polyaliphatic ether may range from approximately 0.02 to 1 for each mole of aromatic compound in the polymer chain, preferably the ratio can range from 0.3 to 0.05 for each mole of the aromatic compound. Ether groups in these compounds provide a polar group which promotes adhesion and repels hydrocarbons and is compatible with most structural metals. The structure of these polyaliphatic ethers may be represented by the following:
Z(OA).sub.y Z
wherein Z is a radical selected from the group consisting of --N=C=O and --NH 2 ; A is an aliphatic radical consisting of alkylene, alkylidene, haloalkylene, or oxyalkylene groups having one to six carbon atoms; and y is an integer from 4 to 50 so that molecular weights of 400 or greater are represented by the formula. Illustrations of the polyaliphatic ether diamines are polyoxoethylene diamines, polyoxobutylene diamines, polyoxoisopropylene diamines, polyoxoamylene diamines, polyoxohexamethylene diamines, and polyoxystyrene diamines.
Other aliphatic ethers of special interest comprise perfluoroaliphatic diisocyano ethers. These aliphatic ethers are represented by the following structure:
O=C=N(CF.sub.2 CF.sub.2 O).sub.m (CF.sub.2).sub.5 0(CF.sub.2 CF.sub.2 O).sub.n CF.sub.2 CF.sub.2 N=C=O
where m+n must total an integer of 9 or greater. Polyimides made from these compounds exhibit thermal-oxidative stability at a substantially higher temperature range than the non-halogenated polyaliphatic ethers.
Of special note are the "Jeffamine ED" series diamines. "Jeffamine ED" poly(oxyethylene) diamines are aliphatic primary diamines structurally derived from propylene oxide-capped polyethylene glycol available from the Jefferson Chemical Company, Inc. Structures of "Jeffamine ED" can be generically illustrated as follows: ##EQU1## were a+c equals 3.5, while b equals 13.5, 20.5, and 45.5 for molecular weights of 600, 900, and 2,000.
Preparation of the aliphatic ether bis(maleimide) is effected by reacting one equivalent weight of a diisocyanate or diamine terminated aliphatic ether with one molecular weight of maleic anhydride. These reactants are mixed with a small amount of solvent to facilitate the mixing process which is subsequently driven off once the bis(maleimide) is formed. Heating of the mixture in a range of from 20° to 60°C for 3 to 6 hours provides complete reaction of the diamine and the anhydride.
Aromatic dianhydrides which are used to produce the aromatic bis(furfurylimide) may be selected from any of the common tetraacid or dianhydride compounds which are commercially available. The aromatic tetracarboxylic compounds suitable for use in this invention may be illustrated by the following structure: ##EQU2## where R is a tetrafunctional radical having the following structure: ##SPC1##
wherein X may be selected from the group consisting of --0--, --S--, --SO 2 --, --CO--, --CH 2 --, --C 2 H 4 --, --C 3 H 6 --, and ##SPC2##
Illustrations of specific aromatic tetracarboxylic compounds suitable for use in this invention include pyromellitic dianhydride, bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride, bis(3,4-dicarboxylic acid phenoxyphenyl)sulfone, bis(3,4-dicarboxyphenyl)sulfone dianhydride, bis(3,4-dicarboxyphenyl)ether dianhydride, diphenyl tetracarboxylic dianhydride, naphthalene tetracarboxylic dianhydride, 2,2-bis(3,4-dicarboxyphenyl)propane dianhydride, benzene-1,2,3,4-tetracarboxylic dianhydride, bis(dicarboxyphenyl)ethane dianhydride, benzophenone tetracarboxylic dianhydride, and bis(dicarboxyphenyl)methane dianhydride. Because of the unusual stability and solubility characteristics, bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride disclosed in U.S. Pat. No. 3,812,159 is preferred. Generally, the mole ratio of the aromatic tetracarboxy compound to the aliphatic ether is approximately 1 to 1, although slightly higher mole ratios may be employed to compensate for the inevitable cross-linking of the bis(maleimide).
Aromatic bis(furfurylimides) are produced by the reactions of one molecular weight of an aromatic dianhydride with two molecular weights of furfuryl amine. The reaction between furfuryl amine and bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride may be illustrated as follows: ##SPC3##
Polyimides according to this invention are made by reacting one equivalent weight of the aromatic bis(furfurylimide) with one equivalent weight of the aliphatic ether bis(maleimide). The bis(furfurylimide) reacts with the bis(maleimide) by a Diels-Alder reaction in the absence of a solvent vehicle. The reaction product is a polymer characterized as a rubbery solid. The poly(Diels-Alder) reaction of bis(3,4-dicarboxyphenoxyphenyl)sulfone furfurylimide with a "Jeffamine" bis(maleimide) may be illustrated as follows: ##SPC4##
where a, b, and c have been set forth previously, and n is an integer of from approximately 5 to 50.
The resulting alicyclic endooxy linked polymer may be applied to a surface for a coating or applied to a seam as a sealant material. After the application, the alicyclic endooxy linkage is aromatized by heating at temperatures ranging from approximately 150°C to approximately 240°C for a predetermined time according to the following reaction: ##SPC5##
where a, b, c, and n have been set forth previously.
These resins may be prepared for sealant use by the incorporation of inert powdered fillers in amounts ranging from 20 to 40 percent by weight of the total resin content. Inclusion of fillers in the resin will change the viscous resin to a paste or caulk consistency ideally suited for fabrication of fillant and faying sealant joints or for fabrication of molded seal and sealant products. Filler material may be selected from substantially any powdered material which is inert to the polyimide resin. Specific examples of suitable filler material are diatomaceous earth, calcium oxide, silicone dioxide, titanium oxide, or aluminum oxide. Particle sizes for the filler powder may range from extremely fine to moderately coarse. Preferably, the particle size will range between 0.005 microns to 325 mesh. Particle sizes in this range provide an excellent thickening agent for the viscous resin.
Table I shows the filler loading for a polyimide paste prepared from bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride and an equal amount of bis(maleimide) of 900 molecular weight "Jeffamine ED." Various types and amounts of fillers were added to the polyimide resin, and the paste-like material was troweled onto aluminum substrates with a spatula and heated to 175°C to cure. All of the resulting polyimide resins had excellent adhesion and strength. When molecular sieves were added as a filler, there appeared to be fewer voids in the resin.
TABLE I__________________________________________________________________________FILLERS EMPLOYED IN POLYIMIDE PASTE PREPARED FROM BIS(FURFURYLIMIDE) OFBIS(3,4-DICARBOXYPHENYL) SULFONE DIANHYDRIDE AND BIS(MALEIMIDE)OF POLYALIPHATIC ETHER DIAMINETotal Filler Ratio of Fillers Employedin Polyimide Powdered*Paste Resin Fumed Silica Fumed Silica Fumed Silica Molecular(% w/w) (100 mesh) nondusting >45μ 0.014μ Sieves 13×__________________________________________________________________________20 10020 80 2020 80 2020 80 80 2024 80 2026 80 2026 60 4026 60 4026 60 4029 50 37 13__________________________________________________________________________ *Powdered resin prepared from polyimide polymer of formulation 60% methylene dianiline; 10% diaminostilbene; 30% polyaliphatic ether diamine 1,000 to 1,400 mol. wt., and bis(3,4-dicarboxyphenoxyphenyl) sulfone dianhydride.
It may be seen from the above table that the polyimide resin prepared according to the present invention may be filled with from 20 percent of another polyimide resin to 20 percent of a filler comprising 50 percent of the other polyimide resin, 37 percent of a submicron fumed silica, and 13 percent of molecular sieve 13×. In all cases excellent adhesion and strength was obtained.
To show suitability of the cured polyimide resin for use as a sealant in hydrocarbon fuels, viz. JP-7, specimens of neat or unfilled polyimide film and filled polyimide film and filled paste were prepared from bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride and bis(maleimide) of 900 molecular weight "Jeffamine ED." Fillers which were used comprised 12.5 percent of "Cab-O-Sil M5," a fumed silica from the Cabot Corporation, and 4.2 percent by weight of molecular sieve 13×. Three specimens were applied to aluminum sheeting and were isothermally aged in order to determine if there was any failure in the adhesion to the aluminum. The results of the aging are found in the following Table II.
TABLE II______________________________________ISOTHERMAL AGING RESULTS OF POLYIMIDE SEALANTS Exposure Adhesion Aged in JP-7 at 450°FSpecimen Time (Hrs) After Aging Weight Retention (%)______________________________________Unfilled film 300 a 96Filled film 300 a 95Filled Paste 500 Excellent 94______________________________________ a -- Not tested
Other films of reasonable uniformity were melt-cast and tested for tensile properties at room temperature. Neat or unfilled films of the resin described in the previous paragraph were processed in this manner to give reproducible tensile strength of 400 psi and an elongation of 150 percent. Retraction measurement indicated that greater than 95 percent of the elongation is recoverable. The neat or unfilled and the filled film samples were flexible at -40°C. All film samples were insoluble in dimethylformamide, indicating that a cross-linking reaction occurs in situ along with linear chain extension, thus eliminating the need for a special cross-linking cure system.
The following examples will illustrate methods employed in preparing the polyimide prepolymers and resins of the present invention, which may be subsequently mixed with an inert filler to form pastes or caulks.
EXAMPLE I
PREPARATION OF THE BIS(MALEIMIDE) OF 900 MOLECULAR WEIGHT JEFFAMINE
To a three-necked 500 ml round bottomed flask, fitted with a nitrogen inlet/outlet, thermometer, dropping funnel, and magnetic stirrer, was added 25.3g (0.26 mole) maleic anhydride and 75 ml dimethylformamide. In a separate beaker 100 ml dimethylformamide was thoroughly mixed with 120.0g (0.13 mole) Jeffamine ED 900. This solution was then placed in the dropping funnel and was slowly added to the stirred maleic anhydride solution. After complete addition of the Jeffamine/dimethylformamide solution, 2.3g (0.028 mole) sodium acetate and 28.6g (0.28 mole) acetic anhydride was added to the reaction mixture, and the mixture was heated at 50°C for at least three hours.
After reacting at 50°C for 3 hours the solution was cooled and the dimethylformamide was stripped off under vacuum with mild heating. When the dimethylformamide was completely removed, the remaining solution was dissolved in about 100 ml. chloroform, and this mixture was washed with distilled water three times to ensure complete removal of the sodium acetate and acetic acid. The resulting organic solution was then dried over night using 10g magnesium sulfate. After the solution was filtered to remove the magnesium sulfate, the chloroform was stripped off in a rotary evaporator under mild heating. The resulting product was a dark brown, viscous liquid.
EXAMPLE II
PREPARATION OF SEALANT FORMULATION
In a small aluminum cup was weighed out 1.400 g (0.002 mole) bis(3,4-dicarboxyphenoxyphenyl) sulfone dianhydride furfurylimide, 2.120g (0.002 mole) Jeffamine 900 bis(maleimide), 0.352g (8% by wt) Cab-O-Sil M5, and 0.528g (12% by wt) molecular sieve 13x. The materials were thoroughly mixed together to form a viscous paste. The paste was then troweled onto a metal substrate with a spatula in any desired form. The specimen was then placed in an oven and heated from room temperature to 175°C. The temperature was maintained at 175°C for at least 4 hours to ensure complete curing of the polymer. The resulting material was a hard, rubbery polymer with excellent strength and adhesion.
EXAMPLE III
FABRICATION OF A FILLET SEALANT
In a small aluminum cup was weighed out 0.70g (0.001 mole) bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride furfurylimide and 1.06g (0.001 mole) Jeffamine ED 900 bis(maleimide). The materials were thoroughly mixed together to form a viscous liquid. The aluminum cup was placed in an oven and heated from room temperature to 175°C. The temperature was maintained at 175°C for at least four hours to ensure complete curing of the polymer melt. The resulting polymer was a rubbery solid with excellent adhesion.
Additionally, if improved thermal-oxidative or hydrocarbon fuel stability is required, the aromatic character of the polyimide should be increased. This is accomplished by preparing prepolymers of bis(maleimide) of a polyaliphatic ether diamine and bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride and reacting those two compounds to form a prepolymer which is subsequently reacted with a prepolymer formed from a bis(maleimide) of methylene dianiline and bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl) sulfone dianhydride. These prepolymers were mixed together in different ratios and reacted together to form films which approximate a theoretical block polymer configuration.
EXAMPLE IV
PREPARATION OF BIS(MALEIMIDE) POLYALIPHATIC ETHER DIAMINES AND BIS(FURFURYLIMIDE) OF BIS(3,4-DICARBOXYPHENOXYPHENYL)SULFONE DIANHYDRIDE POLYMER
Exactly 2.800g (4 mmole) of bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride and 4.240g (4 mmole) of bis(maleimide) of 900 molecular weight Jeffamine ED were mixed together in an aluminum cup and heated in an oven at 110°C for 2 to 3 hours. The resulting product was a brown, very viscous gum which was soluble in dimethyl formamide and acetone.
EXAMPLE V
PREPARATION OF BIS(MALEIMIDE) OF METHYLENE DIANILINE AND BIS(FURFURYLIMIDE) OF BIS(3,4-DICARBOXYPHENOXYPHENYL) SULFONE DIANHYDRIDE PREPOLYMER
Exactly 2.800g (4 mmole) of bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride and 1.432g (4 mmole) of bis(maleimide) of methylene dianiline were added to about 20 ml of dimethylformamide. The compounds completely dissolved and the solution was heated to 80°C for 2 to 3 hours. A dimethylformamide was stripped off and the prepolymer was dried under vacuum at 100°C for 3 hours. Resulting product was a bright yellow polymer of low molecular weight.
EXAMPLE VI
PREPARATION OF NEAT BLOCK POLYMERS
Three specimens of bis(maleimide) of 900 molecular weight Jeffamine ED, and bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride prepolymer weighing 2.81g (1.6 mmole), 2.46g (1.4 mmole), and 2.11g (1.2 mmole), respectively, were mixed together with the bis(maleimide) of methylene dianiline and the bis(furfurylimide) of bis(3,4-dicarboxyphenoxyphenyl)sulfone dianhydride prepolymer weighing 0.423g (0.4 mmole), 0.635g (0.6 mmole), and 0.847 g (0.8 mmole), respectively. The very viscous material was then placed on a sheet of aluminum and heated in an oven to about 120°C for 1 to 2 hours. The heating was then increased until the temperature was 180°C and was held at that temperature for three hours. Properties of the unfilled block polymers are shown in the following Table III:
TABLE III______________________________________Mole Ratio ofPrepolymer Used Tensile Properties.sup.b,c Qualitative.sup.a Strength Elongation(1) (2) Adhesion (psi) (%)______________________________________80 20 Good 770 22070 30 Good 620 120______________________________________ .sup.a Determined by attempts to remove the thin cast films from aluminum plates by hand pulls. .sup.b Average of three breaks determined on thick (ca. 5-10 mil thick) films employing a 0.2 inch/min. crosshead speed. .sup.c Retraction measurements show that recoverable elongation is ≧60% of values stated in Table.
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A compliant polyimide having superior thermal-mechanical properties can be produced by reacting an aromatic bis(furfurylimide) with an aliphatic ether bis(maleimide) via a Diels-Alder reaction. These polyimides display a long-term thermal-oxidative stability and a high percent recoverable elongation to break, and they are suitable for use as films, fibers, coatings, adhesives, structures, and sealants.
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BACKGROUND OF THE INVENTION
The present invention relates to internally cooled panels for metallurgical furnaces, and more particularly relates to an improved construction and arrangement for water-cooled panels adapted for use in assembly into fume hoods, ducts or the like, for metallurgical furnaces, such as basic oxygen furnace, electric furnace, converters and the like. This invention relates to and constitutes a modification over the type of panel and fume hood assembly contained in U.S. application Ser. No. 572,403 filed Aug. 15, 1966 to June H. Reighart, now U.S. Pat. No. 3,445,101.
Heretofore, such panels have been employed in sections and/or assembled into fume hoods for transmitting gasses emitted during operation of the furnace to a stack where they are cooled for ultimate disposition so as to avoid the loss of such gasses and to prevent contamination of the atmosphere. The individual panels, or sections, from which the hood may be assembled are water-cooled in order to protect the hood as well as to aid and cool the gasses emitted during the oxygen blow. By reason of the high temperatures and velocities with which the gasses contact the hood, the water-cooled linings of the hood are subject to rapid deterioration and require frequent repair and/or replacement. Moreover, as there is a considerable difference in temperature between the hot and cold sides of the panel, there results a greater expansion of the metal on the hot side. This heat differential causes the panel to buckle or to warp generally in a vertical direction requiring frequent repair and/or replacement. Specifically, the drastic temperature differentials encountered during the oxygen blow initiates internal stresses in the component parts of the panel and/or fume hood assembly which results in a tendency for the parts to pull and/or tear apart, particularly at the weld joints. Accordingly, in addition to the cost of repair and/or replacement of the panel, the loss of production time during the replacement period represents a considerable increase in production costs.
In addition to the foregoing, the panels should be constructed and arranged to provide an optimum uniform longitudinal coolant flow through the panel with minimum cross flow or channeling for maximum heat transfer. More specifically, the panel of the present invention is constructed and arranged to provide a more uniform and controlled flow of coolant through the panel so as to minimize the diffusion type effect, particularly in the manifolds, so as to remove the concentration of stresses at the weak points, such as the weldments, and so as to otherwise avoid hot spots and failures which have heretofore occurred with prior art panels. Manifestly, by this improved arrangement, the life of each panel may be prolonged so as to increase the over-all efficiency of the furnace operation.
In accordance with one aspect of the present invention, the panels are formed so as to reduce welds, both on the inside and outside of the hot face so that a practically seamless face is presented to the fume, while retaining the necessary resistance to movement under hydrostatic pressure. The panels thus formed provide single-pass unidirectional fluid flow which is non-turbulent so as to effectively wash the panel hot face plate. Preferably, the desired spacing between the hot and cold face plates is achieved by plug welds extending axially thereof, insuring equalization of pressure in all fluid passageways with controlled interflow between passageways. The turbulence-free flow thus obtained has marked advantages; the flow pattern takes maximum advantage of natural convection forces in all vertical and inclined panels. The flow resistance is minimal, thus reducing pressure drop through the panel and reducing the possibility of hose, fitting and pipe leaks, extending pump life, and allowing more water to flow through the panels for a given supply pressure. The flow is without eddy-currents and sharp bends which tend to cause bubbling and to precipitate solids in the water. The smooth stream prevents dead spots for contaminants to settle and accumulate. These advantages give extended trouble-free service life to the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective view, partly in section, illustrating a panel made in accordance with the present invention;
FIG. 2 is a fragmentary, generally perspective view looking at one end of the panel of FIG. 1;
FIG. 3 is an assembly view in perspective of two sheet members shaped to form the corrugated cold face and a smooth hot face respectively;
FIG. 4 is a front elevation view of a fume hood showing the general assembly using panels of the invention;
FIG. 5 is a top plan view illustrating a typical arrangement of the invention;
FIG. 6 is a fragmentary, section view on an enlarged scale taken along the line 6--6 of FIG. 5; and
FIG. 7 is an elevation view showing another modified form of the panel of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now again to the drawings, there is illustrated in FIGS. 1 to 3 a water cooled panel of the present invention, designated generally as 2, for use in a fume hood assembly 1 (FIG. 4). As shown, the fume hood is disposed over a furnnace 4, such as a basic oxygen furnace, for connection to a conventional stack (not shown) through which the fumes pass on their way to a dust separator or other recovery equipment, as desired. In FIG. 4, there is illustrated an aperture, or opening 6, through which the conventional type oxygen lance (not shown) may be inserted into the furnace. The panels, designated generally as 2' are modifications of the panels of the invention constructed and arranged to be disposed around the opening 6. As shown, the panels in the upper sections of the fume hood are rectangular in configuration, while the panels in the flared out lower portion are constructed and arranged to accomodate the cleared configuration. In the invention, the configuration of the fume hood can take various designs dependent upon the particular location of the furnace, the adjoining equipment and the stack to which the hot gasses are to be delivered from the fume hood.
As best seen in FIGS. 1 to 3, the panel 2 may be of a polygonal configuration, such as rectangular, triangular configuration or the like, including an upwardly facing cold face member 8 for securement in a hot face member 10. The cold face member 8 may be fabricated from a piece of plate steel having a series of grooves or corrugations, as at 12, extending axially thereof and disposed in symmetric width-wise spaced relation transversely thereof. By this arrangement, the strength of the panel against vertical bending is achieved to withstand the buckling and other strain to which the panel may be exposed during normal usage. While the corrugations in the form shown are disposed on one side of the cold face member 8, it is to be understood that the corrugations may be placed on both faces of the panel with the corrugations in one face, either directly opposite or disposed in staggered relationship to the corrugations in the other face. Further, the depth, or crest, of the corrugations can be sufficient as to cause contact between the two faces 8 and 10 or can be of a lesser dimension to prevent actual contact between the faces. For example, it is sometimes desirable to prevent actual contact between the corrugations and faces, and thereby allow a flow of water therebetween in order to prevent deposits from accumulating. Such accumulations decrease the heat transfer from the metal to the circulating water and thereby reduce the efficiency of cooling.
In the present invention, the expression "corrugations" as employed herein describe linear indentations or curves in either the cold face member 8 or the hot face member 10. The expression is used herein to denote linear indentations, curved valleys or grooves impressed in one direction into the otherwise flat surface of the respective member which can be made by rolling or forming, as desired. In other instances, the depressions can be singly rolled in a sheet or a pre-fabricated corrugated plate may be employed, if desired.
In the invention, the number of corrugations and the spacing between corrugations in the particular face member will depend, among other things, upon the increase in strength desired. For example, the strength desired depends somewhat upon the shock temperature to be encountered, the number of corrugations required being correspondingly increased with a greater thermal shock to which the panels may be exposed. The depth or thickness of the passageways or channels, as at 14, between the two face members, or in other words, the distance between the hot and cold faces, may vary depending on whether it is desirable to have a high or low flow velocity through the channel, as well as the quantity of the cooling mixes required. The size and shape of the panels is generally dependent upon the particular application and location of the panel. The thickness of the steel plate employed being preferably between 1/4 inch to 1/2 inch.
To provide optimum strength and to achieve longitudinal fluid flow, with minimum cross-over between channels, it is preferred that the corrugations extend a sufficient depth into the space defined by the two face members. This depth may range from that desired to give the minimum increase in strength to the maximum possible distance, which is the full distance between the two face members, and which maximum distance will vary in accordance with variations in the space between the face members. Preferably, the corrugations extend at least a distance twice the thickness of the plate, or to a distance of at least 1/2 inch for 1/4 inch thick plate. Moreover, by this arrangement, there is not only provided an increased panel strength to withstand thermal shock, but such corrugations act to prevent cross flow or angular flow through the panel, thereby providing a more uniform longitudinal flow throughout the interior of the panel. Such avoidance of channeling in the flow of the cooling medium through the panel enables a more uniform cooling of the panel thereby obviating the heating with the resultant formation of hot spots and failures in the panel.
As best seen in FIG. 3, the cold face member 8 is dimensioned so as to be fitted within the interior of the hot face member 10. In the form shown, the cold face member 8 has its lateral edges 16 bent upwardly at right angles to the general horizontal plane, as at 18, of the member 8 to provide longitudinally extending edges which define the interior wall which form side rail channels 20 (FIG. 2) that extend lengthwise of the panel.
In the embodiment shown, the hot face member 10 includes a generally flat, smooth bottom surface 24 (FIG. 3), thereby to avoid the build-up of slag particles, etc., on the surface of the panel. This surface, in the form shown, is bent upwardly 90° to provide lateral side walls 26 which, in turn, are turned inwardly 90° to form top rails 28 which extend generally parallel to the surface 24. The lateral edges 16 of the hot face member 8, together with the edges 26 and top rails 28, define the closed channels 20 which extend throughout the length of and along the opposed sides of the panel. Accordingly, the upper terminal ends of the lateral edges 16 are made integral, such as by welding or the like, to the outer terminal edge, as at 30 (FIG. 2), of the top rails 28 so as to provide a fluid type closure defining the channels 20 for communication with manifold headers disposed at opposite ends of the panel.
As best illustrated in FIG. 1, the panel 2 is provided with a pair of oppositely disposed manifolds or headers 32 and 34 which communicate with each of the individual channels, as at 14, for transfer of fluid flow from end-to-end interiorly of the panel. As shown, suitable connectors 36 can be secured to the manifold 34 for connection to a suitable fluid source of water (not shown) so that water may be circulated longitudinally through the channels 14 out through the manifold 32 via outlets 38. Similarly, the side rail channels 20 communicate at their opposed ends with the respective headers 32 and 34 maximizing longitudinal circulation through the panel between the hot and cold face members. In the embodiment illustrated, the manifolds are generally of an identical construction, whereas, the openings may be provided for water inlet or outlet from either end as desired.
In accordance with the present invention, to improve strength characteristics to withstand heat differentials with resultant stresses and to provide improved control of fluid flow through the panel, an improved construction and arrangement of the hot face, cold face and manifold members are provided to achieve an optimum synergistic heat transfer result. To achieve this purpose, the cold face member is extended interiorly of the manifold 32 (FIG. 2) a predetermined distance, as at X, so as to terminate interiorly of the manifold to enable fluid flow in the direction, as shown by the arrows. Specifically, the terminal end edge, as at 42, of the cold face member 8 terminates a predetermined lineal distance, as at X, from the confronting interior surface of the wall 44 defining the end of the manifold 32. In the invention, the distance X is related to the pipe inlet diameter to achieve turbulence free-flow for maximum heat exchange to the coolant fluid. For example, a pipe with an inlet (O.D.) diameter of 3 inches would provide a minimum distance X of 13/4inches. Similarly, an inlet diameter of 8 inches would provide a minimum distance X of 41/4 inches. Preferably, the ratio of the distance X to the pipe inlet diameter is in the range of 1:2.
In forming this construction, the bold face member 8 is mounted within the hot face member 10 as aforementioned, and the manifold then simply installed over the cold face member. For example, the end wall 44 is bent upwardly at right angles, as at 45, and the outer top of the manifold 46 is welded along the edges, as at 48, to the top rails 28 while the inner right angle face 50 of the manifold is welded, as at 52, at its opposed ends to the confronting interior lateral edge 16 of the cold face member 8 and, hence, axially inwardly of the terminal end of the lateral edge 16 defining the channel 20. The inner face 50 of the manifold is cut so as to have a shape corresponding to the confronting exposed side of the cold face member containing the corrugations 12 and channels 14 and is secured thereto, as at 54. Accordingly, the interior face 50 of the manifold is welded at its opposed edges, as at 52, to the confronting interior lateral edges 16 of the cold face member 8 thereby to eliminate a bend point or corner combination at intersections of 30, 52 and 54, as would be the case with welding abutting edges, as for example in U.S. Pat. No. 3,445,101. By this arrangement, there is provided an improved construction which acts to prevent stresses, deformation and warp which would ordinarily take place adjacent the corner juncture, as at 52, due to the heat differential resulting from heat transfer between the hot and cold faces of the panel. In addition, this greatly facilitates fabrication and installation of the component parts. For example, this eliminates the need for exacting tolerance requirements in dimensioning the manifold in order to secure the proper butt weld at the opposed corners as well as at the juncture, as at 54, with the cold face member 8. Moreover, this enables the manifold to be installed, as a unit, over and in overlapping relation with respect to the cold face member 8 for positive assembly with a relatively reduced tolerance requirements with reduced stress concentrations at the weld points.
As best seen in FIG. 2, the lateral side edges 16 of the cold face member 8 extend interiorly of the manifold, as at 56, so as to be co-terminus with the interior extension of the terminal edge, as at 42 of the cold face member. Moreover, this provides a more controlled uniform flow of fluid through the extending channels 14 and the side rail channels 20 interiorly of the manifolds 32 and 34 so as to minimize any diffusion effect which would otherwise result in heat transfer losses to the exterior of the manifold. As seen in FIGS. 1 and 2, the headers or manifolds 32, and 34 are adapted to feed or exit water into or from the respective channels 14 between corrugations 12, or between the channels 14 and the side rail channels 20. The side rail channels 20 extend above the general plane of the cold plate member 8 an amount equal to the height of the side walls 16 and liner, provide added strength to the longitudinal edges of the panels while at the same time affording coolant flow.
In the invention, the securement of and spacing between the plates 8 and 10 is provided by a series of axially extending plug welds 60 disposed in the corrugations 12 between the channels 14. As best seen in FIG. 2, the welds 60 are symmetrically arranged in staggered relationship to one another accross the width of the cold plate 8 and preferably have a length of about 6 inches, except at the terminal ends, as at 62, wherein the weld length is proportionately reduced (e.g. 2-3 inches) dependent upon the length of the respective plates, etc. Moreover, the plug welds disposed at the confronting areas between the corrugations between the two plates or between the corrugations in one plate and the smooth inner face of the other plate provide sufficient rigidity and strength as permit dispensing with staybolts or the like. Avoiding the use of staybolts and separating strip minimizes the amount of welded areas and also reduces the nonuniformity of heat transfer and strains provided by a large number of welds. Excessive weld areas with consequent repeated heating-cooling cycles produce resultant cracks and separation of the panel elements, thereby requiring a greater frequency of replacements.
In FIGS. 5 and 6, there is shown a modification of the panel for application in the fabrication of a BOF hood transition elbow, for example. As shown, the panel illustrated includes a single hot face 10 and two cold face plates 8' separated at their midpoint by a tight full length corrugation, as at 64, for circulating fluid (water) from an inlet 66 through channels 14 in the panel through a manifold 68 and out through outlet 70. In this form, the hot and cold face plates may be angularly disposed relative to the full length corrugation 64 so as to diverge downwardly and outwardly from one another from the corrugation 64. For example, the cold face plates 8' on either side of the corrugation and the single hot face plate may be disposed so as to provide an included angle of about 60° so that the cold and hot face plates extend divergently outwardly and downwardly from one another on either side of the corrugation 64, as viewed looking from the right hand side of FIG. 5. In this form, one end of the panels may be angularly tapered, as at 72 and 74, in order to facilitate the installation for a particular location. Moreover, in this form the inner terminal edges, as at 42, of the cold face members 8 terminate a distance x interiorly of the manifold 76 for the purposes as aforesaid. In some cases, the extension of the cold face plate 8' interiorly of the header or manifold 76 may be shortened, as at X', to accomodate a baffle or the like 78, as desired.
In FIG. 7, there is illustrated another modified form of the panel 2A wherein the cold 8 inch and hot 10 inch face plates are curved rather than be disposed parallel to one another as in FIG. 1 or angularly disposed as in FIG. 5. For example, in this form, the plates are curved rather than angularly disposed as in FIG. 7.
While certain features of this invention have been described in detail with respect to various embodiments thereof, it will, of course, be apparent that other modifications can be made within the spirit and scope of this invention, and it is not intended to limit the invention to the exact details shown above except insofar as they are defined in the following claims:
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A panel for use in metallurgical type furnaces comprising a pair of outwardly disposed metal plate members spaced apart and joined together at their edges to provide a fluid transmitting passageway with at least one of the plate members including laterally spaced corrugations defining parallel channels in the passageway for directing fluid flow longitudinally of the panel. Manifold members are disposed at the opposed ends of the plate members and communicate therewith with one of the plate members terminating interiorly of at least one of the manifold members and in laterally off-set relation to the other plate member for uniformly controlling fluid flow for heat transfer exteriorly of the panel.
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This application is a divisional of pending U.S. application Ser. No. 09/368,395, filed Aug. 4, 1999, which is a divisional of U.S. application Ser. No. 08/927,113, filed Sep. 29, 1997, now U.S. Pat. No. 5,957,754.
BACKGROUND OF THE INVENTION
This invention relates generally to the polishing and planarization of semiconductor substrates and, more particularly, to the conditioning of polishing pads in slurry-type polishers.
Integrated circuits are typically formed on substrates, particularly silicon wafers, by the sequential deposition of conductive, semiconductive or insulative layers. After each layer is deposited, the layer is etched to create circuitry features. As a series of layers are sequentially deposited and etched, the outer or uppermost surface of the substrate, i.e., the exposed surface of the substrate, becomes successively less planar. This occurs because the distance between the outer surface and the underlying substrate is greatest in regions of the substrate where the least etching has occurred, and least in regions where the greatest etching has occurred. With a single patterned underlying layer, this non-planar surface comprises a series of peaks and valleys wherein the distance between the highest peak and the lowest valley may be the order of 7000 to 10,000 Angstroms. With multiple patterned underlying layers, the height difference between the peaks and valleys becomes even more severe, and can reach several microns.
This non-planar outer surface presents a problem for the integrated circuit manufacturer. If the outer surface is non-planar, then photolithographic techniques to pattern photoresist layers might not be suitable, as a non-planar surface can prevent proper focusing of the photolithography apparatus. Therefore, there is a need to periodically planarize the substrate surface to provide a planar surface. Planarization, in effect, polishes away a non-planar, outer surface, whether a conductive, semiconductive, or insulative layer, to form a relatively flat, smooth surface. Typically, an insulative layer is deposited across the entire surface to be planarized filling valleys but also covering peaks in the surface. Planarization thus removes this layer from above the peaks leaving a substantially uniform planar surface. Following planarization, additional layers may be deposited on the outer layer to form interconnect lines between features, or the outer layer may be etched to form vias to lower features.
Chemical mechanical polishing is one accepted method of planarization. This planarization method typically requires that the substrate be mounted on a carrier or polishing head, with the surface of the substrate to be polished exposed. The substrate is then placed against a rotating polishing pad. The carrier head may also rotate and/or oscillate to provide additional motion between the substrate and polishing surface. Further, a polishing slurry, including an abrasive and at least one chemically-reactive agent, may be spread on the polishing pad to provide an abrasive chemical solution at the interface between the pad and substrate.
Important factors in the chemical mechanical polishing process are: the planarity of the substrate surface, uniformity, and the polishing rate. Inadequate planarity can produce substrate defects. The polishing rate sets the time needed to polish a layer. Thus, it sets the maximum throughput of the polishing apparatus.
Each polishing pad provides a surface which, in combination with the specific slurry mixture, can provide specific polishing characteristics. Thus, for any material being polished, the pad and slurry combination is theoretically capable of providing a specified planarity on the polished surface. The pad and slurry combination can provide planarity in a specified polishing time. Additional factors, such as the relative speed between the substrate and the pad, and the force pressing the substrate against the pad, affect the polishing rate and planarity.
Because inadequate planarity can create defective substrates, the selection of a polishing pad and slurry combination is usually dictated by the required planarity. Given these constraints, the polishing time needed to achieve the required planarity sets the maximum throughput of the polishing apparatus.
It is important to take appropriate steps to counteract any deteriorative factors which either present the possibility of damaging the substrate (such as by scratches resulting from accumulated debris in the pad) or reduce polishing speed and efficiency (such as results from glazing of the pad surface after extensive use). The problems associated with scratching the substrate surface are self-evident. The more general pad deterioration both decreases polishing efficiency, which therefore increases cost, and creates difficulties in maintaining consistent operation from substrate to substrate as the pad decays.
The glazing phenomenon is a complex combination of contamination and thermal, chemical and mechanical damage to the pad material. When the polisher is in operation, the pad is subject to compression, shear and friction producing heat and wear. Slurry, including the abraded material from the wafer and pad, is pressed into the pores of the pad material and the material itself becomes matted and even partially fused, all of which reduce the pad's ability to apply fresh slurry to the substrate.
It is, therefore, desirable to continually condition the pad by removing trapped slurry, and unmatting or re-expanding the pad material.
A number of conditioning procedures and apparatus have been developed. Common are mechanical methods wherein an abrasive material is placed in contact with the moving polishing pad. For example, a diamond coated screen or bar which scrapes and abrades the pad surface to a moderate extent both removes the contaminated slurry trapped in the pad pores and expands and re-roughens the pad. With such systems, abrasive particles from the conditioner may themselves become dislodged from their source and will become contaminates for the pad and the slurry. Further, the mechanical grinding away of the pad reduces pad life. The mechanical abrasive elements themselves are also quite expensive, typically comprising embedded diamond particles, and their use imposes the further downtime required to break-in the abrasive. Typically, a new abrasive element must be broken-in by running it on a pad for approximately thirty minutes to remove any loose abrasive particles prior to the polishing of any wafers so as to avoid scratching the wafers.
An alternative method which largely avoids the dangers of contamination is the ultrasonic agitation of the slurry as disclosed in U.S. Pat. No. 5,245,796 of Gabriel L. Miller and Eric R. Wagner, issued Sep. 21, 1993 (hereinafter Miller, et al.). Miller, et al. discloses the use of an ultrasonic generator placed one-half inch above the pad surface and oscillated at a frequency of 40 KHz to dislodge grit and debris which become embedded in the pad. Miller, et al., however, fails to address the mechanical deterioration of the pad that occurs with glazing.
It is, accordingly, desirable that a conditioner remove debris from the pad and undo glazing while avoiding the introduction of additional mechanical abrasive to the slurry, thus restoring the mechanical structure of the pad without doing unwanted amounts or types of mechanical damage to the pad.
SUMMARY OF THE INVENTION
In one embodiment, the invention provides a chemical mechanical polishing system comprising: a moving polishing pad with a polishing surface; a wafer carrier holding a wafer and placing a face of the wafer in sliding engagement with the polishing surface; and an ultrasonic conditioner. The conditioner has a narrow elongate agitating head positionable at least in partial contact with a liquid on the polishing surface and in close facing relationship to the polishing surface during rotation. An oscillator oscillates the head so as to agitate the liquid at an appropriate frequency and sufficient amplitude to produce cavitation of the liquid in the vicinity of the pad surface. The action of cavitational collapse vigorously conditions the pad, driving out contaminants and re-texturizing the pad so as to maintain its polishing effectiveness.
In certain implementations, the head may have a length that is at least as large as a diameter of the wafer and may have a width less than 0.5 inches. An exemplary spacing between the head and pad may be less than 0.1 inches, or more particularly, even smaller such as between 0.010 inches 0.030 inches. The head may have a concavity along its length so that spacing between the polishing surface and a lower face of the head is relatively greater at intermediate radii of the polishing pad then at central or peripheral radii of the polishing pad. The liquid may comprise a polishing slurry applied to the pad for polishing the substrate or may comprise a separate conditioning liquid, such as deionized water, which may be held in a stationary pool area atop the moving polishing pad, the remaining area atop the polishing pad being covered with polishing slurry.
Among the advantages of the invention are the following. The cavitational conditioning feature reduces damage to wafers caused by abrasives (such as diamond dust) which may be dislodged from a mechanical abrasive conditioner. Furthermore, whereas mechanical abrasive conditioners substantially operate by grinding away the exposed uppermost layer of the polishing pad, the cavitational conditioner can leave a greater amount of the pad intact, thus increasing pad life. A significant benefit of an increase in pad life is less total downtime resulting from the less frequent replacement of pads. This results in higher overall throughput. Downtime is further reduced as the eliminated or reduced use of abrasive elements eliminates or reduces the down time spent replacing and breaking in new elements. Costs of consumables, such as the pad, retaining rings and other components which may be worn by the use of abrasives, are also reduced.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute a part of the specification schematically illustrate the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention.
FIG. 1 is a partial semi-schematic top view of a single platen area of a chemical mechanical polishing (CMP) system having a conditioner according to principles of the invention.
FIG. 2 is a partial, semi-schematic and cut-away, cross-sectional view of the conditioner of FIG. 1, taken along line 2 — 2 .
FIG. 3 is a partial semi-schematic top view of single platen area of a CMP system having an alternate conditioner according to principles of the invention.
FIG. 4 is a partial, semi-schematic and cut-away, cross-sectional view of the conditioner of FIG. 4, taken along line 4 — 4 .
FIG. 5 is a partial semi-schematic side view of a single platen area of a CMP system having a second alternate conditioner according to principles of the invention.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
As shown in FIG. 1, a polishing pad 20 is secured atop a platen 22 (FIG. 2) and rotates about a central axis 100 in a counter-clockwise direction 110 . A circular semiconductor wafer 24 is held by a wafer carrier or polishing head 26 which firmly places a lower face of the wafer in sliding engagement with the upper (polishing) surface of the pad. The carrier and wafer rotate as a unit about their common central axis 102 in a counter-clockwise direction 112 . In addition to the rotation, the carrier and wafer are simultaneously reciprocated between the solid line positions and the broken line positions 24 ′ and 26 ′ shown in FIG. 1 . In an exemplary embodiment, the pad 20 has a diameter of 20.0 inches, the wafer 24 has a diameter of 7.87 inches (for a 200 millimeter wafer, commonly referred to as an “8 inch” wafer), the carrier 26 has a external diameter of 10.0 inches and the carrier reciprocates so that the separation of its central axis 102 from the central axis 100 of the pad ranges between 4.2 and 5.8 inches. The rotational speed of the pad may be in an exemplary range of 20-150 rpm and that of the carrier may be in a similar range. In certain embodiments, the speeds of the pad and carrier may be slightly different from each other (such as by 3-5 rpm) to avoid resonance effects.
An agitator, having an elongate head 30 , is positioned approximately diametrically opposite to the carrier 26 . As shown in FIG. 2 the head 30 is connected to an oscillator 32 via a shaft 34 (removed in FIG. 1 for purposes of illustration). The agitator may comprise a piezoelectric-type ultrasonic transducer and may be supported by a gantry (not shown). The lower face 36 of the head is in close facing relationship with the polishing face 38 of the pad.
A nozzle 40 is located ahead of the agitator (the “ahead” direction corresponding to a direction counter to the rotation of the pad). The nozzle emits a stream 42 of polishing slurry which forms a slurry layer 44 atop the pad. The nozzle may take the form of a point source near the central axis of the pad, relying on a centrifuge effect to disperse the slurry along the length of the conditioner. The nozzle 40 may reciprocate along with the conditioner. A narrow elongate space 50 is defined in the slurry between the polishing surface of the pad and a bottom face 36 of the head. In the illustrated embodiment, the spacing between the polishing surface and bottom face of the head is approximately 0.02 inches, the width of the bottom face is approximately 0.25 inches and its length is approximately 9 inches. This length (L) is selected to be at least as large as the diameter of the wafer which is advantageous for providing a correspondingly broad swath of conditioning. The vigorous oscillation of the head 30 , making a vertical reciprocation along agitator axis 116 is at sufficient amplitude and frequency that it is believed to induce cavitation of the fluid in space 50 . When the induced cavities collapse, the action of cavitational collapse cleans the polishing surface of the pad of debris and re-texturizes the pad. Exemplary oscillation frequencies may typically range between 20 and 100 kHz; for instance, the frequency may be at substantially 40 kHz. An exemplary amplitude of oscillation at 20 kHz is approximately 75 μm. The minimized spacing between head and pad maximizes pressure fluctuations near the pad surface and thus helps efficiently induce cavitation at or near the pad surface. The spacing is less than 0.10 inches and may be between approximately 0.01 and 0.03 inches. Head width or thickness (W) is influenced by concerns for sufficient footprint (width×length of the portion of the bottom of the head in contact with the liquid) to provide the necessary degree of conditioning and not so large a footprint that would require too high a power or provide too much agitation. Preferred head thickness would thus be between approximately 0.1 and 0.5 inches. The oscillation in an exemplary embodiment is sufficient to induce cavitation with a cavity size of approximately 100 μm.
The carrier and conditioner reciprocate substantially in phase, the conditioner operating at the same time as the wafer is being polished. The reciprocation of the carrier 24 and the reciprocation of the conditioner head 30 may be purely linear or pseudo-linear, an example of the latter being reciprocation along an arc segment such as with a gantry that pivots on a remote axis. If desired, the conditioner may be made to operate intermittently or its operational zone may be varied. For example, the agitator can operate only while the carrier is transferring wafers (and may thus be out of the way, permitting a greater range of motion of the agitator, or simply permitting a greater level of agitation than would be tolerated while the wafer was being polished). Especially if coupled to an appropriate device for scanning the pad and determining wear and contamination, the agitator may be made to spend more time over certain areas of the pad than in others to provide a greater degree of conditioning in the former areas or even to remove high spots in those areas. Satisfactory conditioning results have been obtained using a test head with a 6.0 inch by 0.25 inch footprint oscillated at 20 kHz with a power of 180 watts.
An alternate conditioner is shown in FIGS. 3 and 4. Certain structure such as the pad and wafer carrier may be otherwise the same as that of the embodiment of FIGS. 1 and 2. For purposes of illustration, the oscillator and wafer carrier are removed in FIG. 3 . One aspect of this embodiment is the presence of a pool 47 surrounding and stationary relative to the agitator head 30 . Nozzle 41 emits a stream 45 of conditioning fluid directly into the pool to form a body 49 of conditioning fluid (or such mixture of conditioning fluid and polishing slurry as results from leakage or from slurry trapped on the pad) within the pool 47 (the remaining area atop the pad being covered with polishing slurry). The conditioning fluid may differ from the polishing slurry, for example, comprising in part or substantial whole deionized water. Appropriate flow passages and/or a pump (not shown) may be provided for evacuating conditioning fluid from the pool or this may be accomplished through overflow, leakage or a combination of the two. A slurry nozzle 40 ′, otherwise similar to nozzle 40 , may be provided downstream of the pool for generating the slurry layer encountered by the wafer and carrier. The four walls of the rectangular pool may be held in light contact with the polishing surface of the pad either by an independent support or by the same gantry that holds the agitator. The force with which the pool is engaged to the polishing pad should be not so high that the pool walls are undesirably worn away but should be sufficient to hold any mixing of the conditioning fluid and slurry to an acceptable level. A process-compatible material (wear resistant and relatively chemically inert) such as polypenylene sulfide (PPS) is preferable for this barrier. For example, the pool may be made of the same material as is a retaining ring portion of the carrier.
Another alternate agitator head 30 ″ is shown in FIG. 5 . The lower face 36 ″ of the head has slight concavity along its length so that the spacing between the pad and the lower face is relatively greater at intermediate radii of the pad than at the center or periphery. This concavity may be used to compensate for the tendency of the polishing of the wafer to wear down the pad in a region of intermediate radii and thus create an annular trough at such radii which degrades the uniformity of the polishing process, tending to produce a slightly convex crown on the wafer surface. Via increased cavitation adjacent the ends of the bottom face of the head, or by physical wear as the bottom face is brought into contact with the pad, the head produces compensatory wear at the center and the periphery of the pad to keep the pad flatter and thus reduce uniformity degradation.
A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, conditioner positioning may be altered or multiple small conditioners may be provided to facilitate more individualized addressing of glazing and wear at different radial locations of the pad. Additionally, the cavitational conditioner may be used in combination with a more conventional mechanical abrasive conditioner, with the abrasive conditioner primarily keeping the pad flat and the cavitational conditioner primarily keeping the pad clean. Also, the cavitational conditioner may be used with polishers other than the circular pad type, such as belt-type polishers. Accordingly, other embodiments are within the scope of the following claims.
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A chemical mechanical polishing system comprising a moving polishing pad and an ultrasonic conditioning head. The head is positioned in close facing relationship to the pad surface and agitates a liquid on the rotating pad surface at an appropriate frequency and sufficient amplitude to produce cavitation of the slurry in the vicinity of the pad surface. The action of cavitational collapse vigorously conditions the pad, driving out contaminants and re-texturizing the pad.
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TECHNICAL FIELD
The technical field of this invention is the control of motor vehicles and particularly the security of control of motor vehicle operation.
BACKGROUND OF THE INVENTION
The ability of an individual to operate a motor vehicle generally depends on that individual possessing a key which is mechanically cut in a predetermined pattern to activate the tumblers of an ignition lock apparatus to allow rotation of the lock cylinder from a locked position to one or more unlocked, operating positions. In the locked position, the engine and accessory related electrical circuits are disconnected from the vehicle electric power supply; and various safety and/or security related elements, such as a steering column lock and park lock solenoid, for example, are locked to prevent vehicle movement. In fact, United States motor vehicle regulations require most passenger vehicles to be manufactured including a key locking system which, when the key is removed, prevents normal activation of the vehicle engine and either steering or self-mobility of the vehicle.
Motor vehicles are also provided with door locks which are also unlocked by a key to provide vehicle access. Generally, this key has been a different key from that unlocking the ignition lock to allow vehicle operation; but in recent years there has been some movement toward a single key fitting both locks. In addition, so called "keyless entry" access systems are growing in popularity. In these systems, a numerical access code is stored in a transmitter and transmitted by electromagnetic signals to a receiver in the vehicle which extracts and validates the code with reference to its own stored information and unlocks the vehicle door locks for vehicle access without the use of the mechanical key, although the latter is also usually provided for choice or backup. Some of these systems require operator activation of an unlocking switch on the transmitter; but others are passive, in the sense that they require no operator switch activation but operate automatically when carried within close range of the vehicle. Some examples of these systems are shown in U.S. Pat. No. 5,319,364 to Waraksa et al, No. 5,157,389 to Kurozu et al, No. 4,973,958 to Hirano et al, No. 4,942,393 to Waraksa et al, No. 4,763,121 to Tomoda et al, No. 4,719,460 to Takeuchi et al, and No. 4,688,036 to Hirano et al.
In most keyless entry vehicles, once the operator gains access to the vehicle by a keyless entry transmitter, vehicle operation still requires use of a key, usually mechanical. However, a few such systems use the same key for enabling of vehicle engine operation. U.S. Pat. Nos. 5,157,389, 4,973958 and 4,719,460 cited above, for example, provide some references to vehicle ignition or starter enabling in response to an RF keyless entry. In addition, U.S. Pat. No. 4,143,368 to Route et al suggests that a coded infrared transmitter used for door unlocking in vehicle access might be placed in a receptacle in the vehicle as a substitute for an ignition key for unlocking the vehicle ignition and allowing engine starting and vehicle operation. However, none of these references provides any complete description of a system for so doing.
Given the popularity of these keyless entry systems for vehicles and the growing acceptance of a single key for vehicle access and operation, it would appear that there would be a market for a system which provided for vehicle operation by a coded transmitter, preferably the same used for vehicle access, with a simple, "push-button" start. Preferably, such a system would act in a passive manner, so that a vehicle operator would only have to approach the vehicle with a transmitter in a pocket or handbag, open the door which had unlocked automatically during the approach, enter the vehicle, activate a push-button or similar "keyless" start switch to activate an engine electric power circuit with an electronic lock which is unlocked automatically with the transmitter in the vehicle, and wait for several seconds as the system automatically started the engine, all without ever touching the transmitter. Even if vehicle entry or start were actively initiated, however, the starting of the engine would be automatically controlled and vehicle access and control would be automatically taken care of without a need for a standard ignition key.
Of less popularity, but certainly known in the art, are remote vehicle starting systems. These systems allow a vehicle owner or operator to start the engine of a vehicle and warm it up from a remote location before directly accessing the vehicle for entry. Examples of such systems are shown in the U.S. Pat. No. 5,349,931 to Gottlieb et al, No. 5,129,376 to Parmley, No. 5,000,139 to Wong, No. 4,901,690 to Cummins et al, No. 4,674, 454 to Phairr, No. 4,606,307 to Cook, No. 4,392,059 to Nespor, No. 4,345,554 to Hildreth et al, No. 4,236,594 to Ramsperger, No. 4,227,588 to Biancardi, No. 3,577,164 to Baratelli and No. 3,455,403 to Hawthorne. However, these systems do not appear to provide normal vehicle operation capabilities. Since they are designed for use when the legitimate operator of the vehicle is not physically present at or in the vehicle, limitation of allowed vehicle operational functions is important for vehicle security. They are confined to stationary vehicle warm-up; and the operator still must use a key in the usual ignition lock to have full operational use of the vehicle.
SUMMARY OF THE INVENTION
The invention is a motor vehicle comprising an engine, an electric engine power circuit, a start motor, and a vehicle body having a seating space therein associated with a driver seat. Detector means are provided for detecting the presence of a valid radio frequency transmitter only within the seating space by receiving a coded radio frequency signal therefrom, deriving a code from the radio frequency signal and validating the derived code in a predetermined validation process. The vehicle further comprises a RUN signal generator, a steering column lock, an engine speed signal generator and start control means responsive to activation of the RUN signal generator, provided that the detector means has detected the presence of a valid radio frequency transmitter within the seating space, to unlock the steering column lock, activate the engine electric power circuit and the start motor, repeatedly receive an engine speed signal from the engine speed signal generator and compare the received engine speed signal to a predetermined speed reference indicating engine starting. The start means deactivates the start motor when the engine speed signal exceeds the speed reference or, alternatively, deactivates the engine electric power circuit and the start motor and locks the column lock if the engine speed signal does not exceed the speed reference within a first predetermined time. Since the detector means are responsive to the transmitter only within the seating space and thus within the vehicle body, control of vehicle operation is more secure, especially for a system in which the transmitter is a passive transponder. Since the vehicle takes complete control of the vehicle starting process after generation of a RUN signal, it can be securely started with minimal driver involvement, which is also especially useful in a passive transponder system.
The vehicle of the invention preferably further comprises an accessory circuit, a driver door, an OFF signal generator, engine deactivation means responsive to activation of the OFF signal generating means during engine operation to deactivate the engine electric power circuit and activate the detector means, and accessory control means responsive to the engine deactivation means, if a valid transmitter is detected, to activate the accessory circuit for a predetermined time or until the driver door is opened, whichever occurs first, and suspend activation of the detector means for the duration of the activation of the accessory circuit. Thus, the vehicle may securely provide retained accessory power for a limited time after the engine is shut off.
The vehicle preferably further comprises a vehicle driveline component such as an automatic transmission having a condition wherein vehicle self-mobility is enabled and a condition such as PARK wherein vehicle self-mobility is not enabled, means for ending accessory circuit activation, lock determination means responsive to the means for ending accessory circuit activation and the vehicle driveline component for activating a key alarm if vehicle mobility is enabled and repeatedly activating the detector means while vehicle mobility is not enabled, and means responsive to the lock determination means, when a valid transmitter is not detected in the vehicle seating space, to lock the column lock and prevent further activation of the electric engine power circuit and the accessory circuit. Thus, when engine and accessory activation is ended, provided the vehicle is not capable of self-mobility, the detector is repeatedly activated to determine when the transmitter leaves the seating space and, when this occurs, locks the column lock and prevents reactivation of the engine and/or accessory. If the vehicle is capable of self-mobility, a key alarm is alternatively activated.
The vehicle may have a driver door and a vehicle access control effective to detect the transmitter outside the vehicle body and provide vehicle access by receiving a coded radio frequency signal therefrom, deriving a code from the radio frequency signal, validating the derived code in a predetermined validation process and unlocking the driver door. If so, the vehicle access control has a first antenna mounted on the vehicle body for communication with the transmitter outside the body; and the detector means has a second antenna associated with the driver seat, preferably under it, for communication with the transmitter only within the seating space. Thus, the vehicle of the invention may use a single transmitter for both secure vehicle operation and secure vehicle access by providing separate antennas, with the antenna for vehicle access capable of transmitter communication outside the vehicle and the antenna for secure vehicle operation capable of transmitter communication only within the seating space inside the vehicle body.
Preferably, the automatic transmission has park lock solenoid means effective when deactivated to prevent shifting out of the PARK mode and when activated to allow shifting out of the PARK mode; and the park lock solenoid means is also activated when the engine speed signal exceeds the speed reference and deactivated along with the engine electric power circuit.
The vehicle of the invention preferably stores a code datum in memory when the detector means detects the presence of a valid radio frequency transmitter within the seating space. The code datum is a key enabling activation of the engine electric power circuit and an accessory circuit activated when the engine speed signal exceeds the speed reference. The vehicle further comprises means for deactivating the engine electric power circuit and the accessory circuit and repeatedly activating the detector means while retaining the code datum in the memory, the means further being responsive to the detector means, when a valid radio frequency transmitter is no longer detected within the seating space and a vehicle driveline component is in a condition wherein vehicle self-mobility is not enabled, to remove the code datum from the memory and thus prevent activation of the engine electric power circuit and the accessory circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a motor vehicle with an operation control according to the invention.
FIG. 2A, 2B and 2C illustrate the placement and coverage area of an antenna for detecting a radio frequency transmitter in the seating space of a driver seat for use in the vehicle of FIG. 1.
FIG. 3, 4A, 4B, 5, 6A, 6B and 7 are flow charts illustrating the operation of the operation control for the vehicle of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a block and circuit diagram of an operation control for a vehicle having a body 55. A body computer 10 is provided with outputs I-0', I-1', SOL', I-3' and ACC', each of which is connected through a relay of a relay center 12 to independently connect or disconnect a similarly named output line (I-0, I-1, SOL, I-3 and ACC) and a source of DC electric power B+. These output lines provide electric power to different circuits of the vehicle. Line I-0 is used for park lock solenoid 18 and the PRNDL (automatic transmission indicator) system, not shown; line I-1 is used for an engine electric power circuit 2, as well as the fuel injection circuit, not shown, and engine computer 30; terminal I-3 is used for accessory circuits 6 such as HVAC (heater, ventilator and air conditioning) and power windows; terminal ACC is used for an accessory circuit 8 powering the radio; and terminal SOL is used for the start motor 4, which includes a start solenoid.
Body computer 10 further controls a key alarm 14 and an electric steering column lock 16. Key alarm 14 is an alarm, preferably audible, which is activated when the driver door is opened with the ignition key present in the ignition system, in a position wherein the vehicle may be started and operated. In vehicles of the prior art, such a condition is a familiar mechanical key left "in the ignition." In this system, which needs no mechanical key, the presence of a key "in the ignition" may be defined somewhat differently, as will be explained later in this description. The electric column lock 16 is an electrically activated device which, when locked, prevents the steering column from turning and thus effectively prevents the vehicle from being driven any significant distance. It may of the type described in U.S. Pat. No. 5,454,238, Anti-Theft Apparatus for Motor Vehicle Steering Column, issued Oct. 3, 1995. The park lock solenoid 18 must be activated to move an automatic transmission lever out of PARK to put the vehicle in a condition of self-mobility.
Body computer receives inputs from a park switch 20, a neutral (NEUT) switch 22, and a control input module 24 having operation control switches RUN, OFF and ACC, which may be activated by labeled push buttons on the steering column or dashboard of the vehicle. These switches comprise RUN, OFF and ACC signal generators, respectively. The park and neutral switches are part of vehicle driveline component, such as an automatic transmission, which controls vehicle self-mobility; and each switch indicates when an automatic transmission is in the corresponding condition. The operation control switches for RUN, OFF and ACC replace the rotationally chosen switches in the key operated ignition cylinder of a prior art vehicle in providing operator activation and deactivation of electric power for engine and accessories. Body computer 10 further receives an engine speed signal RPM from an engine computer 30 including an engine speed signal generator and is connected via a class II communication bus to engine computer 30 and a remote function activation (RFA) module 40.
RFA module 40 may be part of a passive vehicle access control in which a portable transmitter 50, which may be a transponder, is detected and interrogated by the RFA module, as it is carried up to the vehicle, through an antenna 45 comprising a multi-turn, looped wire which may be mounted vertically in the door of a vehicle having a door with a non-metallic outer skin. RFA module 40 determines the validity of an identification code stored in a memory within transmitter 50 according to any known validation process, but preferably through a public key encryption algorithm. If a valid code is determined, the RFA module unlocks the vehicle driver door to provide entry to the vehicle. The RFA module and transmitter may be of the type described in the U.S. Pat. No. 4,942,393 to Waraksa et al, issued Jul. 17, 1990.
The system of this invention, however, adds a second antenna 48, which may be similar to antenna 45 in form but is located within the vehicle, in a horizontally aligned position under the driver seat 60. The positioning and coverage of antenna 48 are visually indicated in FIG. 2A-2C. FIG. 2B shows a side view of a driver seat 60 having antenna 48 disposed in a horizontal configuration beneath it. FIG. 2C shows a back view of the same seat 60 and antenna 48 and, for reference, also shows the driver door 65 with antenna 45 vertically disposed therein. Antenna 48 is positioned and directed to detect signals from a radio frequency transmitter in a seating space defined by the space above and near driver seat 60 in which a transmitter carried by a vehicle driver would be located. This space is generally shown in FIG. 2A, which shows a view looking down from above on the relevant passenger space of vehicle body 55, with the front of the vehicle to the left. Driver seat 60 is shown with antenna 48 below it indicated by broken lines. Passenger seat 62 is shown above driver seat 60 in the figure but to the right of driver seat 60 from the perspective of the vehicle. The coverage area of antenna 48 is shown horizontally by broken line 70. This coverage area is a seating space which includes the driver seat itself as well as some space behind the driver seat back and at least part of the front passenger seat. Vertically, this seating space extends upward through the space normally occupied by passengers and downward to the vehicle floor 68, shown in FIG. 2B and 2C. Thus, RFA module with antenna 48 will detect a radio frequency transmitter carried by the vehicle operator in a clothing pocket when the operator is entering or seated in the vehicle driver seat and will further detect such a transmitter in a handbag or briefcase placed close to the driver seat, e.g. on part of the front passenger seat or on the floor directly behind the driver seat. However, antenna 48, along with its processing circuitry in RFA module 40, is designed with limited sensitivity so that it will not respond to radio frequency transmitters located outside the seating space as defined above, and particularly outside the vehicle. This is facilitated by the steel floor 68 of the vehicle chassis underneath antenna 48 and, for vehicles with a steel skin, the rest of the vehicle body itself.
Upon entry into the vehicle by a driver holding or carrying transmitter 50, the transmitter is sensed by the RFA through antenna 48. When this occurs, RFA module 40 again interrogates transmitter 50 for a valid code; and, if a valid code is detected, RFA module provides a signal on the Class II bus to body computer 10. This initiates the MAIN ROUTINE of body computer 10 with a wake-up at step 102 of the flow chart of FIG. 3. Since the Class II bus is a general purpose communication bus and body computer 10 may have additional functional routines, RFA module 40 provides an internally generated code to body computer 10 to indicate that a valid transmitter is within the seating space of the vehicle; and body computer 10 receives the code and compares it with one or more internal codes at 104. If no match is detected, body computer 10 goes back to sleep at 106. However, if a correct code is confirmed, the system sets its state as the OFF state at 108 and continues to BEGIN 110, a point reached from wake-up as described above and also as a return point from other parts of the program.
Body computer 10 also responds to the activation of the RUN, OFF or ACC switches in control input module 24. For example, activation of any of these switches may initiate an interrupt routine which sets a flag of the chosen switch. Thus, from BEGIN, the program always checks for a switch activation or other change of operational state and routes the program to the subroutine appropriate for the detected switch or state. The first check is for a RUN state at 112. If the RUN switch was pressed or the RUN state is selected, the START sequence is called at 114. Next, a RAP (Retain Accessory Power) state is checked at 116. There is no operator selectable switch for the RAP state; it is a system determined state in which accessory power is retained for some time after the OFF switch is activated to end normal engine operation. If the RAP state is selected, the system calls the RAP sequence at 118. Next, an ACC (Accessory) state is checked at 120. If the ACC button was pressed or the ACC state is selected, the system calls the ACC sequence at 122. If the routine reaches step 124, the OFF sequence is called.
FIG. 4A and 4B show the START sequence or subroutine in flow chart form. Since the main function of this sequence is the control of engine starting, a RUN flag is first checked at 130 of FIG. 4A. If it is set, the vehicle engine has been started and there is no need for the RUN sequence; therefore, the system proceeds directly to step 132, from which it returns to BEGIN. If the RUN flag is not set, the system checks the state of the park and neutral switches (20, 22) to determine if the vehicle transmission is in PARK or NEUTRAL at 134. If not, engine starting is not permitted; and the system selects the OFF state at 136 and returns to BEGIN from 138. If the transmission is found to be in PARK or NEUTRAL at 134, the system checks at 140 to see if the ECL (Electric Column Lock) is unlocked. If not, the system calls an UNLOCK COLUMN subroutine 142. If so, however, this subroutine is skipped. The system next outputs signals at 144 to turn on circuits I-1 and SOL. The former provides power to the vehicle ignition system, engine computer and fuel injection system for engine operation; and the latter provides power to the vehicle start solenoid and start motor to start engine cranking. The RUN state is selected at 146; and the vehicle engine speed signal RPM from engine computer 30 is read at 148.
Continuing with reference to FIG. 4B, the RPM signal is compared at 150 with a predetermined value indicative of engine start (e.g., 500 RPM); and, if it is less, a START TIMER is incremented at 152; and the timer value is checked at 154. If the timer value is greater than a predetermined value, such as 6 seconds, indicating start failure, circuits I-1 and SOL are turned off at 156, the ECL is locked at 158 and the OFF state is selected at 160 before the system proceeds to step 168 for return to BEGIN. If the timer has not yet timed out at 154, the system proceeds directly to step 168. If the RPM signal indicates engine start at step 150, the system turns off circuit SOL at 162, turns on circuits I-0, I-3 and ACC at 164 and sets the RUN flag at 166 before proceeding to step 168.
FIG. 5 shows the ACCESSORY sequence in flow chart form. This sequence is generally called when the vehicle operator has chosen accessory operation without engine operation by activating the ACC switch, since accessory power is automatically activated when the engine is started. An ACC flag is checked at 170; and, if it is set, the system proceeds directly to step 180, from which it returns to BEGIN. If it is not set, the ECL is checked at 172. If the column is not unlocked, the system proceeds to unlock it in a subroutine 174. If it is unlocked at 172, subroutine 174 is skipped. With the column unlocked, the ACC, I-0 and I-3 circuits are turned on at 176; and the ACC flag is then set at 178 before the system proceeds to step 180 for return to BEGIN. The I-0 circuit is turned on in order to activate the park lock solenoid so that the vehicle may be moved without engine starting, such as by pushing or towing.
FIG. 6A and 6B show the OFF sequence in flow chart form. The OFF state is entered when the OFF switch is activated but also when a valid transmitter is first detected in the seating space before either of the RUN or ACC switches is activated. The system first checks at 200 to see if either of the RUN or ACC flags is set, which would indicate that the engine or accessories are or have been in use. If either is set, the system then checks at 202 to see if the transmitter is present. If so, the RAP state is selected at 204 before returning to BEGIN from 206. If the transmitter is not present, the system turns off the I-0, I-1, I-3 and ACC circuits at 208 and then determines at 210 if the vehicle transmission is in PARK by checking the status of the park switch 20. If so, the system locks the column at 212 before going to sleep at 214. When the system goes to sleep, the code datum that indicated presence of a valid transmitter is erased in the process and is thus removed from the system. If the vehicle transmission is not in PARK, the system turns on the key alarm at 216 before returning to BEGIN from 218. In this case, the code datum indicating the presence of the transmitter is not yet erased, since that would result in effective removal of the key from the system with the transmission out of PARK.
If neither of the RUN or ACC flags is set at 200, the system checks to see if the vehicle transmission is in PARK at 222 of FIG. 6B. If it is not, the system turns off the I-0, I-1, I-3 and ACC circuits at 224 and turns on the key alarm at 226 before returning to BEGIN from 228. If the vehicle transmission is in PARK at 222, however, the system checks for the presence of a valid transmitter in the seating space at 230. If the transmitter is present at 230, the system returns to BEGIN from 232; otherwise, the system locks the ECL at 234 and goes to sleep at 236. Once again, sleep mode resulting from step 236 results in the code datum being erased from system memory; but this only occurs in the OFF state, with no valid transmitter detected and with the vehicle transmission in PARK.
FIG. 7 shows the RAP sequence in flow chart form. RAP stands for Retain Accessory Power; and the RAP state is used to maintain power to the vehicle accessory circuits through terminals I-3 and ACC for a period of time or until the driver door is opened after cessation of the RUN or ACC states. The system activates the I-3 and ACC terminals at 250, deactivates the I-1 and I-0 circuits at 252 and increments a RAP timer at 254. The RAP timer is compared with a predetermined time such as ten minutes at 256; and, if the time is not exceeded, the system checks for an open driver door at 258. If the driver door is not open, the system selects the RAP state at 260 and returns to BEGIN from 262. This path leads to repeat of the RAP sequence and will continue until the RAP timer times out or the driver door opens, whichever occurs first. If the RAP timer has timed out at 256 or if the driver door is open at 258, the system deactivates the I-3 and ACC circuits at 264, clears the RUN and ACC flags at 266, and selects the OFF mode at 268 before returning to BEGIN from 270. This path returns the control to the OFF sequence for the management of control shutdown.
It has been described how, as the vehicle operator approaches the vehicle with the transmitter in a pocket or handbag, the driver door of the vehicle is unlocked and, when the operator carries the transmitter into the seating space of the vehicle, the transmitter is detected and validated and a code datum is stored in the memory of body computer 10. Alternatively, the transmitter validation could be performed at the time when the operator selects either RUN or ACC modes by activating the appropriate switch. In the embodiment described, the code datum is actually a code generated by RFA module 40 after it validates the transmitter code and passed by the RFA module to body computer 10, which stores it in memory. However, the code datum could be a simple flag in the memory of body computer 10 or the transmitter code itself, depending on the details of programming, as long as the code of the transmitter, after detection of the transmitter in the seating space of the vehicle, is validated and, as a result of that validation, the memory of body computer 10 is altered in a way to indicate that validation. This code datum corresponds to a physical key and is required for vehicle engine and/or accessory operation. In order to save battery life in the transmitter, the latter is not ordinarily checked continuously, although it is rechecked at certain events as specified in the preceding description. However, when engine and accessory use is discontinued, the transmitter is checked on a repeated basis to determine when it is removed from the vehicle seating space. While the transmitter is still present, the code datum is retained in memory; and vehicle use is thus still enabled. When the transmitter is removed, assuming that the vehicle is in a self-mobility preventing condition, such as PARK of an automatic transmission, the code datum is removed from memory as the system goes to sleep; and this corresponds to a physical key being removed from the vehicle.
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A motor vehicle has a detector for detecting the presence of a valid radio frequency transmitter only within a seating space inside the vehicle. Start control circuitry is responsive to a RUN signal, provided that the detector has detected the presence of a valid radio frequency transmitter within the seating space, to unlock a steering column lock, activate an engine electric power circuit and a start motor, repeatedly receive an engine speed signal from the engine speed signal generator and compare the received engine speed signal to a predetermined speed reference indicating engine starting. The start motor is deactivated and a park lock solenoid is activated when the engine speed signal exceeds the speed reference. Alternatively, the engine electric power circuit and start motor are deactivated and the column lock is locked if the engine speed signal does not exceed the speed reference within a first predetermined time. Engine deactivation occurs responsive to an OFF signal during engine operation to deactivate the engine electric power circuit and activate the detector; and an accessory control is responsive to engine deactivation, if a valid transmitter is detected, to activate the accessory circuit for a predetermined time or until the driver door is opened, whichever occurs first, and suspend activation of the detector for the duration of the activation of the accessory circuit. A vehicle access control may be responsive to the same transmitter by way of a first antenna mounted on the vehicle body for communication with the transmitter outside the body while the detector has a second antenna associated with the driver seat for communication with the transmitter only within the seating space.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/347,684, filed May 24, 2010, the entirety of which is incorporated herein.
FIELD OF THE INVENTION
[0002] This invention is directed generally to fluid filters, and more particularly to fluid filters, having replaceable filter cartridges.
BACKGROUND
[0003] There exists numerous conventional fluid filters for removing contaminants from liquids, such as shown in U.S. Pat. Nos. 3,720,322 and 4,187,179. One particular style of fluid filter, such as those used in drinking water and swimming pool filtration systems, includes a generally cylindrical tank housing with removable cartridge filters, as shown in U.S. Pat. Nos. 4,561,979 and 5,316,677. The cartridge filters are formed from a filter media positioned between bottom and top plates. Fluids are filtered by directing the fluids into the tank, passing the fluids through the filter media, and expelling the filtered fluids through an outlet tube in the cartridge filter.
[0004] Tanks typically have one or more filter cartridges positioned therein. Often times, filter cartridges receive unequal usage and unequal amounts of kinetic energy and dirt loading. Typically, cartridges within a filter system are replaced at the same time. Replacing cartridges having unequal usage inevitably means that cartridges are replaced with unused cleaning capacity. Typically, the kinetic energy of the water flow is not equally distributed throughout the filter cartridge, and thus the filter cartridge receives unequal amounts of wear and tear. Thus, a more efficient filter system is needed.
SUMMARY OF THE INVENTION
[0005] This invention relates to a fluid filter system that is configured to filter materials from a fluid passing through a filter cartridge. The fluid filter system may be formed to filter materials from a fluid, such as, but not limited to, water. The fluid filter system may be formed from an enclosed housing having an inlet and an outlet, wherein the enclosed housing may be formed from a generally cylindrical tube with a base at one end and a lid at the opposite end. The fluid flow enters one or more filter cartridges positioned in the fluid flow between the inlet and the outlet. The fluid flow enters the housing tangentially, and the kinetic energy is disbursed into rotational flow. This flow rotates around the outer chamber of the housing and then cascades into the inner chamber. The configuration of the system equalizes the fluid flow path of resistance. The filter cartridges are arranged in an involute design where a smooth ever changing curve transfers the kinetic energy of the rotational flow of water at a continuously changing angle, at a continuously changing velocity, and continuously at an ever decreasing amount of kinetic energy. The fluids can flow through the central cartridge elements as easily as the perimeter cartridge elements.
[0006] The fluid filter system may include the enclosed housing formed from a cylindrical tube with a base at one end and a lid at the other opposite end, at least one inlet and at least one outlet and is defined by a longitudinal axis extending from the base to the lid. The inlet may be positioned nonorthogonally in the housing so that fluid entering the housing through the inlet flows in a rotational direction in the housing. A plurality of filter cartridges may be positioned in the enclosed housing such that the cartridges separate the inlet and the outlet such that fluids must flow through at least one filter cartridge when passing from the inlet to the outlet. The plurality of filter cartridges may form at least one involute curved line of filter cartridges extending radially outward from the longitudinal axis toward an inner surface of a side wall forming the enclosed housing such that at least one channel exists between adjacent portions of the at least one involute curved line of filter cartridges. The enclosed housing may include an inner wall offset from the side wall forming the enclosed housing. The inner wall may define an inner chamber and may form an inlet chamber between the enclosed housing side wall and the inner wall for receiving fluids. The inlet chamber may be concentric with the inner chamber housing the plurality of filter cartridges.
[0007] The fluid filter system may include a plurality of filter cartridges positioned to form one or more involute curved lines extending radially outward from a longitudinal axis in a spiral configuration. In one embodiment, the plurality of filter cartridges may form a single involute curved line extending radially outward from the longitudinal axis in a spiral configuration. In another embodiment, the plurality of filter cartridges may form two involute curved lines extending radially outward from the longitudinal axis in a spiral configuration such that the two involute curved lines are meshed together with at least one channel positioned between adjacent portions of the two involute curved lines. In yet another embodiment, the plurality of filter cartridges may form three involute curved lines extending radially outward from the longitudinal axis in a spiral configuration such that the three involute curved lines are meshed together with at least one channel positioned between adjacent portions of two involute curved lines of primary filter cartridges.
[0008] In another embodiment, the plurality of filter cartridges may form four involute curved lines of primary filter cartridges extending radially outward from the longitudinal axis in a spiral configuration such that the four involute curved lines of primary filter cartridges are meshed together with at least one channel positioned between adjacent portions of two involute curved lines of primary filter cartridges. The fluid filter system may include at least one cartridge positioned at and aligned with the longitudinal axis, wherein each of the four involute curved lines of primary filter cartridges may terminate near the longitudinal axis such that a portion of each of the four involute curved lines of primary filter cartridges is generally tangential to the at least one cartridge positioned at and aligned with the longitudinal axis.
[0009] In another embodiment, the fluid filter system may also include one or more involute curved lines of secondary filter cartridges extending radially outward and positioned in a channel between two of the four involute curved lines of primary filter cartridges. One or more secondary filter cartridges may be positioned in each channel between adjacent involute curved lines of primary filter cartridges. Each of the at least one involute curved line of filter cartridges may extend radially outward from a filter cartridge positioned along the longitudinal axis of the fluid filter system. At least two adjacent filter cartridges of the plurality of filter cartridges forming an involute curved line of filter cartridges may be in contact with each other in the at least one involute curved line of filter cartridges. In another embodiment, each filter cartridge of the plurality of filter cartridges may be in contact with adjacent filter cartridges in the at least one involute curved line of filter cartridges. Each of the involute curved line of filter cartridges may comprise a curved filter cartridge axis that is curved along its entire length.
[0010] The enclosed housing may include an inner wall offset from the housing that defines an inner chamber and forms ah inlet chamber between the enclosed housing and the inner wall for receiving fluids. The inlet chamber may be concentric with an inner chamber housing the plurality of filter cartridges. The fluid filter system may include an inlet into the inner chamber near an upper lid of the enclosed housing. In another embodiment, the fluid filter system may include an inlet into the inner chamber between an upper lid of the enclosed housing and the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
[0012] FIG. 1 is a perspective view of a filter system having aspects of this invention.
[0013] FIG. 2 is a top view of the filter system shown in FIG. 1 with the lid removed and displaying a singular involute of the filter cartridges.
[0014] FIG. 3 is a top view of the filter system shown in FIG. 1 with the lid removed and displaying dual involutes of the filter cartridges.
[0015] FIG. 4 is a top view of the filter system shown in FIG. 1 with the lid removed and displaying an octagonal involute configuration of the filter cartridges.
[0016] FIG. 5 is a top view of the filter system shown in FIG. 1 with the lid removed and displaying a staggered involute configuration of the filter cartridges.
[0017] FIG. 6 is a top view of the filter system shown in FIG. 1 with the lid removed and displaying a quad involute configuration of the filter cartridges.
DETAILED DESCRIPTION OF THE INVENTION
[0018] As shown in FIGS. 1-6 , this invention encompasses improvements of kinetic energy distribution of the liquids being filtered. The invention is directed to a fluid filter system 10 that is configured to filter materials from a fluid passing through a filter 12 . The fluid filter system 10 may be formed to filter materials from a fluid, such as, but not limited to, water. The fluid filter system 10 may be formed from an enclosed housing 14 having an inlet 16 and an outlet 18 and a plurality of filter cartridges 20 positioned in the fluid flow between the inlet 16 and the outlet 18 . The filter cartridges 20 may have an involute configuration and may be a removable. The filter cartridges 20 may be generally elongated, cylindrical, pleated cartridges, extruded cartridges, melt blown cartridges, molded cartridges or other appropriate cartridges, and any combination thereof. The filter cartridges 20 may have any appropriate height. In at least one embodiment, the filter cartridges 20 may be, but are not limited to being, about one foot and about six feet in length.
[0019] As shown in FIG. 1 , the housing 14 may be formed from an outer wall 22 , a base 30 and a removable lid 32 . The housing 14 may also include an inner wall 24 offset from the outer wall 22 forming the housing 14 such that the inner wall 24 forms an inlet chamber 26 for receiving fluids. The inlet chamber 26 may be concentric with an inner chamber 28 housing the involute configuration of a plurality of filler cartridges 20 . In other embodiments, the inner chamber 28 may be offset from the inlet chamber 26 . In one embodiment, both the inlet and inner chambers 26 , 28 may be generally cylindrical and, in at least one embodiment, may be formed from cylindrical tubes. In other embodiments, the inlet and inner chambers 26 , 28 may have other appropriate configurations.
[0020] The housing 14 may include an inlet 34 near the lid 32 of the enclosed housing 14 to allow fluids into the inner chamber 28 . As shown in FIG. 2 , the inlet 16 in the housing 14 may be positioned so that fluid entering the housing 14 through the inlet 16 flows in a rotational direction in the housing 14 . In particular, the inlet 16 may be positioned nonorthogonally relative to the housing 14 . In at least one embodiment, the inlet 16 may be positioned tangentially relative to the housing 14 , as shown in FIG. 1 . Thus, the fluid flowing in the inlet chamber 26 may flow generally rotationally about a longitudinal axis 36 extending from the base 30 of the housing 14 . The inlet 34 into the inner chamber 28 from the inlet chamber 26 may be a gap between an upper edge 40 of the inner wall 24 and the removable lid 32 . The fluids flowing from the inlet chamber 26 into the inner chamber 28 keep the rotational motion as the fluids flow into the inner chamber 28 . In another embodiment, the inlet 34 into the inner chamber 28 may be one or more holes in the inner wall 24 . The holes in the inner wall 24 may be positioned in any location between the base and the upper edge 40 .
[0021] The inner chamber 28 houses a plurality of filter cartridges 20 that are configured to enable fluids to flow radially inward to the center of the housing 14 at the longitudinal axis 36 . The plurality of filter cartridges 20 may be positioned in the enclosed housing 14 such that the cartridges fluidly separate the inlet 16 and the outlet 18 . The plurality of filter cartridges 20 may form one or more involute curved lines 42 of filters cartridges 20 extending radially outward from the longitudinal axis 36 such that one or more channels 44 exists between adjacent portions of the one or more curved lines 42 of filters cartridges 20 . The filter cartridges 20 may form a single curved line 42 extending radially outward from the longitudinal axis 36 in a spiral configuration, as shown in FIG. 2 . The plurality of filter cartridges 20 , as shown in FIG. 3 , may form two curved lines 46 , 48 extending radially outward from the longitudinal axis 36 in a spiral configuration such that the two curved lines 46 , 48 are meshed together with one or more channels 44 positioned between adjacent portions of the two curved lines 46 , 48 . The two curved lines 46 , 48 shown in FIG. 3 may start at the center of the inner chamber 28 and may terminate at opposite sides from each other. The fluid filter system 10 may include other numbers of curved lines 42 , such as, but not limited to, three, four and eight curved lines of cartridge filters 20 . In one embodiment, as shown in FIG. 4 , each of the curved lines of cartridge filters 42 extends radially outward from a cartridge filter 50 positioned along the longitudinal axis 36 of the fluid filter system 10 .
[0022] As shown in FIG. 5 , the plurality of filter cartridges 20 that form four curved lines of primary filter cartridges 52 may extend radially outward from the longitudinal axis 36 in a spiral configuration such that the four curved lines of primary filter cartridges 52 are meshed together with channels 44 positioned between adjacent portions of two curved lines of primary filter cartridges 52 . One or more filter cartridges 50 may be positioned at and aligned with the longitudinal axis 36 . Each of the four curved lines of primary filter cartridges 52 may terminate near the longitudinal axis 36 such that a portion of each of the four curved lines of primary filler cartridges 52 is generally tangential to the one or more cartridges 50 positioned at and aligned with the longitudinal axis 36 . One or more curved line of secondary filter cartridges 54 may extend radially outward and be positioned in a channel 44 between two of the four curved lines of primary filter cartridges 52 . A secondary filter cartridge 54 may be positioned in each channel 44 between adjacent curved lines 52 of primary filter cartridges 52 .
[0023] As shown in FIGS. 1-6 , at least two adjacent filter cartridges 20 of the plurality of filter cartridges may be in contact with each other in the curved line of filter cartridges 42 . In another embodiment, as shown in FIGS. 2 , 3 , and 6 , each filter cartridge 20 of the plurality of filter cartridges 20 may be in contact with adjacent filter cartridges 20 in the curved line of filter cartridges 42 . Each of the curved line of filter cartridges 42 may have a curved filter cartridge axis that is curved along its entire length.
[0024] During use, fluid enters the housing 14 through the inlet 16 and flows in a rotational direction in the housing 14 . The fluid flowing in the inlet chamber 26 may flow generally rotationally about the longitudinal axis 36 extending from the base 30 of the housing 14 . After the inlet chamber 26 is filled, fluid may flow through the inlet 34 into the inner chamber 28 from the inlet chamber 26 . The fluids flowing from the inlet chamber 26 into the inner chamber 28 keep the rotational motion as the fluids flow into the inner chamber 28 . The fluids flow into the channels 44 between the adjacent curved lines 42 , 46 , 48 , 52 and 54 of filter cartridges 20 . As a result, the usage load on the filter cartridges 20 is evenly balanced between the outermost filter cartridges 20 and the innermost filter cartridges 20 . Thus, the filter cartridges 20 may be replaced at the same time without sacrificing unused portions of the filter cartridges 20 .
[0025] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.
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A fluid filter system including a filter housing having an inlet chamber that surrounds the inner chamber that houses the filter cartridges. The filter cartridges are positioned in an involute configuration to channel rotationally inward flow of the fluid as it loses kinetic energy and velocity. The configuration provides superior filtering of fluids flowing therethrough and provides superior filter life.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation application which is based upon and claims priority from prior and claims priority from prior U.S. Pat. Ser. No. 12/338,275, filed on Dec. 18, 2008, now U.S. Pat. No. 7,795,044, which is a continuation application of U.S. Pat. Ser. No. 11/926,031, filed on Oct. 28, 2007, now U.S. Pat. No. 7,514,327, which is a divisional of prior U.S. patent Ser. No. 11/117,276, filed on Apr. 27, 2005, now U.S. Pat. No. 7,352,029, each of the aforementioned patent applications is herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
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
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.
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.
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.
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.
The need for such a multiplexing device has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
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.
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.
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.
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.
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.
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
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:
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;
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;
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;
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;
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;
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;
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;
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;
FIG. 7A is a schematic illustration of a further embodiment of the multiplexing device of FIG. 7 , showing alternative embodiments of the discrete regions;
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;
FIG. 9 is a block diagram illustrating a serial connectivity of a plurality of multiplexing devices of the previous figures;
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;
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;
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;
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);
FIG. 14 is a schematic illustration of another embodiment of the multiplexing device of FIG. 7A , showing alternative embodiments of the intermediate regions;
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 ;
FIG. 16 is an isometric, schematic illustration of the multiplexing device of FIG. 14 , rotated about its side; and
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
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 .
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 .
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.
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.
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.
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.
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.
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.
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.
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., w1, w2) of the depletion regions 108 , 112 is determined by the following equation:
w =(2) 1/2 λ n ( v l ) 1/2
where λ n is the extrinsic Debye length of the conducting channel 110 ; v l 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.
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 .
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 .
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 ).
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 .
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.
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 .
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 .
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).
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 .
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 .
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.
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.
While FIG. 6 illustrates only four control gates 502 - 505 , it should be clear that more than four gates can alternatively be used.
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 .
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 .
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.
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 .
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 .
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.
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.
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.
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.
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.
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 .
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 ).
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.
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 .
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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 .
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 .
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 .
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 .
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.
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 .
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 ).
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.
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.
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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.
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RELATED APPLICATIONS
This application claims the priority of U.S. Provisional Application No. 60/988,065, filed Nov. 14, 2007, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to lighting fixtures for landscape and environmental lighting applications and, more particularly, to devices for securing lighting fixtures at or near the ground
BACKGROUND
Outdoor lighting fixtures have been widely adopted for illuminating buildings, gardens, pathways, and entrance ways as the nighttime play of light on the landscape and vegetation can aesthetically pleasing as well as providing sufficient light for safely navigating an otherwise dark walkway. Additionally, such lighting provides enhanced security by eliminating hiding places and unobserved entry points for intruders. The most widely used outdoor lighting systems include one or more low voltage lighting fixtures that are connected to a 12 V transformer that is, in turn, connected to a standard 120 VAC line. Other types of lighting that are gaining popularity are solar powered, where the fixtures are connected by a cable to a solar collector panel that is located at a sunny location during daylight hours. Each lighting fixture generally includes housing, a lamp assembly having a halogen or conventional incandescent bulb and a reflector, and a lens or window. Many configurations are known for providing a variety of different lighting effects.
Many outdoor lighting fixtures that are intended to be located at or slightly above ground level are provided with spikes that can be driven into the ground to provide an inexpensive and stable base for supporting the light. Electrical cables, typically containing copper wire, are employed to supply current to the fixtures. Cables that are placed away from a structure or pavement are preferably buried at a shallow depth, or they may lie directly on the ground. Connection of the fixture to the cable typically involves cutting the cable, stripping the cable insulation a short distance from the cut ends, and twisting together the ends of one wire from the fixture and one conductor from the cable within a twist-on wire connector for both sets of wires. Because this connection is vulnerable to moisture, dirt and/or corrosion that can cause the connection to fail, a recommended practice is to enclose the wire ends and wire connectors in a small plastic bag which can be sealed with a potting material (splice gel) to create a permanent watertight seal. The upper edges of the plastic bag can optionally be sealed around the wires above the junction with electrical tape, a rubber band or a cable tie. Because this seal is permanent, replacement of the fixture, or splicing of additional cables, requires that the existing wires be cut and new connections created. Therefore, it is important to make sure there are excess lengths of conductors to allow the new connections to be made. The extra cable length can lead to an additional point of vulnerability because it might extend away from the spike, making it vulnerable to damage by someone digging near the spike, for example, replacing plants, where the extended sections of wire would be.
Another problem encountered by currently existing methods is that a failure in the outdoor lighting fixture can be difficult to diagnose. In most cases where the failure is an incomplete connection, it can be difficult to pinpoint where the wires are actually connected to identify a potentially defective junction. If the connection at a particular fixture is suspected, it may be necessary to remove the spike from the ground and dig a radius around the spike's location because the excess cable may have caused the junction to be offset several inches from the spike.
Accordingly, there is a need for a device and method to facilitate creation of the connection and for providing protection of the junction to ensure the integrity of the connection. The present invention is directed to such an invention.
SUMMARY OF THE INVENTION
It is an advantage of the present invention to provide a ground spike for supporting a light fixture that has a built-in junction box for protecting the connection and excess cable and keeping them clean.
It is another advantage of the invention to provide a ground spike that allows the connection to be easily viewed to visually check the integrity of the connection.
Still another advantage of the invention is provide ready access to the connection for testing and replacement of fixtures or cables.
In an exemplary embodiment, the present invention comprises a spike for outdoor lighting fixture that includes a receptacle portion integrated into the body of the spike with an open section and a removable transparent window that is configured to enclose the receptacle portion. The transparent window is attached to the receptacle portion using one or more screws or other fasteners. An O-ring seat may be formed along either the edges of the receptacle or the perimeter of the window to retain an O-ring or resilient seal that produces a substantially watertight seal when the window is fastened to the receptacle portion. The spike can include an internally threaded upper portion for receiving a post upon which a lighting fixture is mounted and/or a lamp socket can be attached to the top of the spike and a protective housing fitted around the outer edges of the top of the spike. In a preferred embodiment, the receptacle portion is divided into multiple compartments, e.g., for storing excess cable or spare parts for the fixture, such as extra twist-on wire connectors or lamps, or for securing connection points of a wiring installation. The transparent window that seals the receptacle portion permits visual examination of the connection within the receptacle without removing the transparent window. The receptacle portion includes at least one slot through which the cable connected to a power supply is fed into the spike. If the lighting fixture is powered by batteries, for example, batteries recharged by a solar panel, the batteries and battery connections may be retained within the receptacle portion.
The spike is typically installed in an outdoor location by forcing it into the ground if the ground is sufficiently soft to do so without damaging the spike. In harder ground, a pilot hole can be dug with an auger or pick. Penetration of the ground is facilitated by the pointed end of the spike. Stability of the spike is enhanced by a barb at the bottom portion of the spike. In the preferred embodiment, for further stability the barb is formed from three parallel triangles which form a main central barb with two smaller triangles on either side of the center to form additional barbs.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more clearly understood from the following detailed description of the preferred embodiments of the invention and from the attached drawings, in which:
FIG. 1 is a perspective view of an embodiment of the spike according to the present invention.
FIG. 2 is a perspective view of a first exemplary lighting fixture mounted on the spike.
FIG. 3 is a perspective view of a second exemplary lighting fixture mounted on the spike.
FIG. 4 is an exploded perspective view of the spike according to the present invention.
FIG. 5 is a top view of the spike according to the present invention.
FIG. 6 is a front elevation of a third exemplary lighting fixture incorporating the spike.
DETAILED DESCRIPTION
The following description sets forth numerous specific details such as examples of specific systems and components, and so forth, in order to provide a good understanding of several embodiments of the present invention. It will be apparent to one skilled in the art, however, that at least some embodiments of the present invention may be practiced without these specific details. In other instances, well-known components or methods are not described in detail in order to avoid unnecessarily obscuring the present invention. Thus, the specific details set forth are merely exemplary. Particular implementations may vary from these exemplary details and still be contemplated to be within the spirit and scope of the present invention.
FIG. 1 is a perspective view of an embodiment of the spike 1000 for outdoor lighting fixtures, which includes a receptacle portion 1001 with a transparent window 1002 , an upper portion 1003 for supporting the fixture, and a lower portion 1009 which facilitates placement and enhances stability when installed. The spike 1000 provides a base for secure anchorage of a lighting fixture, examples of which are shown as 2001 and 3001 in FIG. 2 and FIG. 3 , respectively, and described more fully below.
The opening of the receptacle portion 1001 is enclosed by a transparent window 1002 forming at least one compartment in the body of the spike 1000 . The transparent window 1002 is removably attached to the receptacle portion 1001 by a screw 1004 to provide a seal resulting in a compartment in the receptacle portion 1001 that is well protected against mechanical damage and largely resistant to contaminant intrusion. An optional O-ring seat may be formed along either the edges of the receptacle opening or the perimeter of the window 1002 to retain an O-ring or resilient seal that produces a substantially watertight seal when the window is fastened to the receptacle portion. More than one screw, or alternative types of fasteners may also be used. The receptacle portion 1001 can be divided into multiple compartments for storing different materials.
FIG. 4 provides a more detailed view of the receptacle portion 1001 of an exemplary embodiment of the inventive spike. In the exemplary embodiment, the interior cavity of receptacle portion 1001 is partitioned into multiple compartments to enhance storage capability. As illustrated, compartments 4001 , 4002 and 4003 are defined by dividers 4004 and 4005 . In this configuration, compartment 4001 can be used to hold coiled excess wire (sometimes referred to as the “service coil”) and to provide a feed-through opening 4020 (seen in FIG. 5 ) at its top for connection to the fixture, while the wire connectors 4012 and 4013 and their corresponding conductors are retained within compartments 4002 and 4003 , respectively. The three compartments are exemplary only, and other configurations may be used. For example, for a solar fixture, the rechargeable batteries that store the voltage produced by the solar collector can be stored in a single compartment or one of multiple compartments.
Boss 4006 located at the lower end of divider 4005 has an internally threaded bore for receiving screw 1004 for firm attachment of transparent window 1002 . While only one attachment point is shown, it will be recognized that two or more threaded bores may be provided, each for receiving a screw or other fastener for secure attachment of the window 1002 . Located at the lower portion of the interior cavity is a pair of slots 4007 and 4008 through which conductors 1006 are fed into the interior. Generally, multiple slots positioned on opposite sides of the cavity are preferred since the conductors often enter from opposite directions, however, a single, larger slot can be used to insert both wires. The positioning of the slots 4007 , 4008 may also be moved to a position higher on the sides of the receptacle portion, or multiple pairs of punch outs may be provided through the sidewall of the cavity to allow the installer to choose the most appropriate entry points for the particular installation.
As shown in FIG. 4 , the transparent window 1002 has a tab 4014 extending from its upper edge which is inserted into a corresponding slot (not shown) in the plate 4015 that defines the top of receptacle portion 1001 and bottom of top portion 1003 . (Feed-through opening 4020 is located at the center of plate 4015 .) Referring to FIG. 5 , the profile of tab 4014 can be seen as having a curved face that corresponds to the inner curvature of top portion 1003 . Tab 4014 extends though plate 4015 to firmly seat the upper part of window 1002 against receptacle portion 1001 . Screw 1004 is then inserted through reinforced bore 4010 through the window 1002 and screwed into the threaded bore in boss 4006 . Tabs 4019 project from the bottom of window 1002 at positions corresponding to slots 4007 and 4008 to further secure conductors 1006 as they exit from the interior cavity. While the slots 4007 and 4008 are not fully sealed, attachment of the window 1002 to receptacle portion 1001 produces a seal that will exclude most contaminants. To produce a substantially water resistant seal, O-rings or other washers may be fitted over the conductors 1006 at the entry point so that they are compressed against the edges of the slots 4007 , 4008 .
The transparent window 1002 , formed from a hard, impact resistant plastic or polymer, such as clear polycarbonate, permits visual inspection allowing the installer to determine if a faulty connection point exists within the receptacle portion 1001 of the spike 1000 without removing the transparent window.
The upper portion 1003 of the spike can include a concentric threaded bore 1007 , which corresponds to feed-through opening 4020 , configured to receive a threaded post 2002 for supporting a lighting fixture, such as the path light 2003 illustrated in FIG. 2 . Typically, the threads in bore 1007 will be ½ NPS threads. Conductors for providing voltage to a lamp socket mounted at the top of the post 2002 are fed through feed-through opening 4020 and up through the post. Thus, all connections for the fixture other than the connection to the socket itself are securely contained within the receptacle portion 1001 . In this application, the spike 1000 will generally be inserted into the ground so that its top edge is approximately flush with the ground level.
In another application, the spike 1000 can be used in conjunction with a spot light fixture such as fixture 3001 illustrated in FIG. 3 . For this usage, the exterior surface of upper portion 1003 has one or more annular O-ring seats 1008 for retaining an O-ring (shown in FIG. 6 as 6005 ). In the preferred embodiment, at least two O-rings 6005 are used to produce a watertight seal between the spike and the fixture in a manner similar to that described in U.S. Pat. No. 6,874,905, which is incorporated herein by reference. Fixture 3001 is mounted on a knuckle joint 3003 which has a base portion 3002 that is a hollow cap having an interior dimension that closely fits over upper portion 1003 so that the inner surface of the base 3002 , slightly compresses the O-ring(s) that are retained within O-ring seat(s) 1008 . The interference fit created by this compression of the O-ring holds the base 3002 over the top of the spike, but for additional security, a locking screw 3004 may be provided which, when engaged, presses against the outer surface of the top portion 1003 . In this configuration, it may be desirable to install the spike so that it protrudes above the ground level, so that the base 3002 is above ground level.
In the embodiment illustrated in FIG. 6 , the spike itself can be the lighting fixture by attaching a socket mounting bracket 6001 directly to the top portion 1003 . The bracket can be a simple Z-shaped aluminum bracket that is attached via a screw 6002 inserted into one of threaded bores 4017 shown in FIGS. 4 and 5 . Socket 6004 is affixed atop bracket 6001 with conductors 6003 extending down through the feed-through into the interior cavity of receptacle portion 1003 . A closed-top cylindrical diffuser (not shown) or other protective cover has interior dimensions to fit closely over the outer diameter of top portion 1003 in a similar manner to base 3002 in the embodiment of FIG. 3 . The O-ring(s) 6005 provide a water-tight seal to enclose the socket and lamp (not shown) when the cover is put in place. This type of application can be used for lighting very close to the ground. It may even be desirable to plunge the spike to a depth greater than its length, so that a portion of the cover is also below ground level to provide small “dots” of light within landscaping, for example, for subtle marking of a path across a lawn.
The body of the spike consisting of receptacle portion 1001 , the top portion 1003 and the bottom portion 1009 of the spike 1000 are typically injection molded. In particular the receptacle, upper and bottom portions can be formed of high density, high impact plastic or similar material. In the preferred embodiment, Acrylonitrile Butadiene Styrene (ABS), a heat resistant, high impact resistant plastic resin is used.
The spike 1000 is installed in an outdoor location by forcing the spike 1000 into the ground. This process is enhanced by a bottom portion 1009 of the spike 1000 that is configured for initial ground penetration using pointed tip 1010 . The shaft 1011 has a ribbed construction with longitudinal ribs 1013 and 1017 extending radially from the primary axis of the shaft. The ribs add strength to the spike as well as assisting in penetration into the ground. Ribs 1017 , extending to the sides (as viewed from the front), terminate in a barb 1012 . Rib 1013 on the front of the spike and its counterpart on the back terminate in barb 1014 , which is perpendicular to and bisects barb 1012 . Additional strength and stability are provided by two smaller barbs 1016 positioned on opposite sides of barb 1014 . It will be readily apparent that different numbers of ribs may be used, with the ribs preferably being in pairs so that each opposing pair with terminate in a barb.
Near the upper portion of front rib 1013 , an additional barb 1015 serves to reduce any resistance that might be encountered during installation by effectively adding a taper to the lower front of the receptacle portion. Barb 1015 also acts to protect the conductors 1006 at the point that they enter the receptacle portion 1001 to reduce pressure on a potentially vulnerable portion of the conductors as the spike is inserted into the ground. The lower back side of the receptacle portion 1001 has a taper 1018 to further facilitate insertion into the ground.
The foregoing description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly limited by nothing other than the appended claims.
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A spike for outdoor lighting fixture includes a receptacle portion integrated into the body of the spike with an open section and a removable transparent window that is configured to enclose the receptacle portion. The transparent window is attached to the receptacle portion using one or more screws or other fasteners. The spike can include an internally threaded upper portion for receiving a post upon which a lighting fixture is mounted and/or a lamp socket can be attached to the top of the spike and a protective housing fitted around the outer edges of the top of the spike. In a preferred embodiment, the receptacle portion is divided into multiple compartments, e.g., for storing excess cable or spare parts, or for securing connection points of a wiring installation. The transparent window permits visual examination of the connection within the receptacle without removing the transparent window.
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The invention relates to a method and a device for the determination of a vertical acceleration of a wheel of a vehicle for the use in vehicle dynamics control or monitoring, which can be operated in a cost-saving manner, in particular by means of the sensory detection of only a few auxiliary quantities.
Many modern vehicle control systems and vehicle monitoring systems, respectively, which influence or monitor the horizontal or vertical vehicle dynamics, require among others the dynamic normal wheel forces as input quantities. The normal forces are those forces that act upon the wheels through the tire print on the road surface. The dynamic normal wheel forces, however, can only be determined with a significant expenditure, which is the reason for currently making simplifications in applications. However, by this means, the control quality of the control systems is significantly compromised.
Several methods for the determination of the dynamic normal wheel forces are known. In order to determine the dynamic normal forces of the wheel during driving operation, direct measuring methods with multiple-component measuring hubs (see e.g. SAE 980262 “Evaluation of Different Designs of Wheel Force Transducers”) are ruled out due to the high costs for these sensors. In indirect methods, auxiliary quantities are measured, from which the dynamic normal wheel forces can be computed. For the production suitability of these methods, therefore, the expenditure for detection of these auxiliary quantities is crucial. The Braunschweig method, the Munich method, and the tire-inside-pressure method use the tire as a measuring spring, wherein the dynamic normal wheel force is computed via a characteristic curve from the vertical tire spring compression, the lateral tire expansion, or the tire inside pressure, respectively (see e.g. Gersbach et al.: “Comparison of Procedure to the Measurement of Wheel Load Variations, ATZ Periodical Technical Automobile 80, 1978; Bode: “Comparison more Differently Proceed to the Determination of the Dynamic Wheels Load”, German on the Basis of Research Goes and Strove Associate Technology, No. 131, VDI-publishing house, 1959). The measurement of these quantities and the necessary telemetry are very elaborate. Additionally, the required characteristical tire curves are subject to great variations. The Hanover method (Bode, noted above) and the Darmstadt method (Svenson: Investigations of the dynamic krafte between wheel and street and its effects on the stress of the street, No. 130, VDI-publishing house, 1959) use expansion measuring strips in order to make conclusions on the dynamic normal wheel force through the expansion of the axle body or the hub bed, respectively. A method based on expansion strips is not suitable for production, either, due to the high cost and the elaborate calibration.
Significantly more common are, due to their comparably easily measurable auxiliary quantities, the Aachen method (Kotitschke: The dynamic wheels weight of motor vehicles; its measurement and its influential factors, RWTH Aachen, 1957) and the intersecting-forces method (Tiemann: “Investigations to the brake behavior of automobile with ABS on uneven street under special consideration of the influence of the oscillation mute, progress-reports VDI Row 12 nr.s 204, VDI-publishing house, 1994). In the Aachen method, the normal wheel force F z is computed from the proportionate vertical acceleration {umlaut over (z)} B,V , in the following text called partial vertical body acceleration, the proportionate mass of the vehicle body (quarter vehicle) m B,V , and the vertical wheel acceleration {umlaut over (z)} W with the proportionate wheel mass of a wheel m Wz (see FIG. 1 ):
F z =m B,V ·{umlaut over (z)} B,V +m Wz ·{umlaut over (z)} W (1)
The intersecting-forces method evaluates the spring stroke D z of a spring 2 and the vertical wheel acceleration {umlaut over (z)} W for the determination of the dynamic normal wheel force F z (see FIG. 1 ):
F z =c Bz ·Δz+d Bz ·Δ{dot over (z)}+m Wz ·{umlaut over (z)} W (2)
Both methods require the vertical wheel acceleration {umlaut over (z)} w . Accelerometers for the measurement of this quantity, however, are expensive due to the high accelerations occurring at the wheel and to the extreme environmental influences.
SUMMARY OF THE INVENTION
It is an object of the invention to identify, for the use in driving dynamics control, a method and a device for the determination of a vertical acceleration of a wheel of a vehicle that is simple and cost-effective to realize.
This objective is achieved with the features of the independent claims. Dependent claims are directed to preferred embodiments of the invention.
According to the invention, a first determination device can determine a spring acceleration of a spring which is mounted between the body and the wheel and loaded in the vertical direction by the vehicle body. A second determination device can determine a partial vertical body acceleration. A control unit can further determine a vertical acceleration of a wheel (vertical wheel acceleration) by adding the spring stroke acceleration from the first determination unit and the partial vertical body acceleration from the second determination unit. The thus determined vertical wheel acceleration can then be used e.g. for the determination of the normal wheel force. In this invention, an expensive sensor arrangement for the detection of the vertical wheel acceleration can therefore be eliminated, and the results of the determination of the vertical wheel acceleration according to the invention reflect very accurately the actual comparison test results.
Various embodiments of the invention are now exemplarily explained with respect to the attached schematic drawings. Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings that will now be briefly described are incorporated herein to illustrate preferred embodiments of the invention and a best mode presently contemplated for carrying out the invention.
FIG. 1 is a schematic drawing of a simplified vehicle model;
FIG. 2 is charts showing a block diagram of an embodiment of the device according to the invention; and
FIG. 3 shows a comparison of results pursuant to the method according to the invention (re-constructed) with comparison measurements (measured).
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a simplified vehicle model is shown for the illustration of the quantities used in the invention. The model consists of two wheels 1 attached to the rear axle HA and two wheels 1 attached to the front axle VA. The wheels 1 may each be connected to the respective axle by means of a parallel arrangement of a spring 2 and a damping member 6 .
Further, a center of gravity CG of the mass of the vehicle body m B is present. The body can consist of all of the vehicle components without the wheels 1 , shares of the springs 2 , shares of the damping members 6 , and other suspension parts. The longitudinal direction x B can be pre-determined by the roll axis 4 , the lateral direction y B by the pitch axis 3 of the body. The pitch axis 3 can include a non-depicted shift in longitudinal direction l CP and/or vertical direction h CP relative to the center of gravity CG. The roll axis can include a non-depicted shift in lateral direction l CR and/or in vertical direction h CR relative to the center of gravity CG.
The distance from the front axle VA to the pitch axis 3 is labeled as l v in FIG. 1, the distance of the rear axle HA to the pitch axis 3 as l h . The distance of the respective wheel suspension point on the body 7 to the roll axis 4 is labeled as s vl , s vr , s hl , or s hr , respectively, where in this document subscript vl stands for front left, subscript vr for front right, subscript hl for rear left, and subscript hr for rear right. A rotation of the body about the pitch axis 3 , i.e. the pitch angle, is labeled as φ B , a rotation of the body about the roll axis 4 , i.e. the roll angle, is labeled as χ B .
The mass of a wheel m Wz is joined into the respective element 8 . The spring and damping members outlined beneath the respective element 8 symbolize the respective spring and damping properties of the wheels which, however, may remain unconsidered in this invention. The quantity z B,hr identifies the proportional vertical acceleration component of the body z B,V at the rear wheel. This applies accordingly to the components for the other wheels z B,hl , z B,vr , and z B,vl , which, for simplification purposes, are not shown.
According to the invention, the spring acceleration Δ{umlaut over (z)} of the spring 2 , loaded in vertical direction by the body, is determined. This can occur separately for every wheel. Also, a partial vertical body acceleration {umlaut over (z)} B,V effecting the body is determined, which can be effective at the wheel suspension point 7 . This can as well occur separately for each wheel. Afterwards, the spring stroke acceleration Δ{umlaut over (z)} and the partial vertical body acceleration {umlaut over (z)} B,V are added up for each wheel to a respective vertical wheel acceleration {umlaut over (z)} W :
{umlaut over (z)} W =Δ{umlaut over (z)}+{umlaut over (z)} B,V (3)
The spring stroke acceleration Δ{umlaut over (z)} can, for instance, be determined by twice differentiating the respective spring stroke Δz, which itself can for instance be determined by measuring. The partial vertical body acceleration {umlaut over (z)} B,V can, for instance, be determined in dependence on the vertical body acceleration {umlaut over (z)} B in the center of gravity CG and/or of the angular pitch acceleration {umlaut over (φ)} B and/or of the angular roll acceleration {umlaut over (χ)} B , in particular by means of the following equation: z ¨ B , vl = Δ z ¨ vl + z ¨ B - ( 1 v + 1 CP ) · ϕ ¨ B + s vl · χ ¨ B z ¨ B , vr = Δ z ¨ vr + z ¨ B - ( 1 v + 1 CP ) · ϕ ¨ B + s vr · χ ¨ B z ¨ B , hl = Δ z ¨ hl + z ¨ B - ( 1 h + 1 CP ) · ϕ ¨ B + s hl · χ ¨ B z ¨ B , hr = Δ z ¨ hr + z ¨ B - ( 1 v + 1 CP ) · ϕ ¨ B + s hr · χ ¨ B ( 4 )
The vertical body acceleration {umlaut over (z)} B in the center of gravity CG can for example be determined in dependence on the spring strokes Δz vl , Δz vr , Δz hl , Δz hr for the respective wheels 1 and/or of the spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr , Δ{dot over (z)} hl , Δ{dot over (z)} hr , in particular according to the following equation: z ¨ B = - 1 m A · ( C Bz , vl · Δ z vl + d Bz , vl · Δ z . vl + c Bz , vr · Δ z vr + d Bz , vr · Δ z . vr + c Bz , hl · Δ z hl + d Bz , hl · Δ z . hl + c Bz , hr · Δ z hr + d Bz , hr · Δ z . hr ) - g ( 5 )
Here, g represents the gravitational acceleration component, c B,vl , c B,vr , c B,hl , c B,hr the respective spring constants of the springs 2 , and d B,vl , d B,vr , d B,hl , d B,hr the respective damping constants of the damping members 6 . Equation (5) applies in particular to non-inclined road surfaces. For the case of an inclined road surface, equation (5) can for instance be adapted in a known manner by means of corresponding angular components.
The angular pitch acceleration {umlaut over (φ)} B can for instance be determined in dependence on the spring strokes Δz vl , Δz vr , Δz hl , Δz hr and/or of the corresponding spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr , Δ{dot over (z)} hl , Δ{dot over (z)} hr and/or of the longitudinal body acceleration {umlaut over (x)} B , in particular according to the following equation: ϕ ¨ B = - 1 θ y · ( ( c Bz , hl · Δ z hl + d Bz , hl · Δ z . hl + c Bz , hr · Δ z hr + d Bz , hr · Δ z . hr ) · ( l h - l CP ) - ( c Bz , vl · Δ z vl + d Bz , vl · Δ z . vl + c Bz , vr · Δ z vr + d Bz , vr · Δ z . vr ) · ( l v + l CP ) + x ¨ B m B · ( h CG - h PA ) + m B gl CP ) ( 6 )
with the mass moment of inertia about the pitch axis θ y . The angular roll acceleration {umlaut over (χ)} B can for instance be determined in dependence on the can for instance be determined in dependence on the spring strokes Δz vl , Δz vr , Δz hl , Δz hr and/or of the corresponding spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr , Δ{dot over (z)} hl , Δ{dot over (z)} hr and/or of the lateral body acceleration ÿ B , in particular according to the following equation: χ ¨ B = - 1 θ x · ( ( c Bz , vl · Δ z vl + d Bz , vl · Δ z . vl ) · s vl + ( c Bz , hl · Δ z hl + d Bz , hl · Δ z . hl ) · s hl - ( c Bz , vr · Δ z vr + d Bz , vr · Δ z . vr ) · s vr - ( c Bz , hr · Δ z hr + d Bz , hr · Δ z . hr ) · s hr - y ¨ B m B · ( h CG - h RA ) + m B gl CR ) ( 7 )
with the mass moment of inertia about the roll axis θ x . Equation (6) and equation (7) apply in particular to non-inclined road surfaces. For the case of an inclined road surface, they can as well be adapted in a known manner by means of corresponding angular components.
In FIG. 2, a block diagram of an embodiment of the invention is shown, which determines one or more vertical wheel accelerations {umlaut over (z)} W,vl , {umlaut over (z)} W,vr , {umlaut over (z)} W,hl , {umlaut over (z)} W,hr and passes them to a driving dynamics control or monitoring system. A first sensor arrangement 13 determines one or more spring strokes Δ z vl , Δz vr , Δz hl , Δz hr in a known manner, e.g. via spring stroke sensors, and passes these on to a differentiating device 14 . The differentiating device 14 determines from these one or more corresponding spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr Δ{dot over (z)} h , Δ{dot over (z)}hr, which it passes on to the first determination device 10 . The first determination device 10 , which may as well be a differentiating device, determines from these one or more spring stroke accelerations Δ{umlaut over (z)} vl , Δ{umlaut over (z)} vr Δ{umlaut over (z)} h , Δ{umlaut over (z)} hr for forwarding to the control unit 12 .
A second sensor arrangement 20 determines the longitudinal body acceleration {umlaut over (x)} B and passes it on to a third determination device 15 . The longitudinal body acceleration {umlaut over (x)} B does not need to be measured directly but may as well be computed from other vehicle quantities, e.g. from the total braking force. The third determination device 15 receives as further input signals the spring strokes Δz vl , Δz vr , Δz hl , Δz hr from the first sensor arrangement and the spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr Δ{dot over (z)} h , Δ{dot over (z)}{dot over ( )} hr from the differentiating device 14 and determines therefrom the angular pitch acceleration {umlaut over (φ)} B , which it passes on to a second determination device 11 .
A third sensor arrangement 21 determines the lateral body acceleration ÿ B and passes it on to a fourth determination device 16 . The lateral body acceleration ÿ B does not need to be measured directly but may as well be computed from other vehicle quantities. The fourth determination device 16 receives as further input signals the spring strokes Δz vl , Δz vr , Δz hl , Δz hr from the first sensor arrangement and the spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr Δ{dot over (z)} h , Δ{dot over (z)} hr from the differentiating device 14 and determines therefrom the angular roll acceleration {umlaut over (χ)} B , which it passes on to a second determination device 11 .
The second sensor arrangement 20 and/or the third sensor arrangement may for instance contain known accelerometers. The third and/or fourth determination device 15 , 16 may as well contain suitable known accelerometers but may also determine the respective angular acceleration by differentiating the respective angle of rotation and/or the respective angular velocity. The further parameters required for the determination of the angular accelerations are received by the third and fourth determination device 15 , 16 from the control unit 12 , which contains storage elements 19 for storing for instance parameters for the execution, such as the gravitational acceleration g, the masses m B , m W , the distances l CP , l CR , etc.
A fifth determination device 17 receives as input quantities the spring strokes the spring strokes Δz vl , Δz vr , Δz hl , Δz hr from the first sensor arrangement and the spring stroke velocities Δ{dot over (z)} vl , Δ{dot over (z)} vr Δ{dot over (z)} h , Δ{dot over (z)} hr from the differentiating device 14 as well as further required parameters from the control unit 12 and determines therefrom the vertical body acceleration {umlaut over (z)} B , which it passes to the second determination device 11 . The fifth determination device 17 may as well contain an accelerometer for the detection of the vertical body acceleration {umlaut over (z)} B , in which case, for instance, it would be able to do without the mentioned input quantities. The second determination device determines from its input quantities and further required parameters, which it receives from the control unit 12 , one or more partial vertical body accelerations {umlaut over (z)} B,vl , {umlaut over (z)} B,vr , {umlaut over (z)} B,hl , {umlaut over (z)} B,hr , which it passes on to the control unit 12 .
Control unit 12 contains an adder 18 , which adds, for each wheel separately, the respective partial vertical body accelerations {umlaut over (z)} B,vl , {umlaut over (z)} B,vr , {umlaut over (z)} B,hl , {umlaut over (z)} B,hr from the second determination device and the respective spring stroke accelerations Δ{umlaut over (z)} vl , Δ{umlaut over (z)} vr , Δ{umlaut over (z)} hl , Δ{umlaut over (z)} hr according to equation (3) and thus determines the respective vertical wheel accelerations {umlaut over (z)} W,vl , {umlaut over (z)} W,vr , {umlaut over (z)} W,hl , {umlaut over (z)}W,hr for output to the driving dynamics control 9 .
The thick connecting lines shown in FIG. 2 indicate that, through these, multiple quantities can be transmitted. This may occur for instance in parallel lines or as well serially in one line. The remaining thinly drawn connecting lines indicate that here, for instance, only one quantity is transferred. This may be designed differently in other embodiments. Between the individual devices or sensor arrangements, there can be provided further connections, in particular connections to the control unit which may for instance, control the operation of all devices/sensor arrangements. The control unit and/or the other devices/sensor arrangements may for instance communicate with each other through a data and/or control bus. Besides, it is conceivable that the inventive device is integrated into the driving dynamics control and/or monitoring system 9 .
The embodiment shown in Fig. 2 has the advantage that only the spring strokes Δz vl , Δz vr , Δz hl , Δz hr and the longitudinal {umlaut over (x)} B and lateral ÿ B body acceleration need to be sensorily detected or measured, respectively, and the other quantities can be derived from these. The few quantities to be detected can be accurately detected by means of sensors already partially or completely present, whereby costs can be saved. The spring strokes Δz vl , Δz vr , Δz hl , Δz hr are already detected in modern vehicles in series production, e.g. for headlight distance control, load condition recognition or chassis control. The utilization of accelerometers in the center of gravity CG is significantly more cost-efficient than the utilization of wheel accelerometers. They require a small measuring range, and their installation occurs, for instance, in the inner vehicle space. In vehicles equipped with an electronic stability program (ESP), a lateral body accelerometer is already present.
The longitudinal body acceleration {umlaut over (x)} B can also be determined by once differentiating the vehicle velocity determined from the wheel speeds or also directly from the wheel speeds or also from the braking forces. By this means, a further sensor can be eliminated.
For eliminating the sensors for detecting the longitudinal {umlaut over (x)} B and lateral ÿ B body acceleration, the design of the vertical dynamic properties can be made use of. When designing the springs and damping members, these are selected in a way that the natural body frequency ranges at a low frequency, e.g. 1 to 2 Hz. The natural frequency of the system wheel mass/tire, in contrast, ranges, depending on the wheel mass, the tire type, the inner tire pressure, etc., at a higher frequency, e.g. at 10 to 15 Hz. By way of high-pass filtering the spring stroke Δz or the spring stroke acceleration Δ{umlaut over (z)} with a filter cut-off frequency that can range above the natural body frequency and below the natural frequency of the system wheel mass/tire, e.g. at 4 to 8 Hz, the for instance unknown vertical wheel acceleration {umlaut over (z)} W can thus be filtered out of the spring stroke acceleration Δ{umlaut over (z)} according to the following equation:
{umlaut over (z)} W =f high-pass (Δ{umlaut over (z)})
Instead of high-pass filtering, also band-pass filtering can be used, where the lower cut-off frequency corresponds to the above-mentioned filter cut-off frequency and the upper cut-off frequency ranges above the natural frequency of the system wheel mass/tire, e.g. at 18 Hz.
A further application of the invention consists in that, in presence of an accelerometer for the detection of the vertical body acceleration {umlaut over (z)} B , the damping constants d B,vl , d B,vr , d B,hl , d B,hr can be estimated by means of equation (5) with known estimation methods, e.g. a method of the “least squares” (LS). The estimation method can be simplified under the assumption that the spring constants c B,vl , c B,vr , c B,hl , c B,hr do not change over the lifetime of the vehicle. The body mass m a can for instance be determined after closing the doors from the statical spring compression at the four wheel suspensions.
To illustrate the accuracy of the invention, FIG. 3 shows a comparison of results according to the inventive method (re-constructed) with comparison measurements (measured) for the spring damping force F Wz,vl determined by means of the characteristic spring and damping curve from the spring stroke (a), for the partial vertical body acceleration {umlaut over (z)} B,vl , (b), for the vertical wheel acceleration {umlaut over (z)} W,vl (c), and for the dynamic normal wheel force F z,vl (d), each for the left front wheel. For the determination of the normal wheel force F z,vl , the intersecting-forces method according to equation 2 was applied. Due to the good conformance of the intermediate quantities, for instance, also the dynamic normal wheel force F z,vl could be determined with a high accuracy.
The foregoing discussion discloses and describes preferred embodiments of the invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that changes and modifications can be made to the invention without departing from the true spirit and fair scope of the invention as defined in the following claims. The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words and description rather than of limitation.
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A method and a device for the determination of a vertical acceleration ({umlaut over (z)} W ) of a wheel of a vehicle for use in a driving dynamics control or monitoring system. The device includes a first determination device for the determination of a spring stroke acceleration (Δ{umlaut over (z)}) of a spring loaded in vertical direction by the body of the vehicle and installed between the body and the wheel; a second determination device for the determination of a partial vertical body acceleration ({umlaut over (z)} B,V ), and a control unit, which adds the spring stroke acceleration (Δ{umlaut over (z)}) and the partial vertical body acceleration ({umlaut over (z)} B,V ) in order to obtain the vertical wheel acceleration (z{umlaut over (z)} W ) and passes the vertical wheel acceleration ({umlaut over (z)} W ) and passes the vertical wheel acceleration ({umlaut over (z)} W ) for further processing to the driving dynamics control. By this means, an expensive sensor arrangement for the detection of the vertical wheel acceleration can be eliminated, wherein the results of the inventive determination of the vertical wheel acceleration reflect very actual comparison measurements.
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This application claims benefit to the provisional U.S. Application No. 60/650,132, filed Feb. 7, 2005.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a recording device that records data onto a recording medium, and in particular to technology for improving the playback compatibility of recording media.
2. Description of the Related Art
DVDs, on which content such as a movie can be recorded in high quality, are widely used as package media for distributing content. Content is recorded onto DVDs as digital data. Compared to analog data, digital data undergoes much less degredation during copying, and the value of the content is diminished very little by copying. If recording media containing unauthorized copies of content are distributed to the market at cheap prices, the number of consumers who purchase legitimate package media falls, and there is the fear that holders of rights such as copyrights on content will incur extensive losses.
For this reason, copyright protection technology such as CPRM (Content Protection for Recordable media) is used to protect the rights of right-holders. CPRM is copyright protection technology used when recording content or other data to a writable recording medium. A recording device encrypts the data before recording it to the recording medium, in order to prevent unauthorized copying of the data. Here, the data is encrypted using information prerecorded in a predetermined area of the recording medium. Taking the example of the DVD-RAM standard, the recording device encrypts the data with use of an MKB (Media Key Block) recorded in an Initial Zone of the recording medium, a media ID recorded in a BCA (Burst Cutting Area), and the like.
Note that regarding disk layouts in DVD standards, the disk layouts of the DVD+RW standard and the DVD-RAM standard are described in non-patent documents 1 and 2 respectively.
Non-patent document 1: ECMA-337, 3rd Edition—December, 2005. Non-patent document 2: ECMA-272, 2nd Edition—June, 1999.
BRIEF SUMMARY OF THE INVENTION
Problems Solved by the Invention
As described in the above non-patent documents, the disk layout is different depending on the DVD standard. Since there are cases in which the recording positions of data are different depending on the disk layout, it is possible that a playback device will not be able to utilize a recording medium on which data has been recorded according to an incompatible standard. For this reason, manufacturers normally design their playback devices to be compatible with as many established standards as possible, such that there is no detriment to users of their playback devices.
However, when a standard is established after a playback device has been manufactured, it is possible that the playback device will not be able to decrypt encrypted data that has been recorded on a recording medium according to the newly established standard, due to specification-related constraints of the playback device.
For example, if the media ID and other decryption information used in processing for decrypting the encrypted data is recorded in an inner circumferential portion of a disk-shaped recording medium, and a reading unit of a playback device for reading data from the recording medium physically cannot read the inner circumferential portion of the disk, the playback device will not be able to decrypt the encrypted data the decryption information. Given that in this case the information necessary for decrypting the encrypted data physically cannot be read, a countermeasure such as updating a playback processing program of the playback device would have no effect. This is not preferable since the inability to utilize the data on the recording medium is not only a detriment to the user of the playback device, but also diminishes the number of choices of methods by which a content holder can distribute their content to potential content users.
Therefore, an aim of the present invention is to provide a recording device that records data to a recording medium in such away that even a playback device incompatible with a standard of the recording medium due to specification-related constraints can utilize the data that has been recorded onto the recording medium according to the standard.
Means to Solve the Problems
In order to solve the above problem, the present invention is a recording device that performs recording on a recording medium, such that a first area of the recording medium has prerecorded therein decryption information used in decryption processing for decrypting encrypted data, the recording device including: a read unit operable to read the decryption information from the first area; and a record unit operable to record the read decryption information in a second area of the recording medium, the second area being readable by a device that physically cannot read data in the first area.
Effects of the Invention
According to this structure, the recording device reads the decryption information from the first area, and records the read decryption information to the second area.
Accordingly, even a device that physically cannot read data from the first area of the recording medium will be able to decrypt the encrypted data recorded on the recording medium since the device can read the decryption information from the second area.
If some kind of information is recorded in the second area, and furthermore the information is illegitimate decryption information, the playback device can decrypt the encrypted data with use of the illegitimate decryption information, whereby it is possible that the rights of a right-holder are not sufficiently protected. Also, if the decryption information recorded in the second area has been corrupted due to a recording failure or another reason, the playback device cannot decrypt the encrypted data.
Here, the recording device may further include: a detection unit operable to detect that certain information is recorded in the second area; a determination unit operable to, if the certain information is recorded in the second area, determine whether the decryption information recorded in the first area and the certain information are identical; and an overwrite unit operable to, when the determination unit has determined that the decryption information and the certain information are not identical, overwrite the certain information in the second area with the decryption information.
This structure enables reliably recording legitimate decryption information in the second area.
Also, the decryption information may be a key block.
Also, the decryption information may be a media ID that identifies the recording medium.
Also, the second area may be a buffer area included in a lead-in area of the recording medium.
Also, the first area may be an initial zone of the recording medium.
Also, the present invention is an integrated circuit used in a recording device that performs recording on a recording medium, a first area of the recording medium having prerecorded therein decryption information used in decryption processing for decrypting encrypted data, the integrated circuit including: a read processing unit operable to perform processing for reading the decryption information from the first area; and a record processing unit operable to perform processing for recording the read decryption information in a second area of the recording medium, the second area being readable by a device that physically cannot read data in the first area.
Also, the present invention is a control program for causing processing to be executed by a recording device that performs recording on a recording medium, a first area of the recording medium having prerecorded therein decryption information used in decryption processing for decrypting encrypted data, the control program including the steps of: reading the decryption information from the first area; and recording the read decryption information in a second area of the recording medium, the second area being readable by a device that physically cannot read data in the first area.
There are playback devices that can read from both the first and second areas of the recording medium depending on the standard. If the decryption information is recorded in the second area, such playback devices can read the decryption information from either the first or second area.
However, there are cases in which the information recorded in the second area is illegitimate information recorded by an illegitimate recording device. In such cases, decrypting the encrypted data with use of the illegitimate information recorded in the second area of the recording medium is disadvantageous to a holder of a data copyright etc.
Here, the present invention is a playback device that reads encrypted data from a recording medium and controls execution of decryption processing for decrypting the read encrypted data, the recording medium including a first area and a second area, decryption information used in the decryption processing having been prerecorded in the first area before recording of the encrypted data by a recording device, the encrypted data having been generated by encrypting, with use of the decryption information, data targeted for recording, certain information being recorded in the second area, and the playback device including: a determination unit operable to determine whether the decryption information recorded in the first area and the certain information recorded in the second area are identical; and a control unit operable to control execution of the decryption processing, according to a result of the determination.
According to this structure, the playback device determines whether the information recorded in the first and second areas is identical. The execution of the decryption processing is controlled according to the result of the determination.
Accordingly, even if illegitimate information is recorded in the second area, the execution of the decryption processing can be controlled, such that there is no disadvantage to the right-holder etc.
Here, the control unit may execute the decryption processing only when the determination unit has determined that the decryption information recorded in the first area and the certain information recorded in the second area are identical.
According to this structure, in a playback device that can read from both the first and second areas depending on the standard, the decryption processing is performed only if the information recorded in the second area is identical to the decryption information recorded in the first area. Therefore, there is no disadvantage to the right-holder etc. even if illegitimate information is recorded in the second area.
Also, the control unit may suppress the decryption processing when the determination unit has determined that the decryption information recorded in the first area and the certain information recorded in the second area are not identical.
According to this structure, an illegitimate user gains no advantage by recording illegitimate information in the second area, since the decryption processing is suppressed if the information recorded in the second area is illegitimate. This potentially suppresses the recording of illegitimate information in the second area by illegitimate users.
Nonetheless, simply the fact that the information recorded in the second area is not identical to the decryption information recorded in the first area does necessarily mean that the information in the second area was recorded by an illegitimate user. For example, the information recorded in the second area may have been corrupted by degredation of or damage to the recording medium after the decryption information had been recorded in the second area by a legitimate user.
In other words, if the information recorded in the second area is not identical to the decryption information recorded in the first area due to damage to the recording medium etc., the playback device cannot decrypt the encrypted data even though it can read the decryption information from the first area. Therefore, in this case, use of the data on the recording medium is restricted even though the rights of the right-holder etc. are not being violated, which is unfairly disadvantageous to the user of the playback device.
Here, when the determination unit has determined that the decryption information recorded in the first area and the certain information recorded in the second area are not identical, the control unit may execute the decryption processing with use of the decryption information read from the first area.
This structure enables preventing the unfair disadvantage to the user of the playback device in the aforementioned case.
Also, the present invention is an integrated circuit used in a playback device that reads encrypted data from a recording medium and controls execution of decryption processing for decrypting the read encrypted data, the recording medium including a first area and a second area, decryption information used in the decryption processing having been prerecorded in the first area before recording of the encrypted data by a recording device, the encrypted data having been generated by encrypting, with use of the decryption information, data targeted for recording, certain information being recorded in the second area, the integrated circuit including: a determination processing unit operable to perform processing for determining whether the decryption information recorded in the first area and the certain information recorded in the second area are identical; and a control processing unit operable to perform processing for controlling execution of the decryption processing, according to a result of the determination.
Also, the present invention is a control program for causing processing to be executed by a playback device that reads encrypted data from a recording medium and controls execution of decryption processing for decrypting the read encrypted data, the recording medium including a first area and a second area, decryption information used in the decryption processing having been prerecorded in the first area before recording of the encrypted data by a recording device, the encrypted data having been generated by encrypting, with use of the decryption information, data targeted for recording, certain information being recorded in the second area, the control program including the steps of: determining whether the decryption information recorded in the first area and the certain information recorded in the second area are identical; and controlling execution of the decryption processing, according to a result of the determination.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram showing a recording device 1000 of the present invention;
FIG. 2 is a functional block diagram showing a playback device 3000 that reads data from a recording medium 2000 and decrypts the read data;
FIG. 3 shows a disk layout of the recording medium 2000 ;
FIG. 4 is a flowchart showing processing performed by the recording device 1000 ;
FIG. 5 is a flowchart showing processing performed by the playback device 3000 ;
FIG. 6 is a functional block diagram showing a playback device 3100 ; and
FIG. 7 is a flowchart showing processing performed by the playback device 3100 .
DETAILED DESCRIPTION OF THE INVENTION
The following describes an embodiment of a recording device pertaining to the present invention, with reference to the drawings.
Overview
The recording device of the present invention records AV data to a recording medium compatible with CPRM (Content Protection for Recordable Media). Before recording is performed, the AV data is encrypted with use of information prerecorded on the recording medium. Here, the encryption method is CPRM. The information prerecorded on the recording medium includes an MKB (Media Key Block), which is a block of keys, as well as MKB validation data and a media ID.
The MKB is prerecorded in an area of the recording medium called the Initial Zone. The MKB validation data and the media ID are prerecorded in a BCA (Burst Cutting Area) in the Initial Zone.
The recording device encrypts the AV data with use of the MKB, the media ID and the like. Also, in order for a playback device that physically cannot read the MKB, the media ID and the like from the recording medium due to specification-related constraints to be able to decrypt the AV data with use of the MKB etc., the recording device also records the MKB etc. in a predetermined area of the recording medium that is readable by the playback device. This enables the playback device to read the MKB etc. from the recording medium and decrypt the AV data. The present embodiment is an exemplary case in which the recording device records the MKB etc. in a buffer zone 2 of the recording medium.
Furthermore, if information has already been recorded in the buffer zone 2 , the recording device verifies whether the recorded information includes the MKB, media ID and the like that are prerecorded in the Initial Zone of the recording medium, and overwrites the MKB, media ID and the like in the buffer zone 2 according to a result of the verification.
Also, the playback device can read the information recorded in the buffer zone 2 of the recording medium, even though it is unable to read the information recorded in the Initial Zone of the recording medium.
The following is a detailed description of the present embodiment.
Structure
FIG. 1 is a functional block diagram showing a recording device 1000 of the present invention. Note that a recording medium 2000 is also shown in FIG. 1 .
As shown in FIG. 1 , the recording device 1000 includes a device key storage unit 101 , an MKB processing unit 102 , a check unit 103 , a key conversion unit 104 , an encryption unit 105 , and an AV pack storage unit 106 . The encryption unit 105 includes a title key generation subunit 111 , a title key combination subunit 112 , a title key encryption subunit 113 , a DCL_CCI generation subunit 114 , an intermediate key generation subunit 115 , a content key generation subunit 116 , and an AV pack encryption subunit 117 .
The device key storage unit 101 stores a device key allocated to the recording device 1000 .
The MKB processing unit 102 reads the MKB from the Initial Zone of the recording medium 2000 , and generates a media key (Km) by decrypting the read MKB with use of the device key stored in the device key storage unit 101 of the recording device 1000 . The MKB processing unit 102 also records the generated media key in the buffer zone 2 of the recording medium 2000 .
The check unit 103 calculates a hash value for the MKB recorded in the Initial Zone, and verifies the validity of the MKB by comparing the calculated hash value to the MKB validation data recorded in the BCA. The check unit 103 also detects that some kind of information is recorded in the buffer zone 2 , and upon detecting that an MKB is recorded in the buffer zone 2 , calculates a hash value for the MKB recorded in the buffer zone 2 , and verifies the validity of the MKB recorded in the buffer zone 2 by comparing the calculated hash value to the MKB validation data. Also, upon detecting that a media ID is recorded in the buffer zone 2 , the check unit 103 verifies the validity thereof by performing a comparison with the media ID recorded in the BCA. The media ID recorded in the buffer zone 2 is determined to be valid if, for example, a result of the aforementioned comparison is that the media IDs are the same.
The key conversion unit 104 reads the media ID recorded in the BCA, and with use of the read media ID, converts the MKB read by the MKB processing unit 102 , thereby generating a unique media key (Kmu). The key conversion unit 104 also records the media ID read from the BCA in the buffer zone 2 .
The encryption unit 105 encrypts AV data received as an input from the AV pack storage unit 106 in a 2,048-byte AV pack format, and records the encrypted data in a data area of the recording medium 2000 . The AV data encrypted by the encryption unit 105 is recorded in the data area in a 2,048-byte encrypted AV pack format. The first 128 bytes of the 2,048 bytes in the encrypted AV pack make up a plain-text unencrypted portion, and the remaining 1,920 bytes make up an encrypted portion. The first 128 bytes of the 2,048-byte AV pack received as input from the AV pack storage unit 106 are used to generate a content key (Kc) for encrypting the AV data, and are also recorded in the data area as the plain-text unencrypted portion. The encryption unit 105 also encrypts the remaining 1,920 bytes of the 2,048-byte AV pack with use of the content key, and records the generated encrypted data in the data area as the encrypted portion.
The following describes details of the function blocks constituting the encryption unit 105 .
The title key generation subunit 111 generates a title key. The title key generation subunit 111 outputs the generated title key (Kt) to the title key combination subunit 112 and the intermediate key generation subunit 115 .
The title key combination subunit 112 combines an arbitrary value V and the title key generated by the title key generation subunit 111 .
The title key encryption subunit 113 encrypts the title key combined with the arbitrary value V by the title key combination subunit 112 , with use of the unique media key generated by the key conversion unit 104 , thereby generating an encrypted title key. The title key encryption subunit 113 records the generated encrypted title key in the data area.
The DCL_CCI generation subunit 114 generates copy control information etc. of the AV data as DCL_CCI, and records the generated DCL_CCI in the data area. The DCL_CCI generation subunit 114 also outputs analog protection information (APSTB: Analog Protection Single Trigger Bit) to the intermediate key generation subunit 115 .
The intermediate key generation subunit 115 receives the APSTB from the DCL_CCI generation subunit 114 , and generates an intermediate key (Ki) by combining the received APSTB with the title key received from the title key generation subunit 111 . The intermediate key generation subunit 115 outputs the generated intermediate key to the content key generation subunit 116 .
The content key generation subunit 116 receives an input of the first 128 bytes (Dtkc) of the 2,048-byte AV pack, and generates a content key by converting the received intermediate key with use of the received first 128 bytes of the AV pack. Note that as described above, the first 128 bytes of the AV pack are recorded in the data area as the plain-text unencrypted portion.
The AV pack encryption subunit 117 encrypts the remaining 1,920 bytes of the 2,048-byte AV pack with use of the content key generated by the content key generation subunit 116 , and records the encrypted data in the data area as the encrypted portion.
The AV pack storage unit 106 stores the AV data.
The following describes a structure of the playback device.
FIG. 2 is a functional block diagram showing a playback device 3000 that reads data from the recording medium 2000 and performs decryption processing on the read data.
As shown in FIG. 2 , the playback device 3000 includes a device key storage unit 301 , an MKB processing unit 302 , a key conversion unit 303 , a decryption unit 304 , and an AV pack playback processing unit 305 . The decryption unit 304 includes a title key decryption subunit 311 , a DCL_CCI storage subunit 312 , an intermediate key generation subunit 313 , a content key generation subunit 314 , and an AV pack decryption subunit 315 .
The device key storage unit 301 stores a device key of the playback device 3000 .
The MKB processing unit 302 reads the MKB recorded in the buffer zone 2 of the recording medium 2000 , and decrypts the read MKB with use of the device key stored by the device key storage unit 301 of the playback device 3000 , thereby generating a media key.
The key conversion unit 303 reads the media ID recorded in the buffer zone 2 , and with use of the read media ID, converts the media key generated by the MKB processing unit 302 , thereby generating a unique media key.
The decryption unit 304 reads the encrypted AV pack from the data area of the recording medium 2000 , and decrypts the read encrypted AV pack to obtain the AV data. The decryption unit 304 outputs the obtained AV data to the AV pack playback processing unit 305 . The decryption unit 304 also reads the DCL_CCI from the data area and stores the read DCL_CCI.
The following describes details of the function blocks constituting the decryption unit 304 .
The title key decryption subunit 311 reads the encrypted title key from the data area of the recording medium 2000 , and decrypts the read encrypted title key with use of the unique media key generated by the key conversion unit 303 , thereby generating a title key.
The DCL_CCI storage subunit 312 stores the DCL_CCI read from the data area.
The intermediate key generation subunit 313 receives the analog protection information (APSTB) included in the DCL_CCI recorded in the data area, and combines the received analog protection information with the title key generated by the title key decryption subunit 311 , thereby generating an intermediate key. The intermediate key generation subunit 313 outputs the generated intermediate key to the content key generation subunit 314 .
The content key generation subunit 314 converts the intermediate key received from the intermediate key generation subunit 313 , with use of the first 128 bytes of the encrypted AV pack read from the data area, thereby generating a content key.
The AV pack decryption subunit 315 decrypts the remaining 1,920 bytes of the encrypted AV pack with use of the content key generated by the content key generation subunit 314 .
The AV pack playback processing unit 305 performs video output and playback processing on the AV data obtained by the decryption unit 304 .
Note that although not depicted, the recording device 1000 and the playback device 3000 include a reading unit for reading data from the recording medium 2000 . Also, the above constituent elements constitute a computer system composed of specifically a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), etc., and operate in accordance with a program. A portion of the processing, such as the encryption processing, may be performed by a dedicated processor.
Data
The following describes the disk layout of the recording medium 2000 .
FIG. 3 shows the disk layout of the recording medium 2000 . Note that the DVD+RW standard is described as an example in the present embodiment.
As shown in FIG. 3 , the Initial Zone is included in an inner drive area of the recording medium 2000 . A media ID and MKB validation data are prerecorded in the BCA of the Initial Zone. The information recorded in the BCA cannot be tampered with. An MKB is also prerecorded in the Initial Zone. Also, the buffer zone 2 is included in a lead-in area.
In the present embodiment, the recording device 1000 records the MKB and the media ID that were read from the Initial Zone of the recording medium 2000 in the buffer zone 2 of the recording medium 2000 . Also, as described above, the playback device 3000 cannot read the information recorded in the Initial Zone, and performs decryption processing using the MKB and the media ID that were recorded in the buffer zone 2 by the recording device 1000 .
Operations
The following describes operations performed by the recording device 1000 of the present invention.
FIG. 4 is a flowchart showing processing performed by the recording device 1000 .
As shown in FIG. 4 , the recording device 1000 reads the buffer zone 2 of the recording medium 2000 , and judges whether the MKB and media ID are recorded therein (step S 41 ).
If the judgment is negative (step S 41 :NO), the recording device 1000 judges whether a sufficient amount of free space is available in the buffer zone 2 for writing the MKB and media ID (step S 42 ), and ends processing if the amount of free space is insufficient (step S 42 :NO). If a sufficient amount of free space is available in the buffer zone 2 (step S 42 :YES), the recording device 1000 judges whether the MKB and media ID are recorded in the Initial Zone, and ends processing if the judgment is negative (step S 43 :NO). If the MKB and media ID are recorded in the Initial Zone (step S 43 :YES), the recording device 1000 acquires the MKB and media ID from the Initial Zone (step S 44 ). The recording device 1000 records the acquired MKB and media ID in the buffer zone 2 (step S 45 ).
Upon completing the processing of step S 45 , the recording device 1000 encrypts the AV data stored in the AV pack storage unit 106 , with use of the MKB, media ID, title key, etc., and records the encrypted AV data in the Data area (step S 46 ).
Also, if the MKB and media ID have been judged in step S 41 to be recorded in the buffer zone 2 (step S 41 :YES), the recording device 1000 reads the MKB recorded in the buffer zone 2 , as well as reads the MKB validation data from the Initial Zone, and the check unit 103 verifies that the MKB recorded in the buffer zone 2 is valid (step S 47 ).
Processing ends if the MKB is not valid (step S 47 :NO). If the MKB is valid (step S 47 :YES), the check unit 103 similarly verifies that the media ID recorded in the buffer zone 2 is valid (step S 48 ).
If the media ID is not valid (step S 48 :NO), the recording device 1000 overwrites the media ID recorded in the buffer zone 2 with the media ID recorded in the Initial Zone (step S 49 ). If the media ID is valid (step S 48 :YES), the recording device 1000 does not perform the overwrite processing. Thereafter, the recording device 1000 encrypts the AV data stored in the AV pack storage unit 106 , with use of the MKB, media ID, title key, etc., and records the encrypted AV data in the data area (step S 46 ). Note that as mentioned in detail in the description of the encryption unit 105 , the encryption processing in step S 46 is performed similarly to encryption processing in CPRM. Also, although in the above description processing ends if the MKB is not valid (step S 47 :NO), the present invention is not limited to this. Instead, the recording device 1000 may overwrite the MKB recorded in the buffer zone 2 with the MKB recorded in the Initial Zone. Also, although in the above description the recording device 1000 overwrites the media ID recorded in the buffer zone 2 with the media ID recorded in the Initial Zone (step S 49 ) if the media ID is not valid (step S 48 :NO), the present invention is not limited to this. Instead, processing may end if the media ID is not valid.
The following describes operations performed by the playback device 3000 .
FIG. 5 is a flowchart showing processing performed by the playback device 3000 .
As shown in FIG. 5 , the playback device 3000 judges whether the MKB and media ID are recorded in the buffer zone 2 (step S 51 ). If the judgment is affirmative (step S 51 :YES), the playback device 3000 acquires the MKB and media ID from the buffer zone 2 (step S 52 ).
Upon acquiring the MKB and media ID (step S 52 ), the playback device 3000 decrypts the AV data with use of the acquired MKB and media ID (step S 53 ).
Also, processing ends if the playback device 3000 judges in step S 51 that the MKB and media ID are not recorded in the buffer zone 2 (step S 51 :NO).
Supplementary Remarks
Although a recording device pertaining to the present invention has been described based on the above embodiment, variations such as the following are also possible, and the present invention should of course not be limited to the recording device described in the above embodiment.
(1) Although the playback device is described as not being able to read information from the Initial Zone in the above embodiment, the present invention is not limited to this. The playback device may be able to read information from the Initial Zone.
In this case, the playback device may, as in a playback device 3100 shown in FIG. 6 , further include a check unit 306 that reads an MKB etc. from the Initial Zone and the buffer zone 2 and verifies the validity of the read MKB etc. The check unit 306 calculates a hash value for the MKB recorded in the buffer zone 2 , and verifies the validity of the MKB by comparing the calculated hash value to the MKB validation data recorded in the BCA. The check unit 306 also verifies the validity of the media ID recorded in the buffer zone 2 by performing a comparison with the media ID recorded in the BCA.
This enables the playback device 3100 to verify the validity of the MKB and media ID recorded in the buffer zone 2 of the recording medium 2000 .
Furthermore, the playback device 3100 may end processing such as decoding if a result of the verification is negative. FIG. 7 is a flowchart showing processing performed by the playback device 3100 .
As shown in FIG. 7 , the playback device 3100 judges whether the MKB and media ID are recorded in the buffer zone 2 (step S 71 ). If the judgment is negative (step S 71 :NO), the playback device 3100 acquires the MKB and media ID from the Initial Zone (step S 74 ), and decrypts the AV data with use of the acquired MKB and media ID (step S 75 ).
If the playback device 3100 judges in step S 71 that the MKB and media ID are recorded in the buffer zone 2 (step S 71 :YES), the check unit 306 verifies the validity of the MKB recorded in the buffer zone 2 (step S 72 ). If the MKB recorded in the buffer zone 2 is valid, that is, if the MKB recorded in the buffer zone 2 is the same as the MKB recorded in the Initial Zone (step S 72 :YES), the check unit 306 similarly verifies the validity of the media ID recorded in the buffer zone 2 (step S 73 ). If the media ID recorded in the buffer zone 2 is valid (step S 73 :YES), the playback device 3100 acquires the MKB and media ID from the buffer zone 2 or the Initial Zone (step S 74 ), and decrypts the AV data with use of the acquired MKB and media ID (step S 75 ).
Also, if the MKB or media ID recorded in the buffer zone 2 are not valid (step S 72 :NO or step S 73 :NO), processing ends without the AV data being decrypted.
Note that if the MKB or media ID recorded in the buffer zone 2 are not valid (step S 72 :NO or step S 73 :NO), processing such as decryption may be performed with use of the MKB etc. recorded in the Initial Zone.
(2) Although the recording device 1000 reads information from the Initial Zone and records the read information in the buffer zone 2 in the above embodiment, the present invention is not limited to this. Instead of the buffer zone 2 , the recording device 1000 may record the read information in another area such as the data area.
Also, the information to be recorded in the buffer zone 2 may be an ADIP (Address In Pre-groove).
Also, information recorded in an area other than the Initial Zone may be recorded in the buffer zone 2 etc.
(3) Although a media ID is read and recorded in the above embodiment, the present invention is not limited to this. A media ID seed may be read and recorded. A media ID is generated by processing the media ID seed using a random number generating function.
(4) Although an exemplary case of using a DVD+RW disk compatible with CPRM is described in the above embodiment, the present invention is not limited to this. The present invention also includes cases of recording to any optical disk or other recording medium.
(5) The devices of the above embodiment and variations may be computer systems structured specifically from a microprocessor, a ROM, a RAM, a hard disk unit, a display unit, a keyboard, a mouse, etc. A computer program is stored in the RAM or the hard disk unit. The devices achieve their functions as the microprocessor operates in accordance with the computer program. Instruction code which indicates commands to the computer is structured as a combination of multiple instruction codes in order for the computer program to achieve predetermined functions.
(6) A portion or all of the constituent elements of the devices of the above embodiment and variations may be structured as a single system LSI (Large Scale Integration). A system LSI is a super multifunctional LSI manufactured by integrating a plurality of structural units onto a single chip. Specifically, it is a computer system including a microprocessor, a ROM, a RAM, and the like. A computer program is stored in the RAM. The system LSI achieves its functions as the microprocessor operates in accordance with the computer program.
(7) A portion or all of the constituent elements of the devices of the above embodiment and variations may be structured as a removable IC card or stand-alone module. The IC card or the module is a computer system including a microprocessor, a ROM, and a RAM. The IC card and the module may include the above super multifunctional LSI. The IC card and the module achieve their functions as the microprocessor operates in accordance with the computer program. This IC card or module may be tamper resistant.
(8) The present invention may be the methods shown above. Also, the present invention may be computer programs for causing computers to realize the methods, or may be digital signals representing the computer programs.
Also, the present invention may be a computer-readable recording medium such as a flexible disk, a hard disk, a CD-ROM, an MO, a DVD, a DVD-ROM, a DVD-RAM, a BD (Blu-ray Disc), or a semiconductor memory on which the computer programs or the digital signals are recorded. The present invention may be the computer programs or the digital signals which are recorded on these recording media.
Also, the present invention may be the computer programs or digital signals which are transmitted via an electronic communications circuit, a wireless or fixed-line communications circuit, a network such as the Internet, a data broadcast, etc.
Also, the present invention may be a computer system including a microprocessor and a memory, whereby the memory stores the computer programs, and the microprocessor operates in accordance with the computer programs.
Also, the present invention may be carried out by another independent computer system by transferring the programs or the digital signals which have been recorded on the recording media, or by transferring the programs or the digital signals via the network, etc.
(9) The present invention may be any combination of the above embodiment and variations.
INDUSTRIAL APPLICABILITY
The present invention can be used in a recording device that records data such as content to a recording medium such as a DVD, for which more than one standard has been established.
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A recording device performs recording on a recording medium such as a DVD, and playback compatibility of the recording medium is increased. In circumstances such as when a standard is established after the manufacture of a playback apparatus, there are playback devices that physically cannot read information for decrypting encrypted data from a predetermined area of the recording medium due to the specifications of the playback apparatus, and therefore the playback apparatus cannot use the recording medium. In order for the recording medium to be able to be used in such a playback apparatus, the recording device reads data recorded in the predetermined area of the recording medium, and records the read data in another area that is readable by the playback apparatus.
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RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/319,259, filed Jan. 5, 2009, now U.S. Pat. No. 7,773,375 which in turn claims priority from provisional applications 61/019,207 and 61/019,209, both filed Jan. 4, 2008 and both hereby incorporated by reference as if fully set forth herein.
TECHNICAL FIELD
The present disclosure is related to a ruggedized electrical device, able to operate reliably from a power bus that suffers intermittent voltage reductions and aspects thereof. More specifically, the electrical device may be a computer.
BACKGROUND
In vehicles and devices there is an increasing need for a rugged computer assembly that is isolated from the elements and that can function with high reliability even though powered by a bus that is intermittently unable to meet the full power demand placed upon it.
SUMMARY
The embodiments described below generally address the need for a ruggedized computer that can be deployed in a physical environment where it receives physical impacts and where it may have gases, liquids and solid/liquid mixtures (eg. mud) contacting its outside surfaces. Also, available electrical power may be subject to intermittent failure. Many issues arise in the design of this type of device, and many of the solutions to these issues may find application in other fields.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic diagram of a mobile power system employing a power supply unit configured in accordance with an embodiment of the disclosure.
FIG. 2 is a schematic diagram illustrating the power supply unit of FIG. 1 in more detail.
FIG. 3 is a flow diagram showing operation of the power supply unit in accordance with an embodiment of the disclosure.
FIG. 4 is a schematic diagram of the power supply assembly in accordance with an embodiment of the disclosure.
FIG. 5 is a side cross-sectional view of an integrated circuit and a thermal assembly designed to absorb heat therefrom.
FIG. 6 is a cross-section plan view of a liquid-tight computer case and fan, according to the present invention.
DETAILED DESCRIPTION
Several aspects of the present disclosure are directed to aspects of a rugged computer assembly that can function with high reliability even when supplied by a bus that intermittently fails to meet power demand. Skilled persons will understand that additional embodiments may be practiced without several of the details described below, and that other embodiments may include aspects in addition to those described below.
FIG. 1 is a schematic diagram of a mobile power system 100 including a DC power source 102 , one or more electronic devices 104 , and a power supply unit 106 that can operably couple the power source 102 with the electronic devices 104 via input and output power busses 108 and 110 . In several embodiments, the power supply unit 106 can also exchange serial data with the electronic devices 104 via a serial link 112 (described further with reference to FIG. 4 ). In general, the power source 102 provides raw DC power, and can include a variety of elements, such as a battery, an alternator, and/or any one of various types of AC-to-DC converters. In many embodiments, the electronic devices 104 include any of a myriad of consumer electronic devices that are configured to receive DC power (e.g., a personal computer, a mobile phone, a GPS unit, etc.).
In other embodiments, the electronic devices 104 can be incorporated and/or integrated with the power supply unit 106 . Such a combination can be deployed as a single unit, for example, as a computing device that can be energized by the (raw) DC power source on input bus 108 without any intervening components. In addition, embodiments of this type of device can be deployed in a single rugged and protective housing, as described further below with reference to FIGS. 5 and 6 .
FIG. 2 is a schematic diagram illustrating the power supply unit 106 in more detail. In the example shown in FIG. 2 , the power supply unit 106 includes a preregulator 210 coupled to the input bus 108 . For example, in an automobile electronic system, the voltage at the input bus 108 can be in a range of about −50 to +60V, and the preregulator 210 can step down this voltage to a range of about +8 to +22V. In several embodiments the preregulator 210 includes an automotive grade switching regulator to achieve this task. A preregulator output diode 216 , couples the output of preregulator 210 to a first internal bus 214 . In turn, a main switch 212 couples (and de-couples) bus 214 to output bus 110 . The power supply unit 106 also includes a battery 220 (e.g., a sealed lead acid, NiMH, LiPo battery, or UPS battery system of sufficient current capability for the application), the positive terminal of which being connected to an output diode 226 terminal. The other terminal of diode 226 is connected to a second internal power bus 224 . A boost converter 228 is electrically interposed between the first and second buses 214 and 224 . For example, the boost converter 228 can output a regulated voltage in a range of about 13-14V, which can trickle charge a 12 V battery 220 , or a range of 25 to 27V for charging a 24 V battery. A battery switch 222 is couples first bus 214 to second bus 224 . In a representative embodiment, the power supply unit 106 includes a logic/control assembly 230 that controls the main switch 212 , the battery switch 222 , and the boost converter 226 . In addition, the logic/control assembly 230 can also exchange serial communications 232 with the electronic devices 104 . For example, the serial communications 232 can indicate events such as whether the battery 220 is recharging or whether the battery 220 is supplying power to the electric devices 104 . Communications 232 can also provide a way to change other programmable power supply 106 features during operation such as program timing changes and trigger points and can even replace the entire program for the logic control assembly 230 with a newer version (described further with reference to FIG. 4 ).
The logic control/control assembly 230 generally operates the power supply unit 106 in one of at least two states of operation. In a first state of operation and/or when the preregulator output voltage V 1 is at or above a predetermined trigger point, the boost converter 226 charges battery 220 with a boosted voltage V 2 and maintains battery switch 222 in an open state so that first internal bus 214 is powered by preregulator 210 , rather than battery 220 . In a second state of operation commanded when the preregulator output voltage V 1 is below the trigger point, the logic/control assembly 230 de-activates the boost converter 228 and couples the second bus 224 with the first bus 214 via the battery switch 222 , thereby powering devices 104 from the battery 220 .
FIG. 3 is a flow diagram showing an embodiment of a method of operating the power supply unit 106 . The flow chart begins with unit 106 in the first operational state, its most typical condition, receiving above-trigger point voltage on bus 108 and with boost converter 228 activated and switch 222 closed. In the next instant, the logic control assembly 230 detects whether the preregulator output voltage V 1 is still above the trigger point (block 342 ), indicating an adequate voltage V 1 . If it is, nothing is changed (block 344 ). If the first bus voltage V 1 is less than the predetermined trigger point, the second operational state is commanded. Boost converter 228 is disabled and the battery switch 222 is closed (block 348 ). In this second state, the battery 220 drives the first bus 214 , thereby powering devices 104 . From this state, V 1 is tested against the trigger point (block 350 ). The diode 216 permits a higher voltage to exist on bus 214 than at the output of preregulator 210 . This is essential for sensing the restoration of preregulator output voltage after a voltage low condition. (decision box 350 ). When V 1 again rises above the trigger point, it is determined if time conditions have been met (decision box 360 ) to switch back to the first state (block 370 ), in which converter 228 is activated and 222 is closed.
The time conditions of decision box 360 are designed to prevent a rapid toggling between states. If, for example, V 1 has been lowered due to a current demand from another device, the removal of the load of power supply 106 may be enough to cause the V 1 to recover in, for example, a millisecond. If there were no timing conditions, this would cause converter 228 to be immediately reactivated, causing V 1 to go low again in, for example, a millisecond. In this manner unit 106 could oscillate between states at a 0.5 mHz rate, which would be harmful to system operation. In one preferred embodiment a one second timeout is implemented from the time converter 228 is deactivated, to the time when it may be reactivated. Typically battery 220 stores enough charge so that the timeout period could be made quite a bit longer than one second, without threatening to drain battery 220 . In a preferred embodiment, timing conditions are set to match the characteristics of the overall system. In many embodiments the timeout function is performed by a hysteresis circuit associated to the boost converter 226 . In other preferred embodiments, the timeout function is performed by the logic/control assembly 230 .
FIG. 4 is a schematic diagram of components of the power supply unit 106 , including the first and second busses 214 and 224 , the boost converter 228 , the switches 212 and 222 , and individual logic/control components 230 . More specifically, the logic control components 230 include a microcontroller 360 and voltage detect components 362 and 364 hardware wired to the enables of the boost converter 228 and the battery switch 222 , respectively (in many embodiments, the boost converter 228 and the battery switch 222 can also be coupled to the microcontroller 360 ). In general, the microcontroller 360 includes a processor, associated program instructions, and system control and serial communication components. The voltage detect component 362 can measure whether the first bus voltage V 1 is at or above the trigger point voltage, and the microcontroller 360 can enable the battery switch 222 and the boost converter 228 based on the detected first bus voltage V 1 . The voltage detect component 364 , on the other hand, can measure the voltage level of the second bus 224 and/or the battery 220 . For example, the microcontroller 360 can use the voltage detect component 364 to determine whether the battery 220 is operational and/or to determine charge level at the battery —
In many embodiments, the microcontroller 360 can also enable the main switch 212 depending on the state of the first and/or second busses 214 and 224 . If the electronic device 104 is a PC motherboard, for example, the microcontroller 360 can be configured to disable the standby or sleep voltage demand of the power supplied to the motherboard by disabling the main switch 212 only after the motherboard has communicated to the microcontroller 360 that it is completely shut down. In such an example, the motherboard may have one of two interactive logic level bits attached to the front panel header. One bit is an LED output for “CPU-on” and the other is a front panel switch input bit.
The microcontroller 360 can be configured to sense the voltage at the first bus 214 , interpret this as a “computer-on” command and activate the motherboard. To do this, the microcontroller 360 can pulse an off/on switch bit on the motherboard and also verify at the “CPU-on” output that the motherboard has booted. For example, whenever the input bus 108 (or first bus 214 ) is powered, the microcontroller 360 can be configured to verify that the motherboard is running or needs to be booted. When the input bus 108 (or first bus 214 ) has been down for a predetermined amount of time, the microcontroller 360 can interpret this is a command to “turn off” the motherboard and do so by pulsing the on/off front panel bit on the motherboard and request a shutdown from a (power aware) operating system. Battery 220 provides power during an orderly motherboard “turn off” sequence. One aspect of such a configuration of the microcontroller 360 is that many or all of processes carried out by the power supply unit 106 use no (or limited) software drivers, and system control can accordingly be carried out exclusively in hardware, based on the state of power at the input bus 108 and the operating state of the motherboard. This eliminates the need for a third wire, needed to indicate the beginning of a “turn off” sequence, that complicates prior art designs.
The above described system addresses numerous deficiencies in previously available power supply systems. For example, conventional power supplies use a boost converter-regulated front-end to maintain a tightly regulated intermediate bus voltage during DC power deviation or “sag” at the main bus. Such a topology demands proportionally increased current from the main bus in order to offset voltage sag. This creates a conflict condition when another device on the main bus is demanding high current, resulting in neither device being able to draw enough current to maintain its required internal voltage. Also, although the typical boost converter includes storage capacitors to provide power during power interrupts, these capacitors are quickly drained, again resulting in an insufficient intermediate bus voltage. Additionally, although existing uninterruptible power supply (UPS) systems include a battery, the battery is typically in-line-float-charged from the boost converter. Such an arrangement causes the battery to always be in-circuit and prevents the battery from being charged at the optimum charge voltage level. This compromises the life of a conventional battery system and the ability to meet current demand. Furthermore, conventional (controllable) DC based power supplies use fixed timers to control the shutdown and/or reboot sequences and times and are not interactive with external devices or components of an external device (e.g., a motherboard). In general, these supplies require a ‘three wire’ connection with a user switch for shutdown activation, and they have no user communication ports for real-time parameter changes or to control sequences of operation.
Embodiments of the power supply unit 106 , however, mitigate these and other issues associated with conventional power supplies and converters. For example, the boost converter 228 is disabled when the main bus voltage drops below a programmable trigger point, reducing current demand from the pre-regulator 210 and thereby avoiding competition with other devices for main bus current. During these periods switch 222 is closed, permitting battery 220 to maintain proper voltage on intermediate bus 214 for far longer than do the converter storage capacitors in existing systems. Battery 220 is either supplying power or being charged at an ideal charging voltage. This preserves battery life and maximized the probability that when the battery is called upon to supply power it will be able to do so adequately.
Referring to FIGS. 5 and 6 , the electrical network described above finds application in a rugged computer system. In a preferred embodiment, this system includes a processor integrated circuit (IC) 606 and two hard disk drives sealed within a metal case 608 ( FIG. 6 ). One challenge in providing a system of this type is cooling and providing thermal stability for the electrical components without a capability of blowing air in from the outside. To meet the need of cooling the processor IC 606 , a thermal assembly 610 is provided. This system includes the IC 606 , which is electrically and physically connected to a printed circuit board (PCB) substrate 614 by a set of solder balls (not shown). A slide plate 616 is positioned above and placed in thermal contact with the IC 606 . In turn, a thermal mass 618 is positioned above and placed in thermal contact with the slide plate 616 . Finally, the thermal mass 618 is in thermal contact with the case 608 . Thermal grease 619 is interposed between and permits thermal flow between the four components 606 , 616 , 618 and 608 . Accordingly, the heat produced by IC 606 flows to slide plate 616 , from whence it flows to thermal mass 618 , and then to case 608 . Thermal mass 618 also acts as a heat reservoir, changing only slowly and preventing an overly rapid change in the temperature of IC 606 . The whole assembly 610 must maintain a tension to resist shock and vibration so elastomeric bumpers 612 are used to help constrain the PCB substrate 614 and to dampen vibration.
A great challenge in the design of thermal assembly is avoiding physical damage to the system, in particular to the solder balls connecting IC 606 to PCB substrate 614 . If permitted, in the environment of physical shocks in which the rugged computer is designed to be deployed, the physical mass of thermal mass 618 could easily impact slide plate 616 into IC 606 , thereby crushing the solder balls or cracking IC 606 . Also the heating and cooling of the product over its lifetime will expand and contract the internal parts at different rates creating shear conditions on the connections to the IC 606 . To prevent damage to the solder balls, slide plate 616 is mounted from pins 620 mounted in PCB substrate 614 and is suspended from pins 620 by tension springs 622 . Accordingly, slide plate 616 can ride up and down with IC 606 and shift in coplanar dimension relative to the contact surfaces of IC 606 , thereby avoiding stress to the solder balls and to IC 606 .
Thermal mass 618 is fastened to the case 608 by stud 630 . This connection suspends mass 618 over slide plate 616 , to control the pressure of mass 618 on slide plate 616 . As noted, thermal contact is maintained between mass 618 and slide plate 616 by thermal grease 619 , which permits relative movement between the two components.
Referring specifically to FIG. 6 , the above described assembly is housed in case 608 (bottom half shown), which has an internal fan 640 to blow air through a series of plenums, thereby distributing heat throughout the system, and stabilizing any heat contributions not already mechanically connected to the thermal structure. In a preferred embodiment, IC 606 produces 35 Watts of heat at full operation and assembly 610 (including case 608 ) takes 7 hours for its temperature to be elevated from a starting temperature of 15° C. to 50° C. The temperature of assembly 610 thereafter remains at a stable 50° C. in ambient air temperatures of up to 30° C. Moreover, a preferred embodiment includes a chip set that supports IC 606 and that also requires a thermal stack, similar to assembly 610 to remove heat and lessen thermal cycling while avoiding physical damage. In this embodiment slide plate 616 and thermal mass 618 are made of 2024 aluminum alloy, case 608 is of cast aluminum. Slide plate 616 has a mass of 40.8 grams for the CPU assembly 610 and 49.9 grams for the parallel assembly for the chip set. Also, thermal mass 618 has a mass of 99.8 grams for the CPU assembly 610 and 136.1 grams for the parallel assembly for the chip set. Finally, case 608 has a mass of 2536 grams and a surface area of 1332.4 cm 2 .
From the foregoing, it will be appreciated that representative embodiments have been described herein for purposes of illustration, but that various modifications may be made to these embodiments, including adding and/or eliminating particular features. For example, in some embodiments the main switch 212 can be omitted. Also, in other embodiments, the logic/control components 230 may include other components and/or configurations. For example, one or more of the voltage detect circuits 362 and 364 can be functionally programmed into the microcontroller 360 (see also Appendix C). In addition, while representative examples of the system were described above in the context of DC power, other embodiments may include other types of power, such as DC-pulsed power or AC power. Further, while advantages associated with certain embodiments have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. The following examples and appendices provide further representative embodiments.
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A mechanical and thermal assembly adapted to absorb heat from a delicate, heat-producing structure having a planar surface includes a slide plate in thermal contact to said planar surface, and being held in place by a resilient system that permits, but gently resists, movement perpendicular to said planar surface and a thermal mass, suspended over said slide plate, but in thermal contact to said slide plate, so that said delicate, heat-producing structure is not damaged due to force applied from said thermal mass through said slide plate to said structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a seat adjusting device and more specifically, to an improved spring and locking mechanism for an automotive vehicle seat adjusting device of the type which includes a rod pivotally attached to the seat back and slidable for selective positioning within a locking mechanism fixed to the seat.
2. Description of the Prior Art
Seat adjusting devices of the type which the present invention is directed to generally include a shaft or rod slidably received within a locking mechanism which includes a plurality of lockwashers slidably mounted on the rod, a fulcrum and a spring or other means biasing the lockwashers about the fulcrum to engage the edge of the lockwasher apertures with the surface of the rod and thereby hold or "lock" the rod in that position relative to the locking mechanism and the seat to which it is fixed. A manually actuable release mechanism, is usually associated with the locking mechanism to move the lockwashers against the spring or other biasing force and thereby selectively position the rod and seat back relative to the locking mechanism and seat at which point the release mechanism is deactuated thereby permitting the spring or other biasing means to cant the lockwashers into engagement with the rod and thereby hold the selected position. The release mechanism is frequently provided in the form of a rotary or pivoting cam actuated by means of a crank lever or a handle.
Automotive vehicle seat adusting devices of the type to which the present invention is directed are disclosed in U.S. Pat. Nos. 3,271,071 and 4,387,926. Those patents disclose a seat adjusting device comprising a rod slidably received by a locking mechanism enclosed within a stamped or tubular metal housing. Those seat adjusting devices are secured for pivotal movement relative to the seat elements by means of an aperture provided at one end of a rod and an aperture provided to the metal housing at the opposite end of the seat adjusting device. With such an arrangement, the forces developed between the lockwashers and the rod internally of the locking mechanism must be absorbed by the housing or transmitted by the housing through the element pivotally fixing the apertured end of the housing to one of the seat elements. Those seat adjusting devices also utilize coil springs internally of the housing to bias the lockwashers into engagement with the rod. The coil springs require a seat or other means opposite the lockwashers and guiding means such as the rod or other projections provided internally of the locking mechanism housing which constitute additional elements and require a more tedious and complex assembly of the seat adjusting device.
SUMMARY OF THE INVENTION
The present invention provides a locking mechanism for selectively axially positioning a rod relative to a support. The mechanism includes a fulcrum fixed relative to the support with the axis of the fulcrum normal the axis of the rod, a plurality of lock washers slidably received on the rod with at least one lockwasher on each side of the fulcrum, a channel shaped spring including a web extening across the thickness of all the lockwashers, at least one leg at each end of the web contacting the outermost ones of said lockwashers and biasing the lockwashers about the fulcrum to engage said rod, and manually actuable means for releasing said engagement.
The preferred embodiment includes a hollow tubular steel fulcrum and the web of the spring includes a cylindrical depression abutting a portion of the surface of the tubular fulcrum.
DESCRIPTION OF THE DRAWINGS
In the drawings, when like reference numerals refer to like parts:
FIG. 1 is a perspective view of an automotive vehicle seat which includes the seat adjusting device of the present invention;
FIG. 2 is a plan view of the seat adjusting device shown in FIG. 1;
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 2;
FIG. 4 is a front elevation view of the seat adjusting device shown in FIG. 1;
FIG. 5 is a sectional view taken on the line 5--5 of FIG. 3;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 3;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 3;
FIG. 8 is a side elevation view of one member of the locking mechanism housing;
FIG. 9 is a side elevation view of the other member of the locking mechanism housing;
FIG. 10 is a sectional view taken on line 10--10 of FIG. 8.
FIG. 11 is a sectional view taken on line 11--11 of FIG. 9; and
FIG. 12 is a perspective view of the lockwasher biasing spring.
DESCRIPTION OF THE INVENTION
With reference to the drawings, FIG. 1 shows an automotive vehicle seat 10 comprised of a seat portion 11 supported by a frame a portion of the which is shown at 12 and a seat back 14 supported by a pair of side back frames one of which is shown at 15. A seat adjusting device 20 includes a locking mechanism secured to the seat frame 12 and a rod 22 slidably received within the locking mechanism is pivotally secured by means of a pin 21 at the lower end of the seat back frame 15. A seat return coil spring 24 is provided between the side frame 15 and the locking mehchanism to bias the side frame 15 and seat back 14 to the upright position. A manually actuated lever 25 is provided to release the locking mechanism thereby permitting an occupant of the seat 10 to adjust the seat back 14 to a comfortable position by moving the lever 25 to release the locking mechanism and moving the seat back 14 which in turn will move the side frame and rod 22 relative to the locking mechanism at which time the occupant will release the lever 25 thereby locking the rod 22 and seat back 14 in that selected position.
With reference to FIGS. 2 and 3 the lever 25 is seated on the splined end 26 of a shaft 28 rotatably mounted to the locking mechanism generally indicated by the reference numeral 30. A return spring 24 is seated at one end on the locking mechanism 30 and at the other end on a pin carried by the shaft 28 to return the lever 25 and shaft 28 to its inoperative position upon release. The seat return spring 24 coxially with rod 22 is seated at its opposite ends against washers 16 and 17. The washer 16 bears against the housing of locking mechanism 30 to move the rod 22 to its fully extended position as shown in FIGS. 1-3. The end of the rod adjacent washer 17 is provided with an aperture 19 for receiving the pin 21 which pivotally connects the rod 22 to the lower end of the seat back frame 15 which in turn is pivoted for rocking movement about a pin 18.
The locking mechanisms includes a plurality of lockwashers 31 and 32, a fulcrum in the form of a hollow steel tube 34, a formed spring 40 and a cam 35 enclosed within a housing 50.
The lockwasher 31 and 32 are apertured with the diameter of the aperture being slightly larger than the diameter of the rod 22 so as to enable the washers to be tilted or canted about the fulcrum tube 32 with an edge of each aperture engaging the surface of the rod 22 with the net effect of the edges of the apertures of all of the lockwashers 31 and 32 preventing relative movement between the rod 22 and the assembly of lockwashers 31 and 32.
The lockwashers are tilted or canted into engagement with rod 22 by the spring 40 which, as shown by FIGS. 3 and 12 is a formed spring of generally "C" or channel shape having a web portion 41 and a plurality of legs 42-44 and 46-48 at each end of the web. The web 41 is of sufficient width to extend across the combined thickness of the lockwashers 31 and 32 and is formed with a cylindrical depression 45 which is seated across the bottom of the tubular fulcrum 34 as shown by FIG. 3. The legs 42, 44 and 46, 48 are spaced so they may extend parallel to the opposite side walls of the housing 50, one on each side of the rod 22 where the legs 42, 44, 46 and 48 contact the lockwashers 31 which are most distant from the fulcrum 44 and cant those, as well as the intermediate lockwashers, into engagement with the rod 22. The spring leg 43 located between the legs 42 and 44 and the spring leg 47 located between the legs 46 and 48, although not as long as the legs 42, 44, 46 and 48 are nevertheless of sufficient length to extend beyond the axis of the tubular fulcrum 44 and add additional biasing force to urge the lockwashers about the fulcrum 34.
In addition to the locking operation provided by the biasing force of the spring 40, the spring 40 also maintains the stack of lockwashers 31 and 32, the tubular fulcrum 34 and itself as a unit subassembly on the rod 22 during assembly of the seat adjusting device 20.
The cam 35 is integrally formed as part of the shaft 28, see FIG. 5, which is seated for rotation in axially aligned apertures 59 and 69 provided through the locking mechanism housing 50.
The lockwashers 31, 32 are elongate and substantially rectangular in form. As shown by FIGS. 6 and 7, the vertical dimension is greater than the width of the lockwashers 31, 32 and this facilitates a very compact locking mechanism that fits snugly upon the seat frame 12 at the side of the seat. The number and specific arrangement of the lockwashers required depends upon each particular application. In the preferred embodiment, two control lockwashers 32 are provided as the innermost lockwashers immediately adjacent the fulcrum 34. As shown by FIGS. 3, 6 and 7, the control lockwashers 32 are of greater length at the top of the locking mechanism than are the lockwashers 31 to present a slightly larger area facing the rotary cam 35.
The locking mechanism housing 50 is a two-part housing formed by the combination of a first housing member 51 and a second housing member 61. As shown by FIGS. 8 and 10, the first housing member 51 is formed to provide a major side wall 52 and a plurality of other walls normal to the side wall 52 and defining a cavity complementary to the shape of about half of the locking mechanism per se. The edges of the walls normal to the major side wall 52 provide an inner peripheral edge surface 54. The front and the rear end walls of the housing 52 are formed to provide axially aligned semi-circular recesses or bosses 55 and 56. A pair of apertures 58 and 59 are also provided through the side wall 52 of the housing member 51.
The inner peripheral edge 54 of the housing member 51 is interrupted at several locations by the provision of a hook or detent 57, five of which are shown formed integrally with the first housing member 51.
As shown by FIGS. 9 and 11, the second housing member 61 is formed to provide another major side wall 62 and a plurality of other walls normal to the side wall 62 and defining a cavity complementary to the other half of the locking mechanism. The outer edges of the walls normal to the major side wall 62 define an inner peripheral edge surface 64 which is substantially a mirror image of the shape of the inner peripheral edge 54 of the first housing member 51. A pair of axially aligned semi-circular recesses or bosses 65 and 66 are provided to the inner peripheral edge 64 of the second housing member 61.
Portions of the inner peripheral edge 64 of the housing member 61 are also flanged as shown by the reference numberal 63 and a plurality of slots 67, five of which are shown, are formed at the inter section of the flanges 63 and one of the other walls normal to the side wall 62 of the housing member 61. A pair of apertures 68 and 69 are also provided through the side wall 62 of housing member 61.
The two parts 51 and 61 of the locking mechanism housing 50 are formed to be assembled to the seat adjusting device after the lockwashers, fulcrum and spring have been assembled to the rod by placing the housing members 51 and 61 on opposite sides of the rod 22 and applying a slight manual force to secure the two housing members together. The inner peripheral edges 54 and 64 are formed as mirror images one of the other so that they may be readily placed in abutment. The flanges 63 provided about portions of the inner peripheral edge 64 of housing member 61 are formed complementary to the outer surfaces of the walls of the housing member 51 to secure the housing members 51 and 61 against lateral displacement when the inner peripheral edges 54 and 64 are placed in abutment. Each of the detents 57 of the housing member 51 are located opposite one of the slots 67 of the housing member 61 and seat against a reverse surface of the opposing slot thereby securing the housing members 51 and 61 together.
The semi-circular bosses 55 and 56 of housing member 51 are axially algined with each other and with the semi-circular bosses 65, 66 of housing member 61 to surround the rod 22 and thereby permit the rod to extend through the circular apertures provided by the combination of the semi-circular bosses 55 and 65 and 56 and 66.
The aperture 58 of housing member 51 is also aligned on an axis with the aperture 68 of housing member 61 to receive the tubular fulcrum 34.
The aperture 59 of housing member 51 is also axially aligned with the aperture 69 of housing member 61 to receive and rotatably mount axially spaced rotary bearing surfaces of the cam shaft 28.
The housing members 51 and 61 are perferably formed by injection molding a thermoplastic resin and the housing members of the preferred embodiment are injection molded using a 30 percent glass filled nylon resin marketed by Allied Chemical Corporation as Grade 8233.
The injection molded thermaplastic housing members 51 and 61 thus provide a lightweight housing for the locking mechanism which is self-securing and is slidably seated on axially spaced ends of the tubular fulcrum 34. As shown by dotted lines in FIG. 5, the locking mechanism 30 is secured to and supported by the channel shaped seat frame 12 by means of a pin slidably received through the interior of the hollow tubular fulcrum 34 and peened 7 or otherwise secured at the interior of the channel shaped seat frame 12. The forces developed interiorly of the locking mechanism 30 are thus taken at the hollow tubular steel fulcrum 34 independently of the lightweight plastic housing and the fulcrum is attached directly to the seat frame. The biasing force of the spring 40 and the releasing force of the cam 35 are concentrated directly on the hollow steel tubular fulcrum 34.
The invention may also be embodied in other specific forms within departing from the spirit or essential characteristics thereof. The foregoing description is therefore to be considered as illustrative and not restrictive the scope of the invention being defined by the appended claims.
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An improved spring and locking mechanism for an automative seat adjusting device which includes a rod slidably for selective positioning within a locking mechanism fixed to the seat. The locking mechanism includes a hollow tubular steel fulcrum and a formed channel shaped spring having a web extending across the fulcrum and a plurality of lockwashers and a plurality of legs at each end of the web. The spring legs contact the outermost lockwashers and tilt or cant the lockwashers about the fulcrum.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to pellets which comprise at least one oily component which is itself alone an active component or comprises at least one such active component.
[0003] 2. Description of Related Art
[0004] Generally, such oily and/or active components are frequently oxidation-sensitive or readily volatile, so that over greater or lesser time periods the proportion of such active components is decreased or these components lose their activity.
[0005] For this reason, such components must be protected.
[0006] The invention can be used for the most varied types of application. Thus, the inventive pellets, by appropriate choice of suitable active components, can be used in animal and human nutrition, as a dosage form for pharmaceuticals, for cleaning composition additives, as crop protection agents and other fields.
[0007] Thus, it is known from the prior art to emulsify oily components, which can additionally also comprise active components, and use such an emulsion immediately. However, this is only possible over a limited time period, since the long-term stability of such emulsions is not unlimited and, moreover, preservatives frequently cannot be used.
[0008] For this reason, the emulsions are processed to form powders. This is performed, as is also described in EP 0 598 920 B 1, by spray-drying an emulsion. According to the teaching which follows from there, an emulsion is produced with an oil phase and a very specific soybean hemicellulose which is water-soluble as emulsifier. From this emulsion, a powder is produced in the form of microcapsules by spray-drying, and in this process in the microcapsules, in addition to the oily phase, other or further active components can also be present.
[0009] Such a powder which is formed from corresponding microcapsules, however, achieves a limited loading, and therefore has a low content of the respective active component, since the outer casing must be sufficiently thick and sealed to prevent effects due to ambient moisture or the volatilization of active components from the microcapsules.
[0010] Furthermore, due to the process, during the production of powder by spray-drying, an unwanted predominantly thermally caused adverse effect on the active components is unavoidable, so that at least their activity is reduced.
[0011] However, this fact also affects the solution described in EP 1 214 892 A2. In this case, however, it is additionally disadvantageous that the respective active component, whether it be solely an oily component or an oily component additionally with a further active component, is additionally encapsulated around an inert core, so that accordingly the content of active components present in such capsules is reduced per unit volume and in relation to the total mass.
[0012] Furthermore, the conventional powders produced from emulsions have a limited mechanical strength, so that in particular during transport and storage high abrasion occurs, or even fracture of the capsules can occur, and accordingly volatilization of, or unwanted effects on, the components can occur.
[0013] The powders produced by spray-drying are only free-flowing with limitations, so that an exact dosage can only be achieved with great complexity.
[0014] If the powder particles are to be coated with an outer protective coating to improve the abovementioned properties, because of their very high surface areas, a very large amount of coating material is required. Thus, for the development of sealed coatings, mass to ratios of powder and coating material up to 1:1 may be necessary, which leads to increased production costs and a reduction in the proportion of active component to the volume of the mass.
SUMMARY OF THE INVENTION
[0015] Accordingly, it is an object of the invention to provide oxidation-sensitive active components which are also in addition or alone readily volatile in the form of oils and/or active components additionally present in such oils which are long-term stable at elevated concentration for subsequent administration ox further processing.
[0016] These and other objects of the invention are achieved with a pellet in which, in a homogeneous discrete distribution, at least one oily oxidation-sensitive and/or readily volatile active component and/or such an active component present in an oily component is encapsulated without a core in a matrix which comprises at least one water-soluble polysaccharide as film-forming agent and has a particle size of at least 100 μm. The inventive pellets can be produced by a process for producing pellets in which at least one oily component is present in a matrix in encapsulated form without a core alone or with an additional active component and individual capsules are arranged discretely and homogeneously distributed; in which an aqueous emulsion is produced which, in addition to at least one oily component, comprises at least one water-soluble polysaccharide as film-forming agent, in which emulsion the oily component is present in finely divided form, a matrix-forming substance or mixture of substances is added to this emulsion to set a doughy consistency and pellets are produced therefrom. Advantageous further developments and refinements of the invention will now be described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Compared with the solutions known from the prior art, the inventive pellets are distinguished in that the respective active components are present in them at high concentration and nevertheless are reliably protected.
[0018] For this, the active components are encapsulated in a homogeneous discrete distribution in a matrix which comprises a water-soluble polysaccharide as film-forming agent. In the individual pellets, no inert cores whatsoever are present. They each have a particle size of at least 100 μm, preferably of at least 300 μm.
[0019] The high content of active components present in such pellets can be achieved, in particular, by the likewise inventive production process, with more detailed descriptions on this following below. he inventive film-forming polysaccharide to be used should be present at at least a proportion of 0.5% by mass. The content of these film-forming agents can, however, also be chosen to be significantly greater and be up to 60% by mass. In particular, the film-forming agent used ensures that the one or else optionally more enclosed component(s) in the matrix can be incorporated in the form of discretely dispersed capsules.
[0020] Polysaccharides which have proved to be particularly suitable for this are, in particular, water-soluble hemicellulose, which can be produced for example from soybeans or rapeseed, and/or modified starch and/or pectin compounds.
[0021] The water-soluble polysaccharides are harmless physiologically and to the environment.
[0022] In addition, compared with pure natural products, for example gum arabic, they can be provided in virtually identical quality and with virtually constant costs, that is to say independently of climatic conditions which affect the costs of natural film-forming substances.
[0023] Furthermore, a markedly higher consumer acceptance is provided, compared with the gelatin also customarily used for this.
[0024] For the matrix, non-water-soluble carbohydrates can be used. These can be selected from starches or cellulose components.
[0025] Different starches can be used to develop the matrix, in which case malt starch or else cereal starch is particularly suitable for this. These can each be used alone or else in combination with one another.
[0026] For the matrix formation, a suitable cellulose component is in particular microcrystalline cellulose (MCC).
[0027] The mass fraction of starch can be up to a maximum of 90% by mass. In addition to said organic components, a matrix can also be formed from inorganic components, or can comprise such components.
[0028] Suitable inorganic substances are, for example, kaolin, CaCO 3 , Cas, silicates, clay, bentonite, diatomaceous earth or aluminum oxide, which can also be used as a mixture.
[0029] The inorganic components should also be as far as possible non-water-soluble.
[0030] In addition, however, mono-, di- or trisaccharides may also be present, in which case here too differing mass fractions which can be above 50%, by mass can be maintained.
[0031] In addition to neutral oily components, that is to say those which do not have an active effect, oily components haring an active effect can also be used for producing inventive pellets. The content of this component should preferably be at least 15% by mass. Components which have proved to be advantageous are, in particular, the various fruit oils, but also fruit oil extracts. Thus, the oily component can be formed, for example, from orange oil and/or lemon oil. Merely the aromatic flavor and odor notes of these oily components can achieve the desired active effect alone, or if appropriate also together with additional active components.
[0032] Additional active components which can be used, however, are also synthetic or natural colorings. Thus, for example, carotene, preferably betacarotene, canthaxanthin or astaxanthin can be used for this, which, in addition to the coloring action, have the relevant known additional actions.
[0033] Furthermore, active components which can also be used as active component are vitamins, preferably oil-soluble vitamins, for example vitamin A acetate, a combination of these vitamins with carotene also being possible.
[0034] In addition to the vitamins, however, other pharmaceutically active substances can also be used as active component. Other possible active components are various insecticides/biocides.
[0035] For subsequent applications of the inventive pellets in cleaning agents or also, if appropriate, in cosmetics, differing aroma substances having correspondingly 30 pleasant flavor notes can be used, if appropriate together with surfactants. For foods, flavorings having flavor and/or odor notes can be used.
[0036] However, the active component can also be unsaturated fatty acids, for example alpha-omega-polyunsaturated fatty acids.
[0037] Active components additionally present in the capsules together with the oily component need not obligatorily be oil-soluble. They can also be present in dispersed form, as small crystals in an oily component. Thus, there is the possibility of dispersing unstable vitamins, for example vitamin K (MSBC), in fine crystalline form in an oily component and encapsulating them in the pellets correspondingly with the oily component.
[0038] The proportion of the volume occupied by the capsules embedded in the matrix should be kept above 10%, preferably above 20%. However, there is also the possibility of setting the corresponding volume fraction beyond this and accordingly significantly increasing the proportion, that is to say the loading with active components, in the pellets.
[0039] The water content in the finished pellets should be 20 kept less than 10% by mass.
[0040] The inventive pellets, in contrast to the powders which are produced in the prior art by spray-drying, are obtained by a combination of producing emulsion with 25 subsequent direct pelleting or extrusion.
[0041] In this case, for producing the emulsion, at least one starch, one oily component, one water-soluble polysaccharide as film-former and water are used.
[0042] Starch, for example, can additionally be added to the resultant emulsion, in order to increase the viscosity and to establish a doughy consistency.
[0043] In this state, preferably an extrusion can be performed, in which case, from the respective extruder, the still slightly moist pellets can then be removed. The pellets can if appropriate be further mechanically reprocessed, preferably rounded.
[0044] Furthermore, redrying can follow, in order to reduce the water content further, and there is also the possibility of providing the individual pellets with a protective coating which preferably forms moisture protection and if appropriate can also prevent the pellets from sticking together.
[0045] Surprisingly, it has been found that an emulsion in which an oily component is distributed in at least a finely dispersed manner and containing a water-soluble polysaccharide as film-forming agent, by, for example, adding viscosity-increasing further starch, during an extrusion, the capsules formed which comprise the oily component and if appropriate further active components are embedded into the matrix and are not destroyed in the course of this. Furthermore, a homogeneous, that is to say a very uniform, distribution of the small capsules within the matrix of the individual pellets can be achieved. Depending on the number and correspondingly the proportion of the capsules embedded into the matrix, a greater or lesser loading, that is to say a corresponding content of active components, can be established, which can be kept at up to 20% by mass and even above.
[0046] In the extrusion, relatively fine dies can also be used, so that the pellets, after the extrusion, orthogonally to the direction of extrusion can have diameters in the region around 1 mm.
[0047] Obviously, pellet cross sections are achievable which are also larger, and if appropriate also somewhat below 1 mm.
[0048] In the extrusion, in particular a temperature lower than that used in spray-drying can be employed, so that the active components used as a result are also less adversely affected. Fewer evaporation losses occur.
[0049] In the extrusion, relatively low pressures can be employed. Also by this means a gentle treatment of the encapsulated active components can be achieved and can ensure that the active components are protected from the unwanted external influences and can be kept sealed safely within the matrix of the pellets. The starch and/or cellulose component essentially used for forming the matrix is safe physiologically and for the environment and is also predominantly odor-and taste-neutral.
[0050] Furthermore, the inventively produced pellets also have a good mechanical stability, so that a reduced abrasion can be achieved.
[0051] The invention will be described in more detail below by way of example.
EXAMPLE 1
[0052] To produce an emulsion, 10 kg of modified starch (Hicap) were intensively mixed with 30 kg of water, 8 kg of orange oil and 2 kg of malt starch. This was followed by homogenization at approximately 200 bar in a Niro homogenizer. The emulsion thus prepared was brought to a doughy consistency by adding 12 kg of cereal starch powder with subsequent mixing. The resultant mixture was then extruded using a Fuji-Paudal low-pressure extruder. A pellet cross section of 1.2 mm was established using appropriate extruder dies.
[0053] The resultant pellets were then rounded and then redried in a fluidized bed until a water content of about 4% was maintained. The air was dried in a closed circuit by directing the air above a silica gel water-absorbent and returning the air into the fluidized bed.
[0054] The loss of orange oil as active component was 8%, so that the mass fraction of orange oil in the finished pellets could be maintained above 18% by mass.
EXAMPLE 2
[0055] To produce the emulsion, 6 kg of hemicellulose as soybean-based film-forming agent, 6 kg of malt starch, 30 kg of water and 36 kg of orange oil were mixed intensively with one another. This preemulsion was then likewise homogenized at approximately 200 bar in a Niro homogenizer.
[0056] Then 6 kg of malt starch and 9 kg of cereal starch were added to this homogenized emulsion and mixed together in such a manner that a doughy extrudable consistency was established. This was then likewise extruded and dried as already described in example 1.
[0057] The water content, likewise after drying had been performed, was approximately 4% by mass, and the orange oil content was maintained at 54% by mass, a loss of only 2% of orange oil being recorded.
EXAMPLE 3
[0058] In this case, 16 kg of modified starch (Hicap 100), 27.2 kg of water, 6.86 kg of vitamin R acetate oil were intensively mixed at a temperature of 60° C. and then the finished emulsion was obtained as in the examples using subsequent homogenization. 2.5 g of malt starch and 7.6 kg of cereal starch were added to this emulsion and then an extrusion was again performed with subsequent rounding and redrying to a water content of approximately 4% by mass.
EXAMPLE 4
[0059] To produce an emulsion, 6 kg of soybean-based hemicellulose, 12 kg of malt starch, 30 kg of water containing 36 kg of nonanionic acid were mixed intensively with one another at temperatures between 0 and 5° C. and then likewise homogenized. The doughy consistency was set by adding 9 kg of cereal starch and again this was followed by rounding and redrying to a water content of approximately 4% by mass.
[0060] The nonanionic acid was safely encapsulated in the pellets and no loss was observed.
EXAMPLE 5
[0061] In this case, 125 g of pulverulent malt starch were 15 mixed with 125 g of soybean-based hemicellulose in powder form. This powder mixture was dissolved in 1 900 g of demineralized water and mixed. 1 350 g of an oil having a high content of polyunsaturated fatty acid esters were added to this solution and mixed highly intensively. The oil had an iodine value of 170. This preemulsified mixture was homogenized and further emulsified using a Niro two-stage homogenizer at pressures of 200 bar and 220 bar.
[0062] The majority of the oil droplets in the resultant emulsion had a particle size of 1.4 μm.
[0063] A mixture of 1 289 g of a corn starch (Cerestar) and 1 289 g of microcrystalline cellulose was then added to the emulsion which had a mass of 2 380 g and additionally 496 g of water were added and mixed with one another. In this manner, a doughy consistency could be achieved having a moisture content of 36% by mass.
[0064] This doughy mass was extruded at low pressure using a Fuji-Paudal extruder, the extruder dies having a diameter of 0.8 mm.
[0065] The extruded pellets were then dried in a fluidized bed to a water content of 3% by mass.
[0066] The dried pellets had an oil content of 25% by mass which was monitored over a period of four weeks at room temperature with open storage under atmospheric conditions. After these four weeks, an iodine value of 162 was determined. This showed that virtually no oxidation was found during the production and subsequent storage. The free fat content was determined at less than 0.1% by mass.
EXAMPLE 6
[0067] 350 g of a pulverulent soybean-based hemicellulose were mixed with 700 g of malt starch and dissolved in 2 450 g of demineralized water. 1 500 g of orange oil were added to this solution and this was followed by highly intensive mixing. The mixing was kept at a temperature below 10° C.
[0068] The preemulsified mixture was homogenized using a Niro two-stage homogenizer at pressures of 200 bar and 220 bar. The majority of the oil droplets present in the emulsion had a particle size of 0.8 μm.
[0069] 950 g of microcrystalline cellulose (Vivapur) and 100 g of wheat starch were added to 3 950 g of this emulsion and mixed with one another so that a doughy consistency having a moisture content of 39% by mass was achieved. This was followed by extrusion which was followed by spheronizing and drying in a fluidized bed.
[0070] The dried pellets were stored open under the effects of air at 40° C. and a relative humidity of 35%. The contents of cis- and trans-limonene epoxide, carveols and carvones were determined at the start and end of storage. The measured values obtained are shown in table 1 below.
TABLE 1 Concentration of the Concentration of the component being oxidized component being in ppm of orange oil after 3 oxidized in ppm of months at 40° C./35 per- Oxidation component orange oil at start cent relative humidity Cis-limonene epoxide 225 ppm 2 000 ppm Trans-limonene 150 ppm 1 100 ppm epoxide Carveols 75 ppm 1 300 ppm Carvones <10 ppm 900 ppm
EXAMPLE 7
[0071] The extrudable mass having a doughy consistency which was obtained according to example 3 was added, at a mass of 10 kg, to a Glatt granulator and additionally 1 kg of Cerestar corn starch was added.
[0072] The granulation was carried out over a period of five minutes and the resultant granules were fed to a spheronizer, likewise from Glatt. The spheronized pellets were then redried in a fluidized bed until a moisture content of 3%− by mass was achieved.
EXAMPLE 8
[0073] In this example, vitamin D was used instead of vitamin A as in example 3 and after homogenization was carried out enzyme (for example Vitase) dissolved in water was added to an emulsion, a concentration of 200 g of enzyme protein per liter being maintained.
[0074] The proportion of added mass of corn starch was 50% higher. The enzyme and the vitamin D have, for example, a synergistic effect for the phosphate digestibility.
EXAMPLE 9
[0075] 125 g of a pulverulent soybean-based hemicellulose were dissolved in 1 250 g of demineralized water in a 15 mixture with 125 g of malt starch.
[0076] 1 250 g of arachidonic acid were added to this solution and mixed highly intensively.
[0077] The preemulsified mixture was homogenized in two stages at pressures of 200 bar and 350 bar. The individual oil emulsion particles essentially had a size of 0.8 μm.
[0078] 645 g of this emulsion were then mixed with 2 000 g of 25 kaolin (GTY Clay) and 600 g of microcrystalline cellulose and an extrudable doughy consistency having a water content of 28% by mass was achieved.
[0079] The mass was then extruded, and spheronization and drying in a fluidized bed were carried out until a water content of 3% by mass was achieved.
[0080] The content of encapsulated arachidonic acid was 8.5% by mass.
[0081] During storage in air at room temperature, no losses or impairment of arachidonic acid were observed.
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The invention relates to pellets and a production process therefor. Pellets comprise at least one oily component, which is either an active component alone or comprises such an active component. The aim of the invention is to ensure that such active components can be provided at elevated concentration in a long-term stable form for subsequent administration or further processing using such inventive pellets. The at least one oily oxidation-sensitive or else readily volatile active component is distributed homogeneously and discretely in a matrix and encapsulated without a core with at least one water-soluble polysaccharide as film forming agent. The individual pellets have a respective particle size of at least 100 μm, preferably of at least 300 μm.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Italian Patent Application serial number BS2014A000085, entitled: “TRIGGER-DISPENSING DEVICE FOR TWO OR MORE LIQUIDS”: filed Apr. 18, 2014, which is herein incorporated by reference in its entirety.
BACKGROUND
Technical Field
This invention refers to a manual trigger-dispensing device for liquids for at least two substances, generally liquids, for example for the hygiene of the home, the deodorization of rooms, the treatment of fabrics before ironing, and the like.
Description of the Related Art
Trigger devices are very widespread, as can be seen on supermarket shelves, especially for their ease of use and functionality. Every year many hundreds of millions of pieces are produced.
Among the numerous types, there are devices for two or more substances, particularly appreciated in applications such as hygiene of the home. In fact, it was found that the combination of several substances provides accentuated action, for example sanitizing, if the combination takes place shortly before dispensing from the device or even if the combination is realized on the surface itself.
There are numerous trigger-dispensing device solutions for two or more substances.
However, the solutions of the prior art sometimes have the drawback of not achieving a good mixture of the substances to be combined, frustrating, as was said above, the main purpose of this type of devices.
SUMMARY OF THE DISCLOSURE
The purpose of this invention is to provide a trigger-dispensing device for two or more substances that meets the needs of the sector and overcomes the drawbacks referred to above.
This purpose is achieved by a trigger head of a trigger device, wherein the head comprises a trigger and pumping means operable by the trigger to aspirate simultaneously at least two substances and achieve dispensing, wherein the means for pumping are in addition suitable for carrying out a predetermined pre-compression of these substances, separately and simultaneously before dispensing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a trigger-dispensing device for two substances according to an embodiment of this invention, comprising a dispensing head and a bottle (shown separately in the figure);
FIG. 2 is the dispensing head of the device of FIG. 1 , with parts separated;
FIG. 3 illustrates the dispensing head according to a front view;
FIG. 4 illustrates the dispensing head according to a rear view;
FIG. 5 shows a sectional view of the dispensing head;
FIG. 6 illustrates the dispensing head according to a further observation point;
FIG. 7 shows an enlargement of detail VII in FIG. 6 ;
FIG. 8 shows a sectional view of the dispensing head of FIG. 5 , without cover;
FIGS. 9 a to 9 c illustrate the dispensing head, respectively, in a locked configuration, an unlocked and partially actuated configuration and in a final actuated configuration;
FIG. 10 shows a pre-compression valve of the dispensing head according to a further embodiment of the invention;
FIG. 11 shows a pre-compression valve of the dispensing head according to a further embodiment of the invention.
DETAILED DESCRIPTION
With reference to the accompanying figures, 1 generally indicates a trigger dispensing device for two or more substances, generally liquids before dispensing.
For clarity of exposition, hereinafter we will refer to variants of the invention for two substances, without precluding the extension of the innovative features to more than two substances.
The device 1 comprises a first containment compartment and a second containment, separated from each other, respectively for the containment of a first substance and a second substance, usually liquids.
For example, the device 1 comprises a bottle 6 made in a single piece, for example of plastic, provided internally with a partition wall that separates the two containment compartments.
Preferably, the bottle 6 includes a bottle coupling portion 10 for the attachment of a pre-assembled dispensing head 20 .
For example, the bottle coupling portion 10 includes a first neck 12 and a second neck 14 , comprising respective annular neck walls 12 a, 14 a , for example cylindrical, that define respective rectilinear coupling axes X 1 ,X 2 , parallel to each other.
The neck walls 12 a , 14 a define respective openings 12 b , 14 b for access to the respective containment compartments.
Preferably, the dispensing head 20 can be snap-coupled to the bottle 6 .
For example, the coupling portion includes fins for snap coupling; for example, each neck 12 , 14 comprises coupling fins 12 d , 14 d , protruding outward from the respective neck wall 12 a , 14 a.
For example, the coupling fins form two pairs, one for each neck 12 , 14 ; preferably, the fins of each pair have the same angular extension and are arranged symmetrically protruding from the neck, with respect to an imaginary plane containing the two coupling axes X 1 , X 2 .
The dispensing head 20 is preferably pre-assembled and applied to the bottle 6 after filling of the bottle with the substances to be dispensed.
The head 20 comprises a frame or chassis 22 for the support of the components. Preferably, the frame 22 can be snap-coupled to the bottle 6 .
For example, the frame 22 comprises an annular coupling head wall 24 suitable to externally surround the necks 12 , 14 of the bottle, provided with counter-coupling fins for snap engagement with the fins 12 d , 14 d of the necks 12 , 14 .
The head 20 comprises pumping means suitable to operate to simultaneously achieve the suction and pre-compression of two or more substances, and the separate or combined dispensing of the substances.
The pumping means comprise a first pressure chamber 30 a and a second pressure chamber 30 b suitable to be placed in communication respectively with the first containment compartment and the second containment compartment of the bottle 6 , through respective inlet openings 31 a , 31 b , for example by means of respective tubes 32 a , 32 b applied to the inlet openings 31 a , 31 b.
Furthermore, the head 20 comprises a first dispensing duct 40 a and a second dispensing duct 40 b for the dispensing of the substances from the respective pressure chambers 30 a , 30 b.
The pumping means further comprise a first piston 34 a and a second piston 34 b suitable to operate in the respective pressure chambers 30 a , 30 b to pressurize the substances contained therein, for example, for translation along respective piston axes Y 1 ,Y 2 .
Preferably, each piston 34 a , 34 b comprises a piston head 35 a , 35 b and a piston rod 37 a , 37 b , that extend along the respective piston axes Y 1 ,Y 2 and that support the respective piston heads 35 a , 35 b.
Furthermore, the pressure means comprise suction valve means suitable to allow the transit of a substance from a respective containment compartment 2 , 4 of the bottle to the respective pressure chamber 30 a , 30 b during a suction phase and prevent the return of the substance from the respective pressure chamber 30 a , 30 b to the respective containment compartment 2 , 4 during a pre-compression step.
For example, the suction valve means comprise a first check valve 36 a , positioned between a first inlet opening 31 a and the first pressure chamber 30 a , and a second check valve 36 b , positioned between a second inlet opening 31 b and the second pressure chamber 30 b .
According to an embodiment, the check valves 36 a , 36 b comprise an obturator 38 a , 38 b , sensitive to the action of the substance present in the pressure chamber 30 a , 30 b , for example in the form a ball, and an obturator seat.
In addition, the pumping means comprises pre-compression valve means suitable to allow the passage of substances from respective pressure chambers 30 a , 30 b to the respective delivery ducts 40 a , 40 b when the pressure of the substances in the pressure chambers exceeds a predefined threshold pressure and suitable to prevent the transit of the substances from the respective pressure chambers 30 a , 30 b to the respective delivery ducts 40 a , 40 b when the pressure of the substances in the pressure chambers is less than a predefined threshold pressure.
Preferably, the pressure threshold is greater than 1 bar; more preferably, the pressure threshold is greater than 3 bar.
For example, the pre-compression valve means comprise a first pre-compression valve 42 a , operating between the first pressure chamber 30 a and the first delivery duct 40 a , and a second pre-compression valve 42 b , operating between the second pressure chamber 30 b and the second delivery duct 40 b .
For example, the pre-compression valves 42 a , 42 b each comprise an obturator plate 44 a , 44 b , a piston head body 46 a , 46 b , a pre-compression spring 48 a , 48 b (which presses on the piston head body 46 a , 46 b ) and a return spring 50 a , 50 b (which presses on the obturator plate 44 a , 44 b ).
In the step of simultaneous pre-compression of the substances, the pre-compression spring 48 a , 48 b and the return spring 50 a , 50 b , which work in an antagonistic manner, hold integral between them the obturator plate 44 a , 44 b and the piston head body 46 a , 46 b , closing the access of the pressure chamber 30 a , 30 b to the respective delivery duct 40 a , 40 b .
The assembly formed by the obturator plate 44 a , 44 b and the piston head body 46 a operates from the piston head 35 a , 35 b , which compresses the substance in the pressure chamber 30 a , 30 b .
The action of the piston 34 a , 34 b produces a pressure increase in the pressure chamber 30 a , 30 b , until the predetermined threshold pressure is exceeded.
Since the pre-compression spring 50 a , 50 b works in opposition to the action of the pressure in the pressure chamber 30 a , 30 b , upon reaching the threshold pressure, the piston head body 46 a, 46 b separates from the obturator plate 44 a, 44 b , opening the access to the respective delivery duct 40 a, 40 b , simultaneously for the two substances.
Preferably, the pumping means comprise a first hollow casing 60 a and a second hollow casing 60 b , having prevailing extension along the respective piston axes Y 1 , Y 2 .
Inside each casing 60 a, 60 b , the pressure chamber 30 a , 30 b is formed, the piston 34 a, 34 b is operating, for example, slidingly, and the check valve 36 a, 36 b and the pre-compression valve 42 a, 42 b are housed.
Preferably the head 20 comprises a connecting flange for the simultaneous connection of the two casings 60 a, 60 b to the frame 22 .
The casings 60 a, 60 b are applied to the flange 70 , which is, in turn, affixed to the frame 22 , and from the flange the piston rods 37 a, 37 b protrude axially.
Furthermore, the head 20 comprises a trigger 90 hinged to the frame 22 at a trigger-connection point 90 , and actuation means, operable from the trigger 90 , for the simultaneous activation of the pistons 34 a, 34 b.
In a preferred embodiment, the actuation means comprise a transmission member 100 , hinged to the frame 22 at a pivot point 102 , engageable by the trigger 90 , so that a rotation of the trigger 90 corresponds to a counter-rotation of the transmission member 100 .
In particular, having defined an imaginary plane containing the two pistons axes Y 1 ,Y 2 , for the head 20 (and for the device 1 ), a right side is defined by one part of the imaginary plane, and a left side by the other part. Preferably, the imaginary plane so defined intersects the trigger 90 .
Preferably, the trigger 90 comprises a trigger engagement portion 94 for engagement with the transmission member 100 , wherein the portion 94 includes two protrusions 96 , one on one side and one on the other side of the head.
Similarly, the transmission member 100 comprises an engagement organ portion 104 for engagement with the trigger 90 , wherein the portion 104 comprises two elongations 96 , one on one side and one on the other side of the head.
The transmission member 100 also includes a main portion 108 , straddling between the sides of the head 20 , from which protrude the elongations 106 , due to the simultaneous action on the pistons 34 a, 34 b.
Moreover, the actuation means comprise, preferably, an intermediate body 120 , engageable by the transmission member 100 and suitable to translate along the pistons axes Y 1 ,Y 2 .
The two pistons 34 a, 34 b , and in particular the two piston rods 37 a, 37 b , are integrally connected to the intermediate body 120 .
In other words, the rotation of the trigger 90 , for example clockwise, by manual action of a user of the device 1 , causes the counter-rotation, for example counter-clockwise, of the transmission member 100 , that goes to push the intermediate body 120 , to which are integrally connected the two pistons 34 a, 34 b , which are so actuated in compression.
According to a preferred embodiment, as shown, the delivery ducts 40 a, 40 b pass through the piston rods 37 a, 37 b and the intermediate body 102 .
In particular, each delivery duct 40 a, 40 b includes an initial section 122 a, 122 b that extends inside the respective piston rod 37 a, 37 b , an elbow section 124 a, 124 b that extends inside the intermediate body 120 , and an end section 126 a, 126 b that extends in extensible tubes 128 a, 128 b sealingly applied to the intermediate body 120 , up to a nozzle group 150 applied to the frame 22 .
The extensible tubes 128 a, 128 b are suitable to compensate for the variation of position between the intermediate body 120 and the nozzle group 150 due to the movement undergone by the intermediate body 120 during the pre-compression step with respect to the nozzle group 150 , which remains fixed.
For example, the tubes 128 a, 128 b have an over-abundant length or are made of extensible material.
For example, the tubes 128 a, 128 b are made of plastic, for example low-density polyethylene (LDPE) or polyvinyl chloride (PVC).
According to a preferred embodiment, the first delivery duct 40 a and the second delivery duct 40 b flow into a mixing chamber 152 inside the head 20 .
For example, the nozzle group 150 comprises a mixing chamber 152 into which the delivery ducts 40 a, 40 b enter, and in particular their end sections 126 a, 126 b.
For example, the mixing chamber 150 is formed in a nozzle body 154 applied to the frame 22 , to which are sealingly applied the two flexible tubes 128 a, 128 b.
Additionally, the nozzle group 150 compress a nozzle mask 156 having a dispensing opening 158 in communication with the mixing chamber 152 , administered in a manner rotatable by a user to the nozzle body 154 , for example in order to close the dispensing opening 158 by rotation.
According to further variant embodiments, the delivery ducts each comprise a respective dispensing opening for the simultaneous and separate dispensing the two substances to the outside.
Furthermore, the head 20 preferably comprises removable locking means suitable to prevent accidental actuation of the trigger.
For example, the locking means comprise a removable latch 160 , suitable to be placed between the frame 22 and the trigger 90 to prevent the actuation of the trigger 90 .
For example, the latch 160 is hinged to the frame 22 in a latch hinging point 162 and presents an anchoring portion 164 suitable to couple itself to a protrusion 166 of the frame 22 .
Preferably, the latch 160 and the trigger 90 can be snap-coupled to each other.
In a locked configuration, the latch 160 is in an angular position in which it obstructs the actuation of the trigger 90 and the anchoring portion 164 is coupled to the protrusion 166 of the frame, so that the latch 160 stably maintains the position.
Preferably, in the configuration, the latch 160 is snap-coupled with the trigger 90 .
For rotation by a user, the anchoring portion 164 disengages from the protrusion 166 (and preferably the latch 160 and the trigger 90 release the mutual snap coupling) and the latch 160 is brought into an angular position in which it does not obstruct the actuation of the trigger 90 .
The head 20 further comprises a cover 170 , snap-coupleable to the frame 22 .
In particular, the frame 22 comprises a rear fin 172 , projecting externally from the coupling head wall 24 on the part opposite the trigger 90 , the side fins 174 , projecting from one side and the other of the frame 22 , above the coupling head wall 24 , and front side fins 178 , 180 , projecting from one side and the other of the frame 22 in the vicinity of the nozzle group 150 , all snap-coupled with the cover 170 .
Innovatively, the device according to this invention meets the needs of the sector, since it achieves an excellent mixing of the two substances thanks to the separate and simultaneous compression of both substances immediately before being combined with each other.
In other words, the pre-compression of the two substances prior to their combination, makes the mixing particularly effective, both in the event that it takes place in a mixing chamber inside the device and when it takes place on the object to be treated, for example a surface to be cleaned.
Advantageously, moreover, the assembly of the device is particularly fast and efficient, thanks to the snap connection between the head and the bottle. This advantage is especially appreciated in the sector, given the enormous volume of production.
According to a further advantageous aspect, the device is very reliable, thanks to the robust mechanism which ensures the actuation of the pistons in response to the actuation of the trigger.
Advantageously, moreover, the application of the dispensing head to the bottle is particularly fast, to the advantage of high-volume production.
According to further embodiments, the check valves comprise a flexible membrane deformable by the action of the this pressure in the pressure chamber.
For example, according to an embodiment ( FIG. 11 ), the check valve 36 a, 36 b comprises a flexible membrane 236 , affixed to the frame 222 .
According to further embodiments, the pre-compression valve comprises a flexible membrane deformable by the action of the threshold pressure in the pressure chamber.
For example, the pre-compression valve 42 a, 42 b is made in a single piece, for example in plastic, and comprises a deformable membrane 242 , for example of a convex shape towards the respective delivery duct 40 a, 40 b , and a sleeve 244 for positioning in a valve seat 246 of the frame 22 .
For example, the sleeve 244 is coupled to the frame 22 . According to a variant embodiment, the pre-compression valve means comprise a latch member applicable to the frame to clamp the sleeve to the frame.
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A trigger head for a dispensing device for at least two substances including a pumping system to compress the substances separately and simultaneously before dispensing.
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BACKGROUND OF THE INVENTION
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] Directional drilling is the practice of drilling non-vertical wells. This was originally an accidental occurrence caused by rock formations or imprecise operations which caused the drilling head to diverge from the intended vertical course. The value of drilling in a direction other than straight down was realized as beneficial to the industry.
[0004] Several methods for drilling were developed which created inclinations, deviations from the vertical, of the wellbore. Down hole drilling motors, also known as mud motors, driven by the hydraulic power of drilling mud circulated down the drill string allow the drill string to remain stationary while only the bit rotates. By introducing a bent pipe (a “bent housing”) between the mud motor and the drill string, the direction of the wellbore can be selected and controlled. There are also steerable motors which incorporate devices for changing the inclination on the fly. Other techniques and equipment also exist for directional drilling control.
[0005] Three components are measured to determine the position of a wellbore: the depth of the point (measured depth), the inclination at the point, and the magnetic azimuth at the point. These three components are collectively called a survey. Developments in measuring the three components allow wells to be directed to precise locations and orientations.
[0006] A series of consecutive surveys are used to track the progress and location of a wellbore as it progresses along a desired path. For various reasons periodic surveys are only taken at intervals of 30-500 feet, with 90 feet (the length of a typical “stand”) being common during active changes in angle or direction. These periodic surveys result in a series course corrections, and thus a wellbore is a collection of dog leg turns rather than a smooth curving arc. Since drilling often is stopped to produce a more accurate survey, increasing the number of surveys slows the drilling progress. Therefore, the tendency in rig operation is to minimize the frequency of surveys resulting in the need for coarser course corrections.
[0007] Aggressive bits used in progressive drilling results in a rough bore wall. Rough bore walls combined with the dog leg turns described above create a difficult environment for inserting and removing download drilling equipment (“Bottom Hole Assemblies” or “BHA”). The rough geometry of the bore walls also makes it difficult for casing/liners to be inserted into a borehole. A dog leg that is too sharp may exceed the bending radius of the liner. Rough walls and dog legs can catch and snag the liner's leading edge preventing it from reaching the end of the lateral. Increased friction along the sides of the casing may call for more force to be necessary to push the casing into place. This increased force can cause the casing to flex, expand, buckle, or keyhole.
[0008] Use of aggressive bits to widen a bore hole or ease the curves can cause a divergence in the well path. Sidetracks or ledges can be created further resulting in an unshapely hole. Further, aggressive bits can over enlarge a wellbore resulting in added expenses, as extra material is necessary to cement the casing in the wider bore hole. Constantly stopping to measure or check bore hole conditions is time consuming and costly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates dog leg curves which obstruct inserting drill strings down a rough wellbore.
[0010] FIG. 2 illustrates a front view of a drilling apparatus in accordance with an exemplary embodiment of the invention.
[0011] FIG. 3 shows an exploded cut away view of the three possible sub-assemblies of a drilling apparatus in accordance with an exemplary embodiment of the invention.
[0012] FIG. 4 illustrates the use of a fluid circulating sub-assembly to clear cuttings from a side cutting sub-assembly and bullnose in accordance with an exemplary embodiment of the invention.
[0013] FIG. 5A-5C shows the progression of a drilling apparatus through a dog leg curve to reshape a wellbore in accordance with an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Disclosed herein is a design for an apparatus referred to in general terms as a bottom hole assembly (BHA). The apparatus is used during well drilling operations to shape and clean a wellbore after the initial pass by an aggressive drill head. In particular, the apparatus' primary function is to clean the curves and lateral portions of a horizontal well. The preferred embodiment of the apparatus is a series of sub-assemblies which are connected through pin threads and box threads which secure the sub-assemblies end to end along a common central axis in to a single apparatus. The apparatus is then secured to the bottom end of a drill string and ran down an existing rough cut bore hole.
[0015] The sub-assemblies of particular interest to this disclosure are a side cutting sub-assembly, a fluid circulating sub-assembly, and a bullnose sub-assembly. One skilled in the art would appreciate that the features of the individual sub-assemblies could be incorporated into fewer sub-assemblies, or into a complete single assembly without means for separating into sub-assemblies. Further, one skilled in the art would appreciate that additional features may be incorporated in the BHA without compromising the functionality of the assembly as described herein. For simplicity and clarity in this disclosure, each sub-assembly is described as a separable unit. Further, the relative placement of each sub-assembly with respect to the others is described below when doing so makes their function and relative interactions relevant. Nothing in this disclosure is meant, or should be interpreted as limiting the placement of the sub-assemblies, or requiring the strict use of each assembly as a separate assembly, or the incorporation of other functionality or features not described herein.
[0016] The apparatus is fitted to the end of a drill string by use of a pin or box thread connector at the top of the BHA and is used to clean rough bore walls created by aggressive cutting heads during initial and subsequent well borings. Proper use of the device will ease the abrupt angle changes of dog legged turns as well as finish rough bore walls and remove ledges, thus producing smooth flowing curves and clean bores which are more conducive to insertion of liner/casing and the insertion and removal of other BHAs.
[0017] The side cutting sub-assembly is a tubular drill structure which utilizes rows of cutting surfaces oriented longitudinally on the outer surface. The cutting surfaces in the preferred embodiment are Polycrystalline Diamond Compact (PDC) cutters. The plurality of these rows are interspersed around the circumference along with longitudinally oriented flow channels which allow mud to flow past the rows of cutting surfaces thus removing the cuttings produced by drilling operations and carrying them back up the wellbore past the drill string to the surface.
[0018] One skilled in the art would appreciate that the cutting surfaces could be of other materials. One skilled in the art would appreciate that the actual cutting surfaces or structures, the quantity, orientation and rotational speed of such cutting surfaces can be tailored for the environment in which the tool is to be used. Further, a variety of cutting surfaces or structures may be intermixed for specific environments.
[0019] To prevent the cutting surfaces from aggressively re-shaping the wellbore by causing ledges, pockets, or tangents, the cutting surfaces are alternately interspersed with gauging surfaces. Gauging surfaces are hard surfaces which do not substantially wear or cut when in contact with the bore wall. Gauging surfaces prevent the cutting surfaces from penetrating too deeply into the bore walls. In the preferred embodiment, the gauging surfaces are diamond domes (DD) which are hemispheres of approximately the same height as the PDC cutting surfaces. They are oriented around the cutting surfaces such that the gauging surfaces contact the bore wall and prevent cutting surfaces from penetrating too deeply into the bore wall while still allowing the cutting surfaces to contact and remove any formation which intrudes into the wellbore.
[0020] To improve the efficiency of the assembly, fluid flow is used to remove cuttings and to lubricate and cool the BHA. As is traditional in BHA's fluid is circulated down the drill string's hollow center. This fluid reaches the bottom of the drill string and exits the center through voids in the BHA to then return to the surface along the outside of the drill string. The fluid circulating sub-assembly disclosed here uses a plurality of nozzles to further pressurize drilling fluids. These pressurized drilling fluids are then directed back up the wellbore past the cutting surfaces of the side cutting sub-assembly to remove the built up cuttings which slow drilling processes.
[0021] The bullnose assembly has a rounded edge at the lower end so it will not catch on ledges or rough outcropping of the wellbore as it progresses down the well. While the majority of the bullnose has a hollow core, the bottom of the bullnose assembly is closed off with optional nozzles pointing in front or down the bore hole. The nozzles help clear the wellbore before the drilling apparatus by washing the cuttings to the side and back up the wellbore.
[0022] In operating the drilling apparatus, the nozzles can be adjusted to configure the Total Flow Area (TFA) out the bottom of the bullnose sub-assembly, or out the fluid circulating sub-assembly to adjust the clearing of cuttings. There are several factors which afford the choice of nozzle configurations including mud weight, hole depth, drill pipe used, maximum standpipe pressure, desired gallons per minute (gpm) to clean hole, etc. The nozzle configuration can also be adjusted to provide uneven flow in order to create turbulent flow and thus evacuate existing and new cuttings out of the hole. The bullnose nozzles can be configured to ensure the capability to wash through bridges and reduced hole sizes. The fluid circulating sub can be configured to maximize circulation cuttings up and out of the hole.
[0023] When the apparatus or BHA is being lowered down the vertical of a wellbore the side cutting sub-assembly may contact the bore wall with enough force to perform significant cutting actions in areas where the structures penetrate causing a restricted hole size, or irregular shapes of the wellbore. Whenever, when the BHA reaches a dog leg turn, the bullnose will contact the outside of the turn and the weight of the drill string will cause the side cutter assembly to contact the inside of the dog leg with enough force to cut and round the angled corner. When the BHA is lowered past the dog leg turn and into the straight part of the curve, the flex of the drill string will force the side cutter assembly against the outer wall with a force that will allow it to cut into the outside wall, thus widening the curve.
[0024] As the BHA is cutting the wellbore, the gauging surfaces rub against the bore wall and prevent the cutting surfaces from cutting too deeply. The bullnose's curved edges keep the BHA from catching on a ledge or from going off course to diverge from the original wellbore.
[0025] Turning now to the drawings, FIG. 1 illustrates dog leg curves which obstruct inserting drill strings down a rough wellbore. The drilling rig ( 100 ) pushes a casing or liner ( 110 ) down a wellbore ( 150 ). In traditional drilling, intermitting course correction cause curves ( 153 ) in the wellbore ( 150 ) to actually be a series of dog leg turns ( 155 ) which gradually redirect the wellbore to a lateral ( 157 ). However aggressive drilling and formation properties may leave a rough wellbore (illustrated in the enlarged section) where the bottom of the casing or liner ( 120 ) can get caught on edges of the wellbore ( 150 ).
[0026] FIG. 2 illustrates a front view of a drilling apparatus in accordance with an exemplary embodiment of the invention. The drilling apparatus ( 200 ) is an assembly of three sub-assemblies ( 220 , 250 , and 270 ). The sub-assembly illustrated on top of the stack is a side cutting sub-assembly ( 220 ), which has a pin thread ( 201 ) at the top end and a box thread ( 202 , not visible) at the lower end. The tubular body ( 221 , not designated) contains a plurality of cutter arrays ( 222 ) interspersed with flow channels ( 223 ) around the circumference of the tubular body ( 221 ). A cutter array ( 222 ) has alternating cutting surfaces ( 226 ) and gauging surfaces ( 225 ). Cutting channels run between the surfaces ( 225 , 226 ) from one flow channel ( 223 ) to another.
[0027] One skilled in the art would appreciate that the pin thread and box thread described above could be replace with other joining apparatus for linking the sub assembly to other sub assemblies or for linking the sub assembly to the components of the drill string. Further, one skilled in the art would appreciate that the pin threads and box threads could be eliminated such that one or more sub assemblies are joined into a single new assembly comprising all aspects of the described sub assemblies.
[0028] The sub-assembly illustrated in the middle of the stack is a fluid circulating sub-assembly ( 250 ). A plurality of up pointing or backward facing nozzles ( 255 ) direct fluid back up the annulus past the cutter arrays ( 222 ). The fluid circulating sub-assembly ( 250 ) has a pin thread at the top end which is illustrated as a thread joint ( 203 ) where it mates with the box thread located at the bottom of the side cutting sub-assembly ( 220 ).
[0029] The sub-assembly illustrated on the bottom of the stack is a bullnose sub-assembly ( 270 ). The closed bottom ( 288 ) of the bullnose sub-assembly ( 270 ) is rounded on the edges ( 285 ). The bullnose sub-assembly ( 270 ) has a pin thread at the top end which is illustrated as a thread joint ( 203 ) where it mates with the box thread located at the bottom of the fluid circulating sub-assembly ( 250 ).
[0030] FIG. 3 shows an exploded cut away view of the three possible sub-assemblies of a drilling apparatus in accordance with an exemplary embodiment of the invention. The drilling apparatus ( 200 ) is an assembly of three sub-assemblies ( 220 , 250 , and 270 ). It is made up of a hollow tubular body ( 221 ) which has a central channel ( 210 ) The first sub-assembly, illustrated on top of the stack, is a side cutting sub-assembly ( 220 ), which has a pin thread ( 201 ) at the top end and a box thread ( 202 ) at the lower end. The tubular body ( 221 ) contains a plurality of cutter arrays ( 222 ) interspersed with flow channels ( 223 , not illustrated) around the circumference of the tubular body ( 221 ). A cutter array ( 222 ) has alternating cutting surfaces ( 226 ) and gauging surfaces ( 225 ). Cutting channels run between the surfaces ( 225 , 226 ) from one flow channel ( 223 ) to another.
[0031] The second sub-assembly, illustrated in the middle of the stack, is a fluid circulating sub-assembly ( 250 ). A plurality of up-pointing or backward-facing nozzles ( 255 ) direct fluid from the central channel ( 210 ), back up the annulus past the cutter arrays ( 222 ). The fluid circulating sub-assembly ( 250 ) has a pin thread at the top end ( 201 ) and a box thread ( 202 ) at the lower end.
[0032] The third sub-assembly, illustrated on the bottom of the stack, is a bullnose sub-assembly ( 270 ). The closed bottom ( 288 ) of the bullnose sub-assembly ( 270 ) is rounded on the edges ( 285 ) to create the bullnose ( 280 ) at the lower end of the assembly. The upper end of the assembly has a pin thread ( 201 ). The bullnose assembly ( 270 ) has nozzles ( 275 ) in the bottom ( 288 ) of the assembly which direct fluid from the central channel ( 210 ) out into the wellbore.
[0033] FIG. 4 illustrates the use of a fluid circulating sub-assembly to clear cuttings from a side cutting sub-assembly in accordance with an exemplary embodiment of the invention. In this view, the drill string ( 110 ) is shown pushing the drilling apparatus ( 200 , not designated) down through the wellbore ( 150 ). The up nozzles ( 255 ) in the fluid circulating sub-assembly ( 250 ) direct fluid ( 410 ) up the wellbore to remove cuttings ( 450 ) from the wellbore ( 150 ). Further, down facing nozzles ( 275 ) located in the bullnose ( 280 ) direct fluid ( 420 ) ahead of the BHA to loosen and remove cuttings ( 450 ) from the wellbore ( 150 ).
[0034] FIG. 5A-5C shows the progression of a drilling apparatus through a dog leg curve to reshape a wellbore in accordance with an exemplary embodiment of the invention. FIG. 5A show what happens as the drill string ( 110 ) pushes the drilling apparatus ( 200 , not designated) down through a curve ( 153 ) in the wellbore ( 150 ) the bullnose ( 270 ) comes in contact with the side of the curve ( 153 ).
[0035] FIG. 5B show that as the drill string ( 110 ) continues to push the drilling apparatus ( 200 ) through the dog leg turn ( 155 ) of a curve ( 153 ) in the wellbore ( 150 ), the side cutting sub-assembly ( 220 ) is forced against the inside of the dog leg turn ( 155 ) allowing the side cutting sub-assembly ( 220 ) to cut into the bore wall easing the curve ( 155 ′ in FIG. 5C )
[0036] FIG. 5C shows that as the drill string ( 110 ) continues past the eased dog leg turn ( 155 ′) the drill string ( 110 ) will continue to flex (exaggerated for clarity) to force the side cutting assembly ( 220 ) against the outside wall of the curve ( 153 ). The bullnose ( 270 ) will continue to steer the drilling apparatus ( 200 ) through the existing wellbore ( 150 ) preventing divergent paths from being cut.
[0037] The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the particular proportions illustrated. Additionally some elements illustrated in the singularity may actually be implemented in a plurality. Further, some element illustrated in the plurality could actually vary in count. Further, some elements illustrated in one form could actually vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.
[0038] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A method of shaping a wellbore comprising attaching a drilling apparatus to a drill string, which has a side cutting sub-assembly with both cutting and gauging surfaces; a fluid circulating sub-assembly which has nozzles directing fluid up the wellbore and past the cutting surfaces; and a bullnose assembly with forward pointing nozzles and a bullnosed front end to prevent catching in ledges of a rough drilled wellbore. The drilling apparatus is then passed through the wellbore such that the side cutting sub shears arch wellbore walls of dog legs to ease the turns and smooth the bore wall in preparation for running liner/casing or other down hole assemblies which previously may have had difficulty going in hole.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit to U.S. provisional application Ser. No. 60/581,107 filed Jun. 18, 2004.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The present invention relates to fuel control systems for stationary and propulsion gas turbine engines.
[0005] 2. Description of the Related Art
[0006] The high burn rates of gas turbine engines require the fuel delivery systems to be capable of rapidly and precisely metering fuel. Traditionally, fuel delivery systems for turbine engines, particularly those used for jet propulsion, have included a fuel pump, a pressure accumulator and a fuel metering device, all of which are separate components mounted on or near the engine and coupled to the engine and fuel source by suitable fuel lines. The accumulator operates to dampen pulsation or ripple in the fuel caused by the pump so that the metering device can accurately dispense the appropriate amount of fuel to the engine fuel atomizer. The use of multiple components is expensive and occupies space, which is especially limited for propulsion systems.
[0007] It is desirable to reduce the number of components in the fuel delivery system by combining the fuel pump and metering device into one unit. However, such combined devices must meet both the extreme pump and the metering requirements for turbine engines. Specifically, it must be able to pump particle contaminated fuel for an extended time period. It must have good dry lift capability and be able to operate with high vapor-to-liquid ratios at the pump inlet. Moreover, if no accumulator or fluid muffler is to be used, the pump must also be able to provide generally non-pulsating fuel flow. It should be exhibit low power consumption and hysteresis and operate with high efficiency and low friction. The device must also have a high turn-down ratio to accurately meter a wide range of flow rates. Additionally, the device must be compact and have minimal internal leakage.
[0008] In the turbine industry, the fuel delivery systems typically employ gear pumps which create a pressure differential by moving the fuel through a series of intermeshing teeth running at a high frequency. Gear pumps consume a lot of power and leak internally and are therefore less than ideal for jet engine use. Moreover, due to reliability concerns, gear pumps used for propulsion applications typically are powered by an engine driven gear box (rather than an electric motor) and therefore must be coupled to a separate metering valve via suitable fuel lines, which increases expense and occupies additional space.
[0009] U.S. Pat. No. 6,371,740, assigned to the assignee of the present invention and hereby incorporated as though fully set forth herein, discloses a fuel metering pump for turbine engines. The metering pump employs a rotating face cam to alternately reciprocate a pair of actuators that in turn drive a pair of rolling diaphragms to pump and meter the fuel. The metering pump is specially designed to drive the pumping members at a constant velocity to minimize pressure ripple and thus provide essentially non-pulsed metering of the fuel. The rolling diaphragm design assists in keeping contaminants commonly found in jet fuel from degrading the working components of the metering pump.
[0010] While the aforesaid metering pump provides a marked improvement in accurate fuel metering at high flow rates, the diaphragms have pressure limitations that can make it less suitable for certain sustained high pressure applications. In particular, it can be necessary in some jet engine applications to achieve a sustained pressure rise of over 500 psi. This pressure must be generated and maintained while metering the high flow rates required for sustained combustion, which can be 700 pph or more.
[0011] U.S. application Ser. No. 10/891,269, filed Jul. 14, 2004, assigned to the assignee of the present invention and hereby incorporated as though fully set forth herein, discloses a precision fuel metering pump suited for the aggravated temperature and pressure conditions of turbine engines applications having a unique cam-driven double-ended spool piston arrangement that is very efficient and accurate with little leakage and wide operational parameters. The pump is contained in a compact package, however, a separate DC motor is mounted to the pump housing to drive the piston cam and piston arrangement. Moreover, other components used to control fuel flow must be coupled to this device to achieve proper fuel control, for example, the motor drive control, a fuel shut off valve and a flow divider, which divides flow between the primary outlet port and a secondary outlet port to send fuel to the secondary burner nozzle(s) of the engine after engine light off. These additional components may require their own housings as well as conduit and other fluid and electrical line connections, thus increasing the space and weight requirements of the system. Further, the use of several separate components makes installation and replacement of the control system more time consuming and costly.
[0012] Moreover, this pump relies on small, open weave inlet filters to filter debris and contaminants from the fuel prior to entering the pump. Open weave type filters are used to minimize the pressure drop across the inlet, while still providing some filtering, so that the pump will operate at low inlet pressure, near true vapor pressure, without cavitation. However, this comes with somewhat reduced filtering capacity. Excessive debris in the pump can cause binding of the operating member, and reduce its efficiency or lead to pump failure. Thus, filtering of the fuel can be critical to proper performance of the pump and the fuel control system generally.
SUMMARY OF THE INVENTION
[0013] The present invention provides an entire fuel control system in a single, compact, yet highly accurate and efficient modular unit. The fuel control module provides high pressure and flow rates of non-pulsed liquid fuel, while exhibiting very low leakage and having excellent dry lift and turn-down capabilities. These attributes and its compact form factor, metering accuracy and high temperature and pressure capabilities make it suitable for fuel delivery to gas turbines, particularly jet engines in aircraft where space and weight restrictions are stringent.
[0014] Specifically, one aspect of the present invention provides a fuel control module for controlling the flow of fuel from a fuel supply to a fuel consuming device having at least two consumption components. The fuel control module has a housing containing a drive section, a pump section and a flow divider section. The drive section has a motor and an electronic motor drive. The pump section has an operating member moved by the motor in response to a signal from the motor drive to effect flow of fuel between housing inlet and outlet ports. The flow divider section has a valve for selectively providing fuel flow at the outlet in one or multiple flow paths for communication one or both of the consumption components of the fuel consuming device.
[0015] For gas turbine engine applications with multiple combustion zones and burner nozzles, high pressure output fuel flow can initially be sent through a single output port to the primary burner for engine light off. Following ignition and upon reaching a particular threshold pressure, the onboard flow divider can then route output fuel to a second output port to send fuel to the secondary burner(s). Preferably, the flow divider is a pressure operated valve that moves to open the secondary outlet automatically upon reaching the threshold pressure.
[0016] In another aspect the invention provides a fuel control module with a drive section, a pump section, a filter section, a flow divider section, and a shut-off section all contained as a single unit in a shared housing. The drive section includes the motor and an electronic motor drive. The pump section includes at least one piston moved by the motor in response to a signal from the motor drive. The flow divider section includes a valve for selectively dividing flow at the outlet. The filter section includes a filter element disposed in communication with the inlet of the housing and the pump section. The shut-off section includes a shut-off valve in communication with the pump section and the outlet of the housing. A pressure relief section can also be contained in the housing which includes a relief valve in communication with downstream (outlet) and upstream (inlet) sides of the pump section.
[0017] For efficient operation of the control module fuel contaminants are filtered at the inlet side of the pump. Over time, particularly with heavily contaminated fuel, flow through the filter can be compromised. A filter bypass valve can be provided to route fuel to the pump without first passing through the filter. The filter bypass valve is preferably pressure activated by the force of the fuel acting on an enlarged area downstream side of the valve, which moves the valve against a spring and opens a port leading directly to the pump. Once the pressure subsides, for example, should the filter unclog or be cleaned, the spring will reset the bypass valve to again route the fuel through the filter. Since fuel contaminates can adversely impact the performance and efficiency of the pump, a pressure sensor can be provided to sense pressure downstream from the filter and provide a signal to a system computer or dedicated user interface to provide indication that the filter will need to be cleaned or replaced. Preferably, this user feedback is provided before the bypass valve is activated so that the filter can be attended to before contaminants are passed to the pump.
[0018] Yet another aspect of the invention provides a fuel control module with a housing defining interior fluid and dry chambers. The fluid chamber contains the pump and the pump motor, including stator and rotor, and receives fuel through an inlet. The dry chamber is isolated from fuel and contains an electronic motor drive. The drive controls the motor to operate a movable operating member of the pump to move fuel from the inlet through the fluid chamber to an outlet. The pump and motor are thus immersed in fuel such that the pumped fuel cools the motor and other internal components. Preferably, the motor is frameless to allow for better motor cooling.
[0019] The pump is preferably a highly accurate metering pump suitable for operation over a pressure range of about 0 to 800 psig in aggravated temperature conditions. Preferably, the pump has at least one operating member in the form of a double-ended spool piston. More preferably, there are two such spool pistons arranged in parallel and operated by a cam arrangement. The pistons can having one or more circumferential pressure balancing grooves to collect debris in the piston chambers and prevent binding of the pistons. This allows the pistons to slide smoothly within the piston chambers with minimal clearances, which in turn provides low internal leakage without the use of piston seals. Residual air space at top dead center is minimized to improve dry lift capability. Also, low pressure drop valves, such as reed valves, and open weave type filters can be used at the inlet to allow for very low inlet pressure, in the range of 2-5 psi above true vapor pressure, without cavitation or the need for a boosted inlet.
[0020] These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is a preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment is not intended as the only embodiment within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an end elevational view of a fuel control module according to the present invention;
[0022] FIG. 2 is a side elevational view thereof;
[0023] FIG. 3 is a bottom plan view thereof;
[0024] FIG. 4 is an exploded assembly view thereof;
[0025] FIG. 5 is an exploded assembly view of a pump section thereof;
[0026] FIG. 6 is a cross-sectional view taken along line 6 - 6 of FIG. 2 , showing the internal components of the fuel control module;
[0027] FIG. 7 is a cross-sectional view similar to FIG. 6 albeit showing the pump 180 degrees later in the pump cycle; and
[0028] FIG. 8 is a schematic diagram of the fuel control module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The present invention provides a fuel control module (“FCM”), generally referenced in the drawings by number 10 , that fits in line between a fuel supply 11 and a fuel consuming device 13 , for example which can be a gas turbine engine for power generation or propulsion applications, such as a jet engine or auxiliary power unit therefor consuming standard jet fuel (Jet A, Jet B, JP4 or JP5). In typical applications, the FCM 10 is electrically coupled via a 2-way bus to a remote master computer that controls high level fuel management and other system operations.
[0030] The FCM 10 is designed to provide a single device incorporating all of the components for controlling fuel delivery to the engine downstream from the master computer and fuel supply. Installation, as well as serviceability and replacement, of these components is thus simplified. The modular nature of the FCM 10 also allows it to be swapped easily for another unit having different operating parameters should fuel delivery requirements differ or change. Furthermore, the cost, weight and space requirements of separate components and connecting lines therefor are thus avoided.
[0031] Referring now to FIGS. 1-4 , the FCM 10 is confined to a single housing 12 of a compact form factor capable of fitting within a small space envelope. The housing has an inlet port 14 and primary 16 and secondary 18 outlet ports in communication with an interior fluid chamber 20 through which the fuel passes during operation. The housing 12 is capped at a flanged end by a cover 22 held in place by a clamp collar 24 . The other end of the housing 12 has a motor end bell 26 enclosing the fluid chamber 20 and an end cap 28 which defines an interior dry chamber 30 . The housing 12 is preferably mounted, to an interior space of the aircraft in a jet engine application, in a vertically down orientation with the end cover 22 downward. The housing 12 has mounting structure 32 and 33 bounding the center of gravity of the FCM 10 to minimize structural distortion caused by vibration, shock and asymmetric loading, which can effect the tight clearances of the pumping components.
[0032] As mentioned, and with reference to FIGS. 4, 6 and 7 , the housing 12 contains all of the essential components for sending fuel from its source to the engine, including a pump section 34 , a drive section 35 , a filter section 36 , flow shut-off section 37 , a flow divider section 38 and a pressure relief section 39 . The arrangement of these components is shown schematically at FIG. 8 . In particular, from the fuel supply, fuel enters the housing through the inlet port and passes first to the filter section.
[0033] The filter section includes a filter element 40 , a filter bypass valve 47 and a filter pressure differential sensor 41 . The filter element 40 is a toroidal pleated wire mesh, preferably rated 10 μm nominal and 25 μm absolute, providing suitable filtration for at least 50 hours of 500 pph jet fuel flow. The filter element 40 sits in an annular valve member 42 of the bypass valve which is biased by a spring 43 to close off a bypass ports 44 in an annular guide/retainer member 31 that lead directly to the inlet side of the pump section. The bypass valve member 42 has a larger diameter at a downstream end. This asymmetric configuration is used to control operation of the bypass valve. As the filter element 40 collects debris, the pressure drop across the filter will rise. A high pressure drop at the inlet is to be avoided to prevent cavitation and other performance problems with the FCM. When the filter element becomes filled, the fuel pressure acting on the larger surface area (downstream) part of the bypass valve member 42 will force it against the spring 43 so that fuel can flow to the pump section through the bypass ports 44 rather than through the filter element. Because this leaves the pump section subjected to unfiltered fuel, bypass operation is intended to be minimized by using the filter pressure differential sensor 41 located downstream from the filter element. The sensor 41 has a piston member 45 that moves in response to pressure changes and provides a calibrated feedback signal to the master computer or other user interface to indicate the state of the filter element. Thus, for example, a warning light can be energized when the pressure sensor detects a downstream pressure corresponding to a dirty filter. Preferably, this pressure value will be near but less than the crack pressure of the bypass valve so that the filter element can be cleaned or replaced prior to a filter bypass condition occurring.
[0034] Fuel is drawn into the pump section 34 , which is controlled by the drive section 35 , pressurized and passed through the fuel shut off section 37 and the flow divider section 38 downstream from the shut off section. The fuel shut off section includes a normally open solenoid operated valve that can be controlled by the master computer (or onboard circuitry) to positively close off the outlet of the FCM. The flow divider section includes a pressure activated spring loaded piston valve that selectively controls flow to the secondary outlet port 18 . The flow divider valve is normally closed so that outlet fuel flows through the primary outlet port 16 so that the FCM initially sends fuel to only the primary burner nozzle of the engine during light off. The flow divider valve opens at a crack pressure reached upon sufficient engine speed so that fuel flows through both the primary 16 and secondary 18 outlet ports and on to the primary and the one or more burner nozzles of the secondary combustion zone(s) of the engine.
[0035] The pressure relief section 39 is provided in return porting between the outlet pressure side of the pump section and its inlet side. The relief section includes a pressure-activated, spring-biased one-way valve that opens in excess pressure conditions to return fuel to the inlet side of the pump.
[0036] The heart of the FCM 10 is the highly efficient metering pump 34 . The pump 34 is a face cam-actuated, double-acting spool piston pump capable of precisely metering non-pulsating fuel at high pressure and flow rates. The pump flow rate is directly proportional to the command signal and exhibits very low internal leakage such that the pump speed signal can be used by the master computer to accurately calculate fuel burn rate without the need for any ancillary flow measurement device.
[0037] The pump includes a pair of pistons 46 and 47 , a face cam assembly 48 , and a pair of cam follower assemblies 50 and 51 . The pistons 46 and 47 are double-acting pistons having flat heads at each end of an elongated cylindrical spool body. The pistons 46 and 47 reciprocate along parallel piston axes within piston chambers 52 and 53 . Since the pistons 46 and 47 are double-acting, both ends of the pistons are creating pressure or suction, one end being in a pump stroke while the other is in a suction stroke. The pistons 46 and 47 do not have piston rings or seals because of the high pressure and rapid stroke would generate high friction and in turn wear the rings. Close clearances are thus required to achieve compression and suction. The closer the clearance, the better the pumping action. When no piston rings are present to create a sliding seal, some amount of fuel can leak into the small clearance space around the pistons. If this fuel contains contaminants, the small particles can build up and/or become lodged in the small space between the piston and its chamber. And, since there are no piston rings to center the pistons, the pistons can be moved off of their axes and pushed against the walls of the chambers. This binding can reduce efficiency and even destroy the operation of the pump. To prevent this, the pistons 46 and 47 have a series of spaced apart circumferential grooves 54 and 55 , which are preferably slightly larger in width and depth than the clearance of the pistons in the chambers. Small particle contaminants can thus be taken up in the grooves so that they do not interfere with the movement of the pistons. In this way, these grooves act to pressure balance the pistons and allow them to slide along the piston axes without binding.
[0038] The pistons 46 and 47 are moved by the cam follower assemblies 50 and 51 , which have sliders 56 and 57 that extend through transverse recesses in the pistons 46 and 47 . Journals 58 and 59 have outer raceways for rollers 60 and 61 that are rotatably captured between the pistons and end flanges of the journals 58 and 59 . Squared ends of the journals 58 and 59 fit into the recesses 50 and 51 in the pistons to prevent their rotation. The sliders 56 and 57 ride within two guides 62 and 63 that fit into openings in an inner pump enclosure 64 .
[0039] The face cam assembly 48 includes a cam shaft 66 with two integral face cams 68 and 70 that define respective smooth, generally linear ramps, each being a continuous circular surface including a 180 degree incline and a 180 degree decline extending in the axial direction at the same slope and magnitude. The ramps are in opposed facing relation and are spaced axially apart such that the rollers 60 and 61 engage both ramps simultaneously. The face cams 68 and 70 are clocked 180 degrees out of phase so that the beginning of the incline of one ramp is axially aligned with the beginning of the decline of the other ramp. Thus, as the face cams 68 and 70 are rotated, the ramps will maintain the same axial spacing as they revolve through 360 degrees, and thus maintain contact with the rollers 60 and 61 . The rollers 60 and 61 will be on opposite parts of the ramps throughout the rotation of the face cams 68 and 70 so that the pistons 46 and 47 will move axially in opposite directions. The face cams 68 and 70 mount respective bearings 72 and 74 , which have their outer races pressed into a cam chamber 76 of the pump housing 64 to rotatably support the cam shaft 66 . Washers and spacers also mount onto the cam shaft 66 for each bearing. The cam shaft 66 is turned, and thus the pump is driven, by the drive section, which includes a motor, with a stator 82 and a rotor 84 , and an electronic motor drive “EMD”) 86 . A quill shaft 88 is coupled to a motor shaft 90 pressed into the motor rotor 84 and the motor shaft 90 is journalled to a pump cover 92 by a bearing 94 .
[0040] The motor is preferably a frameless, brushless DC motor capable of operating the pump to create a fuel flow rate of 550 pph and a pressure rise of 450 psid continuous and 800 pph and 680 psid transient. The motor is contained in the fluid chamber of the housing and is thus fully immersed in fuel during operation. This permits the fuel to cool the motor as it is pumped through the FCM. Moreover, it obviates the need for an interstitial drain porting ordinarily present between the pump and motor, thereby improving hermetic sealing of the unit. The EMD is a housed in the dry chamber of the housing with power and other heat producing components preferably being located near the motor end bell so that the fuel can indirectly cool these components as well.
[0041] The EMD is a microprocessor based controller electrically coupled over a network bus to the master computer, such as an airframe computer, which provides analog speed input signals to the EMD. The EMD uses high frequency pulse-width modulation of a four quadrant amplifier to precisely control input current to the motor. The EMD holds the angular velocity of the pump constant with minimum ripple in speed during each revolution of the motor using position and speed sensing circuitry to monitor the rotational velocity of the motor via a toothed disk 95 at the end of the motor shaft and three variable reluctance sensors. Motor speed is electronically monitored and compared with the commanded speed from the master computer. A correction can be applied to the motor drive signal to maintain the commanded speed, and a feed forward component consisting of speed and/or torque commands can be added to the motor drive signal to rapidly move the motor to the newly commanded speed with minimal settling time.
[0042] The motor rotates the face cam assembly which reciprocates the cam followers and in turn the pistons. The tandem push-push face cam arrangement provides consistent and accurate control of the piston movement, and thus metering of the fuel. Moreover, the dual cams provide a smooth transition between strokes and impart an essentially constant velocity motion to the pistons, at any motor speed, so as to minimize pressure ripple and provide non-pulsating fuel output well suited for high precision turbine applications. The stroke length effected by the face cam arrangement, and the length of the pistons and piston chambers, are selected so that residual air volume at top-dead-center is very small, which enhances dry-lift capability of the metering pump as well as the expulsion of entrained air.
[0043] As shown in FIG. 5 , valve plates 96 and 98 are disposed at each end of the pump housing 30 , each having two sets of sealed inlets 100 and outlets 102 (one set for each end of each of the pistons) controlled by low inertia valves. The inlet ports 100 are recessed in the valve plates to accommodate filters 104 and are controlled by oblong reed valves 106 mounted at the back side of the valve plates. The outlet ports 102 controlled by reed valves 108 mounted at the front of the valve plates. The inlet and outlet ports are arranged, and the pump housing is ported, so that a set of inlet and outlet ports is in communication with each of the piston chambers as well as the inlet 14 and the outlet 16 and 18 ports of the housing.
[0044] The valve plate inlet ports, filters and valves are selected to achieve very low pressure drop across the inlets of the valve plates. Specifically, the inlets have a plurality of small orifices, which in addition to making the inlets less susceptible to contamination, help break up the forces from the high speed flow that would otherwise impinge on the inlet valves. Reducing these forces allows thin, low inertia valves to be used, which require less pressure to open. The filters are preferably large capacity, open weave type screen filters. These features allow the metering pump 12 to operate at inlet pressures very near true vapor pressure, preferably 2-5 psi of true vapor pressure, with minimal risk of cavitation without a boosted or pressurized inlet.
[0045] It should be appreciated that merely a preferred embodiment of the invention has been described above. However, many modifications and variations to the preferred embodiment will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced.
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A fuel control system is provided in a single compact modular unit. The unit includes a motor driving a highly accurate cam-operated double-acting piston metering pump, both of which are contained in a liquid fuel environment. As the liquid fuel is pumped it works to cool internal components including the motor. An electronic motor drive is contained in a dry chamber of the unit for controlling operation of the motor and pump and is cooled indirectly by the fuel as well. A pressure sensitive flow divider is also included for selectively providing one or multiple output fuel flow paths depending upon whether a pressure threshold is reached, for example to send fuel to primary and secondary burner nozzles. Filter, filter bypass, pressure relief, and fuel shut-off components are also integrated into the single modular unit.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Patent Application No. 60/795,743, filed 27 Apr. 2006, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to turbines and generators and, more particularly, to turbines with integrated generators.
BACKGROUND OF THE INVENTION
Turbine generators that exploit passive pressurized sources such as natural gas well heads have found utility in low power applications (100 watts or less). An example of such a generator is disclosed in U.S. Pat. No. 5,118,961 to Gamel and owned by S&W Holdings, Inc., the assignee of the present patent application. The reliability of these units has resulted in a wider variety of applications by relevant consumers, and attendant demands for higher power output.
A challenge with increased power output is the requirement for higher voltage levels. Devices that rely on the spatial separation of electrical connections to provide electrical isolation between the winding terminations may require a larger footprint to accomplish the required isolation. Units that service the petrochemical industry are often powered by high pressure hydrocarbon gases. Increased potential between electrical connections may result in arcing, creating an explosion hazard. Even where an explosion does not result, such arcing may lead to a build up of carbon deposits on the exposed connections that may eventually bridge between the connections, causing the unit to short out and incur structural damage.
One approach to increasing the power is to increase the size of the various components. Exemplary is U.S. Patent Application Publication No. 2005/0217259 by Turchetta, which discloses an in-line natural gas turbine that utilizes bevel gears to transmit the rotational power to a generator outside a pipeline. However, in spatially constrained areas (e.g. off shore drilling platforms), the footprint of such an approach may be prohibitive.
Increased power output generally requires a higher mass flow rate through a given unit, which leads to an increase in the amount of condensate that forms and accumulates in the unit. Existing units have been known to become flooded with accumulated condensation to the point of becoming inoperable.
Another issue in certain applications, independent of power level, is the effect of corrosive gases. Natural gas wells, for example, are known to contain hydrogen sulfide (H 2 S), also referred to as “sour gas.” The sour gas has a highly corrosive effect on metals commonly used in electric generators. Another common component indigenous to natural gas wells is water vapor, which is also corrosive and can cause operational problems when condensing out as a liquid.
Certain technologies utilize pressurized liquids to prevent hazardous gasses from entering unwanted portions of an assembly, such as disclosed in U.S. Pat. No. 5,334,004 to Lefevre et al. Where isolation from electrical machinery is desired, such an approach may require an isolation chamber distinct from the compartment housing the electrical machinery, as the use of liquids may be precluded for reasons of electrical isolation. The need for an isolation chamber will generally add to the required footprint of the generator.
What is needed is a gas turbine generator capable of utilizing a hydrocarbon medium without posing an explosion or carbon forming hazard, is resistive to the corrosive components that may be indigenous to the pressure source, and eliminates the potential of condensation flooding while maintaining a small footprint.
SUMMARY OF THE INVENTION
The various embodiments of the disclosed invention provide an arrangement that prevents arcing between adjacent lead connections, thereby minimizing the explosion hazard and eliminating carbon bridging between connections. Various units have also been made more compact relative to existing designs, to provide more electrical generation capacity within a smaller footprint. For example, the present disclosure may produce a natural gas turbine that produces 500 Watts while occupying only a 250-mm×250-mm plan view footprint. The problem of condensation buildup is also mitigated.
In one embodiment, the turbine generator has a core assembly that includes windings with terminations connected to lead wires. The core assembly is encapsulated in a dielectric potting or casting which hermetically seals the windings, the winding terminations, and at least a portion of the lead wires leading to the connection with the terminations. The lead wires, either individually or as a group, may also be contained within a dielectric shroud such as shrink fit tubing that terminates on one end within the dielectric casting and on the other end within a packing in a sealed container. By this approach, all current-bearing components are isolated from the flow stream. Certain embodiments of the invention have found favor in an industrial context, earning Factory Mutual (FM) approval for use with natural gas.
The turbine generator has a rotor that is motivated by a high pressure fluid such as natural gas that is directed tangentially to impinge on the outer perimeter of the rotor. A design is disclosed wherein the full axial length of the rotor is utilized as the impingement surface, thereby increasing the power imparted to the rotor over a minimum length, thereby maintaining a small overall footprint for the turbine generator.
The fluid enters the turbine generator via inlet passages and exits the unit via outlet passages. The outlet passages are configured to penetrate the interior of the turbine generator at a substantially horizontal angle and at the bottom of the cavities that house the components of the turbine generator, thus enabling the cavities to drain and reducing build up of condensation within the cavities.
In another embodiment, a natural gas turbine generator includes a housing that defines an interior chamber in fluid communication with an inlet and an outlet for passage of a gas therethrough, the gas including a hydrocarbon. A rotor is operatively coupled within the interior chamber, the rotor including an impingement surface and cooperating with the interior chamber to form an annular passageway about the impingement surface. The rotor is rotationally driven when the gas passes through the annular passageway. An electric generator including a core assembly is operatively coupled with at least one magnetic element, the core assembly being stationary relative to the housing and hermetically sealed within a dielectric casting for isolating the core assembly from the gas. The at least one magnetic element is secured to the rotor for rotation with respect to the core assembly.
Another embodiment may further include a framework portion having a first axial length, the framework portion including an impingement surface having a second axial length, the second axial length being is greater than one-half of the first axial length.
In another embodiment, the rotor includes a shaft portion having a standoff portion that separates two end portions, the end portions being operatively coupled with bearings. The standoff portion may have a length substantially equal to the axial length of the framework.
In yet another embodiment, the interior chamber defines a lower extremity. The outlet passage extends from the lower extremity in an orientation for draining condensation from said interior chamber.
In still another embodiment, a turbine generator for generating electricity that is powered by a flow of gas therethrough includes a housing that defines an interior chamber in fluid communication with an inlet and an outlet for passage of the gas therethrough. The gas may contain a hydrocarbon. A rotor is operatively coupled within the interior chamber, the rotor including a continuous impingement surface and cooperating with the interior chamber to form an annular passageway bounded on an inner perimeter by the continuous impingement surface. The rotor is rotationally driven when the natural gas passes tangentially through the annular passageway. The embodiment includes an assembly of armature plates having an inner radial portion and an outer radial portion, and at least one winding interlaced with the outer radial portion of the assembly of armature plates. The at least one winding has a plurality of terminations. A plurality of leads, each having a proximal portion and a distal portion, one each of the plurality of lead wires, is electrically connected to one of the plurality of terminations at the proximal portion. A dielectric casting encases the outer radial portion, the at least one winding and the proximal portions of the plurality of lead wires and hermetically seals the at least one winding and the proximal portions from contact with the natural gas.
In another embodiment, an orifice passes through the inner radial portion of the assembly of armature plates and has a front end located on the front face of the assembly of armature plates. The dielectric casting encases the front end of the orifice.
Another embodiment of the invention includes a housing that defines an interior chamber in fluid communication with an inlet and an outlet for passage of a fluid therethrough, the interior chamber having a lower extremity, the outlet passage extending from the lower extremity in an orientation for draining condensation from the interior chamber. A rotor is operatively coupled within the housing and has a continuous impingement surface. A flow restricting device is disposed between the inlet and the continuous impingement surface of the rotor, the flow restricting device directing the fluid onto the continuous impingement surface and causing the rotor to rotate about an axis. An electric generator is mounted within the interior chamber and includes a core assembly and a magnetic element. The core assembly is stationary relative the housing, and the magnetic element is secured to the rotor and rotates proximate the core assembly. The embodiment also includes means for isolating the core assembly from the fluid.
An electrical generating system is also disclosed that includes a turbine generator in fluid communication with a pressurized gas source, the pressurized gas source producing a gas flow, the gas flow including a natural gas. The turbine generator includes a stationary core assembly operatively coupled with a magnetic element that rotates relative to the stationary core assembly to produce electricity. The core assembly includes current-bearing components that are encapsulated within a dielectric casting that hermetically seals the current-bearing components from the gas flow. A throttling device may be disposed between said pressurized gas source and the turbine generator, the throttling device imposing a reduced pressure in the gas flow entering the turbine generator. A pre-heating system may be disposed between the pressurized gas source and the rotor for transferring heat to said gas flow.
In another embodiment of the invention, a method of using a natural gas turbine includes selecting a turbine generator that has a plurality of electrical outputs and an interior chamber in fluid communication with an inlet and an outlet. The interior chamber contains a stationary core assembly operatively coupled with at least one magnetic element mounted on a rotor rotatable relative to the stationary core assembly for producing electricity at the plurality of electrical outputs. The rotor in this embodiment has a continuous impingement surface. The core assembly has current-bearing components that include a plurality of windings and being at least partially encapsulated within a dielectric casting that hermetically seals the current-bearing components. The method further entails connecting the plurality of electrical outputs to an electrical load and connecting a gas supply line to the inlet, the gas supply line being in fluid communication with a pressurized gas source, the pressurized gas source including a natural gas composition. A gas return line is connected to the outlet, and a gas flow is enabled from the pressurized gas source to flow through the turbine generator, the gas impinging the continuous impingement surface and causing the rotor to rotate the at least one magnetic element relative to the core assembly and produce electricity at the plurality of electrical outputs. The method may further include operating a switch between the electrical output and the electrical load, the switch being switchable between at least a load position and a no-load position. The switch is repeatedly cycled between the load position and the no-load position according to a periodic cycle to increase the average rotational speed of the rotor.
Another method according to the present invention includes operating a plurality of switches, one each in line with one of the plurality of windings, each of the plurality of switches being switchable between one of the plurality of the electrical outputs and a plurality of resistive elements. Each of the plurality of resistive elements are operatively coupled between two of the plurality of windings, wherein switching the plurality of switches to the plurality of resistive elements causes dynamic braking of the turbine generator.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1 a and 1 b are perspective views of a turbine generator in an embodiment of the invention;
FIG. 2 is a front elevation view of the turbine generator of FIG. 1 a with the front housing portion and the rotor removed for clarity;
FIG. 3 is an exploded view of the turbine generator of FIG. 1 a;
FIG. 4 is a perspective view of the rotor of FIG. 3 ;
FIG. 5 is a sectional view of the turbine generator of FIG. 1 a along the datum indicated in FIG. 2 ;
FIG. 6 is a plan view of an assembly of armature plates in an embodiment of the invention;
FIG. 7 is a sectional view of the assembly of armature plates of FIG. 6 ;
FIG. 8 is a sectional view of a turbine generator in an embodiment of the invention;
FIG. 8 a is a sectional view of the rotor of FIG. 8 in isolation;
FIG. 9 a is a sectional view of a nozzle arrangement for directing a jet onto the impingement surface at a substantially tangential angle of incidence;
FIG. 9 b is an enlarged partial sectional view of the rotor and nozzle ring of FIGS. 5 and 8 ;
FIG. 9 c is an enlarged partial cut-away view of the rotor of FIG. 9 b;
FIG. 10 is a perspective view of a core assembly secured to a back housing portion in an embodiment of the invention;
FIG. 11 is an enlarged partial view of the core assembly of FIG. 10 with a cut-away view of the plate assembly within;
FIG. 12 is an enlarged partial view of the core assembly of FIG. 10 in the vicinity of an encased front end of an orifice for feeding through wire terminations;
FIG. 13 is a schematic of a turbine generator system in an embodiment of the invention;
FIG. 14 is a cut-away view of a turbine generator depicting the use of heating elements in a plenum of the turbine generator in an embodiment of the invention;
FIG. 15 is a sectional view of a turbine generator with a control board mounted therein in an embodiment of the invention;
FIG. 16 is a partial sectional view of a turbine generator with a control board that is convectively cooled in an embodiment of the invention;
FIG. 16 a is a sectional view of the control board of FIG. 16 having finned elements for convective heat transfer in an embodiment of the invention;
FIG. 17 is a partial sectional view of a turbine generator with a control board that is conductively cooled in an embodiment of the invention;
FIG. 18 is a perspective view of a front housing of a turbine generator in an embodiment of the invention; and
FIG. 19 is an electrical schematic of an operating circuit in accordance with an embodiment of the invention.
DESCRIPTION OF THE INVENTION
Referring to the FIGS. 1 through 7 , a turbine generator 10 including a housing 12 with an inlet passage 14 and a pair of fluid outlet passages 16 is depicted in an embodiment of the invention. In this embodiment, a rotor 18 having a continuous impingement surface 20 and a magnetic element 22 attached to the rotor 18 is disposed in the housing 12 . The rotor 18 may be configured to substantially surround a core assembly 24 . The continuous impingement surface 20 may be characterized by a roughened or structured surface such as a saw-tooth profile. A flow restricting device 26 such as a nozzle ring may be fixed in the housing 12 about the rotor 18 .
The housing 12 may include a front housing portion 28 and a back housing portion 30 separated by a spacer ring 32 that combine to form an interior chamber 33 in fluid communication with the inlet passage 14 and the outlet passages 16 . The front housing portion 28 includes a flange 34 in which one of the fluid outlet passages 16 may be formed. The flange 34 may also include a recess 36 for receiving an o-ring 38 and side portion of the flow restricting device 26 .
The spacer ring 32 has front and back faces 40 and 42 for bearing against the front and back housing portions 28 and 30 , respectively. An o-ring gland 41 for housing an o-ring 43 may be formed on the front face. The spacer ring 32 may further include the inlet passage 14 formed therein and an interior perimeter 44 . A plenum or intake manifold 45 may be formed by the separation between the interior perimeter 44 and the outer peripheral surface 27 of the flow restricting device 26 . A pressure regulating device (not depicted) that reduces the pressure of the incoming fluid without reducing the mass flow through the turbine generator 10 may be placed upstream of the inlet passage 14 .
The front housing portion 28 may further include an annular shaped cavity 46 that defines part of the interior chamber 33 . A rotor mount 48 may be formed about a central axis 49 . The rotor mount 48 in this embodiment includes a pedestal portion 50 and a collar portion 52 extending from the pedestal portion 50 . The collar portion 52 extends in a substantially horizontal direction from the pedestal portion 50 when the gas turbine generator 10 is in an upright (i.e. operating) position. A rotor bearing 54 is contained within the collar portion 52 .
The back housing portion 30 may include an annular shaped cavity 56 about the core assembly 24 that defines a portion of the interior chamber 33 and a concentric mount 58 for the rotor 18 . The concentric mount 58 in this embodiment includes a rotor bearing 60 and a shoulder 62 with threaded screw taps 64 . The core assembly 24 is secured to the concentric mount 58 with socket head cap screws 66 .
In the FIGS. 1 through 7 embodiment, the back housing portion 30 also includes a partition 68 and an annular wall portion 70 extending from the partition 68 . The partition 68 may include the other outlet passage 16 extending from the cavity 56 to the exterior of housing 12 and a pair of annular recesses 74 , 76 in which respective o-rings 78 and 80 are disposed. A front face 82 runs parallel to the back face 42 of the spacer ring 32 . The annular recess 76 fixedly and sealingly receives a side portion of the flow restricting device 26 , thereby exerting a compression force on o-ring 80 . The annular wall portion 70 defines a large cavity or compartment 84 that may house electronic appurtenances such as buck converters, RS 485 interfaces, and assorted instrumentation.
The housing 12 may be held together by bolts 88 that pass through the front housing portion 28 and spacer ring 32 and threadably engage tapped bores 89 on the front face 82 of the partition 68 of the back housing portion 30 . The housing 12 is supported by a foot structure 90 fastened to the bottom of the back housing portion 30 . The passages 14 and 16 may be partially threaded with standard pipe threads.
The flow restricting device 26 may take the form of a nozzle ring that includes a plurality of apertures or jet orifices 92 for directing fluid onto the center of the continuous impingement surface 20 . Typically, between fourteen and eighteen jet orifices 92 are uniformly distributed about the outer peripheral surface 27 of the nozzle ring. The number of jet orifices 92 may be changed to accommodate space and optimize torsion requirements. The structure and function of the nozzle ring and its interaction with the continuous impingement surface 20 is further described in U.S. Pat. No. 5,118,961, the disclosure of which is hereby incorporated by reference other than any express definitions of terms specifically defined therein.
The rotor 18 ( FIG. 4 ) may include a cylindrical side wall 94 having an axial length 96 that extends axially from the perimeter of a base portion 98 , wherein the side wall 94 and base portion 98 define a receptacle or framework portion 100 that substantially covers or surrounds the core assembly 24 . The base portion 98 may be disc-shaped as depicted, or of other structure suitable for supporting the side wall 94 such as a hub-and-spoke arrangement. In the depiction of FIG. 4 , the framework portion 100 is further characterized as having an interior perimeter surface 102 and a base surface 104 .
In one embodiment, the perimeter portion 106 of the rotor 18 is recessed to provide gaps 108 between the perimeter portion 106 and the front and back portions 28 and 30 of the housing 12 . The rotor 18 further includes a rotor shaft 109 having a standoff portion 111 that separates end portions 110 , 112 that mount within bearings 60 , 54 , respectively. The rotor shaft 109 may be integrally formed with the rotor 18 .
The axial length 96 of the continuous impingement surface 20 may extend over a majority of an overall length 97 of the framework portion 100 . The rotor of FIG. 8 a , for example, depicts the axial length 96 of the continuous impingement surface 20 as almost equal to the overall length 97 of the framework portion 100 ; the length 96 is shorter than the overall entire length 97 only by the amount of the recess at the perimeter portion 106 . Hence, in this configuration, the length 96 of the continuous impingement surface 20 is over 90% of the overall length 97 of the framework portion 100 .
The interior perimeter surface 102 defines a recess 114 extending radially into the cylindrical side wall 94 . The magnetic element 22 may be comprised of eight rare earth magnets disposed in pairs equally spaced at 45° from each other. Each of the magnet pairs may abut each other and have an inner peripheral surface 116 that is substantially flush with the non-recessed portion of the interior perimeter surface 102 .
In certain embodiments, the core assembly 24 includes an armature plate assembly 118 comprising a plurality of laminated steel armature plates 120 ( FIG. 6 ) configured for mounting on concentric mount 58 of back housing portion 30 via the cap screws 66 . A trio of windings 122 (one for each phase of a 3-phase generator) is interlaced with an outer radial portion 124 of the armature plate assembly 118 . Further details of the armature plates 120 and the configuration of the windings 122 are presented in U.S. Pat. No. 5,118,961.
The armature plate assembly 118 is characterized as having an inner radial portion 126 in addition to the outer radial portion 124 that includes a plurality of poles 125 extending radially outward and an armature interface 127 on the tangential face of the outer radial portion 124 . The individual plates 120 of the armature plate assembly 118 may be angularly offset with respect to the neighboring plates to provide a trapezoidal shape 129 on the armature interface 127 of the armature plate assembly 118 (best depicted in FIG. 11 ).
In one embodiment, the inner radial portion 126 is further characterized as having a front face 128 and a back face 130 . The back face 130 of the armature plate assembly 118 rests against the shoulder 62 of the concentric mount 58 . An orifice 132 passes through the inner radial portion 126 , the orifice 132 having a front end 134 that faces the framework portion 100 of the rotor 18 and a back end 136 adjacent the shoulder 62 of the concentric mount 58 . The orifice 132 is aligned with a wire way passage 138 passing between the shoulder 62 and the compartment 84 of the back housing portion 30 .
The windings 122 may have terminations 140 that are located within the framework portion 100 of the rotor 18 , in close proximity to the front end 134 of the orifice 132 . A set of three phase leads 142 having a proximal portion 143 and a distal portion 145 are connected to the terminations 140 at the ends of the proximal portion 143 . The distal portion 145 is routed through the orifice 132 , the wire way passage 138 and a sealed connector 146 attached to the back end 136 of the wire way passage 138 . A neutral lead 144 may also be similarly routed and connected. The leads 142 , 144 may be shrouded in a sleeve 147 such as a shrink fit tube, either individually or as a group. The sleeve 147 extends from the packing gland of the connector 146 , through the wire way passage 138 and into the orifice 132 .
Referring to FIG. 8 , the terminations 140 depend from the windings 122 into the annular cavity 56 , with the wire way passage 138 being in substantial alignment with the terminations in another embodiment of the invention. The leads 142 , 144 traverse the annular cavity 56 between the terminations 140 and the wire way passage 138 . Again, the leads 142 , 144 may be wrapped with sleeve 147 extending from the terminations 140 through the wire way 138 and through the packing gland of the connector 146 . The configuration of the wiring in FIG. 8 negates the need for an orifice 132 passing through the armature plate assembly 118 .
The embodiment of FIG. 8 also depicts a rotor shaft 109 a as having a standoff portion 111 that is substantially equal to the overall length 97 of the framework portion 100 of the rotor 18 . The standoff portion 111 of the rotor shaft 109 a is characterized by a length L that is longer than the comparable portion of the rotor shaft 109 of FIG. 5 . To accommodate the longer length L, the bearing 60 may be recessed within the concentric mount 58 , such that the shoulder 62 extends beyond the end portion 112 of the rotor shaft 109 a.
Functionally, the extended length L of the rotor shaft 109 a may enhance the dynamic balance of the rotor 18 , particularly at higher rotational speeds. The working fluid 149 may be directed through the flow restricting device 26 to impinge on the axial center of the continuous impingement surface 20 of the rotor 18 . Referring to FIG. 8 a , forces are generated on the rotor having a radial component directed F R inward toward the central axis 49 . Any moments supported by the rotor shaft 109 a will cause unequal loading between the bearings 54 and 60 , which can manifest itself as a vibration, particularly at high rotational speeds. Also, if the radial forces F R are not uniform, the shaft may experience a net load in a direction orthogonal to the central axis 49 .
The extended length L of the rotor shaft 109 a enables the radial force components F R to intersect substantially coincident with the center 109 b of the rotor shaft 109 a , thereby reducing the moment supported by the rotor shaft 109 a and promoting the uniform loading of the bearings 54 and 60 . The configuration may provide dynamic stability across a range of rotational speeds.
Referring to FIG. 9 a , each of the orifices 92 may be configured with a larger aperture portion 92 a having a concave end and a smaller diameter aperture portion 92 b . An axis 93 of each of the orifices 92 may be substantially tangential to the continuous impingement surface 20 of the rotor 18 .
Referring to FIGS. 9 b and 9 c , an enlarged view of the fluid flow about the cylindrical sidewall 94 of the rotor 18 is presented in an embodiment of the invention. As fluid pressure builds in the plenum 45 , the working fluid 149 flows through the jet orifices 92 to tangentially impinge the continuous impingement surface 20 to rotationally drive the rotor 18 . The working fluid 149 exiting the jet orifices 92 fan out over the continuous impingement surface 20 through the gaps 108 into cavities 46 , 56 ( FIG. 9 b ) and is conveyed by pressure out of the housing 12 through fluid outlets 16 .
The continuous impingement surface 20 subtends the diverging angle of the fanning jet until the fluid pours over the edge of the continuous impingement surface 20 and into gaps 108 . A wider continuous impingement surface 20 (i.e. greater axial length 96 ) may extract more momentum extracted out of the fluid because the working fluid 149 is in contact with continuous impingement surface 20 over a longer tangential track ( FIG. 9 c ).
Accordingly, a majority of the overall length 97 of the framework portion 100 of the rotor 18 may be utilized as an impingement surface to increase the area and length over which angular momentum is imparted on the rotor 18 for the given axial length 96 . The axial length 96 may exceed 90% of the overall length 97 in some embodiments. Integration of the continuous impingement surface 20 and the interior perimeter surface 102 on a common cylindrical side wall 94 provides further compactness and economization of space.
The continuous impingement surface 20 may include a roughened or structured surface. Impingement surfaces 20 that include a structured surface may possess a higher degree of aerodynamic drag than a machine finished surface, which also can extract more momentum out of the working fluid 149 . For example, the continuous impingement surface 20 may have a saw-tooth profile as depicted in FIG. 9 a across the entire axial length 96 . The structure may have a peak-to-valley dimension greater than 0.17-mm. A representative and non-limiting range for the peak-to-valley dimension of the saw-tooth profile is 0.5- to 1.0-mm. An increased transfer of momentum may result in a greater rotational velocity of and/or more rotational power to the rotor 18 . Other structured surfaces include knurled surfaces, hobbed or herring bone, and may have typically the same peak-to-valley dimensions.
The continuous impingement surface 20 may be characterized by a roughness parameter. A representative and non-limiting value for the surface roughness is a root-mean-square (RMS) value of 0.1-mm or greater. Accordingly, the continuous impingement surface 20 may roughened by other structural means, such as by sandblasting.
Referring to FIGS. 10 through 12 and again to FIGS. 5 and 8 , the core assembly 24 is depicted as being hermetically sealed in an embodiment of the invention. The outer radial portion 123 , windings 122 , terminations 140 and the portion of the leads 142 , 144 that extend between the terminations 140 and the front end 134 of the orifice 132 are encased in a dielectric potting or dielectric casting 148 . The dielectric casting 148 also floods the orifice 132 during the potting process, encasing the leads 142 , 144 and an end of the sleeve 147 located within. The other end of the sleeve 147 is sealed against the leads 142 , 144 by the packing gland of the connector 146 . The dielectric casting 148 may be of any suitable potting having appropriate dielectric, thermal and mechanical characteristics. An example is an epoxy such as Epoxylite 230 manufactured by Altana Electrical Insulation of St. Louis Mo. Other candidates for the casting material 148 include electrical resins such as Scotchcast Electrical Resin 251 and general purpose electronic impregnation materials. Some applications may require dielectric castings suitable for elevated temperatures, for example to 200° C. Silicone-based materials may also be appropriate in some applications.
The housing 12 , including the housing portions 28 , 30 and spacer ring 32 , as well as the foot structure 90 , are typically formed of a stainless steel. Alternative materials include aluminum and plated 8620 steel. The rotor 18 is also typically formed of a stainless steel, although aluminum may be used. The nozzle ring 26 is typically fabricated from a stainless steel or anodized aluminum. The various o-rings 38 , 43 , 78 and 80 provide a gas tight seal between respective mating components.
In operation, a working fluid 149 such as natural gas, passes through the inlet passage 14 and through nozzle ring 26 , impinging on the continuous impingement surface 20 to drive the rotor 18 and magnetic element 16 about the core assembly 24 . As the rotor 18 is driven by the impinging fluid on the continuous impingement surface 20 , the magnetic element 22 spins about core assembly 24 to generate electricity in a brushless fashion. Approximately 500 watts of alternating current power may be generated. Both the FIG. 5 and FIG. 8 embodiments are motivated in this manner.
The standard pipe threads in the passages 14 and 16 enable the coupling of supply and return lines to the turbine generator 10 . Fluid flowing through the inlet passage 14 impinge on the outer peripheral surface 27 of the nozzle ring 26 , circulates tangentially through the plenum 45 and over the jet orifices 92 .
The implementation of a pressure regulating device upstream of inlet passage 14 (discussed above but not depicted) may increase the aerodynamic drag of the fluid against the continuous impingement surface 20 , thereby transferring more momentum from the fluid to the rotor 18 . The density ρ of an ideal gas is generally proportional to the pressure P of the gas. For a given mass flow rate mdot of the gas through a passage having a flow cross-section AC, the corresponding velocity U of the gas through the passage is derived from the relationship
m dot=ρ· U·A C
Thus, a reduction in the pressure P generally causes a proportional increase in the velocity U for a fixed mdot and A C . The drag force D exerted on a surface is proportional to the density ρ and the square of the velocity U of the gas, that is:
D∝ρ·U 2
The tradeoff between the reduced density ρ and the increased velocity U caused by a reduction of the upstream pressure may result in an increase in the drag force D, which in turn imparts more momentum from the gas to the rotor 18 . An increase in the drag force D results in a more powerful rotation of the rotor 18 and a higher rotational speed. Therefore, where head losses permit, regulation of the pressure to the inlet to a lower pressure without an attendant reduction in mass flow rate should result in enhanced performance of the turbine generator 10 .
The use of anodized aluminum for a nozzle ring 26 provides a surface that is softer than a stainless steel rotor 18 , thus minimizing damage to the continuous impingement surface 20 of the rotor in the event that the rotor 18 contacts the nozzle ring 26 during operation.
The extension of the collar portion 52 helps prevent moisture from entering the rotor bearing 54 . If the rotor bearing 54 were mounted flush with the pedestal portion 50 , condensation forming on the face of the pedestal portion 50 could run down and into the rotor bearing 54 . The extension provided by the collar portion 52 causes accumulated condensation on the face of the pedestal portion 50 to flow around the collar portion 52 , preventing the condensation from entering the rotor bearing 54 .
The dielectric casting 148 , in combination with the sleeve 147 , hermetically seals all current-bearing components that would otherwise come in contact with the flowing fluid. In particular, the connections between the terminations 140 and the leads 142 , 144 , which may otherwise be in direct contact with the flowing gas, are well isolated by the disclosed potting scheme. The isolation provided by the dielectric casting 148 prevents arcing between the connections and the accompanying damage and reliability problems that arcing poses. Embodiments utilizing the dielectric casting 148 eliminate the formation of carbon build up on the leads due to arcing, and are also deemed explosion proof for natural gas or other hydrocarbon gas applications.
The sleeve 147 , whether applied to individual leads 142 , 144 or to the group, is sealed on one end by the potting material 148 and on the other by the packing gland in the connector 146 . Accordingly, it is possible to affect the isolation of the leads 142 , 144 from fluid of the turbine generator 10 by other means that encase the wire, such as a rubber or silicone dip that coats the wires along an equivalent portion.
The trapezoidal shape 129 of the armature interface 127 of FIG. 9 promotes smooth revolution of the rotor 18 at low rotational rates. For generators utilizing magnetic elements 22 and armature interfaces 127 that are rectangular in shape, the rotor 18 may jump from one equilibrium position to another as the magnetic elements 22 cross between segments of the armature interface 127 . This phenomenon, known as “cogging,” is mitigated by the trapezoidal shape 129 because the trapezoid provides a bridging between the armature interface 127 and the discrete, rectangularly-shaped magnetic elements 22 .
Referring to FIG. 13 , a generator system 150 including the turbine generator 10 and a gas pre-heater 152 is depicted in an embodiment of the invention. The generator system 150 may further include a gas supply line 154 , a gas return line 156 and a throttling device 158 located between the gas supply line 154 and a pressurized gas source 160 . In the embodiment depicted, the pre-heater 152 may apply energy to a heated segment 162 of the gas supply line 154 for transfer to an incoming gas stream 163 . In other embodiments, the pre-heater 152 may be mounted within the gas supply line 154 to impart energy directly to the incoming gas stream 163 . Hence, energy delivered to the heated segment 162 may be applied externally and transferred through the walls of the gas supply line 154 , or applied internally, within the boundaries of the gas supply line 154 .
The energy source for the pre-heater 152 may comprise any of several heat sources, including but not limited to a heating element such as heat tape operatively coupled to the heated segment 162 , or a heat exchanger operatively coupled to the heated segment 162 which draws heat from an ancillary process. Other mechanisms that can be utilized to introduce energy into the incoming gas stream 163 include a slip stream used to introduce a hot gas into the incoming gas stream. A controlled vitiation process wherein a fraction of the incoming gas is combusted may also be implemented to add heat. Furthermore, several heat source mechanisms may be combined to provide the pre-heating function at various times, depending on availability.
In practice, the throttling device 158 may be utilized to reduce the pressure of the pressurized gas source 160 upstream of the turbine generator 10 . The throttling process may cause expansion of the gas across the throttling device 158 , reducing the temperature of the gas. The reduced temperature of the gas limits the expansion of the gas as it enters the turbine generator. The density ρ of the gas increases, but as previously discussed, the increased density ρ will proportionately reduce the velocity U of the gas as it flows across the rotor 18 resulting in a net loss to the drag force D that motivates the rotor 18 .
A similar reduction in temperature may also occur as the gas passes through the nozzle ring 26 . Depending on the magnitude of the combined step down in pressure, the temperature reduction may be enough to degrade the performance of the generator system 150 to a level that does not meet specification.
The pre-heater 152 may restore at least partially the temperature of the gas and bring the generator system 150 to within performance specifications. The power or energy imparted by the pre-heater 152 may be a predetermined value, or adjustable to enable trimming, such as in a feedback control scheme.
The skilled artisan will recognize that the energy addition may be made anywhere upstream of the turbine generator 10 and, aside from non-adiabatic losses, still counter the temperature losses associated with the expansion across the throttling device 158 .
Referring to FIG. 14 , an alternative heating arrangement 162 for providing the pre-heating function internal to the natural gas turbine 10 is depicted in an embodiment of the invention. A plurality of passages 163 may be formed in the partition 68 to penetrate the plenum 45 . Each of the passages may be capped on the end opposite the plenum 45 with a feedthrough 164 such as a compression fitting. Only one such passage 163 and feedthrough 164 is depicted in FIG. 14 and is discussed herein. A heating element 165 such as a cartridge heater may be fed through the feedthrough 164 and passage 163 so that a distal end 166 extends into the plenum 45 . The heating element 165 may comprise a heated portion 167 near the distal end 165 , an unheated portion 168 adjacent the partition 68 , and lead wires 169 that may be terminated within the compartment 84 .
In operation, the working fluid 149 enters the inlet 14 and courses through the plenum 45 before passing through the nozzle ring 26 . Heat is transferred to the working fluid 149 as it passes over the heated portion 167 of the heating element 165 , thereby raising the temperature and providing the pre-heating function prior to passage through the nozzle ring 26 . The feedthrough 164 provides a gas-tight seal about the passage 163 and the heating element 165 , thereby preserving the integrity and explosion-proof rating criteria of the compartment 84 .
The unheated portion 168 , which resides in the passage 163 , may be tailored for a substantially lower watt density than the heated portion 167 . One reason for including an unheated portion 168 is because the unheated portion 168 of the heater 165 is in a region of stagnant flow, and may not be adequately cooled if the unheated portion 168 were subject to the same watt density as the heated portion 167 . An untailored heating element (i.e. one with a uniform watt density across its entire length) may fail because of overheating of the portion within the passage 163 , or the untailored heating element may have to be operated at a reduced capacity to prevent such failure, thereby delivering inadequate heat to the working fluid Another reason to configure the heating element 165 with an unheated portion 168 is to limit unnecessary heating of the partition 68 and preserve the cooling capabilities that the partition 68 provides, which is described below.
Referring to FIGS. 15 through 17 , various embodiments of a turbine generator 170 are depicted as including a control board 172 . The control board 172 may include heat-generating components 173 for operations such as switching or power relay or other control and monitoring functions, including but not limited to buck converters, silicon-controlled rectifiers (SCRs), RS 485 interfaces, and assorted instrumentation to control or condition the electrical output and/or operation of the turbine generator 170 .
In the embodiments of FIG. 15 , the control board 172 is mounted on a back surface 174 of the partition 68 of the back housing portion 30 , within compartment 84 , using fasteners 176 and spacers 178 . The spacers 178 may provide a gap 180 . The gap 180 may be bridged between selected heat-generating components 173 and the back surface 174 with heat conducting bridges 181 comprising a heat conducting medium such as aluminum or copper. The heat conducting bridges may be formed on a single plate that is coupled to the back surface 174 , with varying thickness to accommodate varying heights of the heat-generating components relative to the control board 172 . Individual heat conducting bridges 181 attached to individual heat generating components 173 may also be used. A heat conductive paste 183 may be disposed between the heat conducting bridges 181 and the back surface 174 and heat-generating components 173 , respectively.
In other embodiments, the gap 180 that may be left open ( FIG. 16 ) or may be filled with an interstitial material 182 ( FIG. 17 ). The interstitial material 182 may be in the form of a bonding or cement that provides intimate contact with both the control board 172 and the back surface 174 . The interstitial material 182 may possess dielectric properties as appropriate to prevent shorting between the heat-generating components 173 or other components of the control board 172 , as well as electrical isolation between these components and the back surface 174 . In certain embodiments, the open gap 180 may include a finned structure 185 coupled to the board 172 ( FIG. 16 a ).
A cover or lid 184 may be placed over the back housing to form a enclosure 186 with compartment 84 . A seal 188 such as a gasket or o-ring may be secured between the lid 184 and the back housing portion 30 to form a substantially air tight enclosure 186 .
In operation, a byproduct of the control board 172 may be a substantial amount of heat generation within the various heat-generating components 173 . Certain embodiments of the present invention provide a synergistic way to cool the heat-generating components 173 . As discussed above, gas entering the turbine generator 170 undergoes an expansion, potentially at the nozzle ring 26 as well as upstream such as with throttling device 158 ( FIG. 13 ). The gas is in intimate contact with the partition 68 as it courses through the annular cavity 56 and the outlet passages 16 , and may cause the partition 68 to operate at a temperature significantly below ambient temperatures.
The partition 68 may thereby act to cool the heat-generating components 173 , via conductive coupling ( FIGS. 15 and 17 ) or convective coupling ( FIGS. 16 and 16 a ) to the back surface 174 of the partition 68 . The heat conductive paste 183 , when utilized, enhances the conductive heat transfer by reducing the contact resistance between the heat conducting bridges 181 and the back surface 174 and heat-generating components 173 , respectively (e.g. FIG. 15 ).
In FIG. 16 , a natural convection loop 187 may be established and driven between the cool back surface 174 and the opposing face of the warmer control board 172 . When utilized, the finned structure 185 ( FIG. 16 a ) enhances the effect of convective cooling by increasing the effective heat transfer area. Fins may also be formed or disposed on the back surface 174 (not depicted) to further enhance the heat exchange between the heat-generating components 173 and the partition 68 .
Radiative heat transfer to the back surface 174 of the partition 68 is also generally present, and may be enhanced by providing a coating of high emissivity on either the back surface 174 or the surfaces adjacent the back surface 174 (e.g. the heat emitting components 173 of FIG. 15 or the control board 172 of FIG. 16 , or the finned structure 185 of FIG. 16 a ) to further enhance the cooling of the heat emitting components 173 . The finned structure 185 , as well as any fins formed or disposed on the back surface 174 , may further enhance the radiative coupling by increasing the apparent emissivity of the radiative surface.
In certain embodiments of FIG. 17 , the interstitial material 182 may provide sufficient bonding between the control board 172 and the back surface 174 of the partition 68 to forego the use of fasteners. The dielectric requirements of the interstitial material 182 may manifest a lower thermal conductivity than the highly conductive materials available for the heat conducting bridges 181 , the combination of a larger surface area and a smaller dimension for the gap 180 may still provide sufficient cooling of the heat conducting components 173 .
By virtue of such cooling mechanisms being provided by the expanded gas in contact with the partition 68 , the compartment 84 may still be maintained as the enclosure 186 without encountering excessive temperatures therein. The capability of maintaining the enclosure 186 enables the gas turbine generator 170 to retain certain safety ratings, such as a Class 1, Division 1 or Division 2 certification from Underwriters Laboratories or equivalent.
Referring to FIG. 18 , the front housing portion 28 is depicted in an embodiment of the invention. When the gas turbine 10 is in an upright (i.e. operational) position, the central axis 49 of the gas turbine 10 is in a horizontal orientation, thereby defining a lower extremity 85 for each of the annular cavities 46 and 56 , respectively. The outlet passages 16 are formed along axes 87 that are substantially horizontal when the gas turbine generator 10 is in an upright position, as depicted in FIG. 19 . The outlet passages 16 penetrate the annular cavities 46 and 56 near their respective lower extremities 85 .
Functionally, the orientation of the outlet passages 16 enable active purging of condensates from the gas turbine 10 . Another potential consequence of the expansion of the working fluid 149 (discussed above) is the formation of condensation as the working fluid 149 cools. The location and horizontal orientation of the outlet passages 16 enable condensation to be cleared from the unit as a matter of course. Condensation that flows to the lower extremities 85 is propelled out of the annular cavities 46 and 56 and through the passages by the flowing gas. Even where flow rates or pressure differentials are marginal, the configuration enables condensate to drain hydrostatically out of the outlet passages 16 .
Referring to FIG. 19 , an electrical schematic of an operating circuit 200 of a turbine generator is depicted in an embodiment of the invention. A trio of windings 202 a , 202 b and 202 c contained within the core assembly 24 are connected in a 3-phase wye configuration and terminating at a plurality of electrical outputs 204 . The operating circuit 200 is depicted as powering a load 206 . The load 206 may be any device that can operate off the power provided by the turbine generator, with or without attendant conditioning circuitry. Examples include a battery, a lamp, a video camera or a three-phase motor.
The operating circuit 200 may include a multi-pole switch 208 that alternates between a load position (depicted) and a no-load position. The multi-pole switch 208 may be cycled between the load and the no-load position.
Functionally, cycling multi-pole switch 208 between the load and no-load positions may increase the average speed of the rotor 18 . When current is flowing through the windings (i.e. multi-pole switch 208 is in the load position), the rotor 18 experiences a torque load or resistance to rotational movement due to the electromotive force that is generated. When current is absent (i.e. the multi-pole switch 208 is in the no-load position), the rotor 18 rotates more freely in the absence of the electromotive force. Switching multi-pole switch 208 between the load and no-load positions cyclically allows the rotor 18 to speed up during the off cycle and gather additional angular momentum which in turn produces more electromotive force during initial stages of the on cycle immediately following the off cycle. The on/off duty of the cycle may be tailored to produce a desired average operating speed of the turbine generator 10 . A range of on-duty cycles from 70% to 95% is exemplary, but not limiting. For example, the on/off duty cycle may comprise approximately 60-sec. of on duty and approximately 10-sec. of off duty.
The operating circuit 200 may also include a resistive load 210 , depicted by the resistive elements 210 a , 210 b and 210 c configured in a delta configuration. The windings 202 a - 202 c may be connected to the resistive load 210 through a multi-pole switch 212 that switches current away from the load 206 to the resistive elements 210 a - 210 c.
Functionally, switching to the resistive load 210 may be tailored to increase the torque load experienced by the rotor 18 , thereby causing the resistive load 210 to function as a dynamic brake. The torque load is a function of the current generated, which in turn is a function of the rotational speed of the rotor; hence the functional description “dynamic brake.” The resistive load 210 may be tailored to optimize the braking torque load.
Alternatively, the multi-pole switch 212 may be directed to a shorting bridge (not depicted). The shorting bridge may be affected by replacing resistive elements 210 a and 210 b with an electrical short and leaving the connections to resistive element 210 c open.
In yet another alternative, the multi-pole switch 212 may divert current to a battery for charging (not depicted). The load imposed by the battery may also affect dynamic braking.
In either configuration (resistive load 210 or a short bridge or charging battery), current through the windings may increase compared to normal loads, thereby increasing the joule heating effect in the windings. Certain embodiments can tolerate this effect by virtue of the core 24 being immersed in the cooling flow of the working fluid 149 . Accordingly, the resistive elements 210 a - 210 c or shorting bridge elements may be encased within the dielectric casting 148 to provide cooling of these elements. Alternatively, the resistive elements 210 a - 210 c or shorting bridge elements may be contained within the enclosure 186 and coupled to the back surface 174 of the partition 68 for the transfer of heat in a manner similar to that described in connection with FIGS. 15 through 17 .
The invention may be embodied in other specific and unmentioned forms, apparent to the skilled artisan, without departing from the spirit or essential attributes thereof, and it is therefore asserted that the foregoing embodiments are in all respects illustrative and not to be construed as limiting.
References to relative terms such as upper and lower, front and back, left and right, or the like, are intended for convenience of description and are not contemplated to limit the present invention, or its components, to any specific orientation. All dimensions depicted in the figures may vary with a potential design and the intended use of a specific embodiment of this invention without departing from the scope thereof.
Each of the additional figures and methods disclosed herein may be used separately, or in conjunction with other features and methods, to provide improved systems and methods for making and using the same. Therefore, combinations of features and methods disclosed herein may not be necessary to practice the invention in its broadest sense and are instead disclosed merely to particularly describe representative and preferred embodiments of the instant invention.
For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.
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A turbine generator utilizing a passive high pressure fluid source such as a natural gas well head. The generator includes a core and lead wires encapsulated in a dielectric medium to isolate current-bearing components from the motivating fluid, thereby preventing carbon bridging and reducing the explosion hazard when the motivating fluid is a hydrocarbon. The turbine generator includes a rotor that utilizes the full length as an impingement surface for imparting momentum to the rotor, thereby maintaining a compact design that reduces the overall footprint of the turbine generator. Fluid exits the generator via horizontal passages that penetrate the lower extremities of the turbine generator, preventing the buildup of condensation in the unit.
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[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] The following documents are incorporated herein by reference as if fully set forth: German Patent Application No.: DE 102012007275.9, filed Apr. 13, 2012.
BACKGROUND
[0003] The invention relates to a condensation dryer, in particular a tumble dryer, comprising a heat exchanger for the condensation of moisture from an air circuit, which has been absorbed in a drying chamber and a method for operating a condensation dryer.
[0004] One differentiates on the one side traditional dryers, where the resulting hot humid air is usually vented outside, and on the other side condensation dryers. The invention relates to a condensation dryer, in which air is located in a closed air circuit within the dryer. In this closed air circulation, process air is heated in a first step. The dry warm process air passes through a drying chamber. The drying chamber is usually performed as a drum. The dry warm process air passes through the wet laundry and absorbs humidity.
[0005] The moisture-laden process air flows from the drying chamber into a heat exchanger for the condensation of moisture from the air circuit. This heat exchanger is usually located under the drum and is sometimes called a condenser. The heat exchanger has the task to condense the moisture from the closed “loop” of circulating air. Therefore the hot humid process air is cooled down.
[0006] In conventional condensation dryers a fan, which is coupled to the drum motor, promotes the movement of cool ambient fresh air through the heat exchanger. The cool fresh air, which is called “outside loop”, is separated from the closed air circulation of the process air, which is called “inside loop”, by heat-transferring walls. Heat exchangers of this category are also known as recuperators. The “inside loop” of air is sealed from the outside environment. The flow of cool “outside” fresh air is directed generally transversely to the flow of the “inside” process air. Such a flow arrangement is also known as cross-flow.
[0007] In the heat exchanger, the air is cooled below the dew point and moisture condenses from the process air. The fluid accumulates in a downstream bin. The condensed water is conveyed via a cyclically operating pump into a container, which is often mounted adjacent to the operating unit. The container has to be emptied regularly. After the deposition of the moisture the process air is reheated and recycled to the drying chamber.
[0008] DE 695 25 350 T2 discloses a condensation dryer, which comprises a zeolite adsorption system. The system consists of an adsorber-desorber, which contains zeolite as a solid adsorbent and an evaporator-condenser, which contains water. This zeolite adsorption system is located after a heat exchanger, which condenses from an air circuit. The condensation efficiency of the heat exchanger is not improved in this condensation dryer.
[0009] DE 103 56 786 A1 discloses a process for drying in a domestic appliance. The household appliance comprises a container with water and a sorber with reversibly dehydratable material such as zeolite. In the sorber an electrical heating element is present, which can heat the reversibly dehydratable material for desorption. The sorber and the container are connected via a pipe. Both the container and the sorber are positioned in a closed air circuit of the domestic appliance. In difference to the invention this household appliance does not have a heat exchanger for the condensation of moisture from the process air flow.
SUMMARY
[0010] The object of the invention is to improve the efficiency of condensation of moisture in a heat exchanger of a condensation dryer. Due to the higher efficiency of the heat exchanger the drying time shall be reduced. Also the total energy shall be reduced, which is required for the drying process.
[0011] According to the present invention this object is achieved by a condensation dryer with one or more features as described below and in the claims.
[0012] The condensation dryer comprises a sorption unit, which is connectable with a liquid reservoir for generating a cooling fluid flow between the liquid reservoir and the sorption unit through the heat exchanger. Preferably the liquid reservoir is a container with a liquid.
[0013] According to the invention, the heat exchanger is not cooled by ambient fresh air but by a fluid stream, which is generated between a liquid reservoir and a sorption unit.
[0014] The term “fluid” is to be understood to include gases, vapors, liquids or a mixture of these. For example it can be a water vapor—air mixture. Particularly favorable proves a cooling fluid stream of pure water vapor.
[0015] The sorption unit comprises a solid compound, which can adsorb the fluid. Such solids are referred to as adsorbents. Volatile substances as the fluid, which adsorb at the solid, are referred to as adsorbate.
[0016] Preferably the solid compound is a zeolite. Zeolites are crystalline aluminosilicates, which occur in numerous modifications in nature, but can also be produced synthetically. Preferably zeolite granulate is used in the sorption unit to ensure a better heat and mass transfer, compared to the use of zeolite powder.
[0017] The term “sorption” is to be understood to comprise adsorption and desorption. Adsorption is the enrichment of substances from gases or liquids at the surface of a solid body, generally at the interface between two phases. Desorption is the separation of the fluid from a solid surface. Desorption is the reverse process of adsorption. Adsorption and desorption are surface phenomena.
[0018] For generating the cooling fluid flow through the heat exchanger a connection between the sorption unit and the liquid reservoir is opened. For this purpose a shutoff device can be opened, such as a valve or a slider. The sorption unit and the liquid container are preferably connected at least one hermetically sealed passage, which leads through the heat exchanger. The hermetically sealed passages can be designed as one or more pipes, as one or more hoses or as one or more channels, which lead through the heat exchanger.
[0019] The container may be formed of different materials and may have different shapes. The liquid in the container may also be stored in a medium, such as a porous solid, such as a sponge.
[0020] Liquid molecules accumulate in the gas phase above the liquid phase.
[0021] The liquid reservoir and the sorption unit are connected with at least one passage. Preferably this is a closed system. In a preferred embodiment of the invention, this system is largely free of air. The system is preferably evacuated of air in the production process of the condensation dryer.
[0022] Preferably the passages between the liquid reservoir and the sorption unit are first closed in an initial state.
[0023] Preferably there is no air above the fluid in the container. The space above the liquid is filled by liquid particles, which pass from the liquid phase into the gas phase. A vapor-liquid equilibrium sets in. The pressure in the gas space corresponds to the vapor pressure of the liquid. The vapor pressure or equilibrium vapor pressure is the pressure exerted by a vapor in thermodynamic equilibrium with its condensed phases at a given temperature in a closed system.
[0024] As for the liquid in the container water is particularly suitable. Preferably pure water vapor is present in the gas space of the closed liquid container-sorption unit-system.
[0025] After opening the connection between the sorption unit and the liquid container, fluid molecules, which are located in the gas phase, are adsorbed at the solid in the sorption unit. Therefore the pressure drops in the liquid container after opening the shutoff and liquid evaporates.
[0026] Due to evaporation heat, which is necessary for evaporation, the liquid cools down. Therefore a cold fluid stream is generated, which flows from the liquid container to the sorption unit. According to the invention this cool fluid stream is passed through the heat exchanger. In conventional condensation dryers only air flows through the heat exchanger. In the inventive device a cooler fluid stream flows through the heat exchanger. Because of the stronger cooling a higher proportion of moisture condenses from the air circuit. The heat exchanger of the inventive condensation dryer has a higher condensation efficiency compared to state of the art devices. Therefore the drying time is reduced because the recycled air is drier after the heat exchanger and can absorb more moisture from the laundry in the drying chamber per cycle.
[0027] Because of the adsorption of the fluid, the sorption unit heats up during this first phase. This heat is used for the heating of the air circuit.
[0028] In a variant of the invention the sorption unit is at least partially embedded in the air circuit. The sorption unit is passed by process air of the air circuit and heat is transferred from the heated sorption unit to the air circuit.
[0029] The process air can flow around the sorption unit during the adsorption phase. This is particularly advantageous because if the adsorbent has a low temperature it has a high adsorption capacity for the fluid.
[0030] It is also possible that air of the air circuit continues to flow around the sorption unit even after the adsorption phase has ended.
[0031] In another variant the first adsorption phase is performed first and only afterwards the sorption unit is passed by air.
[0032] In an alternative embodiment of the invention the sorption unit is embedded at least partially in a passage of a fresh airflow. During and/or after the adsorption phase a fresh air stream flows around the sorption unit and heats up. Afterwards this fresh airflow transfers the heat it has absorbed to the air circuit using a heat exchanger.
[0033] In a favorable variant of the invention the sorption unit and the liquid reservoir are connected with at least one additional hermetically sealed passage, which does not pass through the heat exchanger. Through this passage desorbed fluid is fed back into the liquid container during a second phase of the operation.
[0034] Before the beginning of this second phase, the connection between the sorption unit and the liquid container, which leads through the heat exchanger, is closed. Afterwards the second connection between the sorption unit and the liquid container, which does not pass through the heat exchanger, is opened.
[0035] Preferably the sorption unit comprises a heater. If the solid bed of the sorption unit is saturated with fluid, the heater is turned on. The desorption-phase starts. The fluid is released from the solid. The dissolved fluid vapor is led back through the second passage into the liquid container where it condenses. Passages can be designed as one or more pipes, as one or more tubes or as one or more channels.
[0036] Because of the condensation of fluid vapor in the liquid container, condensation heat is released. To use this condensation heat it proves to be particularly advantageous if the condensation dryer comprises a passage for a flow of fresh air. In this passage the liquid container is at least partially embedded. During and/or after the second phase a fresh air stream passes the liquid container and heats itself. Afterwards the air stream transfers the heat via a heat exchanger to the “closed loop” air circuit of the condensation dryer.
[0037] Preferably fresh air flows around the liquid container even during the desorption-phase. It is also possible that even after the desorption-phase has ended fresh air continues to flow around the liquid container.
[0038] In an alternative variant of the method a third phase follows the desorption phase. During this third phase connections between the sorption unit and the liquid container are closed and a fresh air stream passes the sorption unit and/or the liquid container. Absorbed heat is then transferred to the air circuit via a heat exchanger.
[0039] In the inventive process the switching on and off of the fresh air streams is preferably accomplished by a control system due to process data, which have been collected. For this reason the apparatus is preferably equipped with temperature sensors, which are connected to a control system. The control system switches the individual fans according to the temperature data.
[0040] Because of the above-described forms of energy recovery the total energy required is reduced in this inventive drying process.
[0041] The transfer of heat from the respective fresh air streams to the air circuit may be accomplished by means of one or more components. The components can be heat exchangers for example.
[0042] In a variant of the invention the cooling process of the condensing heat exchanger is carried out continuously with a plurality of sorption units and/or a plurality of liquid reservoirs. While one sorption unit is operated in adsorption mode, the second sorption unit operates in the desorption mode. Afterwards the operation modes are changed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Other features and advantages of the invention will become apparent from the description of embodiments with reference to drawings and from the drawings themselves.
[0044] In the drawings:
[0045] FIG. 1 shows a variant in which the sorption unit is arranged in a fresh-air passage.
[0046] FIG. 2 shows a variant in which the sorption unit is arranged in the air circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] FIG. 1 shows a condenser clothes dryer with a drying chamber 1 . In this embodiment the drying chamber 1 is a rotatable drum. The drum rotates around a horizontal axis. Carriers are attached within the drum for moving the laundry during tumbling.
[0048] The warm dry process air flows through the damp laundry and becomes laden with moisture. The moist process air stream flows through heat exchanger 2 . The process air flows in a closed air circuit 3 .
[0049] In the heat exchanger 2 is a cross flow heat exchanger. It may be a conventional heat exchanger used in a conventional condenser dryer. But it proves to be particularly advantageous when a heat exchanger is used, which has a larger surface for the condensation of moisture from the air circuit 3 , compared to conventional heat exchangers.
[0050] Upstream of the heat exchanger 2 a fluff filter is arranged. The moist process air of the air circuit 3 flows through the heat exchanger 2 and moisture is condensed from the process air. According to the invention the heat exchanger 2 is passed through by a cooling fluid flow 4 . In the embodiment said cooling fluid flow 4 is of cold water vapor. In the heat exchanger 2 the cooling fluid flow is separated from the process air flow.
[0051] The cooling fluid flow 4 is generated with a sorption unit 5 . In the embodiment the sorption unit 5 comprises a bed of solid adsorbent material. As adsorbent material a zeolite adsorbent is used. At the beginning of a first phase of operation a shutoff device 6 is opened. In the embodiment the shutoff device 6 is a valve.
[0052] In a liquid container 7 there is water. The liquid container 7 is connected to the sorption unit 5 via a hermetically sealed passage 8 .
[0053] In the heat exchanger 2 the passage 8 divides into a plurality of channels. The channels for the fluid flow are perpendicular to the channels where the process air of the air circuit 3 flows through.
[0054] After flowing through the heat exchanger 2 the cooling fluid enters the sorption unit 5 where it is adsorbed at the zeolite bed. By the adsorption of water vapor at the zeolite solid material the sorption unit 5 heats up.
[0055] The sorption unit 5 is embedded in a passage 9 and is being passed by a fresh air flow 10 . In the embodiment the passage 9 is an air duct. The fresh air flow 10 is generated by a fan 11 .
[0056] When flowing around the sorption unit 5 the flow of fresh air 10 receives the heat liberated in the adsorption process and transfers the heat by means of a heat exchanger 12 to the process air of the air circuit 3 .
[0057] Because of the cold water vapor, the heat exchanger 2 is cooled significantly more than in a conventional air-to-air operation. The condensation efficiency of the heat exchanger 2 is increased.
[0058] Downstream to the heat exchanger 2 the process air first flows through the heat exchanger 12 and then through a multistage electric heater 13 . For energetic reasons the heater 13 should be constructed with multi-stages so only the lack of energy can be added to the process air stream before the process air stream flows back into the drying chamber 1 .
[0059] The multi-stage heater 13 heats the process air flow, before it reenters the drying chamber 1 . Because of the higher condensation level in the heat exchanger 2 the process air flow of the inventive device has a lower relative humidity. Therefore it can absorb more moisture when it passes through the laundry in the drying chamber 1 . Therefore the drying time is reduced compared to conventional condensation dryers.
[0060] The process air flow in the air circuit 3 is maintained by means of a fan 14 .
[0061] During a second phase of operation the shutoff device 6 is closed and the fan 11 is off. At the beginning of the second operating phase a further shutoff device 15 is opened. In the embodiment the shutoff device 15 is a valve.
[0062] The sorption unit 5 and the liquid container 7 are connected with another hermetically sealed passage 16 , which does not pass through the heat exchanger 2 . After opening of the further passage 16 a heater 17 is activated, which is part of the sorption unit 5 . The heater 17 heats the zeolite material and fluid is desorbed. The desorbed water vapor flows through the passage 16 into the liquid container 7 and there it condenses. The condensation releases condensation heat.
[0063] Through the use of a fan 18 a further fresh air flow 18 is generated, which passes around the liquid container 7 and receives the liberated heat of condensation. The liquid container 7 is embedded into a further passage 19 . In the embodiment the passage 19 is an air duct. The heated fresh air flow 18 flows through the heat exchanger 12 . It transfers the heat to the process air of the air circuit 3 . The fresh air flow 18 leaves the condensation dryer after the transfer of heat to the process air flow.
[0064] After the desorption phase the shutoff device 15 is closed and a fresh air flow 10 passes the sorption unit 5 . A cooling phase can follow, during which the sorption unit 5 and/or the liquid container 7 can be cooled by fresh air flows 10 and/or 18 . The heated fresh air flows 10 , 18 transfer heat via the member 12 , which is configured as a heat exchanger in the embodiment, to the process air of the air circuit 3 and afterwards they leave the condensation dryer.
[0065] FIG. 2 shows a variant, in which the sorption unit 5 is embedded in the air circuit 3 of the process air flow. During the first operating phase, the adsorption phase, and during the second operating phase, the desorption phase, the sorption unit 5 transfers heat to the process air flow, which flows around the sorption unit 5 and is conveyed by the fan 14 .
[0066] The fresh air stream 18 , which receives the heat of condensation from the container 7 during the second phase of operation, transmits its heat by means of a heat transfer device 20 to the process air flow.
[0067] One operation cycle comprises a first and a second phase. During the drying process several cycles are carried out.
[0068] In a not illustrated embodiment of the invention the cooling process of the heat exchanger 2 is continuously operated with several sorption units 5 . While one sorption unit 5 is in the adsorption mode, the second sorption unit 5 operates in desorption mode. Afterwards the modes change.
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A condensation dryer, in particular a tumble dryer, having a heat exchanger ( 2 ). In the heat exchanger ( 2 ) moisture, which has been absorbed in a drying chamber ( 1 ), is separated from an air circuit ( 3 ). The condensation dryer includes a sorption unit ( 5 ). The sorption unit ( 5 ) is connectable to a liquid reservoir ( 7 ). Between the liquid reservoir ( 7 ) and the sorption unit ( 5 ) a cooling fluid flow ( 4 ) can be generated. The cooling fluid flow ( 4 ) passes through the heat exchanger ( 2 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/609,969 filed Sep. 15, 2004, the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
Fuel cells, in particular so-called proton exchange membrane fuel cells (PEMFCs) require for operation, among other things, a compressor for the cathode air, and a system for letting off the water generated on the cathode side by electrochemical reaction. In order to prevent oversaturation by the generated water on the cathode side, which oversaturation would be disadvantageous for implementation, and in this way achieve an effective water production rate, the water must be continuously removed in the form of water vapour and water droplets. Often the air stream generated by the compressor is insufficient for optimal removal of the water generated on the cathode side.
There may be a need to provide an improved fuel cell system for generating electrical energy, mechanical energy or water.
SUMMARY OF THE INVENTION
The present invention relates to fuel cell systems. In particular, the present invention relates to a fuel cell system for generating electrical energy, mechanical energy and water; to the use of such a fuel cell system in an aircraft; and to an aircraft comprising such a fuel cell system.
According to an exemplary embodiment of the present invention, as stated in claim 1 , the above object may be met by means of a fuel cell system for generating electrical energy, mechanical energy and water. The fuel cell system comprising a fuel cell held so as to be rotatable, a motor and a first non-positive connection between the fuel cell and the motor, wherein by way of the first non-positive connection energy is transferable from the motor to the fuel cell so that the fuel cell can be made to rotate.
As a result of the design of the fuel cell system the fuel cell may be made to rotate in such a way that an additional conveying force is provided, which may promote removal of the water generated by the electrochemical reaction within the fuel cell. This force may be derived from a centrifugal force in that the fuel cell held so as to be rotatable is made to rotate. In this way the removal of water may be significantly accelerated, which can lead to a more effective cathode reaction and thus to an increase in the efficiency of the fuel cell.
According to a further exemplary embodiment of the present invention, as stated in claim 2 , the fuel cell system further comprises a compressor, wherein the compressor is designed to provide cathode air to the fuel cell, and wherein as a result of the rotation of the fuel cell the water generated in an electrochemical reaction in the fuel cell on a cathode side of the fuel cell is extractable by centrifugal force.
Thus, a fuel cell system may be provided in which removal of the water generated on the cathode side takes place not only by means of the centrifugal force which may result from the rotation of the fuel cell system or of the fuel cell, but also by means of compressed air which may be generated by the compressor and which is fed into the cathode of the fuel cell. The addition of centrifugal force and conveying force (resulting from the air stream generated by the compressor) may accelerate water removal from the cathode space and thus causes an effective cathode reaction.
According to a further exemplary embodiment of the present invention, as stated in claim 3 , the first non-positive connection between the fuel cell and the motor comprises a first clutch and a torque converter, wherein the first clutch is a mechanical or electromechanical clutch.
Thus, the power may be transmitted in a metered way from the motor to the fuel cell. For example, if necessary, decoupling the fuel cell from the motor may also be possible so that for example the motor can drive other components without driving the fuel cell.
According to a further exemplary embodiment of the present invention, as stated in claim 4 , the fuel cell system further comprises a load controller, wherein the load controller is designed to distribute the required electrical energy between the motor and further electrical consumers, or is designed to control or regulate the torque converter and the clutch. The electrical energy required for this may be internally supplied by the fuel cell or by an external energy source.
It may be thus possible to ensure electronic energy management which may provide energy to the motor or to other electrical consumers as required. Furthermore, the load controller may control or regulate the torque converter and the clutch of the non-positive connection between the fuel cell and the motor so that in this way electronic speed control of the fuel cell may be ensured.
According to a further exemplary embodiment of the present invention, as stated in claim 5 , the rotary speed of the fuel cell and thus a water discharge from cathode-side air channels of the fuel cell can be regulated or controlled, either continuously or intermittently, by way of the load controller and the torque converter, depending on the electrical or mechanical load.
Thus, it may for example be possible, in the case of an increased mechanical load on the motor, to regulate the rotary speed of the fuel cell down so that the energy requirement of the motor may drop accordingly.
According to a further exemplary embodiment of the present invention, as stated in claim 6 , a rotary speed of the compressor can be regulated or controlled, either permanently or intermittently, by way of the load controller and the torque converter, depending on the electrical or mechanical load, wherein a rotary speed of the fuel cell can be regulated or controlled, either permanently or intermittently, by way of the load controller and the torque converter, independently of the electrical or mechanical load.
In this way the rotary speed of the compressor and the fuel cell may be set independently of each other, wherein the rotary speed of the compressor may be guided by the electrical or mechanical load, and wherein the rotary speed of the fuel cell may be set or regulated independently thereof.
According to a further exemplary embodiment of the present invention, as stated in claim 7 , the fuel cell system further comprises a water pump and a second non-positive connection between the motor and the water pump, wherein, by way of the second non-positive connection, energy from the motor can be transmitted to the water pump so that the water pump can be made to rotate, and wherein the water pump returns a condensate from the cathode exhaust air of the fuel cell for further utilisation by the fuel cell, or removes said condensate from the fuel cell system.
Thus, a fuel cell system may be stated which can independently return the cathode air removed by centrifugal force, or, if applicable, may return said cathode air to the fuel cell for further utilisation within the fuel cell.
According to a further exemplary embodiment of the present invention, as stated in claim 8 , the fuel cell system further comprises a shaft which is non-positively connected to an armature of the motor or to a displacement device of the compressor.
According to a further exemplary embodiment of the present invention, as stated in claim 9 , the fuel cell is constructed from rotation-symmetrical components as a hollow cylinder.
This may ensure smoothness of running and low mechanical load for example of the shaft during rotation of the fuel cell on its longitudinal axis.
According to a further exemplary embodiment of the present invention, as stated in claim 10 , in the region of the fuel cell the shaft is a first hollow shaft, wherein the first hollow shaft is designed to feed hydrogen to an anode of the fuel cell.
Thus, even with rotation of the fuel cell on the rotary axis, hydrogen may be fed to the fuel cell anode in an easy manner.
According to a further exemplary embodiment of the present invention, as stated in claim 11 , a second hollow shaft is provided which encloses the first hollow shaft, wherein the second hollow shaft is designed for feeding air to the fuel cell.
It may thus be possible to feed different gases independently of each other to the fuel cell.
According to a further exemplary embodiment of the present invention, as stated in claim 12 , the fuel cell comprises air channels on the cathode side, and gas channels on the anode side, wherein the air channels are arranged so as to extend radially or in a spiral shape from the inside towards the outside, and wherein the arrangement of the gas channels corresponds to the arrangement of the air channels.
Thus, the removal of water from the cathode space may thus be further enhanced.
According to a further exemplary embodiment of the present invention, as stated in claim 13 , the fuel cell comprises a collection space for water, and a housing which encloses the collection space, wherein the housing accommodates bearing elements for the shafts and also accommodates rotary transmission leadthroughs.
It may thus be possible to collect within the fuel cell the water removed from the cathode.
Further objects, embodiments and advantages of the invention are disclosed in the dependent claims and in the further independent claims.
Below, the invention is described in more detail by means of exemplary embodiments with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagrammatic view of a fuel cell system according to an embodiment of the present invention.
FIG. 2 shows a diagrammatic view of a further fuel cell system according to another embodiment of the present invention.
FIG. 3 shows a diagrammatic cross-sectional view of a bipolar plate according to an embodiment of the present invention.
FIG. 4 show a diagrammatic section view of a fuel cell system according to an embodiment of the present invention.
DETAILED DESCRIPTION
In the following description of the figures the same reference signs are used for identical or similar elements.
FIG. 1 shows a first diagrammatic view of a fuel cell system according to an embodiment of the present invention. As shown in FIG. 1 , the fuel cell system comprises a proton exchange membrane fuel cell (PEMFC) 1 , an electric motor 12 , a compressor 11 , a clutch 10 , a torque converter 9 and a pump 14 .
By way of a corresponding line, hydrogen 17 is fed to the fuel cell 1 , and by way of a corresponding other line, humid air 19 is removed from the fuel cell 1 . In this arrangement, the feeding in of hydrogen 17 is by way of a hollow shaft (not shown in FIG. 1 ) which forms part of a main shaft 4 . The hydrogen is then fed to an anode (not shown in FIG. 1 ) of the fuel cell 1 so that an electrochemical reaction within the fuel cell can take place, by way of which reaction electrical energy and water are generated.
The water that arises in the cathode of the fuel cell 1 , is removed from the cathode and is removed as humid air 19 or as water.
In this arrangement the fuel cell 1 is held, so as to be rotatable, on the shaft 4 and by way of the clutch 10 and the torque converter 9 is non-positively connected to the electric motor 12 . Furthermore, the fuel cell 1 can be made to rotate by means of the electric motor 12 . According to the invention, this rotary movement leads to improved removal of the water from the cathode system of the fuel cell 1 , which improved removal is due to the centrifugal force generated, and thus leads to improved efficiency of the fuel cell.
As shown in FIG. 1 , the fuel cell system further comprises a pump 14 which, by way of a second non-positive connection that is consists of and/or comprises a second clutch 15 and a second torque converter 16 , is connected to the shaft 4 , and is thus drivable by way of the electric motor 12 . The water pump 14 can for example be used to return a condensate from the cathode exhaust air 19 to the fuel cell 1 so that it can continue to be used within the fuel cell. Of course, the pump 14 can also be used to entirely remove the condensate from the humid air 19 from the fuel cell system. Subsequently, the condensate can for example be fed to the water supply system of an aircraft in which the fuel cell system is installed.
The electric motor 12 comprises an armature (not shown in FIG. 1 ), while the compressor 11 comprises a displacement device (not shown in FIG. 1 ). Both the displacement device and the armature are non-positively connected to the shaft 4 .
In order to minimise the mechanical load on the rotating parts, the fuel cell 1 is constructed from rotationally symmetrical components as a hollow cylinder.
Furthermore, the fuel cell 1 comprises air channels on the cathode side, and gas channels on the anode side, which channels are arranged radially or in a spiral shape from the inside towards the outside. In this way the efficiency of the fuel cell can be further enhanced.
FIG. 2 shows a second diagrammatic view of a fuel cell system according to another embodiment of the present invention. In this arrangement the fuel cell 1 is designed such that hydrogen gas 17 can be fed to it by way of a first hollow shaft (see FIG. 4 ), and such that air 18 can be fed to it by way of a second hollow shaft (see FIG. 4 ).
No compressor is provided in the fuel cell system shown in FIG. 2 .
A mechanical or electromechanical clutch 10 and a torque converter or gear arrangement 9 is arranged between the electric motor 12 and the fuel cell 1 .
FIG. 3 shows a diagrammatic cross-sectional view of a bipolar plate according to an embodiment of the present invention. As shown in FIG. 3 , the bipolar plate 2 comprises cathode air channels 21 . Furthermore, in radial direction the bipolar plate 2 is designed in the manner of cooling lamellae or blades. The cooling lamellae or blades 22 can be used for cooling the fuel cell. The fuel cell, together with the bipolar plates 2 , is held in its housing so as to be rotatable (see FIG. 4 ). In this arrangement the housing comprises an inflow channel and an outflow channel for cooling air. The bipolar plates are held, so as to be rotatable, in the region of the central borehole 3 .
According to one embodiment of the present invention the housing is an axial blower.
FIG. 4 shows a diagrammatic section view of a fuel cell system according to an embodiment of the present invention. The PEMFC 1 is made from rotationally symmetrical components as a hollow cylinder. In the central borehole 3 (see FIG. 3 ) of the bipolar plates 2 there is a through shaft 4 which is rigidly connected to the displacement device 111 , which is for example a piston or a rotary slide valve, of the compressor 11 and to the armature 121 of the electric motor 12 . Of course, according to another embodiment of the present invention the compressor 11 can also be done without.
In the region of the fuel cell 1 the shaft 4 is a hollow shaft 5 . By way of this hollow shaft 5 , hydrogen 17 flows to the anode of the fuel cell 1 . A further hollow shaft 6 encompasses the hollow shaft 5 for the air supply. By way of rotary transmission leadthroughs, the hydrogen 17 is supplied on the free side of the fuel cell 1 . If there is no compressor 11 , the air too is supplied by way of the rotary transmission leadthroughs on the free side of the fuel cell 1 .
When the fuel cell 1 rotates on the shaft 4 , the water generated on the cathode side during the electrochemical reaction is extracted by centrifugal force into the collection space 7 . To this effect the cathode-side air channels 21 in the bipolar plate 2 are radially aligned (see FIG. 3 ). The collection space 7 is enclosed by a housing 8 which accommodates the bearing elements of the shafts ( 4 , 5 , 6 ) and further accommodates the rotary transmission leadthroughs. The rotary axle 4 and the hollow shafts 5 , 6 of the fuel cell or of the fuel cell system are held in the housing 8 so that in the space enclosing the fuel cell 1 the cathode water can be collected and removed by way of an aperture 81 . However, it is also possible for the rotary axle 4 and the hollow shafts 5 , 6 of the fuel cell 1 not to be held in a housing 8 so that the cathode water can be removed into the free space enclosing the fuel cell 1 .
The drive for rotation of the fuel cell 1 is provided by the electric motor 12 , which is non-positively connected to the shaft 4 . A mechanical or electromagnetic clutch and a torque converter (gear arrangement) can be arranged between the electric motor 12 and the fuel cell 1 .
The end plate 41 of the fuel cell 1 can comprise gas channels.
Within the hollow shafts 5 , 6 and the compressor 11 there is an air space 45 which can accommodate corresponding gases.
The clutch 10 and the torque converter 9 (shown in FIG. 1 ) are constructed in such a way that, with the clutch disengaged too, the air stream can flow from the compressor 11 to the fuel cell 1 by way of the hollow shaft 6 . The electrical energy required by the electric motor 12 is supplied by the fuel cell 1 .
The electric motor 12 comprises a ventilator 46 , an exciting winding 47 , a stator 48 and a commutator 49 .
By way of the clutch 15 , mechanical energy can be transmitted to further (mechanical) consumers such as for example to a pump.
By way of the electrical load controller 13 , distribution of the electrical energy required is regulated between the electric motor 12 (by way of lines 44 ) and the external electrical consumers, and furthermore the switch state of the torque converter 9 of the clutch (see FIG. 1 ) is regulated. By way of the load controller 13 , external electrical energy can also be supplied to the electric motor 12 for other operating states, e.g. for starting up the system. The external electrical energy is fed to the load controller 13 by way of supply lines 131 . The internal electrical energy (generated by the fuel cell 1 ) is fed to the load controller 13 by way of current collectors 42 and lines 43 . The electrical energy for further electrical consumers is discharged from the load controller by way of lines 132 .
The water arising in the collection space 7 and the humid air from the cathode channels 21 are let out by way of an aperture 81 in the housing 8 , for example by way of a condenser with condensate separator, or by way of a humidity-heat exchanger (not shown in FIG. 4 ) for further utilisation in the process.
Cooling of the PEMFC 1 takes place by way of the bipolar plates or cooling plates of the fuel cell 1 , which are enlarged in radial direction to the extent that the projecting rings are cooling lamellae or blades 22 (see FIG. 3 ).
The fuel cell system according to the invention can for example be used within an aircraft.
Implementation of the invention is not limited to the preferred embodiments shown in the figures. Instead, a multitude of variants are imaginable which use the solution shown and the principle according to the invention even in the case of fundamentally different embodiments.
In addition it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that features or steps which have been described with reference to one of the above embodiments can also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be interpreted as limitations.
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For operation, PEMFCs require among other things a compressor for the cathode air, and a system for removing the water which is generated on the cathode side as a result of the electrochemical reaction. According to an embodiment of the present invention the removal of water is supported in that the fuel cell is made to rotate by way of an electric motor so that the water contained in the cathodes of the fuel cell can be extracted by centrifugal force. To this effect the air channels on the cathode side are arranged so as to extend radially or in a spiral shape from the inside towards the outside. In this way the efficiency of the fuel cell can be significantly improved.
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